TM-10-3930-643-34

TM-10-3930-643-34
TM 10-3930-643-34*
DIRECT SUPPORT AND GENERAL
SUPPORT MAINTENANCE
TRUCK, FORKLlFT, DED
PNEUMATIC TIRE,
10,000 LB. CAPACITY
ROUGH TERRAIN,
ARTICULATED FRAME STEER
(DRESSER INDUSTRIES
MODEL M10A, MHE 236)
(NSN 3930-01-054-3833)
CHAPTER 1
Page 1-1
Introduction
Chapter 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page 1-1
GeneraI Maintenance Procedures . . . . . . .Page 2-1
DIRECT SUPPORT MAINTENANCE
CHAPTER 3
Troubleshooting Symptom Index . . . . . . . .Page 3-1
CHAPTER 4
. age 4-1
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
CHAPTER 5
Electrical System Maintenance . . . . . . . . . . .Page 5-1
CHAPTER 6
Transmission Troubleshooting and
6-1
.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
CHAPTER 7
Axle Troubleshooting and
7-1
.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
CHAPTER 8
Brake Troubleshooting and Maint8-1
.
enance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
CHAPTER 9
Steering Troubleshooting and
9-1
.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
CHAPTER 10
Frame and Towing Attachment
10-1
.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
CHAPTER 11
Body, Chassis and Hull Accessory
. age 11-1
Items Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
CHAPTER 12
Hydraulic System Troubleshooting
. age 12-1
and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P
GENERAL SUPPORT MAINTENANCE
CHAPTER 13
Engine, Fuel, Exhaust and Cooling
13-1
.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page
CHAPTER 14
Electrical System Maintenance . . . . . . . . . .Page 14-1
CHAPTER 15
Transmission Maintenance . . . . . . . . . . . . . . . . . Page 15-1
CHAPTER 16
Propeller and Propeller Shaft
16-1
.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Page
CHAPTER 17
. age 17-1
Brake Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . P
APPENDICES A, C, D, E
- GLOSSARY
ALPHABETICAL INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index-1
*This TM supersedes the Direct and General Support Maintenance portion
of TM 10-3930-643-14&P, dated 30 November 1981, and the
Direct and General Support Maintenance portions of all changes.
APPROVED FOR PUBLIC RELEASE, DISTRIBUTION IS UNLIMITED.
HEADQUARTERS, DEPARTMENT OF THE ARMY
JANUARY 1990
TM 10-3930-643-34
Make sure
Diesel fuel used in this equipment is highly flammable.
open flames or sparks cannot ignite diesel fuel when working on or
near the vehicle. Do not smoke when working on the fuel system.
Failure to follow this procedure could result in SEVERE INJURY or
DEATH. If injured, obtain medical aid immediately.
OIL UNDER 2500 PSI PRESSURE
High pressure hydraulics operate this equipment. NEVER disconnect any
hydraulic lines or fittings without checking manual to see how to drop
the pressure to zero. Failure to follow this procedure could cause
SEVERE INJURY. If you are struck by a high pressure oil stream, seek
medical aid immediately.
ELECTRICAL SHOCK HAZARD
Always disconnect the battery ground cable before working on
electrical components of this equipment.
DEATH
or SEVERE INJURY may result if you fail to observe this procedure. If
you receive an electrical shock, seek medical aid immediately.
FALLING EQUIPMENT HAZARD
Never crawl
equipment is
being raised
suspended by
near a cable
under equipment when performing maintenance unless
securely blocked. Keep clear of equipment when it is
or lowered. Do not allow heavy components to swing while
lifting device. Exercise extreme caution when working
or chain under tension.
a
TM 10-3930-643-34
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used for cleaning parts, is toxic and
flammable. Wear protective goggles and gloves and use only in a
well-ventilated area. Avoid contact with skin, eyes and clothes. Do
not breathe vapors. Do not use near open flame or excessive heat. Do
not smoke when using it. Failure to do so could cause SEVERE INJURY.
If you become dizzy while using cleaning solvent, get fresh air
immediately, if necessary, seek medical attention. If contact with
skin or clothes is made, flush thoroughly with water. If the solvent
contacts your eyes, wash eyes with water immediately, and obtain
medical aid.
EXHAUST GASES CAN BE DEADLY
Exhaust gases can produce symptoms of headache, dizziness, loss of
muscular control or coma. Permanent brain damage or DEATH can result
from severe exposure. You can insure your safety by following these
rules:
Do not operate the engine in an enclosed area unless properly
ventilated.
Do not drive with any inspection plates, cover plates or hoods
off unless for maintenance.
If you notice exhaust odors or exposure symptoms, IMMEDIATELY
VENTILATE the area. If symptoms persist, remove and treat the
affected personnel:
Expose them to fresh air.
If necessary, give artificial respiration.
Keep them warm.
Do not permit physical exercise.
Refer to FM 21-11, First Aid for Soldiers, for first aid treatment of
injured personnel.
SEAT BELT
Be sure your seat belt is fastened before operating the vehicle.
Avoid sudden stops and operate at a safe speed.
b
TM 10-3930-643-34
NOISE HAZARD
Excessive noise levels are present any time the equipment is
operating. Wear hearing protection while operating or working around
equipment while it is running. Failure to do so could result in
damage to your hearing. Seek medical aid should you suspect a hearing
problem.
STEAM UNDER PRESSURE
Remove radiator cap slowly to relieve pressure before completely
removing it when the engine is hot. Failure to follow this procedure
could cause SEVERE INJURY. If you are scalded by steam, seek medical
aid immediately.
OIL UNDER PRESSURE
Keep hands and feet clear of steering cylinder assemblies while
checking for hydraulic leakage when engine is running. SEVERE INJURY
may result if you fail to follow this procedure.
OIL UNDER PRESSURE
When bleeding air from hydraulic cylinder assemblies, do not look
directly at bleed fitting. Hydraulic oil is under high pressure.
SEVERE INJURY may result if you fail to follow this procedure.
FUEL UNDER PRESSURE
When testing fuel injectors, always direct fuel injector tip away from
you. Fuel from orifices can penetrate clothing and skin. This can
cause SERIOUS INFECTION. Be sure fuel injector tip is enclosed in a
receptacle to contain the spray. If skin is broken by fuel injector
spray, seek medical aid.
c
TM 10-3930-643-34
BURN HAZARD
Avoid
Batteries contain sulfuric acid which can cause severe burns.
contact with skin, eyes or clothing. Wear safety goggles and gloves.
If battery electrolyte is spilled, take immediate action to stop its
burning effects:
EXTERNAL: Flush with cold water to remove all acid.
EYES: Flush with cold water for 15 minutes.
attention at once.
Get medical
INTERNAL: Drink large amounts of water or milk.
milk of magnesia, beaten egg, or vegetable oil.
attention at once.
CLOTHING OR VEHICLE: Wash at once with cold water.
with baking soda or household ammonia solution.
Follow with
Get medical
Neutralize
HIGH VELOCITY AIR
Compressed air, used for cleaning purposes, must not exceed 30 psi.
Safety glasses must be used when cleaning parts with compressed air.
Failure to protect your eyes could cause SEVERE INJURY and possible
blindness. If you injure your eyes or if a foreign object is blown
into your eyes, seek medical attention immediately.
TOXIC/FLAMMABLE
Starting fluid is toxic
pressurized to act as an
discharge starting fluid
SEVERE INJURY may result
and highly flammable.
Container is
expellent. Do not heat container and do not
in confined areas or near an open flame.
if you fail to follow this procedure.
BURN HAZARD
Allow engine to cool off before you perform maintenance on the
muffler, exhaust pipe, exhaust manifold or turbocharger.
If
necessary, use insulated pads and gloves. If YOU are burned, seek
medical aid immediately.
d
TM 10-3930-643-34
Hot coolant and alkali conditioner can burn severely. Cooling system
conditioner contains alkali. Contact with skin or eyes could result
in SEVERE INJURY and/or skin rash. If alkali is splashed on skin or
clothes, flush with large amounts of water and seek medical attention.
Hot coolant and a hot radiator can cause severe burns. Even when the
system is drained, some coolant remains in the lines and fittings.
1.
Wear protective goggles and clothing when handling cooling
system components.
2.
Remove the radiator fill cap slowly to release pressure.
Release all pressure before removing cap.
3.
Drain engine coolant only when the engine is stopped and the
radiator and fill cap are cool enough to touch.
JACKING VEHICLE
Make sure that vehicle will not roll or shift.
Secure with wood
blocks. DEATH or SEVERE INJURY may result by your failure to follow
this procedure due to vehicle turning and slipping off jack or jack
stands.
FLAMMABLE
Battery gases can explode. DO not smoke, have open flames or make
SEVERE
sparks around a battery, especially if the caps are off.
INJURY may result if you fail to follow this procedure.
PARTS UNDER SPRING TENSION
Exercise care when removing parts under spring tension. SEVERE INJURY
may result by the part striking your eye if you do not observe this
caution. If your eye is struck by a foreign object, seek medical help
immediately.
e
TM 10-3930-643-34
Do not let fuel spill or leak onto hot surfaces or electrical parts.
Failure to follow this procedure may cause fire and injury. If you
are injured or burned, get medical help.
Fuel
Wear gloves and safety goggles when loosening fuel line nut.
under pressure can penetrate eyes and skin. If injured, seek medical
aid immediately.
f
TM 10-3930-643-34*
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
Washington D.C.,30 January 1990
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
TRUCK, FORKLIFT, DED
PNEUMATIC TIRE, 10,000 LB. CAPACITY
ROUGH TERRAIN, ARTICULATED FRAME STEER
(DRESSER INDUSTRIES MODEL M10A, MHE 236)
(NSN 3930-01-054-3833)
REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS
You can help improve this manual. If you find any mistakes or if you know of a
way to improve the procedures, please let us know. Mail your letter, DA Form
2028 (Recommended Changes to Publications and Blank Forms) or DA Form 2028-2
located in the back of this manual directly to: Commander, U.S. Army TankAutomotive Command, ATTENTION: AMSTA-MBS, Warren, MI 48397-5000. A reply will
be furnished to you.
TABLE OF CONTENTS
Page
HOW TO USE THIS MANUAL
iii
CHAPTER 1
INTRODUCTION
1-1
CHAPTER 2
GENERAL MAINTENANCE PROCEDURES
2-1
CHAPTER 3
TROUBLESHOOTING SYMPTOM INDEX
3-1
CHAPTER 4
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING
AND MAINTENANCE
4-1
CHAPTER 5
ELECTRICAL SYSTEM MAINTENANCE
5-1
CHAPTER 6
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE
6-1
CHAPTER 7
FRONT AND REAR AXLES TROUBLESHOOTING AND
MAINTENANCE
7-1
This TM supersedes the Direct and General Support Maintenance portion of TM 10-3930-643-14&pi
dated 30 November 1981, and the Direct and General Support Maintenance portions of all changes.
APPROVED FOR PUBLIC RELEASE. DISTRIBUTION IS UNLIMITED.
i
TM 10-3930-643-34
TABLE OF CONTENTS (cont)
Page
CHAPTER 8
8-1
CHAPTER 9
9-1
CHAPTER 10
10-1
CHAPTER 11
11-1
CHAPTER 12
12-1
CHAPTER 13
13-1
CHAPTER 14
14-1
CHAPTER 15
15-1
CHAPTER 16
16-1
CHAPTER 17
17-1
APPENDIX A
A-1
APPENDIx B
APPENDIX C
C-1
APPENDIX D
D-1
APPENDIX E
E-1
INDEX-1
ii
TM 10-3930-643-34
HOW TO USE THIS MANUAL
This manual is designed to help you maintain the M10A Forklift. It is divided
into chapters, sections and appendices.
Chapter 1 contains information
concerning the vehicle, its characteristics, systems and components. Chapter 2
provides useful general maintenance information. Chapters 3 through 15 contain
procedures necessary for troubleshooting, maintenance and general upkeep. The
maintenance procedures contained in these chapters tell you several things:
what tools you need to do the job
materials or parts required
what condition the vehicle is to be in before work is started.
The appendices contain supplemental information which assist you in the
performance of the maintenance procedures.
In addition to the text, you’ll have either an assembled or an exploded view
illustration of the associated parts. Sometimes the illustration will be keyed
by an arrow to an overall view of the vehicle to help you determine the
approximate location of the parts. The illustration is keyed to the text by
numbers and shows you how to take the part off and put it on. The following
example will show some of the features of this manual.
iii
TM 10-3930-643-34
EXAMPLE
An operator brings his M10A Forklift into the shop with an engine cooling
problem: the engine stalls frequently or does not develop full power.
The
best way to solve his problem is by using your manual. This is what you do:
1.
How do you start?
Look at the cover of the manual. On the cover you’ll find a listing for
TROUBLESHOOTING SYMPTOM INDEX. To find the page fast, open the manual by using
the black tab that lines up with the listing on the cover.
2.
What kind of problem do you have?
Find it in the symptom index. The symptom index is a list of problems covered
by a chapter. It tells you that your problem, “Engine stalls or lacks power”
is covered in paragraph 4-1, malfunction entry D.
3.
How do you determine what is causing the problem?
Go to paragraph 4-1, malfunction entry number D. There you will find the
troubleshooting procedures you will need. The procedure has columns with the
headings: MALFUNCTION, TEST OR INSPECTION, and CORRECTIVE ACTION. Starting at
step 1, read the procedure. Each step tells you what to do and what to look
for. Follow the steps, in order, until you find your problem. The corrective
action column will tell you what to do next.
Let’s assume that the troubleshooting procedures lead you to a faulty fuel
4.
injector nozzle. The replacement procedure is in paragraph 4-13.
The
procedure contains all the information you will need to repair or replace the
fuel injector nozzle. First, check the introductory material. It tells you
what you will need before you start the job. Below the introductory material
is an assembled view of the vehicle showing the approximate location of the
fuel injector nozzles and an illustration which shows you how to do the job.
5.
If on the other hand, you know the cause of the problem, refer to the
alphabetical index located at the rear of this manual. Find the name of the
part to be replaced and the paragraph number for the maintenance procedure.
For example, you notice a leak in the fuel pump. You know the fuel pump must
be replaced or repaired. Refer to the alphabetical index under the listing
“Fuel pump.” Turn to the page referenced for replacement and repair
procedures.
iv
TM 10-3930-643-34
CHAPTER 1
INTRODUCTION
INDEX
Section
I
Title
Page
1-1
1-2
1-3
1-3
1-3
1-4
1-5
1-3
1-3
1-4
1-6
1-7
1-4
1-4
1-8
1-5
GENERAL INFORMATION
Scope
Maintenance Forms, Records and Reports
Destruction of Army Material to Prevent
Enemy Use
Quality Assurance/Quality Control (QA/QC)
Nomenclature Cross Reference
Reporting Equipment Improvement
Recommendations (EIR)
Warranty Information
II
Paragraph
EQUIPMENT DESCRIPTION AND DATA
Differences in Models
1-1
TM 10-3930-643-34
1-2
TM 10-3930-643-34
CHAPTER 1
INTRODUCTION
Section I.
GENERAL INFORMATION.
1-1. Scope. This chapter provides general descriptive data to aid the
maintenance specialist in understanding the various mechanical functions of the
M1OA Forklift.
a.
Type of Manual.
Direct Support and General Support Maintenance Manual.
b. Model Number and Equipment Name.
MHE 236, (NSN 3930-01-054-3833) Rough
Terrain 10,000 Pound Capacity, Articulated Frame Steer, Pneumatic Tire, DED,
M1OA Forklift.
c. Purpose of Equipment. Handle, transport, and stock materials on various
types of terrain. The vehicle has a capacity of 10,000 pounds, 48 inch load
center and can lift the load to a maximum of 121.6 inches.
d. Metric Dimensions. The equipment described herein is non-metric and
does not require metric common or special tools. Therefore, metric units are
not supplied.
1-2. Maintenance Forms, Records, and Reports. Department of the Army forms
and procedures used for equipment maintenance will be those prescribed by DA
PAM 738-750, The Army Management System (TAMMS).
TM 750-244-6,
1-3. Destruction of Army Material to Prevent Enemy Use.
“Procedures for Destruction of Equipment to Prevent Enemy Use.”
1-4.
Quality Assurance/Quality Control (QA/QC).
a. No particular quality assurance or quality control technical manuals
pertain specifically to the M1OA Forklift. Use standard QA/QC procedures.
b. Defective material received through the supply system should be reported
on a Quality Deficiency Report (QDR), SF368. QDR’s should be mailed directly
to: Commander, U.S. Army Tank Automotive Command, ATTN: AMSTA-QRT, Warren, MI
48397-5000. A reply will be furnished directly to you.
1-3
TM 10-3930-643-34
INTRODUCTION. (cont)
1-5. Nomenclature Cross Reference.
references used in this manual.
This listing includes nomenclature cross-
Official Nomenclature
Common Name
Truck, Forklift, DED
Pneumatic Tire,
10,000 Lbs. Capacity,
Rough Terrain,
Articulated
Frame Steer
Technical Manual
Lubrication Order
Level Indicator
Capscrew
Safety Wire
Gauge
Water Temperature Regulator
Servicemeter
O-Ring
XMSN
Hydraulic Tank
Air Reservoir
Self-Locking Nut
Drive Shaft
Fork Carriage
Final Filter
Forklift
TM
LO, Lube Order
Sight Gage, Dipstick
Bolt
Lockwire
Gage
Thermostat
Hourmeter
Preformed Packing
Transmission
Hydraulic Reservoir
Air Tank
Locknut
Propeller Shaft
Boom
Secondary Filter
1-6. Reporting Equipment Improvement Recommendations (EIR). If your M10A
Forklift needs improvement, let us know. Send an EIR. You, the user, are the
only one who can tell us what you don’t like about your equipment. Let us know
why you don’t like the design. Put it on a SF 368. EIR’s should be mailed
directly to: Commander, U. S. Army Tank Automotive Command, ATTN: AMSTA-QRT,
Warren, MI 48397-5000. A reply will be furnished directly to you.
1-7. Warranty Information. The model, MHE Forklift is warranted by Dresser
Industries for 15 months or 1500 hours of operation, whichever occurs first.
The warranty starts on the date found on DA Form 2408-9 in the logbook. Report
all defects in material or workmanship to your supervisor.
He will take
appropriate action through your direct support and general support maintenance
shop.
For warranty processing information see DA PAM 738-750.
1-4
TM 10-3930-643–34
INTRODUCTION.
Section II.
EQUIPMENT DESCRIPTION AND DATA
1-8. Differences in Models. Read Operator’s Manual (TM 10-3930-643-10)
paragraph 1-9 and Organizational Maintenance Manual (TM 10-3930-643-20)
paragraph 1-8 for differences in models. In addition, note the following
differences as they affect maintenance tasks.
a.
b.
Front Axle Assembly.
(1) S/N 2000 and below.
Three piece axle assembly.
(2) S/N 2001 and above.
One piece axle assembly.
Rear Axle Assembly.
(1) S/N 2000 and below.
Three piece axle assembly.
(2) S/N 2001 and above.
One piece axle assembly.
Nomenclature
c. Power Cluster/Pressure Converter and Reservoir.
difference. Power cluster is on S/N 2000 and below and pressure converter is
on S/N 2001 and above.
d. Two-Way Valves/Check Valves-Treadle. Nomenclature difference. Two-way
valves are on S/N 2000 and below and check valves are on S/N 2001 and above.
e. Treadle Valve.
f.
Internal design difference.
Ground Driven Steering Pump.
Internal design differences.
g. ROPS/Cab.
h.
(1) S/N 2000 and below.
Equipped with ROPS.
(2) S/N 2001 and above.
Equipped with cab.
Heater Assembly.
(1) S/N 2000 and below. N O heater assembly.
(2) S/N 2001 and above.
Equipped with heater assembly.
1-5/(1-6 blank)
TM 10-3930-643-34
CHAPTER 2
GENERAL MAINTENANCE PROCEDURES
INTRODUCTION.
This chapter describes the general maintenance procedures
applied during performance of all maintenance tasks.
that
should be
INDEX
Section
I
Title
2-2
2-2
2-3
2-4
2-4
2-5
2-6
2-5
2-5
2-7
2-8
2-9
2-10
2-11
2–12
2-13
2-14
2-6
2-6
2-6
2-6
2-7
2-7
2-10
2-26
DISASSEMBLY AND ASSEMBLY PROCEDURES
Condition OF Vehicle
Disassembly and Assembly Procedures
IV
2-1
2-2
2-3
STANDARD TOOL REQUIREMENTS
Tool Kits
III
Page
SAFETY PROCEDURES
Remedies of Injuries
Personnel Precautions
Vehicle Precautions
II
Paragraph
GENERAL REPAIR PRACTICES
Replacement of Parts
Cleaning
Inspection Criteria
General Repair Practices
Lubrication
Application of Adhesives
Electrical Repair
Bearing Procedures
2-1
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
Section I.
SAFETY PROCEDURES
2-1. Remedies of Injuries. Refer to FM 21-11, First Aid for Soldiers, for
first aid treatments of injured personnel. For any injury, always seek medical
attention immediately. The following first aid procedure should be done to
prevent further injury until medical attention is available.
a. Overcome by Exhaust Gases or Toxic Fumes. Expose victim to fresh air.
Do not
If necessary, administer artificial respiration. Keep victim warm.
permit physical exertion. Seek medical attention immediately.
b.
Chemical Burns.
(1) Eyes.
immediately.
Flush with cold water for 15 minutes.
Seek medical attention
(2) Internal. Drink large amounts of milk or water.
magnesia, beaten egg, or vegetable oil.
(3) External.
Follow with milk of
Flush with cold water until all acid has been removed.
(4) Clothing or Vehicle. Wash with cold water at once. Neutralize acid
with baking soda or household ammonia, refer to TM 9-6140-200-14.
c. Foreign Object in Eye. Do not attempt to remove object.
Object may
cause cuts and abrasions. Close eye and seek medical attention immediately.
2-2. Personnel Precautions. Observe all warnings listed in this manual.
Basic safety precautions are listed before the procedures to which they apply.
WARNING labels have also been put on the vehicle to provide instructions ‘and
identify specific hazards which could cause bodily injury or death. The word
WARNING appears in this technical manual to alert you to situations that could
cause you injury. Other general safety precautions to follow are:
a. Use Personal Protective Equipment. Protect your eyes against acid burns
and Foreign objects. Operate vehicle only when necessary to keep sound levels
down and prevent hearing loss. Guard your skin from burns, rashes and toxic
substances that are absorbed through the skin.
b. Stay Clear of Moving parts. Remove watches, rings and other jewelry
that could catch in moving parts and cause injury. Keep your hand, feet and
clothing away from all machinery in motion.
C. Use Care in the Handling of Flammable Materials.
Notify others in the
area that you are handling flammables. Know emergency procedures in case of
accident or fire.
2-2
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-2.
Personnel Precautions.
d. Ventilate. Do not operate engine or heater in a closed area unless area
is properly ventilated. If you notice exhaust odors or exposure symptoms,
immediately ventilate the area.
e. Handling Heavy Items. Properly support heavy items before removing.
Keep clear of suspended items. Use sufficient number of personnel to maintain
control of item. If item begins to fall; let it fall. Ensure that hoist or
hydraulic floor jack has sufficient capacity to do the job and provide an ample
safety margin.
f. Prevent Accidental Movement. Never leave vehicle unattended while the
engine is running. Observe all pre-conditions before performing maintenance.
g. Use Sturdy Supports. Do not climb on tires. Use mounted steps and
ladders when climbing onto vehicle. If needed, use a sturdy step ladder to
perform maintenance on equipment not safely within reach.
The
2-3. Vehicle Precautions. Observe all cautions listed in this manual.
word CAUTION appears in this manual to alert you to conditions that could cause
damage to the vehicle and its components. Cautions are listed before the
procedure to which they apply. Other general vehicle precautions include:
a. During service maintenance turn master disconnect switch off to prevent
damage to the electrical system.
b.
Disconnect battery ground when required.
c. Use a hoist or hydraulic floor jack of sufficient capacity to remove and
support heavy items.
2-3
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
Section II. STANDARD TOOL REQUIREMENTS
2-4. Tool Kits.
tools.
The following are general practices regarding the use of
a. To prevent personal injury and damage to tools always use the proper
tool for the task being performed.
b. Be sure to keep tools clean and lubricated.
will reduce wear and prevent rust.
c.
Keep track of your tools.
Following this practice
Do not be careless with them.
d. Return tools to tool box when you are finished with repair or maintenance.
e.
Return tool boxes to tool storage when not in use.
f.
Inventory tools before and after each use.
g. Use the tool kit specified in the procedure. It contains the tools you
will need to complete the maintenance task. The three authorized tool kits used to
perform maintenance on this vehicle are:
(1) Shop Equipment, Automotive Maintenance and Repair:
Maintenance, Common No. 1, Less Power (NSN 4910-00-754-0654).
Organizational
(2) Shop Equipment, Automotive Maintenance and Repair:
Maintenance, Common No. 2, Less Power (NSN 4910-00-754-0650).
Organizational
(3) Tool Kit, General Mechanic’s Automotive (NSN 5180-00-177-7033).
h. Some maintenance tasks require special or fabricated tools. The initial
page of the task will name any special or fabricated tool needed for that
procedure. Use these special tools only for the maintenance tasks for which
they are designed or called out. Personnel should be carefully instructed in
the use of these tools.
2-4
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
Section III.
DISASSEMBLY AND ASSEMBLY PROCEDURES
2-5. Condition of Vehicle. Before performing any maintenance task ensure that
the following conditions have been observed, unless otherwise specified.
a.
Forks must be lowered to the ground.
b.
Vehicle must be parked on level ground.
c.
Parking brake must be applied.
d.
Transmission must be in neutral and locked.
e.
Engine must be shut off.
f.
Master disconnect switch must be off.
g.
Components must be at operating temperature to be tested.
h.
Air system must be vented.
2-6. Disassembly and Assembly Procedures. Follow these general practices when
performing disassembly and assembly procedures:
a. Read the procedure and thoroughly understand it before performing
maintenance or repair. Be alert during procedure.
b. Keep major components and assemblies together whenever possible and
practical.
c. Tag hoses, electrical wires, cables and harnesses to identify them
aid in installation.
and
d. Have all the necessary parts, tools, material and personnel before
starting procedure.
e. Keep related parts together for identification purposes.
f. To prevent loss, temporarily reinstall attaching
screws, bolts, washers and nuts.
hardware
g.
Only disassemble to point of problem.
h.
Make sure parts are clean and lubricated” before assembly.
such as
2-5
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
Section IV.
GENERAL REPAIR PRACTICES
2-7. Replacement of Parts. Only replace unserviceable or discarded parts.
Always discard the following: cotter pins, lockwire, preformed packings,
rubber seals and gaskets.
2-8. Cleaning. Cleaning is a necessary part of most tasks.
guidelines when cleaning:
Use the following
a.
Use cleaning solvent P-D-680 for cleaning metal parts only.
b.
Use a mild detergent solution For rubber, plastic and nylon parts.
c.
Always clean parts before inspecting them.
d.
Dry parts with lint free cloths.
Use compressed air when specified.
e. Use a wire brush, tap or die to clean rust, accumulated dirt,
and paint from bolts, screws, nuts and threaded holes.
f.
After cleaning, protect all parts from dust and dirt.
g. Keep work area floors and workbenches clean and dry.
prevent accidents.
h.
sealant
Clean as you go to
Dispose of oily rags in specified containers to prevent fire hazard.
i. Keep the vehicle clean. Oil, grease and debris may hide a serious
problem.
j.
Clean all new parts before installation.
2-9. Inspection Criteria. Proper inspection of parts and operating equipment
prevents small problems from becoming major problems. Visually check for any
of the following problems: broken welds, loose fasteners, damaged threads,
bending, cracking, deformity, nicks, cuts, scratches, gouges, distortion,
blockage or inoperability. Equipment defects can be discovered by performing
PMCS at both crew and organizational levels. Inspect disassembled, clean parts
for damage listed above. Check for wear. Inspect all new parts for defects
before installation.
2-10. General Repair Practices. The following are additional general repair
practices. Discard broken and non-reusable parts. Paint exposed metal to
protect from rust. Do not paint electrical harnesses, wiring, hoses or
finished machine parts. Routinely check hoses, lines and fittings for leaks.
Perform all lubrication and PMCS on schedule. To prevent further damage to
components, take corrective action promptly when indicated. Be sure to follow
all warnings, cautions and notes. Remove burrs, scratches or raised metal.
Use a fine file, stone or crocus cloth dipped in oil.
2-6
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-11. Lubrication. Refer to LO 10–3930-643-12 for detailed, illustrated
instructions on proper lubrication. Some general practices to remember
include:
a. Use the correct lubricant.
b.
Keep lubricants clean.
c.
Clean all fittings prior to lubrication.
d.
Lubricate clean disassembled and new parts to prevent rust.
2-12. Application of Adhesives. Liquid gasket, silicone rubber adhesive and
Loctite retaining and sealing compounds are recommended in some tasks to ensure
and strengthen seals. The following procedures describe their correct use and
application:
a. Liquid Gasket. Can be
specified), ground joints and
all types of gaskets. Liquid
low pressure gases, gasoline,
used on machined surfaces (where no gasket is
threaded connections. It can also be used with
gasket is heat and cold resistant, unaffected by
oil or other liquids, and prevents seizure.
TOXIC/FLAMMABLE
Liquid gasket is toxic and flammable. Use only in well ventilated
areas. Avoid contact with eyes or skin. If injured, seek medical
attention immediately. Do not allow near open flame, heat or sparks.
Do not smoke when working with liquid gasket.
Liquid gasket is applied as follows:
(1) Thoroughly clean the mating surfaces. Surfaces must be free of
grease, paint, rust or any other foreign substance.
(2) Brush each mating surface with a thin, even coat of liquid gasket.
(3) Allow 10-20 minutes to dry until tacky. Temperature and humidity
will affect drying time. Adhesive is right consistency when it will not
transfer to finger when touched.
(4) Press surfaces together. Ensure full contact between surfaces. Do
not pull or pry either surface after mating.
2-7
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-12.
Application of Adhesives. (cont)
b. Silicone Rubber Adhesive. Except for the instrument panel which is
sprayed with anti-corrosive varnish, all electrical connections are sealed
against moisture with a room temperature vulcanizing silicone rubber sealant,
MIL-A-46146A, Type 1. If you must break into this seal for repair work you
must remove the switch involved completely from the machine and thoroughly
Replace the
clean all existing sealant and dirt that may remain on switch.
switch if corroded. The sealant must have a clean surface to adhere to or
there will not be an effective seal. After switch is cleaned and reassembled
or replaced apply sealant. Cover the switch and terminals completely with
sealant. Press sealant into and around the terminals to ensure complete
coverage.
Sealant will set in 15-30 minutes depending on temperature and
humidity.
c. Loctite Retaining and Sealing Compounds. These compounds will resist
solvents, heat, shock and vibration. They provide a positive seal against
leakage and sheer strength resistance to loosening when used in the assembly of
threaded, slipfit or press fitted parts. Use the grade of Loctite specified.
Once cured these compounds have an operating temperature range of -65 to 300
degrees F (-54 to 149 degrees C), and will resist attack by oils, chemicals,
hydraulic fluids and solvents. Do not use Loctite where other retaining means
are provided, such as lock wires, lock washers, lockplates and fasteners.
Do
not substitute grades or usage unless specified. Do not use Loctite on items
that need frequent servicing, or on brass fittings or plugs, or when operating
temperatures exceed 300 degrees F (149 degrees C) (Example:
Engine exhaust
systems). Loctite is applied as follows:
(1) Threadlock adhesives. Loctite MIL-S-46163, Type II, Grade O, a high
strength adhesive for fasteners and Loctite MIL-S-46163, Type I, Grade L, a
high viscosity, high strength adhesive for large bolts and studs, are
recommended for use on this vehicle. Primers are not required with threadlock adhesives, but if used will speed up the cure and act as a cleaner.
Surface preparation depends on type of metal and purpose of application. In
general, most surfaces must be cleaned thoroughly. Apply Loctite to bolts and
studs by filling full length of thread with one strip in diameters up to 1
inch, two strips 180 degrees apart, on diameters up to 2 inches, and three
strips 120 degrees apart, on diameters over 2 inches. Apply one strip into
tapped holes. For blind hole applications, apply enough Loctite to fill the
bottom 2 to 3 threads of engagement, then insert stud. If engagement length
exceeds one diameter use proportionally more Loctite. For non-seated studs
(studs that go deeper in hole than required) turn stud one turn deeper than
required. After bubbling stops, apply a ring of Loctite around stud at top of
hole, then back stud to required height. Loctite will set in 10 minutes to 2
hours. Temperature and humidity affect drying time.
2-8
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2–12.
Application of Adhesives.
(2) Plastic gasket. Plastic gasket is used as a seal on large close
fitting metal parts. Mating surfaces must be clean and degreased. Spread an
even coat (0.061 cubic inch per 40 square inches) on one of the mating
surfaces. Assemble and tighten bolts.
Plastic gasket will dry in
approximately 12-24 hours. Temperature and humidity affect drying time.
(3) Unfilled pipe sealant. Pipe sealant MIL-S-22473D, Product CW, seals
against moderate pressures instantly and working pressures when completely dry.
Before application, clean threads to remove oil, grease and metal chips. Fill
For system
the second and third threads completely for 360 degrees.
cleanliness, do not fill leading thread. Pipe sealant will dry in 6-24 hours
at room temperature. Adjustments for elbows, gages and valves can be made up
to 24 hours after application without affecting seal.
2-9
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13. Electrical Repair. Specific electrical system maintenance tasks are
covered in Chapter 5 of this manual. The following are general electrical
repair practices and procedures:
a.
Clean electrical ground contacts with crocus cloth or emery cloth.
b.
Make sure that all connections are tight.
c. Electrical wires, cables and connections should be checked for cracks
due to aging and for exposed wires which could cause an electrical short.
d.
Use distilled water for batteries.
If unavailable, use clean water.
e. Use of multimeter. Maintenance functions authorized for performance at
the organizational level require the use of the multimeter. Wire, harness and
cable repairs may be indicated as a result of tests performed with the
multimeter. Procedures for repairing these electrical components can be found
in Chaper 5. After any repairs or replacements are done, test again. The
following procedures outline the uses of the multimeter for electrical testing:
(1) Using the ohms scale. The ohms scale is used to make tests for
continuity, shorts and resistance.
NOTE
Proper operation of electrical components depends upon proper grounding. In all troubleshooting procedures of devices which depend on
screws or physical contact for their electrical ground (lamp sockets,
transmitters, batteries, etc.) use a jumper wire from the device to
the hull to check grounding.
The multimeter must be set up and zeroed before making these tests.
the following steps for the multimeter you are using:
(a) AN/URM-105.
1 Set selector switch (1) to Xl ohms
position.
2 Now zero the meter. Touch the two
probes (2) together while turning
OHMS ADJ knob (3) until needle (4)
is over 0 on the top scale.
3 If needle will not zero, replace the
batteries. If needle still will not
zero after replacing the batteries,
turn in the multimeter for repair.
2-10
Perform
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
Electrical Repair.
2-13.
(b) TS-352 B/U.
1 Set RANGE switch (1) on RX1.
2 Put black (-) lead (2) into the OHMS
-DC ± AC jack.
3 Put red (+) lead (3) in the upper
left OHMS jack.
4 Turn FUNCTION switch (4) to OHMS.
5 Touch the two probes (5) together.
6 Zero meter by turning the OHMS ZERO
ADJ (6) knob until needle (7) is
over O on top scale. If needle will
not zero, replace batteries.
If
needle still will not zero after
replacing the batteries, turn in the
multimeter for repair.
(2) Testing for continuity. Continuity tests check for breaks in a
circuit, such as the switch, light bulb, or electrical cable, as shown.
To
make a continuity check, do the following steps:
(a) Set up and zero the multimeter.
Do not touch terminal caps with probes.
reading.
This will give false
Failure to do the following step can damage the multimeter.
(b) Disconnect the circuit being tested from the power source. To be
safe, disconnect the battery ground strap.
(c) Connect the meter probes to both terminals of the circuit being
tested.
(d) Observe needle movement. If the needle swings to the far right
over the 0 on the top scale, the circuit has continuity. If the needle doesn’t
move, the circuit is open (broken). If the needle jumps or flickers, there is
a loose connection in the circuit being tested.
(3) Testing for short circuit. A short circuit occurs when two circuits
that should not be connected, have contact with each other.
A short also
occurs when a circuit that should not touch ground, has contact with ground.
To check for shorts, do the following steps:
2-11
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13.
Electrical Repair. ( cont)
(a) Set up and zero the multimeter.
Failure to do the following steps
damage the multimeter.
can
(b) Disconnect the circuit being tested
from the power source. To be safe, disconnect
the battery ground strap.
(c) Connect one probe to one circuit and the other probe to the other
circuit or ground (if checking for a short to ground). The example shows a
check to see if wire A is shorted to wire B in the wiring harness.
(d) Observe needle movement. If the needle swings to the far right
over the O on the top scale, the circuits are short circuited.
If the needle doesn’t move, the circuits are not short circuited. If needle
jumps or flickers, the circuits are intermittently short circuited.
(4) Measuring resistance.
To measure resistance, do the following steps:
(a) Set up and zero the multimeter.
(b) Disconnect the circuit being tested
from the power source. To be safe, disconnect
the battery ground strap.
Failure to do the following step can
damage the multimeter.
(C) If the test calls for an ohms range
different than RX1 or X1, set the selector
switch to that range (RX10 or X10). Zero the
meter every time you change ranges.
(d) Connect the probes across the
The example
circuit or item to be measured.
shows measuring the resistance of one wire in a
three-wire cable.
2-12
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-13.
Electrical Repair.
(e) Read the meter. If the meter switch
is on the RX1 or X1 range, the reading is taken
If the meter
directly from the top scale.
switch is on a different range, multiply the
reading on the scale according to the table
below.
OHMS SWITCH SETTING
SCALE
X1 or RX1
Read number on scale
X10 or RX10
Multiply reading by 10
X100 or RX100
Multiply reading by 100
X1K or RX1K
Multiply reading by 1000
X10K or RX10K
Multiply reading by 10,000
For example, the meters show the following readings:
OHMS SWITCH SETTING
READING
X1 or RX1
40 ohms
X10 or RX10
400 ohms
(5) Using the DC volts scale. Setting up the meter. Before using the
multimeter to measure DC voltage, do the following steps pertaining to the
multimeter you have.
Multimeter must be set to a voltage range higher than that being
measured or multimeter could be damaged.
NOTE
If
Before using multimeter, check the mechanical zero of the meter.
using
the meter pointer is not exactly over the zero line, reset by
the proper size screwdriver to adjust the small screw.
(a) AN/URM-105. Set meter switch to DC
volts range. (To measure 24 volts DC, set
switch on 100 DC volts range).
2-13
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13.
Electrical Repair. (cont)
(b) TS-352 B/U.
1 Set FUNCTION switch (1) to DIRECT.
2 Put black lead (2) in LHMS-DC/± AC
jack.
3 To measure 24 volts DC, plug
lead (3) into 50V jack on left
of meter. (If measuring less
10 volts DC, use 10V jack.
measuring less than 2.5 volts
use 2.5V jack).
(6) Measuring DC voltage.
red
side
than
If
DC,
To measure DC voltage, do the following steps:
(a) Set up and zero multimeter.
If you are unsure of the voltage to be
measured on the vehicle, always start on
the hightest range. This will protect
the meter.
(b) Connect the red probe to the positive (+) side of the circuit and the black probe
to the negative (-) side. The example shows 24
volts DC being measured across the batteries.
(c) Read the meter. If the needle moves
off scale to the left, reverse the probes on the
circuit.
NOTE
The following examples show how to read
both multimeters.
1 AN/URM-105. Read the DC volts scale
for the range at which the selector
switch is set.
SWITCH SETTING
SCALE
1000 DC Volts
0-10 (and multiply by 100)
100 DC Volts
0-10 (and multiply by 10)
10 DC Volts
0-10 (read the number of scale)
1 DC Volts 0-10
2-14
(and divide by 10)
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-13.
Electrical Repair.
Thus the meter illustrated is showing the following readings:
SWITCH SETTING
READING
1000 DC Volts
200 Volts DC
100 DC Volts
20 Volts DC
10 DC Volts
2 Volts DC
1 DC Volts
0.2 Volts DC
2 TS-352 B/U. Read the DC volts scale for the range at which the red
lead is plugged.
RANGE
SCALE
50V
0-5 (and multiply by 10)
10V
0-10 (read the number on the scale)
2.5V
0-2.5 (read the number on the scale)
Thus the meter illustrated is showing the following readings:
RANGE
READING
50V
20 volts DC
10V
4 volts DC
2.5V
1 volt DC
(7) Using the AC Volts scale. The AC Volts scale on the multimeter is
used to measure the voltage in the alternator-to-rectifier circuit.
Before using the multimeter to measure AC volts, do the following steps for the
multimeter you have:
2-15
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13.
Electrical Repair. (cont)
NOTE
Before using the multimeter, check the
mechanical zero of the meter. If the
meter pointer is not exactly over the
zero line, reset by using proper size
screwdriver to adjust the small screw.
(a) AN/URM-105. Set meter switch to
1000 AC volts.
(b) TS-352 B/U.
1 Set FUNCTION switch (1) to AC.
2 Put black lead (2) in OHMS-DC/± AC
jack.
3 Put red lead (3) in 250V jack on
right side of meter.
f. Repairing of wiring harnesses and cables consist of replacement of
defective connectors, shells and terminals or taping cut or worn insulation and
exposed wire conductors. The following disassembly and assembly procedures are
to help you make replacement and repairs to electrical wires and cables.
2-16
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-13. Electrical Repair.
(1) Terminal-type connector, with shell.
DISASSEMBLY
Cut wire close to shell.
Remove and discard shell.
ASSEMBLY
1.
Strip wire, refer to Wire Size Chart. Do not nick or cut strands.
2.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
3.
Strip new wire, refer to Wire Size Chart. Do not nick or cut strands.
4.
Tin bare wires. Use resin-core solder to coat bare wires.
solid-core solder, clean wires with flux before tinning.
5.
Slide shrink tubing on wire before splicing.
6.
Splice wires.
7.
Secure wires to prevent movement and solder.
8.
Position shrink tubing over spliced wire.
9.
Apply heat to shrink tubing.
If using
If using
Twist together tightly.
Shrink until tubing fits snuggly.
2-17
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13.
Electrical Repairs. (cont)
(2) Connector with ring-type terminals.
DISASSEMBLY
Cut wire close to terminal.
Remove and discard terminal.
ASSEMBLY
NOTE
New terminal must be selected to match the ring size of the terminal
with the mounting screw at the connection. New terminal must also
match crimp tabs with the thickness of the wire.
1.
Strip wire, refer to Wire Size Chart. Do not nick or cut strands.
2.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
3.
Insert wire into new terminal.
4.
Crimp new terminal.
new terminal.
5.
Secure wire to prevent movement and solder new solder-type terminal. Use
solder sparingly.
2-18
If using
Securely fasten wire to new crimp-type, insulated
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-13.
Electrical Repairs.
(3) Terminal-type connector, pin and socket.
DISASSEMBLY
1.
Slide shell (3) back on the wire (4) to expose metal parts.
2.
Remove C-washer (1).
3.
Cut wire (4) close to terminal (2).
4.
Remove shell (3).
Remove and discard terminal (2).
ASSEMBLY
1.
Strip wire (4), refer to Wire Size Chart. Do not nick or cut strands.
2.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
3.
Slide shell (3) onto wire (4).
If using
NOTE
New terminal must be selected to match the size of the mating contact
at the terminal connection. New terminal must also match the crimping
area with the thickness of the wire.
4.
Insert wire (4) into new terminal (2).
5.
Crimp terminal (2).
6.
Install C-washer (1).
Securely fasten wire (4) to terminal (2).
NOTE
Shell is held in position over terminal by the C-washer. Make sure the
C-washer is firmly seated in shell.
7.
Slide shell (3) up over new terminal (2) and C-washer (1).
2-19
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13.
Electrical Repairs. (cont)
(4) Flag-type connector, terminal with shell.
DISASSEMBLY
Cut wire close to terminal.
Remove and discard terminal.
ASSEMBLY
1.
Strip wire, refer to Wire Size Chart. Do not nick or cut strands.
2.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
3.
Roll back insulation on new terminal to expose crimping area.
4.
Insert new wire in terminal.
5.
Crimp new terminal. Securely fasten wires to new terminal.
6.
Unroll insulation on new terminal to cover parts.
2-20
If using
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-13.
Electrical Repairs.
DISASSEMBLY
NOTE
All wires must be tagged when removed from connector.
Indicate
whether wire is connected to pin-type or socket-type terminal, refer
to illustration.
1.
Using pin removal tools, push connector terminals out of connector.
2.
Record location of terminal.
3.
Remove and discard terminals.
ASSEMBLY
1.
Strip wires, refer to Wire Size Chart. Do not nick or cut strands.
2.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
3.
Insert wires into new terminals.
terminals are used as required.
4.
Crimp new terminals. Securely fasten new terminals to wires.
5.
Using pin insertion tools, install new terminals in holes of connector as
required.
If using
Make sure pin-type and socket-type
2-21
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13.
Electrical Repairs. (cont)
(6) Ring-type connector, soldered.
DISASSEMBLY
Cut wire close to terminal.
Remove and discard terminal.
ASSEMBLY
NOTE
New terminal must be selected to match the ring size of the terminal
with the mounting screw at the connection. New terminal must also
match the wire solder area with the size of the wire.
1.
Strip wire, refer to Wire Size Chart. Do not cut or nick strands.
2.
Tin bare wires. Use resin-core solder to coat bar wires.
core solder, clean wires with flux before tinning.
3.
Insert wires in new terminal.
4.
Secure wires to new terminal.
5.
Fill wire cavity with melted solder. Allow to cool several minutes
before moving wires or new terminal.
2-22
If using solid
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-13.
Electrical Repairs.
(7) Connector, terminal-type, weather-proof.
DISASSEMBLY
1.
Slide shell (3) back to expose sleeve (2).
2.
Slide sleeve (2) back to expose terminal (1).
3.
Remove and discard terminal (1).
4.
Remove sleeve (2) and shell (3).
ASSEMBLY
1.
Strip wire (4), refer to Wire Size Chart. Do not nick or cut strands.
2.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
3.
Slide shell (3) and sleeve (2) onto wire (4).
If using
NOTE
New terminal must be selected to match the size of the mating contact
at the terminal connection. New terminal must also match the crimping
area with the thickness of the wire.
4.
Strip wire (4), refer to Wire Size Chart. Do not nick or cut strands.
5.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
6.
Insert wire (4) into new terminal (1).
If using
NOTE
Connector sleeve and shell are held in position over terminal by
compression. Sleeve must be firmly seated on terminal and shell must
be firmly seated over sleeve.
7.
Slide shell (3) over sleeve (2) and terminal (1).
2-23
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-13.
Electrical Repairs. (cont)
(8) Multi-wire connector, hard shell.
DISASSEMBLY
1.
Loosen two screws until wire is free to rotate.
2.
Remove terminal assembly from shell.
NOTE
Indicate
All wires must be tagged when removed from connector.
whether wire is connected to pin-type or socket-type terminal.
3.
Cut wires close to terminals. Discard terminals.
4.
Record location of terminals.
5.
Remove and discard shell.
ASSEMBLY
1.
Strip wires, refer to Wire Size Chart. Do not nick or cut strands.
2.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
3.
Slide new shell onto wires.
4.
Insert wires into connector pins or socket wells as indicated on tags.
5.
Crimp wires.
6.
Secure wires and new terminal to prevent movement and solder. Use solder
sparingly.
2-24
If using
Securely fasten wires to new terminals.
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-13.
Electrical Repairs.
(9) Multi-wire connector, compression type.
DISASSEMBLY
1.
Loosen compression nut from shell assembly.
2.
Slide compression nut and spanner nut up on wire to expose pin and socket
terminals.
NOTE
Indicate
All wires must be tagged when removed from connector.
whether wire is connected to pin-type or socket-type connector.
3.
Cut wire close to terminals.
Remove and discard terminals.
4.
Remove and discard shell assembly, spanner nut and compression nut.
ASSEMBLY
1.
Slide new compression nut and new spanner nut onto wire.
2.
Strip wires, refer to Wire Size Chart. Do not cut or nick strands.
3.
Tin bare wires. Use resin-core solder to coat bare wires.
solid core solder, clean wires with flux before tinning.
4.
Insert wires into connector pins or socket wells as indicated on tags.
5.
Secure wires and new terminals to prevent movement and solder.
solder sparingly.
If using
Use
2-25
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES. (cont)
2-14. Bearing Procedures. Special care should be taken when removing,
cleaning, inspecting and installing bearings. The following procedures are
recommended to avoid problems that could occur from improper handling of
bearings:
a. Bearing Removal.
(1) Keep area around bearings clean. Prevent loose dirt from entering
bearings. Study the assembly before removing bearing and handle carefully.
(2) The best tool for removing a bearing is an arbor press. Press only
on the race that is tight. Press evenly to prevent the race from cocking and
scoring the shaft or damaging the bearing. Keep press table and support blocks
clean and square. Prevent the shaft from falling on the floor. Protect the
end of the shaft with a pad of lead, copper, or hardwood.
Install
(3) If an arbor press is not available, use a bearing puller.
bearing pullers to pull or push bearings straight and square. Do not damage
threads, keyways, and shoulders.
(4) With proper care, bearings may be removed safely with other methods
if the proper tools are not available. A vise and drift may be used in place
of an arbor press and press ram. If the shaft is to be held in a vise, protect
its surface with a copper sheet or hardwood blocks. A hardwood block may be
used to permit hammer blows to be struck dead center and prevent bearing from
cocking.
(5) If the bearing fit does not permit the use of a bearing puller or
arbor press, grind off or cut off with an acetylene torch. Cut the outer race
and ball retainer and burn the inner race part way through to avoid damaging
the shaft. Crack the race the rest of the way using a hammer and chisel. Use
caution to avoid personal injury from flying parts.
b.
Cleaning Bearings.
(1) Clean all bearings before installation. An accurate judgement about
the condition of a bearing cannot be made unless it is thoroughly free from
dirt. Do not spin dirty bearings. Rotate them slowly while cleaning in
cleaning solvent P-D-680. Bearings with a shield or seal on one side only
Bearings
should be cleaned and inspected in the same way as other bearings.
with shields or seals on both sides should not be cleaned in cleaning solvent
P-D-680. Wipe with a clean cloth to prevent dirt or other contamination.
(2) Dry bearings thoroughly with compressed air. When drying bearing,
rotate to expose all parts of the bearing.
2-26
TM 10-3930-643-34
GENERAL MAINTENANCE PROCEDURES.
2-14.
Bearing Procedures.
c. Inspection. Bearings are inspected by holding the inner race so that
the axis is vertical (bearing horizontal). Turn the outer race slowly.
Bearing may have a small amount of tarnish, stain, or corrosion on the outside
surfaces of the races. Operation of the bearing is not affected and they need
not be rejected. If bearings feel slightly rough or have a tendency to stick
at certain points when rotated, reclean. Determine cause of sticking and
reject if necessary. Reject bearings with the following defects: broken or
cracked races, dented shields or seals, cracked or broken separators, balls or
rollers, flaked areas on balls, rollers or raceways, bearings with signs of
heating (darkened to brownish blue or blue black), and indentations from ball
or roller impressions. An anti-friction bearing, properly lubricated, should
not wear unless dirt or abrasive foreign matter gets into it. Dirt mixed with
grease or oil will lap down balls and rollers. Load carrying surfaces of antiFriction bearings are finished with extreme care and will sustain very heavy
loads unless the surfaces are damaged by abusive handling or by foreign matter.
d.
Bearing Installation.
(1) Before installing bearings, clean shafts and bearing housings
thoroughly. Remove all dirt from keyways, splines, and grooves. Remove burrs
and slivers. If new bearings are to be used, keep them in their original
cartons or wrappings until ready for use. New bearings are shipped with a
protective lubricant. Do not clean the oil or grease from a new bearing.
Before
Handle the bearing with clean hands and use clean tools to install.
installing bearings, make sure bearing seats are cleaned and oiled.
(2) Press bearings only on the tight fitting race and press straight and
square. The same protective measures for shafts and bearings used during
removal should be applied during installation.
(3) In some applications, bearings must be heated to ensure proper fit.
A bearing may be heated in a temperature controlled oven or in clean oil at a
temperature of 200 to 250 degrees F. The high temperature expands the inner
race enough to allow it to slip over the shaft to the bearing seat.
Do not
overheat bearing. Overheating will cause bearing to lose hardness. If
expanding race will not allow installation of the bearing, freeze shaft in dry
ice for approximately 30 minutes. Chilling will cause shaft to shrink enough
to allow bearing installation.
2-27(2-28 blank)
TM 10-3930-643-34
CHAPTER 3
TROUBLESHOOTING SYMPTOM INDEX
CHAPTER OVERVIEW
This Chapter is to provide the troubleshooting symptom index.
INDEX
Title
TROUBLESHOOTING SYMPTOM INDEX
Troubleshooting Symptom Index
Paragraph
3-1
Page
3-2
3-1
TM 10-3930-643-34
TROUBLESHOOTING SYMPTOM INDEX. (cont)
3-1.
Troubleshooting Index. (cont)
This paragraph contains an index of the troubleshooting data located within the
manual. Included in the index are the paragraph/malfunction and page where the
detailed procedure will be found. The list of MALFUNCTIONS will give you an
indication of where a possible problem might be found. To use the index
effectively, follow this procedure:
FIRST:
Locate the appropriate MALFUNCTION from this index and go to the
troubleshooting procedure paragraph designated . . locate the
MALFUNCTION.
SECOND:
DO the TEST OR INSPECTION until you verify where the problem
originates.
THIRD:
Do the CORRECTIVE ACTION procedure to correct your problem.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
Component/System
Paragraph/
Malfunction
Page
ENGINE, FUEL, EXHAUST AND COOLING
Engine cranks but will not start
Engine starts but will not run
Engine misfires, is erratic or visual smoke
from exhaust
Engine stalls or lacks power
Excessive crankcase pressure
Engine knocks
High intake manifold pressure
Low intake manifold pressure
Engine cylinder compression test
Intake manifold pressure boost test
Crankcase pressure test
3-2
4-la
4-lb
4-2
4-3
4-lc
4-ld
4-le
4-lf
4-lg
4-lh
4-li
4-lj
4-lk
4-4
4-5
4-8
4-9
4-9
4-9
4-10
4-11
4-13
TM 10-3930-643-34
TROUBLESHOOTING SYMPTOM INDEX.
3-1.
Troubleshooting Index.
Paragraph/
Malfunction
Page
TORQUE CONVERTER
High torque converter oil temperature
High torque converter “in” pressure
Low torque converter "in" pressure
Loss of power
High engine speed at torque converter stall
Low engine speed at torque converter stall
6-la
6-lb
6-lc
6-ld
6-le
6-lf
6-2
6-3
6-3
6-4
6-4
6-5
6-2a
6-2b
6-2c
6-2d
6-2e
6-2f
6-6
6-6
6-6
6-7
6-7
6-7
6-2g
6-8
6-2h
6-8
6-2i
6-8
6-2j
6-2k
6-8
6-9
7-la
7-lb
7-lc
7-ld
7-le
7-lf
7-2
7-3
7-3
7-3
7-3
7-4
TRANSMISSION
High oil temperature
Slow or erratic clutch engagement
High clutch pressure
Low clutch pressure
High or low torque converter “in” pressure
Loss of power
Vehicle drives in one direction and creeps in that
direction in neutral but stalls when shifted to
the opposite direction
Vehicle drives in one range but stalls when
shifted to another range
All range pressures normal in one direction but
all low in opposite direction
Low clutch pressure in one range (clutch in either
direction)
Clutch pressure check at full power stall
AXLE
Noise when driving
Noise on turns
Noise while vehicle is coasting
Differential overheats
Loss of lubricant
Differential oil level rises
3-3
TM 10-3930-643-34
TROUBLESHOOTING SYMPTOM INDEX. (cont)
3-1. Troubleshooting Index. (cont)
Paragraph/
Malfunction
Page
SERVICE BRAKE
Brakes do not engage
Brakes do not release
Brakes squeal or scrape
Low air pressure
High air pressure
Noisy compressor
8-la
8-1b
8-1c
8-1d
8-1e
8-1f
8-2
8-2
8-2
8-3
8-4
8-4
8-2a
8-2b
8-5
8-5
9-1a
9-1b
9-1c
9-1d
9-1e
9-1f
9-1g
9-1h
9-2
9-2
9-3
9-3
9-3
9-4
9-4
9-5
12-1a
12-1b
12-1c
12-1d
12-1e
12-2
12-2
12-3
12-4
12-5
12-1f
12-1g
12-1h
12-1i
12-1j
12-1k
12-1l
12-5
12-6
12-6
12-6
12-7
12-8
12-8
PARKING BRAKE
Parking brake drags
Parking brake slips
STEERING
Slow steering at low engine RPM and slow boom
hydraulics at high engine RPM
Slow steering
Noisy operation
Hydraulic oil heating up
Insufficient steering pressure
Sticking control valve plunger
Play in steering gear
Hard steering while driving
HYDRAULIC SYSTEM
All implements fail to operate
All cylinder assemblies operate slowly
A particular cylinder assembly operates slowly
Loss of cylinder motion during operation
Load slowly drops with lift control lever in “hold”
Momentary drop of load when lift control lever
is moved from “hold” to “raise” or “raise” to “hold”
Noisy operation
Hydraulic oil heating up
Insufficient pump pressure build-up
Sticking loader control valve spool(s)
Hydraulic pump not delivering oil
Oil leakage at hydraulic pump
3-4
TM 10-3930-643-34
CHAPTER 4
ENGINE, FUEL, EXHAUST AND COOLING
TROUBLESHOOTING AND MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently troubleshoot
and repair malfunctioning equipment and to perform authorized direct support
level maintenance procedures on the M10A Forklift.
INDEX
Title
Engine, Fuel, Exhaust and Cooling
Troubleshooting
Engine Assembly
Engine Mounts
Cylinder Head Assembly with Valves
Vibration Damper
Rocker Arm Assembly and Valve Cover
Oil Pan
Oil Filter Base
Oil Cooler
Oil Pressure Regulator Valve
Intake and Exhaust Manifolds
Fuel Injectors
Fuel Injector Lines
Fuel Injection Pump, Cover Plate, Adapter
and Drive Gears
Turbocharger and Piping
Fuel Tank
Radiator Assembly
Water Pump Assembly
Fan and Clutch
Paragraph
Page
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-2
4-15
4-25
4-29
4-47
4-51
4-60
4-64
4-68
4-73
4-76
4-83
4-88
4-14
4-15
4-16
4-17
4-18
4-19
4-93
4-101
4-107
4-110
4-112
4-117
4-1
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting.
-----------—-------------------------------------------------------------MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
-----------------------—— -----------------------------------------------—
a.
ENGINE CRANKS BUT WILL NOT START.
Step 1.
Test for worn or plugged fuel injection nozzles, refer to
paragraph 4-13.
If fuel injection nozzles are satisfactory, proceed to step 2.
Step 2.
Check for faulty solenoid.
If fuel solenoid is not functioning properly, notify General Support.
Step 3.
4-2
Check for broken timing gear, camshaft or sheared keyway in camshaft
drive gear, notify General Support.
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
b.
ENGINE STARTS BUT WILL NOT RUN.
Step 1.
Test fuel injector nozzle opening pressure, refer to paragraph
4-12.
If fuel injectors are satisfactory, refer to step 2.
Step 2. Check for bent push rods and proper valve adjustment.
If push rods are bent, inspect rocker arm assembly and replace push
rods. Adjust valves, refer to paragraph 4-6.
Contact General Support.
4-3
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
C.
ENGINE MISFIRES, IS ERRATIC OR VISUAL SMOKE FROM EXHAUST.
Step 1. Test for damaged fuel injector nozzles or low nozzle valve
opening pressure, refer to paragraph 4-12.
If fuel injectors are satisfactory, proceed to step 2.
Step 2.
Check for proper fuel injection pump timing, refer to paragraph
4-14.
If timing is correct, proceed to step 3.
Step 3. Check for proper valve lash adjustment, refer to paragraph 4-6.
If valve lash adjustment and fuel injection pump timing are correct,
proceed to step 4.
Step 4. Test for proper engine cylinder compression (335-365 psi),
refer to paragraph 4-1.i.
If compression does not meet specifications, check for proper valve
adjustment, refer to paragraph 4-6.
If valves are properly adjusted, check for worn valves and/or valve
seats or a blown cylinder head gasket, refer to paragraph 4-4.
4-4
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
ENGINE STALLS OR LACKS POWER.
Step 1.
Perform engine stall test to isolate engine, refer to paragraph
6-3.
Step 2.
Perform engine cylinder compression test, refer to paragraph
4-1.i.
Step 3.
Check for dirty or leaking fuel injection nozzles, refer to
paragraph 4-12.
If repair is necessary, contact General Support.
Step 4.
Check for loose fuel injection nozzle cap nut.
If loose, tighten.
Step 5. Check for sticking fuel injection nozzle valve.
If repair is necessary, contact General Support.
Step 6.
Check for blockage in fuel injection nozzle spray holes.
If repair is necessary, contact General Support.
4-5
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
ENGINE STALLS OR LACKS POWER. (cont)
Step 7. Check turbocharger operation.
paragraph 4-1.j.
Check boost pressure, refer to
If repair is necessary, contact General Support.
Step 8. Check for leaks at intake and exhaust manifolds.
4-6
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
ENGINE STALLS OR LACKS POWER.
Step 9. Check for leakage at turbocharger.
If no leakage exists, proceed to step 10.
Step 10. Check for proper fuel injection pump timing, refer to
paragraph 4-14.
If timing is correct, proceed to step 11.
Step 11. Check for proper valve lash adjustment, refer to
paragraph 4-6.
If valve lash adjustment is correct, proceed to step 12.
Step 12. Test for proper crankcase pressure, refer to paragraph 4-1.k.
If crankcase pressure is in excess, contact General Support.
If crankcase pressure meets specifications, proceed to step 13.
4-7
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
ENGINE STALLS OR LACKS POWER. (cont)
Step 13. Test for proper engine cylinder compression
refer to paragraph 4-1.i.
(335-365 psi),
If compression test does not meet specifications, remove cylinder
head and inspect for worn valves and/or valve seats or worn rings,
refer to paragraph 4-4.
If compression test meets specifications, proceed to step 14.
Step 14. Check for malfunctions in the transmission,
Transmission Troubleshooting.
refer to
Step 15. Perform Stall Test, refer to paragraph 6-3.
If transmission is operating properly, proceed to step 16.
Step 16. Test for excessive hydraulic pressure, refer to Hydraulic
System Troubleshooting.
e.
EXCESSIVE CRANKCASE PRESSURE.
Step 1.
Perform crankcase pressure test, refer to paragraph 4-1.k.
Step 2.
Test for proper engine cylinder compression (335-365 psi),
refer to paragraph 4-1.i.
If compression test does not meet specifications, check cylinder
head gasket for cracking, nicks, cuts and distortion, refer to
paragraph 4-4 for replacement.
If cylinder head gasket is satisfactory, check for worn, stuck,
broken piston rings or cracked pistons or cylinder liners.
If any of these conditions exist, contact General Support.
4-8
TM 10-3930-643-34
E4NGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
f.
ENGINE KNOCKS.
Step 1.
Check for bad gaskets or crack in manifolds, replace as necessary,
refer to paragraph 4-11.
Step 2.
Perform Intake Manifold Pressure Boost Test, refer to paragraph
4-1.j.
Step 3.
Check low intake manifold pressure, refer to paragraph 4-1.h.
If any knocks or sound of metal to metal contact exists, and if manifolds
do not leak and boost pressure meets specifications, shut engine off
immediately and contact General Support.
g.
HIGH INTAKE MANIFOLD PRESSURE.
Check for defective or incorrectly adjusted fuel injection pump, refer
to paragraph 4-14.
If repair is necessary, contact General Support.
h.
LOW INTAKE MANIFOLD PRESSURE.
Step 1.
Check for defective or incorrectly adjusted fuel injection
pump, refer to paragraph 4-14.
Step 2.
Check for defective intake or exhaust manifolds
refer to paragraph 4-11.
or gaskets,
If manifolds and gaskets are satisfactory, proceed to step 3.
Step 3. Check fuel injectors, refer to paragraph 4-12.
If repair is necessary, contact General Support.
Step 4.
Check turbocharger, refer to paragraph 4-15.
If repair is necessary, contact General Support.
4-9
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
h.
LOW INTAKE MANIFOLD PRESSURE. (cont)
Step 5. Test crankcase pressure and engine cylinder compression, refer to
paragraphs 4-1.k and 4-1.i.
If crankcase pressure test does not meet specifications, refer to
General Support.
If crankcase pressure is satisfactory and engine compression does
not meet specifications, check for blown head gasket or cylinder
head repair, refer to paragraph 4-4.
i. ENGINE CYLINDER COMPRESSION TEST.
4-10
1.
Start and run engine until normal operating temperature is obtained,
refer to TM 10-3930-643-10.
2.
Stop engine and remove fuel injectors, refer to paragraph 4-12.
3.
Clean and remove foreign material from cylinder head fuel injector
sealing surfaces.
4.
Install compression test adapter, DRO2-3031-10, to
port on number one cylinder.
5.
Connect adequate cylinder compression gage to adapter.
fuel injector
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
Engine, Fuel, Exhaust and Cooling Troubleshooting.
4-1.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
i.
ENGINE CYLINDER COMPRESSION TEST.
NOTE
Batteries must be fully charged to provide correct cranking speed for
compression test.
6.
Turn engine through four intake strokes using starter.
7. Read gage and record results.
NOTE
Increase in altitude above sea level will lower compression on test
results. Compression test results should read 335-365 PSI.
8. Release pressure from cylinder through gage and perform the same
test to remaining cylinders.
j. INTAKE MANIFOLD PRESSURE BOOST TEST.
1.
Start and run engine until normal operating temperature is obtained,
refer to TM 10-3930-643-10.
2.
Stop engine. Remove plug from center of intake manifold on left
side of engine and install pressure gage.
4-11
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Engine, Fuel, Exhaust and Cooling Troubleshooting. (cont)
4-1.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
j. INTAKE MANIFOLD PRESSURE BOOST TEST. (cont)
When performing test with vehicle at full stall, apply brakes before
engaging transmission and clear all personnel from the immediate area.
Failure to follow this procedure could result in SEVERE INJURY or
DEATH.
During full stall, do not engage steering system; to prevent overheating, do not exceed 15 seconds per stall check; do not allow torque
converter to exceed normal operating temperature.
NOTE
Full stall is the speed of engine with throttle at maximum, vehicle in
highest gear with brakes applied and hydraulic control valve activated
to demand maximum hydraulic relief pressure.
4-12
3.
Start engine and operate vehicle under full stall conditions. Read
pressure gage. Pressure of intake manifold should be 13-17 psi.
4.
Stop engine.
manifold.
Remove pressure gage.
Install plug in intake
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-1.
Engine, Fuel, Exhaust and Cooling Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
k. CRANKCASE PRESSURE TEST.
1.
Remove crankcase ventilation breather tube and thoroughly clean
breather element, refer to TM 10-3930-643-20.
2.
Install new gasket (5), clean breather element (4), housing (3),
three washers (2) and nuts (1) on valve cover in place of standard
breather tube.
3.
Connect orificed restrictor (6) to housing (3) and secure with hose
clamp.
4-13
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Engine, Fuel, Exhaust and Cooling Troubleshooting. (cont)
4-1.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
k. CRANKCASE PRESSURE TEST. (cont)
4-14
4.
Check oil in crankcase for proper level.
5.
Connect water manometer to orifice connector, as shown.
6.
Run engine until correct operating temperature is obtained, refer to
TM 10-3930-643-10.
7.
Run engine at high idle, observe manometer for two minutes and
record average reading, refer to Engine Troubleshooting if there is
an average reading of above 5.5 inches of water.
8.
Remove orificed restrictor (6), three nuts (1), washers (2) and
housing (3).
9.
Install crankcase ventilation breather tube, refer to TM 3930643-20.
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-2.
Engine Assembly. (Sheet 1 of 10)
This task covers:
a. Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Liquid gasket, Type I
(App. C, Item 14)
Small tag (App. C, Item 28)
Tie strap (2)
Torques
Bolts (28) to 80 lb-ft.
Nuts (30) to 160 lb-ft.
Clamp to 25 in-lb.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Air pressure vented.
Coolant drained.
LO 10-3930-643-12
Engine oil drained.
TM 10-3930-643-20
Battery cables disconnected.
Engine top access cover removed.
Air cleaner connections removed.
Air cleaner assembly and mounting
removed.
Hydraulic oil drained.
Transmission oil drained.
Paragraph 4-17
Paragraph 12-2
Radiator removed.
Hydraulic pump removed.
Go to sheet 2
4-15
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-2.
Engine Assembly. (Sheet 2 of 10)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
All wire must be tagged when
removed
from
connector.
Indicate whether wire is
connected to pin-type or
socket-type connector.
1.
Cut and discard two tie straps (1)
from right side of engine (38).
2.
Using a 7/16” open end wrench,
disconnect hose assembly (2) from
air governor and move to one side,
away from engine assembly.
3.
Using 1" and 3/4” open end wrenches,
disconnect hose assembly (3) at
adapter and move to one side, away
from engine assembly.
4.
Using long round nose pliers,
disconnect spring (5) from bracket on
fuel pump cover.
5.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
disconnect cable (4) from injection
pump arm and mounting bracket.
6.
Using a 15/16” open end wrench, loosen
two nuts (4a) and remove cable (4) from
mounting bracket and lay away from
engine.
7.
Using an 11/16” open end wrench, disconnect tube assembly (6) from rear of
engine assembly.
Go to sheet 3
4-16
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE AND TROUBLESHOOTING.
4-2.
Engine Assembly. (Sheet 3 of 10)
REMOVAL
8.
Using an 11/16” open end wrench,
disconnect tube assembly (7) from
filter.
9.
Using a 3/8” open end wrench,
disconnect tube assembly (8) from
ether temperature switch.
10.
Using a 9/16” socket and socket
wrench handle, disconnect ground
strap (9) from frame stud at right
side of engine and starter motor.
11.
Using a 3/4” open and box end
wrench, disconnect wire assembly
(10) at solenoid connector.
12.
Using a 3/8” open end wrench,
disconnect wire assembly (11) from
solenoid.
13.
Using flat tip screwdriver, loosen
hose clamp and disconnect hose
assembly (12) from oil pan.
14.
Disconnect wire assembly connector
(13) from hydraulic reservoir,
beneath battery compartment.
15.
Using a 9/16” open and box end
wrench, remove four bolts (13a),
washers (13b) and plate (13c).
16.
Using a cross tip screwdriver,
remove four screws (14) and connector (14a) from hydraulic
reservoir bulkhead.
Go to sheet 4
4-17
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-2.
Engine Assembly. (Sheet 4 of 10)
REMOVAL (cont)
NOTE
The following are differences
between M10A Forklift models. The
removal/installation procedures
are identical.
17.
Using a flat tip screwdriver, loosen
heater hose clamp and disconnect hose
assembly (16), from front, right side
of engine on vehicles S/N 2001 and
above.
18.
Using a 5/8” open end wrench,
disconnect hose assembly (17) from
flywheel housing on torque converter
at front of engine assembly.
19.
Disconnect ground cable (18).
20.
Using a 1-1/2” open end wrench,
disconnect hose assembly (19) from
regulator valve.
Go to sheet 5
4-18
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-2.
Engine Assembly. (Sheet 5 of 10)
REMOVAL
21.
Using a 9/16” open and box end
wrench, remove charging pump (20).
Leave hoses attached.
22.
Using a 1/2” open end wrench,
disconnect drive shaft (22) and slide
forward, away from torque converter.
23. Using 15/16” and 1-1/2” wrenches,
disconnect hose assemblies (23 and
24).
24.
Using a flat tip screwdriver,
disconnect hose assembly (25) from
flywheel housing.
Go to sheet 6
4-19
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-2.
Engine Assembly. (Sheet 6 of 10)
REMOVAL (cont)
Weight of engine is approximately
1555 lbs. Use adequate hoist and
chains for removal and installation.
Keep area clear of
unnecessary personnel. Failure to
follow this procedure could result
in SEVERE INJURY.
25.
Attach hoist and chains to lifting
eyes (26 and 27) on top of engine
(35). Take up slack in chains.
26.
Using a 3/4” open and box end
wrench, remove eight bolts (28)
and washers (29) from bottom,
front of engine (35).
27.
Using a 15/16” socket, socket wrench
handle and a 15/16” open end wrench,
remove two nuts (30), washers (31),
bolts (32), washers (33) and mounts
(34) from bottom, rear of engine
(35).
28.
Using hoist and chains, remove engine
(35) from engine compartment. Place
engine (35) on solid surface.
29.
Remove hoist and chains from lifting
eyes (26 and 27).
30.
Remove two washers (36) and mounts
(37).
Go to sheet 7
4-20
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-2.
Engine Assembly. (Sheet 7 of 10)
INSTALLATION
31.
Position two mounts (37), washers
(36) and mounts (34) in engine
compartment.
Use care when attaching hoist and
chains to prevent any damage to
engine or vehicle.
32.
Attach hoist and chains to lifting
eyes (27 and 26). Lower engine (35)
slowly into position.
33.
Using a 15/16” socket, socket wrench
handle, a 15/16” open end wrench and
a 1/2” torque wrench, install two
washers (33), bolts (32), washers
(31) and nuts (30) on bottom, rear of
engine (35). Tighten nuts (30) to
160 lb-ft.
34.
Using a 3/4” open and box end
wrench, install eight washers (29)
and bolts (28) in bottom, rear
side of engine (35). Tighten bolts
(28) to 80 lb-ft.
35.
Remove hoist and chains from lifting
eyes (27 and 26) at top of engine
(35).
Go to sheet 8
4-21
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-2.
Engine Assembly. (Sheet 8 of 10)
INSTALLATION (cont)
36.
Using a flat tip screwdriver, connect
hose assembly (25) to flywheel
housing in front of engine assembly.
37.
Using 15/16” and 1-1/2” open end
wrenches, connect hose assemblies (24
and 23).
38.
Using a 1/2” open end wrench, connect
drive shaft (22).
NOTE
It may be necessary to disconnect
lines of charging pump to install
charging pump on engine.
39.
Using a 9/16” open and box end
wrench, install charging pump (20).
40.
Using a 1-1/2” open end wrench,
connect hose assembly (19) to
regulator valve.
41.
Using a 5/8” open end wrench,
connect ground cable (18).
42.
Connect hose assembly (17) to flywheel housing in front of engine
assembly.
43.
Using a flat tip screwdriver, connect
heater hose assembly (16) and tighten
hose clamp to front, right side of
engine on vehicles S/N 2001 and above.
Go to sheet 9
4-22
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-2.
Engine Assembly. (Sheet 9 of 10)
INSTALLATION
44.
Using a cross tip screwdriver,
install connector (14a) and four
screws (14) on hydraulic reservoir
bulkhead in hydraulic reservoir,
beneath battery compartment.
45.
Using a 9/16” open and box wrench,
install plate (13c), four washers (13b)
and bolts (13a).
46.
Connect wire assembly connector (13).
47.
Using a flat tip screwdriver, connect
hose assembly (12) oil pan and tighten
hose clamp.
48.
Using a 3/8” open end wrench, connect
wire assembly (11) to solenoid.
Go to sheet 10
4-23
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-2.
Engine Assembly. (Sheet 10 of 10)
INSTALLATION (cont)
49.
Using a 3/4” open and box end wrench,
connect wire assembly (10) at
connector to solenoid on starter
motor.
50.
Using 9/16” socket and socket wrench
handle, connect ground strap (9) to
frame stud and starter motor.
51.
Using a 3/8” open end wrench,
connect tube assembly (8) to ether
temperature switch at right side of
engine assembly.
52.
Using an 11/16” open end wrench,
connect tube assembly (7) to filter.
53.
Connect tube assembly (6) to front of
engine assembly.
54.
Install cable (4) in mounting
bracket and using a 15/16” open
end wrench, tighten two nuts (4a).
55.
Using a 7/16” socket, socket wrench
handle-and a 7/16” open end wrench,
connect cable (4) to injection pump
arm and mounting bracket.
56.
Using long round nose pliers, connect
spring (5) to bracket on fuel pump
cover.
57.
Using 1" and 3/4” open end wrenches,
connect hose assembly (3) at adapter.
58.
Using a 7/16” open end wrench,
connect hose assembly (2) to
governor.
59.
Install two new tie straps (l).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-24
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-3.
Engine Mounts. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(APP. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Torques
Bolt (12) to 320 lb-ft.
Bolts (1, 3, and 6) to 160 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 4-2
Condition Description
Engine removed.
Go to sheet 2
4-25
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-3.
Engine Mounts. (Sheet 2 of 4)
REMOVAL
1.
Using a 15/16” socket and socket
wrench handle, remove two bolts
(1), washers (2), bolts (3), washers
(4) and front mount (5) from bottom
of engine.
2.
Remove two bolts (6), four washers
(7), two nuts (8) and support (9)
from frame.
3.
Using a 1-5/16” socket and socket
wrench handle, remove nut (10),
washer (11), bolt (12), washer (13),
mount (14), support (15), mount (16)
and washer (17) from frame in rear,
left engine compartment.
4.
Repeat step 3 for rear, right engine
mount assembly.
Go to sheet 3
4-26
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-3.
Engine Mounts. (Sheet 3 of 4)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
5.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
6.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
4-27
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-3.
Engine Mounts. (Sheet 4 of 4)
INSTALLATION
7.
Using a 1-5/16” socket and socket
wrench handle, install washer (17),
mount (16), support (15), mount (14),
washer (13), bolt (12), washer (11)
and nut (10) in frame of rear left
engine compartment. Tighten bolt
(12) to 320 lb-ft.
8.
Repeat step 7 for rear right engine
mount assembly.
9.
Using a 15/16” socket and socket
wrench handle, install support (9),
two nuts (8), four washers (7) and
two bolts (6) on frame at front of
engine compartment. Tighten bolt
(6) to 160 lb-ft.
10.
Install front mount (5), two washers
(4), bolts (3), washers (2) and
bolts (1) on bottom front of engine.
Tighten bolts (3 and 1) to 160 lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-28
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 1 of 18)
This task covers:
a. Removal
c. Assembly
e. Adjustment
b.
d.
Disassembly/Cleaning/Inspection
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Detergent (App. C, Item 33)
Engine oil SAE 50
(App. C, Item 19)
Emery paper (App. C, Item 4)
Loctite 262 (App. C, Item 15)
Prussian blue (App. C, Item 23)
Clean cloth (App. C, Item 24)
Silicone sealant (App. C, Item 27)
Anti-seize compound
(App. C, Item 1)
Thermostat housing pressure plate
(App. D, Item D-1)
Thermostat housing gasket
(App. D, Item D-2)
Bottom pressure plate
(App. D, Item D-3)
Gasket
Wood block (4)
Sleeve (6)
Test Equipment
Spring Resiliency Tester
NSN 6635-00-641-7346
Torques
Bolts (4) to 110 lb-ft., 155 lb-ft.
and 165 lb-ft.
Go to sheet 2
4-29
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-4.
Cylinder Head Assembly with Valves. (Sheet 2 of 18)
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Thermostat, housing and by-pass valve
removed.
Engine water temperature sender
removed.
Engine water temperature switch
removed.
Paragraph 4-6
Valve cover and rocker arm assembly
removed.
Paragraph 4-11
Manifolds removed.
Paragraph 4-12
Fuel injectors removed.
Paragraph 4-15
Turbocharger removed.
Go to sheet 3
4-30
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 3 of 18)
REMOVAL
1.
Using a flat tip screwdriver, disconnect hose (1) in top, right front
of engine.
2.
Using a standard pipe wrench or slip
joint pliers, remove valve (2) and
tee (3).
3.
Using a 13/16” socket and socket
wrench handle, remove 20 bolts (4)
and washers (5) in top of engine.
4.
Insert a pry bar at front, left side
of cylinder head (6) between
indentation and crankcase. Pry with
rolling motion to break seal formed
by head gasket sealant.
Weight of cylinder head assembly
with valves is 200 lbs.
Use
adequate hoist and adjustable
lifting beam for removal and
installation. Keep area clear of
unnecessary personnel. Failure to
follow this procedure could result
in SEVERE INJURY.
5.
Attach hoist and adjustable lifting
beam to two lifting brackets (20) and
remove cylinder head (6). Supporting
cables or chains should be parallel
near
to each other and as
perpendicular to cylinder head (6) as
possible. Cylinder head (6) must be
placed on wood blocks to protect
valves and deck.
6.
Using a gasket scraper or putty
knife, remove and discard gasket (7).
Go to sheet 4
4-31
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Cylinder Head Assembly with Valves. (Sheet 4 of 18)
4-4.
DISASSEMBLY/CLEANING/INSPECTION
NOTE
Identify valves (exhaust valvessmall head or intake valves-large
head) and their locations.
All
valves are to be installed in the
same location from which they were
removed.
7.
Using a valve spring lifter tool,
compress springs (11) and remove 24
keys (8), 12 rotors (9), shields
(10), springs (11) and spring seats
(12).
8.
Remove 12 rotors (9), shields (10),
springs (11) and spring seats (12).
9.
Remove six exhaust valves-small head
(13) and intake valves-large head
(14) from bottom of cylinder head
(6).
NOTE
If valve cannot be removed easily,
inspect for burrs.
If burr
exists, remove with a hone to
prevent valve guide damage.
Go to sheet 5
4-32
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 5 of 18)
DISASSEMBLY/CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
After any machining operation or
inspection such as Magnaflux,
clean parts with P-D-680 and dry
with compressed air. Failure to
do so will result in premature
engine failure.
10.
Remove deposits from upper and lower
deck of cylinder head (6) using
cleaning solvent P-D-680. Refer to
paragraph 2-8.
Go to sheet 6
4-33
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-4.
Cylinder Head Assembly with Valves. (Sheet 6 of 18)
DISASSEMBLY/CLEANING/INSPECTION
11.
Using cleaning solvent
brass wire brush, clean
clean valve guides with
brush. Blow out carbon
compressed air.
(cont)
P-D-680 and
bores. Do not
a brass wire
deposits with
12.
Clean valve guides with cleaning
solvent P-D-680 and a nylon brush
that has a slightly larger diameter
than guide I.D. Insert brush into
guide and with a turning motion, run
brush through to insure removal of
gum, carbon
deposits and rust
preventive.
13.
Clean six exhaust valves-small head
(13) and intake valves-large head
(14) with cleaning solvent P-D-680
and a brass wire brush. Remove any
burrs from stem and grooves with
crocus cloth.
14.
Dry all parts with compressed air.
15.
Inspect cylinder head (6) for cracks
using Magnaflux or dye penetrant
method.
NOTE
If cracks are found, cylinder
head must be replaced.
16.
Using a 9/16” socket and socket
wrench handle, install injector
nozzles, thermostat housing plate,
bottom pressure plate and new gasket
(7). Plug ports for water temperature and sending switches.
Go to sheet 7
4-34
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 7 of 18)
DISASSEMBLY/CLEANING/INSPECTION
17.
Attach fitting, pressure gage and
hose to thermostat housing plate.
Run hot water into cylinder head (6)
at 25 psi.
18.
Observe cylinder head (6) for leakage
at injection nozzle sleeve flanges,
upper deck, lower deck, ports and
seat insert areas.
19.
Inspect lower deck for flatness. Use
a straight edge long enough to span
both length and width of cylinder
head (6). Follow checking pattern
shown. Insert feeler gage under each
point shown.
NOTE
Cylinder head must be replaced if
0.003 inch feeler gage can be
inserted under straight edge
across length or width.
Sudden
changes in contour such as
scratches, gouges, etc., must not
exceed 0.002 inches in depth.
20.
Remove and discard six sleeves (15)
with slide hammer and nozzle sleeve
puller adapter.
Go to sheet 8
4-35
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Cylinder Head Assembly with Valves. (Sheet 8 of 18)
4-4.
DISASSEMBLY/CLEANING/INSPECTION
(cont)
21. Place six new sleeves (15) in
cylinder bores
and
position
installing tool. Keep tool centered
and tap squarely with brass hammer
until six sleeves (15) are bottomed
in bores.
22.
Inspect 12 coolant directors (16).
Replace if loose or restricted. If
required, coolant directors (16) may
be removed using a slide hammer with
a small enough jaw to hook under
coolant directors (16) opening.
23.
Install new coolant directors (16),
as shown, if removed, by tapping into
place with a small hammer and block.
Recess 0.06 inches below bottom deck
of cylinder head (6).
24.
Aim 12 new coolant directors (16), as
shown.
25.
Inspect six exhaust valves-small head
(13) and intake valves-large head
(14) for excessive wear, burn marks,
warpage, pitting or scuffing at valve
stem grooves, valve stems and heads.
Replace if bent, worn, burned,
warped, pitted or scuffed.
26.
Measure valve stem diameter in two
places, as shown. Valve stem should
be 0.3718 inches.
NOTE
If stem is more than 0.001 inches
undersize, replace valve.
Go to sheet 9
4-36
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 9 of 18)
DISASSEMBLY/CLEANING/INSPECTION
worn,
27.
Check valve stem ends. If
grind ends square.
28.
Resurface valve face angle, if
Maintain valve face
necessary.
margin, as shown. A minimum margin
must be maintained of 0.088 inches
for intake valves-large head (14) and
0.045 inches for exhaust valves-small
head (13).
29.
Maintain valve face angles, as shown.
Valve must be replaced if more than
0.008 inches of stock is removed or
below
minimum
margin falls
specification in Step 31.
30.
After resurfacing, check valve face
runout with dial indicator.
NOTE
Valve must be replaced if total
indicator reading is greater than
0.002 inches.
31.
Check valve face contact with
Prussian blue. Bluing should appear
around entire contact surface of
valve face and valve seat. If bluing
does not appear around entire contact
surface, angles do not match. Valve
seats must be resurfaced.
Go to sheet 10
4-37
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Cylinder Head Assembly with Valves. (Sheet 10 of 18)
4-4.
DISASSEMBLY/CLEANING/INSPECTION
(cont)
32.
Recheck valve face contact with
Prussian blue if valve seats are
resurfaced.
33.
Place valves in proper guides and
position dial indicator against stem.
Raise valve approximately 0.5 inches.
Move valve against and away from dial
indicator parallel to cylinder head
(6).
NOTE
If total indicator reading is more
than 0.004 inches, send cylinder
head to General Support.
Check valve seat for correct width,
as shown. If necessary, correct
width by grinding top edge of valve
seat with a stone of smaller angle
(preferably 15 degrees) than valve
seat.
34.
NOTE
If valve does not seat properly
after resurfacing valve seats,
cylinder head must be sent to
General Support.
35.
Insert valves in cylinder head (6).
Place
Invert cylinder head (6).
straight edge across valves. Measure
distance from valves to straight
edge. Distance should be 0.000 to
0.014 inches. If necessary, grind
seat to different angle to obtain
correct distance.
Go to sheet 11
4-38
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 11 of 18)
DISASSEMBLY/CLEANING/INSPECTION
NOTE
Valve springs are tested on spring
tester.
36.
Check 12 springs (11) and spring
seats (12) for rust, pitting and
cracks. Replace if rusted, pitted or
cracked.
37.
Measure free length of springs (11).
Free length should be 2.34 inches.
38.
Apply 66 to 70 lbs. pressure to
springs (11) in spring resiliency
tester and measure length (maximum
length with valve open). Spring (11)
length should be 2.007 inches.
39.
Apply 156 to 164 lbs. pressure to
springs (11) in spring resiliency
tester and measure length (minimum
Spring
length with valve open).
length should be 1.552 inches.
40.
Inspect 24 keys (8) inside rib and
outside of 24 keys (8). Replace if
worn.
41.
Inspect 12 rotors (9). Place springs
(11) with rotor (9) in spring tester.
42.
Place ball bearing between rotor and
ram of spring tester.
43.
Compress valve spring (11) and
Rotor
observe motion of rotor.
counterclockwise.
turn
should
Replace rotors which do not turn.
44.
Check oil seal on rotor for wear.
Replace rotor with worn seal.
Go to sheet 12
4-39
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-4. Cylinder Head Assembly with Valves. (Sheet 12 of 18)
DISASSEMBLY/CLEANING/INSPECTION (cont)
45. Using a ball peen hammer and flat
punch, a 13/16” socket, a socket
wrench handle, 2-7/16” nuts and two
5/8” open end wrenches, remove six
plugs (17 and 18), sleeves (19),
and 12 studs (20).
Using a 13/16” socket and socket
wrench handle, remove two bolts
(21) and brackets (21a).
46.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
47.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Inspect all parts.
paragraph 2-9.
Go to sheet 13
48.
4-40
Refer to
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 13 of 18)
ASSEMBLY
49.
Using a 13/16” socket and socket
wrench handle, install two brackets (21a) and bolts (21).
50.
Coat 12 studs (20) with anti-seize
compound.
51.
Coat back and sides of plugs (18 and
17) with silicone sealant.
52.
Using two 7/16” nuts and two 5/8”
open end wrenches, a 13/16” socket,
socket wrench handle and ball peen
hammer, install 12 studs (20), six
sleeves (19) and plugs (18 and 17).
53.
Coat six intake valves-large head
(14) and exhaust valves-small head
(13) with clean engine oil.
NOTE
Valves must be installed in same
location from which they were
removed.
54.
Install valves from bottom of
cylinder head (6).
55.
Using a valve spring lifter tool,
install 12 spring seats (12), springs
(11), shields (10) and rotors (9) on
valve stems.
56.
Compress valve springs (11) with
valve spring lifter and install 24
keys (8). If necessary, tap top of
valves with rubber or plastic mallet
to seat keys (8).
Go to sheet 14
4-41
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Cylinder Head Assembly with Valves. (Sheet 14 of 18)
4-4.
INSTALLATION
NOTE
Before installing cylinder head,
check cylinder sleeve protrusion
on crankcase, refer to paragraph
13-3.
If protrusion above
crankcase is less than 0.002 to
0.005 inches, return crankcase to
General Support.
57.
Install new gasket (7) in top of
engine. New gasket (7) is provided
with premeasured sealant. Do not use
gasket cement. Cylinder head (6)
transfer may be adversely affected.
58.
Insure that gasket (7) surfaces on
cylinder head (6) are clean and dry.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
59.
Blow out holes in cylinder head (6)
and crankcase with compressed air.
NOTE
Bolt holes must be free of foreign
matter to prevent hydrostatic lock
and possible block cracking when
bolts are tightened.
Go to sheet 15
4-42
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 15 of 18)
INSTALLATION
60.
Attach adjustable lifting beam and
hoist to two lifting brackets (20).
Supporting cables or chains should be
parallel to each other and as near
perpendicular to cylinder head (6) as
possible.
61.
Install cylinder head (6). Be sure
to maintain gasket (7) alinement
during installation.
62.
Lubricate bolt threads and head
seating areas with clean engine oil.
63.
Install 20 washers (5) and bolts (4).
Do not tighten.
64.
Using a standard pipe wrench or slip
joint pliers, install tee (3) and
valve (2) in top, right front of
engine.
65.
Using a flat tip screwdriver, connect
hose (1).
66.
Install rocker arm assembly on cylinder
head (6), refer to paragraph 4-6.
NOTE
Rocker arm mounting bolts are
included in tightening sequence
with 20 cylinder head mounting
bolts.
Go to sheet 16
4-43
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-4.
Cylinder Head Assembly with Valves. (Sheet 16 of 18)
INSTALLATION (cont)
67.
Using a 1/2” drive torque wrench,
tighten bolts (4) to 110 lb-ft
following sequence A.
68.
Check two end rocker arms for freedom
of motion.
69.
Tighten bolts (4) to 155 lb-ft
following sequence A.
70.
Tighten bolts (4) in rows to 165
lb-ft following sequence B.
NOTE
Return vehicle to original
equipment condition.
71.
Operate engine under load for at
least one hour, refer to TM 10-3930643-10.
72.
Retighten cylinder head bolts according to procedure given in step 69.
Go to sheet 17
4-44
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-4.
Cylinder Head Assembly with Valves. (Sheet 17 of 18)
ADJUSTMENT
NOTE
● Adjustment
is to be made on a
warm engine.
● All
valves are adjusted by only
cranking the engine twice.
73.
Remove valve cover, refer to paragraph 4-6.
74. Turn crankshaft until number one
piston is on the compression stroke
and timing pointer on front cover is
in line with the TDC mark (pin) on
vibration damper.
Do not adjust valves with engine
running. Severe damage can result
if feeler gage is inserted between
valve and valve lever due to close
clearance of valve to piston.
NOTE
Be sure that the number one piston
is on the compression stroke.
75. Turn both push rods by hand until
both valves are closed. Valves are
closed when push rods are loose and
can be turned easily.
Go to sheet 18
4-45
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-4.
Cylinder Head Assembly with Valves. (Sheet 18 of 18)
ADJUSTMENT (cont)
76.
Adjust valves.
Six valves are
adjusted when No. 1 piston is at TDC
(compression) and remaining six are
adjusted when No. 6 piston-is at TDC
Refer to Valve
(compression).
Arrangement
illustration
for
numbering sequence of valves which
correspond to the chart. Numbers 1,
3, 5, 7, 9 and 11 are intake valves _
and numbers 2, 4, 6, 8, 10 and 12 are
77.
Tighten adjusting screw nuts to 20
lb-ft.
78.
Install valve cover, refer to
graph 4-6.
para-
END OF TASK
4-46
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-5.
Vibration Damper. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Machine
Shop : Field Maintenance,
Basic, Less Power
NSN 3470-00-754-0708
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
No. 2 Permatex sealant
(App. C, Item 26)
Torques
Bolt (4) to 125 lb-ft.
Test Equipment
Dial indicator
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Drive belts removed.
Go to sheet 2
4-47
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Vibration Damper. (Sheet 2 of 4)
4-5.
REMOVAL
NOTE
Before removing vibration damper,
check for wobble using dial
indicator. If wobble exceeds 0.06
inch total indicator reading,
replace vibration damper.
1.
Using a 9/16” socket and socket
wrench handle, remove four bolts (1),
washers (2) and plate (3) in front,
bottom of engine.
2.
Using a 3/4” socket and socket wrench
handle, remove three bolts (4) and
plate (5).
3.
Pull vibration damper (6) and key (7)
off crankshaft using puller.
4.
Remove spring washer (8).
Use care during removal to avoid
damaging the vibration damper hub.
5.
Remove wear sleeve (9) from vibration
damper (6) using chisel to split wear
sleeve (9). Remove wear sleeve (9)
only if it is worn, scratched or
nicked.
Go to sheet 3
4-48
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-5.
Vibration Damper. (Sheet 3 of 4)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
6.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
7.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
4-49
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Vibration Damper. (Sheet 4 of 4)
4-5.
INSTALLATION
8.
Using sleeve installer, press wear
sleeve (9) on vibration damper (6).
9.
Install spring washer (8) in bottom,
front of engine.
●
Do not attempt to install
vibration damper cold.
● Do
not heat vibration damper for
more than one hour to avoid
damage to the elastic member.
10.
Heat vibration damper (6) in boiling
water.
11.
Lightly coat key (7) and keyway area
with No. 2 Permatex sealant.
12.
Using a ball peen hammer, install key
(7) and vibration damper (6).
13.
After installing vibration damper
(6), remove excess No. 2 Permatex
sealant from mounting surfaces.
14.
Using a 3/4” socket and socket wrench
handle, install plate (5) and three
bolts (4). Tighten three bolts (4)
to 125 lb-ft.
15.
Using a 9/16” socket and socket
wrench handle, install plate (3),
four washers (2) and bolts (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-50
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-6.
Rocker Arm Assembly and Valve Cover. (Sheet 1 of 9)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Adjustment
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Liquid gasket, Type I
(App. C, Item 14)
Gasket
Preformed packing (6)
Torques
Bolt (7) to 26 in-lb.
Stud (9) to 26 in-lb.
Bolt (13) to 110 lb-ft. and
165 lb-ft.
Nut (24) to 20 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Engine top access cover removed.
Crankcase ventilation and mounting
removed.
Go to sheet 2
4-51
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-6.
Rocker Arm Assembly and Valve Cover. (Sheet 2 of 9)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a flat tip screwdriver, loosen
clamps (1 and 2) on top of engine.
2.
Remove tube assembly (3).
3.
Using a 1/2” socket and socket
wrench handle, remove nut (4),
washer (5) and clamp (6). Push
hose assembly (7) to side of
engine.
4.
Remove five bolts (8), preformed
packings (9), stud (10), preformed
packing (11), access cover (12)
and gasket (13). Discard five
preformed packings (9), preformed
packing (11) and gasket (13).
Remove all gasket material from
mounting surfaces.
5.
Using a 9/16” socket and socket
wrench handle, remove six bolts
(14), washers (15) and items 17
through 26 as an assembly.
6.
Remove 12 push rods (16) from
cylinder head.
Go to sheet 3
4-52
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-6.
Rocker Arm Assembly and Valve Cover. (Sheet 3 of 9)
DISASSEMBLY
NOTE
Take note of the position of the
rocker arms to aid in installation.
7.
Using internal snap ring pliers or
small flat tip screwdriver, remove
retaining ring (17), 12 rocker arms
(18), six brackets (19), five
springs (20) and retaining ring
(21).
8.
Using a small flat drift punch and
hammer, remove plugs (22 and 23)
from shaft (24).
9.
Using a flat tip screwdriver and
9/16” open end wrench, remove
setscrew (25) and nut (26) from
rocker arm (18).
Go to sheet 4
4-53
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Rocker Arm Assembly and Valve Cover. (Sheet 4 of 9)
4-6.
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
10.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
11.
Inspect shaft (22) for rocker arm
wear and on flat surface for
straightness. Replace shaft (22) if
worn or bent.
Go to sheet 5
4-54
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-6.
Rocker Arm Assembly and Valve Cover. (Sheet 5 of 9)
CLEANING/INSPECTION
12.
Inspect setscrew (25) for wear at
contact surface and for thread wear.
Replace worn setscrew (25).
13.
Inspect valve stem contact surface
on 12 rocker arms (18). Replace
rocker arms (18) if severely worn.
14.
Measure outside diameter of five
springs (20).
Outside diameter
should be 1.02 inches.
15.
Measure free length of five springs
(20). Length should be 4.06 inches.
16.
Using a spring resiliency tester,
apply 7 lb. compression load to five
springs (20) and measure test
length. Length of five springs (20)
should be 2.07 inches.
17.
Inspect all other parts.
paragraph 2-9.
Refer to
ASSEMBLY
18.
Using a flat tip screwdriver and 9/16”
open end wrench, install nut (26) and
setscrew (25) on rocker arm (18).
19.
Apply liquid gasket to threads on
plugs (23 and 22) and in shaft (24)
and install plugs (23 and 22) in shaft
(24).
Go to sheet 6
4-55
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING
4-6.
TROUBLESHOOTING AND MAINTENANCE. (cont)
Rocker Arm Assembly and Valve Cover. (Sheet 6 of 9)
INSTALLATION
20.
Slide spring (20) to center of shaft
(24). Position shaft (24) with side
marked TOP up, as shown.
21.
Install two rocker arms (18) on each
side of spring (20). Adjusting screw
must be toward assembler, as shown.
22.
Install two brackets (19) on each
end of spring (20) next to two
rocker arms (18). Tapped hole must
be away from assembler and the bolt
holes must aline with notches in
shaft (24).
23.
Install four springs (20), ten
rocker arms (18) and four brackets
(19). Observe order of assembly,
as shown.
24.
Using internal snap ring pliers,
install retaining rings (21 and
17).
Go to sheet 7
4-56
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-6.
Rocker Arm Assembly and Valve Cover. (Sheet 7 of 9)
INSTALLATION
25.
Install 12 push rods (16) in
cylinder head.
Bolts must be tighten evenly to
avoid bending shaft,
26.
Using a 9/16” socket and socket
wrench handle, install items (26
through 17) as an assembly, six
washers (15) and bolts (14). Tighten
six bolts (14) in two stages to 110
lb-ft and 165 lb-ft.
NOTE
It is necessary to adjust the
rocker arm assembly before
completing the installation
procedure.
Go to sheet 8
4-57
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Rocker Arm Assembly and Valve Cover. (Sheet 8 of 9)
4-6.
ADJUSTMENT
Do not adjust valves with engine
running. Severe damage can result
from inserting feeler gage between
valve and rocker arm because of
limited clearance.
NOTE
All valves are adjusted by cranking the engine twice.
Perform
valve lash adjustment with the
engine at any temperature above
freezing.
27.
Turn crankshaft on bottom, front of
engine until exhaust valve closes on
No. 1 cylinder.
Continue turning
until TDC mark (pin) on vibration
damper is in line with timing pointer
on front cover. No. 1 piston will be
on compression stroke.
VALVE LASH ADJUSTMENT CHART
ENGINE
ENGINE
Serial No.
INTAKE EXHAUST
In.
In.
DT 466B 110913 and below 0.020
0.025
DT-466B 110914 and above 0.025
0.025
Go to sheet 9
4-58
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-6.
Rocker Arm Assembly and Valve Cover. (Sheet 9 of 9)
ADJUSTMENT
28.
Using a flat tip screwdriver, a 9/16”
open end wrench and a feeler gage,
adjust rocker arm numbers 1, 2, 3, 6,
7 and 10 in top of engine, refer to
Valve Lash Adjustment Chart.
29.
Turn crankshaft on bottom, rear of
engine until No. 6 piston is at TDC
(compression) which is one complete
revolution of vibration damper,
30.
Adjust rocker arm numbers 4, 5, 8, 9,
11 and 12, refer to Valve Lash
Adjustment Chart.
31.
Using a flat tip screwdriver, a 9/16”
open end wrench and a feeler gage,
tighten 12 nuts (26) to 20 lb-ft.
NOTE
If valve are in correct adjustment,
proceed to installation.
INSTALLATION
32.
Using a 1/2” socket and socket wrench
handle, install new gasket (13),
access cover (12), new preformed
packing (11), stud (10), five new
preformed packing (9) and bolts (8).
Tighten bolts (8) and stud (10) to 26
lb-ft.
33.
Position hose assembly (7) and using
a 1/2” socket and socket wrench
handle, install clamp (6), washer (5)
and nut (4).
34.
Install tube assembly (3).
35.
Using a flat tip screwdriver, tighten
clamps (2 and 1).
NOTE
Return M10A Forklift to original END OF TASK
equipment condition.
4-59
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-7.
Oil Pane (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Gasket
Torques
Bolts (1) to 20 lb-ft.
Drain plug (4) to 33 lb-ft.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Oil drained.
TM 10-3930-643-20
Oil drain line and fittings removed.
Paragraph 4-16
Fuel tank removed.
Go to sheet 2
4-60
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-7.
Oil Pan. (Sheet 2 of 4)
/9
REMOVAL
1.
Using a 1/2” socket, socket wrench
handle and a putty knife, remove 34
bolts (l), oil pan (2) and gasket (3)
Discard
from bottom of engine.
Remove all gasket
gasket (3).
material from mounting surfaces.
2.
Using a 1-1/4” socket and socket
wrench handle, remove drain plug (4)
and washer (5) from oil pan (2).
Go to sheet 3
4-61
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Oil Pan. (Sheet 3 of 4)
4-7.
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
If
with eyes, skin or clothing.
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
air
get
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
3.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
4.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
4-62
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-7.
Oil Pan. (Sheet 4 of 4)
INSTALLATION
5.
Using a 1-1/8” socket and socket
wrench handle, install washer (5) and
drain plug (4) in oil pan (2).
Tighten drain plug (4) to 33 lb-ft.
6.
Using a
handle,
pan (2)
engine.
lb-ft.
1/2” socket and socket wrench
install new gasket (3), oil
and 34 bolts (1) in bottom of
Tighten bolts (1) to 20
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
4-63
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-8.
Oil Filter Base. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Test Equipment
Spring Resiliency Tester
NSN 6635-00-641-7346
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Teflon thread sealant
(App. C, Item 31)
Gasket (2)
Torques
Plug (7) to 50 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
4-64
Condition Description
Oil filter elements removed.
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-8.
Oil Filter Base. (Sheet 2 of 4)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a 3/4” open end wrench,
disconnect turbocharger oil line (1)
on front, left side of engine.
2.
Using a 9/16” socket and socket
wrench handle, remove six bolts (2),
washers (3), oil filter base (4) and
gasket (5). Discard gasket (5).
Remove all gasket material from
mounting surfaces.
NOTE
● On
vehicles S/N 2001 and above,
slide oil filter base and gasket
out from behind oil sampling
valve bracket.
● Do
not mix bolts with any other
hardware.
One bolt hole
connects oil pressure gallery
and requires special bolts to
prevent leaks.
3.
Using a 3/4” open end wrench, remove
elbow (6).
4.
Using a 5/8” socket and socket wrench
handle, remove plug (7), gasket (8),
spring (9) and check valve (10).
Remove all
Discard gasket (8).
gasket material from
mounting
surfaces.
Go to sheet 3
4-65
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cent)
Oil Filter Base. (Sheet 3 of 4)
4-8.
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
5.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
6.
Inspect oil filter base (4). Replace
if cracked, warped, distorted or
damaged. Check inlet and outlet
passages for dirt or blockage.
Remove blockage or replace.
7.
Inspect check valve (10).
worn or damaged.
8.
Using a spring resiliency tester,
measure free length of spring (9).
Free length should be 2.075 inches.
Go to sheet 4
4-66
Replace if
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-8.
Oil Filter Base. (Sheet 4 of 4)
CLEANING/INSPECTION
9.
Apply test load of 6.12 lb-ft to
spring (9).
10.
Measure test length of spring (9).
Test length should be 0.927 inches.
11.
Replace spring (9) if free or test
length does not meet specifications.
12.
Inspect all other parts. Refer to
paragraph 2-9.
INSTALLATION
13.
Using a 5/8” socket, socket wrench
handle and torque wrench, install
check valve (10), spring (9), new
Tighten
gasket (8) and plug (7).
plug (7) to 50 lb-ft.
14.
Using a 3/4” open end wrench, coat
threads of elbow (6) with sealant and
install elbow (6).
NOTE
On vehicles S/N 2001 and above,
slide gasket and oil filter behind
oil sampling valve.
15.
Using a 9/16” socket and socket
wrench handle, install new gasket
(5), oil filter base (4), six washers
(3) and bolts (2) on front, left side
of engine.
16.
Using a 3/4” open end wrench, connect
turbocharger oil line (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-67
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-9.
Oil Cooler. (Sheet 1 of 5)
This task covers:
a.
c.
Removal
Testing
b.
d.
Cleaning/Inspection
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Oil cooler pressure plate (2)
(App. D, Item D-5)
Seal (4)
Preformed packing (4)
Nut (4)
Torques
Except for special torques shown,
all fasteners are tightened to
standard torques. Refer to
Appendix E.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Oil drained.
TM 10-3930-643-20
Coolant drained.
Left side engine access cover removed.
Go to sheet 2
4-68
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-9.
Oil Cooler. (Sheet 2 of 5)
REMOVAL
Using a flat tip screwdriver, loosen
four clamps (12) and remove hose
assembly (l).
Using a 9/16” socket and socket
wrench handle, remove four bolts (2),
lock washers (3), washers (4) and oil
cooler (5) from left side of engine.
3.
Using a gasket scraper or putty
knife, remove and discard two seals
(6).
4.
Remove two connectors (7) and four
Discard
preformed packings (8).
preformed packings (8).
5.
Using a 9/16” socket and socket
wrench handle, remove plugs (9 and
10) from oil cooler (5).
Go to sheet 3
4-69
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-9.
Oil Cooler. (Sheet 3 of 5)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
6.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
7.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
4-70
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-9.
Oil Cooler. (Sheet 4 of 5)
TESTING
NOTE
Plugs must be installed in oil
cooler for testing.
8.
Install two new seals (6) and two
pressure plates to inlet and outlet
flange of oil cooler (5), refer to
Appendix D, Part D-5 for fabrication
of pressure plates.
9.
Using a 9/16” socket and socket
wrench handle, install four washers
(4), bolts (2) and nuts (11).
10.
Attach air hose and immerse oil
cooler (5) in water. Water should be
at 120 degrees F.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
11.
Using an air hose, apply 15 psi
pressure. No moving or growing
bubbles should be visible for about
one minute. If moving or growing
bubbles are present after one minute,
replace cooler.
12.
Remove oil cooler (5) from water and
disconnect air hose.
Go to sheet 5
4-71
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-9.
Oil Cooler. (Sheet 5 of 5)
INSTALLATION
13.
Using a 9/16” socket and socket
wrench handle, remove four nuts (11),
washers (4) and bolts (2).
14.
Remove two pressure plates and seals
(6). Discard seals (6).
15.
Install plugs (10 and 9) in oil
cooler (5).
16.
Install four new preformed packings
(8) and two connectors (7) in left
side of engine.
17.
Position and install two new seals
(6).
18.
Install oil cooler (5), four washers
(4), lock washers (3) and bolts (2).
19.
Using a flat tip screwdriver, install
hose assembly (1) and tighten four
clamps (12).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-72
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-10.
oil Pressure Regulator Valve. (Sheet 1 of 3)
This task covers:
b.
a, Removal
c. Installation
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Torque Wrench
NSN 5120-00-643-6364
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Preformed packing
Gasket
Torques
Valve cap (1) to 170 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Left side engine access cover removed.
REMOVAL
1. Using a 1-3/4” open end wrench,
remove valve cap (l), preformed
packing (2), gasket (3) and valve (4)
in front, left side of engine.
Discard preformed packing (2) and
Remove all gasket
gasket (3).
material from mounting surfaces.
Go to sheet 2
4-73
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-10
●
Oil Pressure Regulator Valve. (Sheet 2 of 3)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
air
fresh
solvent,
get
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
2.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
3.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 3
4-74
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-10.
4.
Oil Pressure Regulator Valve. (Sheet 3 of 3)
Using a 1-3/4” socket and torque
wrench, install valve (4), new
gasket (3), new preformed packing
(2) and valve cap (1) in front,
left side of engine. Tighten
valve cap (1) to 170 lb-ft.
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
4-75
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-11.
Intake and Exhaust Manifolds. (Sheet 1 of 7)
This task covers:
a.
c.
Removal
Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Feeler Gage
NSN 5210-00-221-1999
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Anti-seize compound
(App. C, Item 1)
Gasket (8)
Torques
Bolts (7) to 20 lb-ft.
Bolts (14) to 35 lb-ft.
Nuts (16) to 60 lb-ft. and 57 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
4-76
Condition Description
Engine side access covers removed.
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
Intake and Exhaust Manifolds. (Sheet 2 of 7)
4-11.
REMOVAL
1.
Using a 3/8” open end wrench, loosen
nut (1) and disconnect tube assembly
(2).
2.
Remove elbow (3) and ether nozzle
(4).
3.
Using a flat tip screwdriver, loosen
clamps (5), disconnect and remove
pipe (6) at turbocharger and intake
manifold (9).
4.
Using a 1/2” socket and socket wrench
handle, remove 12 bolts (7), washers
(8), intake manifold (9) and gasket
Remove
(10). Discard gasket (10).
from
mounting
all gasket material
surfaces.
Go to sheet 3
4-77
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-11.
Intake and Exhaust Manifolds. (Sheet 3 of 7)
REMOVAL (cont)
5.
Using 3/8” and 3/4” open end
wrenches, loosen two bolts (11) and
nuts (12).
6.
Remove two drive belts (13) from
alternator pulley. Rotate alternator
away from engine as far as possible.
7.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove four bolts (14) and locknuts
(15).
NOTE
Front and rear exhaust manifolds
are removed together as a unit.
8.
Using a 5/8” socket and socket wrench
handle, remove 12 nuts (16), washers
(17), front exhaust manifold (18),
rear exhaust manifold (19), six
gaskets (20) and gasket (21).
Discard gaskets (20 and 21). Remove
all gasket material from mounting
surfaces.
9.
Using a 7/16” socket and socket
wrench handle, remove two pipe plugs
(22) from rear exhaust manifold (19).
Go to sheet 4
4-78
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-11.
Intake and Exhaust Manifolds. (Sheet 4 of 7)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
10.
Using hot water and compressed air,
steam clean intake manifold (9),
front exhaust manifold (18) and rear
exhaust manifold (19). Remove all
dirt and carbon accumulation.
11.
Wipe drive belts (13) with clean
cloth.
12.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 5
4-79
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-11.
Intake and Exhaust Manifolds. (Sheet 5 of 7)
CLEANING/INSPECTION (cont)
13.
Inspect intake manifold (9), front
exhaust manifold (18) and rear
exhaust manifold (19). Replace if
cracked or distorted.
14.
Inspect all other parts. Refer to
paragraph 2-9.
INSTALLATION
15.
Using a 7/16” socket and socket
wrench handle, install two pipe plugs
(22) on rear exhaust manifold (19).
16.
Install rear exhaust manifold (19)
and front exhaust manifold (18).
NOTE
Install exhaust manifold sections
as a unit on cylinder head without
gasket.
17.
Using a 5/8” socket and socket wrench
handle, install 12 washers (17) and
nuts (16). Tighten nuts (16) to 60
lb-ft.
18.
Use a 0.015 inch feeler gage to measure
gap between cylinder head and
manifold flange face. If feeler gage
will pass through
area
of
measurement, as shown, replace
manifold.
19.
Using a 5/8” socket and socket wrench
handle, remove 12 nuts (16), washers
(17), front exhaust manifold (18) and
rear exhaust manifold (19).
Go to sheet 6
4-80
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-11.
Intake and Exhaust Manifolds. (Sheet 6 of 7)
INSTALLATION
NOTE
Front and rear exhaust manifolds
are installed together as a unit.
20.
Using a 5/8” socket and socket
wrench handle, install new gasket
(21), six new gaskets (20), rear
exhaust manifold (19), front
exhaust manifold (18), 12 washers
(17) and nuts (16) on left side
of engine. Tighten nuts (16) to
57 lb-ft.
21.
Apply anti-seize compound to bolts
(14) before installation.
22.
Using a 9/16” socket, socket wrench
handle, and a 9/16” open box wrench,
install four locknuts (15) and bolts
(14). Tighten bolts (14) to 35
lb-ft.
23.
Install two drive belts (13) on
alternator pulleys.
24.
Using a 9/16” socket and socket
wrench handle, tighten two nuts
(12) and bolts (11). Refer to
TM 10-3930-643-20 for alternator
drive belt adjustment.
Go to sheet 7
4-81
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-11.
Intake and Exhaust Manifolds. (Sheet 7 of 7)
INSTALLATION (cont)
25. Using a 1/2” socket and socket wrench
handle, install new gasket (10),
intake manifold (9), 12 washers (8)
and bolts (7) in right side of
engine. Tighten bolts (7) to 20
lb-ft.
26.
Position pipe (6), clamps (5) and
using a flat tip screwdriver, tighten
clamps (5) at intake manifold (9) and
turbocharger.
27.
Using a 3/8” open end wrench, install
ether nozzle (4) and elbow (3).
28. Connect tube assembly (2) and tighten
nut (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-82
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-12.
Fuel Injectors. (Sheet 1 of 5)
This task covers:
a. Removal
c. Installation
b.
Testing/Cleaning/Inspection
INITIAL SETUP
Tools
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, Less Power
NSN 4910-00-754-0714
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, MAP only
NSN 4910-00-919-0083
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Torque Wrench
NSN 5120-00-247-2536
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Bolts (1) to 20 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Right side engine access cover
removed.
Paragraph 4-13
Fuel injector lines removed.
Go to sheet 2
4-83
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-12.
Fuel Injectors. (Sheet 2 of 5)
REMOVAL
Using a 9/16” socket and socket
wrench handle, remove six bolts (1),
injector crabs (2), fuel injectors
(3) and grommets (4) from top, right
side of engine.
1.
TESTING/CLEANING/INSPECTION
Keep hands away from nozzle spray.
At opening pressure, velocity of
spray could puncture skin. Wear
safety glasses during test.
2.
Using a 3/4” open end wrench, connect
six fuel injectors (3) loosely to
test pump. Pump handle several times
Tighten
to flush out fittings.
connections.
Go to sheet 3
4-84
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-12.
Fuel Injectors. (Sheet 3 of 5)
TESTING/CLEANING/INSPECTION
3.
Operate test pump until nozzle
opening pressure is reached.
All
orifices in nozzle tip should be
clear. Fuel should spray in atomized
mist. Nozzle should emit a sharp
high-pitched chatter. If chattering
does not occur, flush with pump in
rapid complete strokes.
Spray
pattern should be uniform and equal
in all directions.
4.
Operate test pump a few strokes to
clear air from nozzle.
Raise
pressure steadily. Observe pressure
at which nozzle opens.
Opening
pressure for new nozzles is 3600 to
3750 psi. Minimum opening pressure
for used nozzles is 2900 psi.
5.
Wipe nozzle tip dry. Bring pressure
slowly to 500 psi below nozzle
Maintain this
opening pressure.
pressure for 5 seconds. Wetting of
nozzle is permissible
without
formation of a droplet. Do not wipe
the tip with fingers. This will draw
fuel present in sac hole through
orifices and give false leak
Hold wiper lightly
indication.
against tip of nozzle.
6.
Bring pressure on nozzle to 1500 psi.
Collect any leakage from fuel return
stem. Maximum allowable leakage is
1.5 cubic inch in one minute.
7.
Wipe retainers (4) with a damp clean
cloth using a mild detergent and
water solution.
Go to sheet 4
4-85
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-12.
Fuel Injectors. (Sheet 4 of 5)
TESTING/CLEANING/INSPECTION
(cont)
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
8.
Clean all other parts using cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
9.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
4-86
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-12.
Fuel Injectors. (Sheet 5 of 5)
INSTALLATION
10. Using a 9/16” socket and socket
wrench handle, install six retainers
(4), fuel injectors (3), injector
crabs (2) and bolts (1) in top,
right side of engine. Tighten six
bolts (1) to 20 lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-87
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-13.
Fuel Injector Lines. (Sheet 1 of 5)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, Less Power
NSN 4910-00-754-0714
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, MAP only
NSN 4910-00-919-0083
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Torque Wrench
NSN 5120-00-247-2536
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Suitable container
Torques
Injection pipes (19, 18, 17, 16,
15 and 14) to 30 lb-ft.
Fittings to 30 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
4-88
Condition Description
Right side engine access cover removed.
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
Fuel Injector Lines. (Sheet 2 of 5)
4-13.
REMOVAL
FIRE HAZARD
Diesel fuel and combustible
materials are used in operation
and maintenance of this equipment.
Do not smoke or allow open flames
or sparks in areas where diesel
fuel and combustible materials are
used or stored. DEATH or injury
may result if personnel fail to
observe this precaution. If you
are burned, seek medical help
immediately.
1.
Using a flat tip screwdriver, remove
screw (1), retaining clip (2), two
clamps (3) and spacers (4) from right
side of engine.
2.
Remove three screws (5), retaining
clips (6), six clamps (7), three
clips (8) and twelve spacers (9).
3.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
remove bolt (10), nut (11), two
clamps (12) and spacers (13).
NOTE
Use a suitable container to catch
any draining fuel.
4.
Using a 3/4“ open end wrench,
disconnect injection pipes (14, 15,
16, 17, 18 and 19) from fuel
injectors.
5.
Disconnect injection pipes (14, 15,
16, 17, 18 and 19) from fuel
injection pump and remove from
vehicle.
6.
Using long round nose pliers, remove
eleven hose clamps (20), cap (21) and
five hoses (22).
Go to sheet 3
4-89
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-13.
Fuel Injector Lines. (Sheet 3 of 5)
CLEANING/INSPECTION
Clean two spacers (4), 12 spacers
(9), spacer (13), cap (21) and five
hoses (22) with warm water and
detergent.
7.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
solvent,
get
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
8.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 4
4-90
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-13.
Fuel Injector Lines. (Sheet 4 of 5)
CLEANING/INSPECTION
9.
Inspect injection pipes (14, 15, 16,
17, 18 and 19). Replace if cracked,
twisted or if inside diameter is
blocked with dirt or foreign
materiel.
10.
Inspect all parts. Refer to paragraph 2-9.
INSTALLATION
11.
Using round nose pliers, install five
hoses (22), cap (21) and eleven hose
clamps (20) in right side of engine.
12.
Using a 3/4” open end wrench,
position and connect injection pipes
(19, 18, 17, 16, 15 and 14) to
injection pump. Tighten to 30 lb-ft.
13.
Connect injection pipes (19, 18, 17,
16, 15 and 14) to fuel injectors.
Tighten fittings to 30 lb-ft.
Go to sheet 5
4-91
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-13.
Fuel Injector Lines. (Sheet 5 of 5)
INSTALLATION (cont)
14.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
install two spacers (13), clamps
(12), nut (11) and bolt (10).
15.
Using a flat tip screwdriver, install
twelve spacers (9), three ClipS (8),
six clamps (7), three retaining clips
(6) and screws (5).
16.
Install two spacers (4), clamps (3),
retaining clip (2) and screw (l).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-92
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 1 of 9)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Timing
INITIAL SETUP
Tools
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, Less Power
NSN 4910-00-754-0714
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, MAP only
NSN 4910-00-919-0083
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Torque Wrench
NSN 5120-00-247-2536
Wrench, Open End 2-1/2”
NSN 5120-00-277-3022
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Silicone sealant (App. C, Item 27)
Small tag (App. C, Item 28)
Gasket (2)
Torques
Except for special torques shown,
all fasteners are tightened to
standard torques. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Right side engine access cover removed.
Go to sheet 2
4-93
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 2 of 9)
REMOVAL
Before performing injection pump
removal procedure, rotate engine
clockwise until the No. 1 piston
is on compression stroke and
timing pointer is at 15 degrees
BTDC plus or minus 1 degree.
If the pump is to be reinstalled,
DO NOT rotate the pump drive shaft
after the pump has been removed.
Thoroughly clean left side of
engine to prevent dirt from
entering pump. Be sure to plug all
openings of pump and lines to
prevent entry of dirt.
Failure to observe the preceding
can result in severe damage to
engine or fuel injection pump.
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a 3/4“ open end wrench,
disconnect six fuel injector lines
(1) from right side of engine.
3*
Using a flat tip screwdriver, remove
nut (2), washer (3) and terminal (4).
3.
Using long round nose pliers, a 7/16”
socket and a 7/16” open end wrench,
remove spring (5), nut (6), washer
(7), bolt (8) and two washers (9).
4.
Using a 9/16” socket and socket
wrench handle, remove bolt (10), lock
washer (11) and washer (12).
Leave
clip attached to tube assembly (13).
5.
Using a 3/4” open end wrench,
disconnect tube assemblies (13, 14,
15 and 16).
Go to sheet 3
4-94
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 3 of 9)
REMOVAL
6.
Using a 1/2” open end wrench, remove
bolt (17) and washer (18).
7.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
remove nut (19), bolt (20) and two
straps (21).
8.
Using 3/4” open end wrench, remove
hose assembly (22). Cap port on fuel
injection pump (36).
9.
Using a flat tip screwdriver, loosen
clamp (23).
10.
Disconnect hose (24).
11.
Using a 1/2” socket and socket wrench
handle, remove five bolts (25) and
washers (26).
12.
Remove three nuts (27), washers (28),
bolts (29) and washers (30).
13.
Support fuel injection pump (36) and
using a 1/2” socket, socket wrench
handle and a 1/2” open end wrench,
remove nut (31), washer (32), bracket
(33), bolt (34) and washer (35).
14.
Remove fuel injection pump (36), then
using a gasket scraper or putty
knife, remove gasket (37), cover (38)
and gasket (39). Discard gaskets (37
and 39). Remove all gasket material
from mounting surfaces.
If the same fuel injection pump is
to be installed, DO NOT rotate the
pump drive shaft after the pump has
been removed. Failure to follow
this procedure will damage the fuel
injection pump timing.
Go to sheet 4
4-95
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 4 of 9)
DISASSEMBLY
15.
Using an 11/16” open end wrench,
remove adapters (40, 41 and 42) and
elbows (43, 44 and 45) from fuel
injection pump (36).
16.
Using a 9/16” socket and socket
wrench handle, remove two nuts (46),
washers (47) and adapter (48).
17.
Remove three bolts (49) and gear
(50).
18.
Using a 1/2” socket, socket wrench
handle and a 1/2” open box wrench,
remove two locknuts (51), washers
(52), plate (53), two spacers (54),
bolts (55), washers (56), gear (57)
and pin (58) from adapter (48).
19.
Using a 1/2” open end wrench and vise
grip, remove two studs (59) and pins
(60)0
20.
Remove plug (61).
NOTE
The following are differences
between M10A Forklift models. The
disassembly/assembly procedure is
identical.
210
Using 1–5/16” and 1-1/4” open end
wrenches, remove tachometer drive
(62) and locknut (62a) from cover
(38), from vehicles S/N 2001 and
above, or remove plug (63) from
cover (38), from vehicles S/N 2000
and below.
22. Using a 3/4” open end wrench, remove
elbow (64) from cover (38).
Go to sheet 5
4-96
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 5 of 9)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
23.
Clean all parts, except fuel
injection pump (36), with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
24.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 6
4-97
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 6 of 9)
ASSEMBLY
25.
Using a 3/4” open end wrench, install
elbow (64).
26.
Using 1-5/16” and 1-1/4” open end
wrenches, install plug (63) in cover
(38) in vehicles S/N 2000 and below or
using a 1-1/8” open end wrench, install
tachometer drive (62) and locknut (62a)
in cover (38), in vehicles S/N 2001 and
above. Refer to TM 10-3930-643-20.
27.
Using a 1/2” open end wrench, install
plug (61) in adapter (48).
28.
Using a small hammer, 2-5/16” nuts
and 2-1/2” open end wrench, install
two pins (60) and studs (59).
29.
Using a small hammer. a 1/2” socket,
socket wrench handle and 1/2” open
end wrench, install pin (58), gear
(57), two washers (56), bolts (55),
spacers (54), plate (53), two washers
(52) and locknuts (51).
30.
Using a 9/16” socket and socket
wrench handle, install adapter (48),
two washers (47) and nuts (46) in
fuel injection pump (36).
31.
Using an 11/16” open end wrench,
install elbows (45, 44 and 43) and
adapters (42, 41 and 40).
Go to sheet 7
4-98
TM 10–3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 7 of 9)
INSTALLATION
32.
Position new gaskets (37 and 39),
fuel injection pump (36) and cover
(38), in right, rear side of engine.
33.
Support fuel injection pump (36) and
using a 1/2” socket., socket wrench
handle and a 1/2” open end wrench,
install washer (35), bolt (34),
bracket (33), washer (32) and nut
(31).
34.
Install two washers (30), bolts (29),
washers (28) and nuts (27).
35•
Using a 1/2” socket and socket wrench
handle, install two washers (26),
bolts (25), washer (18) and bolt
(17).
36.
Using a flat tip screwdriver, tighten
clamp (23) to connect hose (24).
37.
Using a 3/4” open end wrench, connect
hose assembly (22).
38.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
install two straps (21), bolt (20)
and nut (19).
39.
Using a 3/4” open end wrench, connect
tube assemblies (16, 15, 14 and 13).
Tighten fittings to 35 lb-ft.
Go to sheet 8
4-99
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 8 of 9)
4-14.
INSTALLATION (cont)
40.
Using a 9/16” socket and socket
wrench handle, install washer (12),
lock washer (11) and bolt (10).
41.
Position throttle control cable.
Using a 7/16” socket, socket wrench
handle, a 7/16” open end wrench and
long round nose pliers, install two
washers (9), bolt (8), washer (7),
nut (6) and spring (5).
42.
Using a flat tip screwdriver, install
terminal (4), washer (3) and nut (2).
Apply silicone sealant over entire
connection.
43.
Using a 3/4” open end wrench, install
six fuel injector lines (1). Tighten
fittings to 35 lb-ft.
TIMING
44.
Rotate engine clockwise till number 1
piston is on compression stroke and
timing pointer is at 15 % BTDC plus
or minis one percent.
45.
Using a 7/8 socket and socket wrench
handle, rotate pump shaft until
timing mark on shaft lines up with
timing pointer.
Make sure timing marks on
drive gear and idler gear are
in alignment.
46.
Install drive gear (50), aligning the
timing marks with the idler gear.
GO to Sheet 9
4-100
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-14.
Fuel Injection Pump, Cover Plate, Adapter and Drive Gears. (Sheet 9 of 9)
47.
Using a 7/8 socket and socket wrench
handle, hold pump shaft in position
while installing install three bolts
(49) using a 1/2” open end wrench.
Tighten three bolts (49) to 30 lb-ft.
48.
Perform fuel system hand priming
procedure, refer to Fuel System Vent
Procedure, in TM 10-3930-643-20.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-100.1
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-15.
Turbocharger and Piping. (Sheet 1 of 6)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Lubricating oil (App. C, Item 19)
Liquid gasket (App. C, Item 14)
Anti-seize compound (App. C, Item 1)
Small tag (App. C, Item 28)
Gasket (2)
Torques
Except for special torques shown,
all fasteners are tightened to
special torques. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Top access cover removed.
Go to sheet 2
4-101
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Turbocharger and Piping. (Sheet 2 of 6)
4-15.
REMOVAL
1.
Using a 9/16 socket and socket wrench
handle, remove exhaust manifold (1)
from top, left side of engine, refer
to paragraph 4-11.
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
2.
Using 1/2” and 9/16” sockets and a
socket wrench handle, remove turbocharger oil lines (2 and 3) from
left side of engine, refer to
TM 10-3930-643-20.
3.
Using a flat tip screwdriver, loosen
clamp (4) and disconnect turbocharger
inlet hose.
4.
Remove clamps (5 and 6), hose (7),
clamps (8 and 9), hose (10) and pipe
(11).
5.
Remove turbocharger (12), seal (13),
bushing (14) and seal (15).
6.
Using a 15/16” socket and socket
wrench handle, remove bolt (16),
washer (17), two bolts (18), washers
(19) and elbow (20).
Go to sheet 3
4-102
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-15.
Turbocharger and Piping. (Sheet 3 of 6)
CLEANING/INSPECTION
7.
Clean hoses (7 and 10) with cloth
moistened with detergent.
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
8.
Clean exterior of turbocharger (12)
with cloth moistened with cleaning
solvent P-D-680. Allow to air dry.
9.
Clean all other parts with cleaning
solvent P-D-680.
Dry thoroughly
with compressed air.
Refer to
paragraph 2-8.
10.
If turbocharger fails, check for
small parts dropped into exhaust
manifold.
11.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 4
4-103
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-15.
Turbocharger and Piping. (Sheet 4 of 6)
INSTALLATION
12.
Using a 15/16” socket and socket
wrench handle, install elbow (20),
two washers (19), bolts (18), washer
(17) and bolt (16) in top, left side
of engine.
13.
Apply anti-seize compound to seals
(15 and 13).
14.
Apply liquid gasket to hose at inlet
connection of turbocharger.
15.
Install seal (15), bushing (14), seal
(13) and turbocharger (12).
16.
Using a flat tip screwdriver, install
hose (10), pipe (11), clamps (9 and
8), hose (7) and clamps (6 and 5).
Do not tighten clamps (9,8,6 and 5).
17.
Connect turbocharger inlet hose,
position and tighten clamp (4).
Turbocharger must be primed prior
Failure
to starting the engine.
to follow this procedure could
result in damage to turbocharger
and/or engine.
18.
Apply four or five ounces of clean
lubricating oil into the oil inlet
opening of the turbocharger to
lubricate the turbocharger bearings
during initial start up.
Go to sheet 5
4-104
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-15.
Turbocharger and Piping. (Sheet 5 of 6)
INSTALLATION
19.
Using a 1/2” socket and socket wrench
handle, install turbocharger oil
lines (2 and 3) at left side of
engine, refer to TM 10-3930-643-20.
20•
Using a 9/16 socket and socket wrench
handle, install exhaust manifold (1),
refer to paragraph 4-11.
21.
Check that all piping is alined and
mounting bolts are tightened in
turbocharger (12).
22.
Using a flat tip screwdriver, tighten
clamps (4,5,6,8 and 9).
NOTE
Air induction system and turbocharger assembly must be tested
following installation.
23.
Using a 9/32” open end wrench, remove
pipe plug and apply compressed air at
5 psi to pipe plug opening in air
cleaner. Air intake pipe must be
blocked off completely.
24.
Apply detergent and water solution
and check for leaks in all
connections in air induction system.
Air bubbles indicate leaks. Tighten
any loose connections.
Go to sheet 6
4-105
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Turbocharger and Piping. (Sheet 6 of 6)
4-15.
INSTALLATION (cont)
25.
Using a flat tip screwdriver,
disconnect protective boot (23) and
remove screw (21) and washer (22).
26.
Disconnect wire assembly (24) from
fuel injection pump.
27.
Crank the engine, without starting,
until oil pressure is indicated on
the oil pressure gage, to provide
an adequate amount of oil to
lubricate the turbocharger (12).
28.
Connect wire assembly (24) to the
fuel injection pump.
29.
Using a flat tip screwdriver, install
washer (22), screw (21) and connect
protective boot (23).
Shut engine down and immediately
correct the following conditions:
unusual noises, lubrication leaks,
insecure mounting,
excessive
vibration or smoke,
30.
Operate engine and observe turbocharger (12).
31.
Using 9/16” and 1/2” sockets and
socket wrench handle, tighten all
bolts, nuts, clamps and
oil
connections.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-106
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-16.
Fuel Tank. (Sheet 1 of 3)
This task covers:
a. Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Wood block (4)
Torques
Except for special torques shown,
all fasteners are tightened to
standard torques. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Step removed.
Fuel tank drained.
Filler cap assemblies removed.
Fuel strainer removed.
Fuel level sending unit removed.
Fuel tank lines and fittings removed.
Paragraph 4-9
Transmission oil cooler removed.
Go to sheet 2
4-107
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Fuel Tank. (Sheet 2 of 3)
4-16.
REMOVAL
1.
Using 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove two nuts (1), washers (2),
bolts (3), washers (4) and oil drain
adapter (5) from bottom, rear of
vehicle. Move oil drain adapter (5)
and hose to one side.
Weight of fuel tank is approximately 500 lbs. Use transmission
and differential lift for removal
and installation. Fuel tank must
be centered and balanced on lift.
Keep area clear of unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY.
2.
Position transmission and differential lift under fuel tank (12).
3.
Using a 15/16” socket, socket wrench
handle and a 15/16” open end wrench,
remove two nuts (6), washers (7),
bolts (8) and washers (9).
4.
Using a 15/16” socket and socket
wrench handle, remove two bolts (10)
and washers (11).
5.
Using transmission and differential
lift, remove fuel tank (12) and place
on wood blocks.
Go to sheet 3
4-108
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-16.
Fuel Tank. (Sheet 3 of 3)
INSTALLATION
6.
Using transmission and differential
lift, position fuel tank (12) at
bottom, rear of vehicle.
7.
Using a 15/16” socket and socket
wrench handle, install two washers
(11) and bolts (10).
8.
Using a 15/16 socket, socket wrench
handle and a 15/16” open end wrench,
install two washers (9), bolts (8),
washers (7) and nuts (6).
9.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
install oil drain adapter (5), two
washers (4), bolts (3), washers (2)
and nuts (l).
10.
Remove transmission and differential
lift from fuel tank (12).
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
4-109
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-17.
Radiator Assembly. (Sheet 1 of 2)
This task covers:
a. Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Hoist and lifting strap,
capacity of 216 lbs.
3/8-16 eyebolt (2)
Materials/Parts
Wood block (2)
Torques
Except for special torques shown,
all fasteners are tightened to
standard torques. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
4-110
Condition Description
Radiator drained.
Engine top access cover removed.
Fan, guard, housing and supports
removed.
Grille and supports removed.
Radiator piping and mounting removed.
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
Radiator Assembly. (Sheet 2 of 2)
4-17.
REMOVAL
10
Attach two 3/8-16 eyebolts in
support-to-radiator mounting holes in
rear of vehicle.
Weight of radiator assembly is
Use
approximately 216 lbs.
adequate hoist and lifting strap
for removal and installation.
Keep area clear of unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
2.
Attach hoist and lifting strap to
eyebolts.
3.
Using a 3/4” socket and socket wrench
handle, remove two bolts and washers.
4.
Using hoist and lifting strap, remove
radiator assembly. Place securely on
wood blocks on floor.
INSTALLATION
5.
Using hoist and lifting strap,
install radiator assembly.
6.
Using a 3/4” socket and socket wrench
handle, install two washers and
bolts.
7.
Remove hoist and lifting strap.
8.
Remove two 3/8-16 eyebolts from
mounting holes.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-111
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Water Pump Assembly. (Sheet 1 of 5)
4-18.
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubrication oil (App. C, Item 19)
Grease (App. C, Item 9)
Seal and boot
Water pump seal assembly
Front bearing grease seal
Rear bearing grease seal
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT DESCRIPTION
References
TM 10-3930-643-20
Condition Description
Water pump assembly removed.
DISASSEMBLY
1.
Use puller to engage two 1/2 inch
holes in impeller (1). If impeller
(1) is equipped with 1/4 inch holes,
enlarge them to accept puller, then
remove impeller (1).
Go to sheet 2
4-112
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-18.
Water Pump Assembly. (Sheet 2 of 5)
DISASSEMBLY
2.
Using a flat tip screwdriver, pry out
and discard seal and boot (2).
3.
Remove seal assembly (3) and discard.
Metal part of seal assembly (3) will
remain in water pump housing (16).
4.
Remove sleeve (4).
5.
Remove and discard grease seal (5).
6.
Using internal snap ring pliers or a
small flat tip screwdriver, remove
retainer ring (6).
7.
From rear of water pump housing (16),
press out shaft (7), spacer (8),
bearing (9), spacer (10), spacer
(11), spacer (12) and bearing (13).
Spacers (8, 10, 11 and 12) and
bearings (9 and 13) will come out
with shaft (7).
8.
Using a drive pin punch and small
hammer, drive out metal part of seal
assembly (3) and discard.
9.
Using a flat tip screwdriver, remove
and discard grease seal (14).
10.
Using vise grip pliers, remove two
pins (15).
Go to sheet 3
4-113
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-18.
Water Pump Assembly. (Sheet 3 of 5)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
11.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
12.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
4-114
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-18.
Water Pump Assembly. (Sheet 4 of 5)
ASSEMBLY
13.
Using a small hammer,
pins (15).
14.
Grease and position new grease seal
(14) so open end faces bearing (13).
15.
Pack bearing (13) with grease and
install. Inner and outer race must
be pressed together into water pump
housing (16) against shoulder.
16.
Install spacer (10).
17.
Press outer race of bearing (9) into
water pump housing (16) insuring that
the outer races of bearings (9 and
13) and spacer (10) are bottomed.
18.
Lubricate new grease seal (14) with
engine oil and install.
19.
Press shaft (7) into rear of water
pump housing (16) until rear inner
race stops shaft (7).
20.
Install spacers (12 and 11).
Fill
cavity between spacers (12 and 11)
with 0.6 oz. of grease.
21.
Pack inner race of bearing (9) with
grease. Press inner race into water
pump housing (16) until it bottoms on
shaft (7).
Shaft (7) must be
supported at rear.
22.
Using internal snap ring pliers,
install spacer (8) and retainer ring
(6).
23.
Position new grease seal (5) against
retainer ring (6) so open end faces
bearing (9).
24.
Install sleeve (4).
install two
Go to sheet 5
4-115
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Water Pump Assembly. (Sheet 5 of 5)
4-18.
ASSEMBLY (cont)
25.
Press new seal assembly (3) into
water pump housing (16).
26.
Moisten new rubber boot with water
and install new ceramic seal into
boot. Identification mark on ceramic
seal must be down.
27.
press new seal and boot (2) into
impeller (1) until seal and boot (2)
bottoms in counterbore.
28.
Support front end of shaft (7) and
push down on water pump housing (16)
to take bearing end plate toward the
rear of water pump assembly.
NOTE
Since shaft will protrude slightly
from impeller, use care not to
damage shaft during installation.
29.
Place two 0.030 inch feeler gages on
opposite sides of water pump housing
(16) and press impeller (1) on shaft
(7) until feeler gages are snug.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
4-116
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-19.
Fan and Clutch. (Sheet 1 of 4)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Loctite 262 (App. C, Item 15)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Fan, guard, housing and supports
removed.
Fan and clutch removed.
DISASSEMBLY
1.
Separate armature, items 1 thru 9 as
an assembly from field and rotor,
items 10 thru 17 as an assembly.
Go to sheet 2
4-117
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
4-19.
Fan and Clutch. (Sheet 2 of 4)
DISASSEMBLY (cont)
2.
Using internal snap ring pliers,
remove rings (1 and 2) on armature.
3.
Using a 3/8” open end wrench, remove
four bolts (3), disk (4) from housing
(5).
4.
Press sleeve (6) from bearing (8).
5.
Press bearing (8) from housing (5).
6.
Remove bearing sleeve (9).
7.
Remove shim (7).
8.
Remove two spacers (10) from field and
rotor.
9.
Remove ring (11).
10.
Using a 3/8” open end wrench, remove
four bolts (12), clutch (13), hub
(14) and disk (15).
11.
Remove ring (16).
12.
Press hub (14) from bearing (17).
13.
Press bearing (17) from disk (15).
Go to sheet 3
4-118
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE.
4-19. Fan and Clutch. (Sheet 3 of 4)
CLEANING/Inspection
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
14.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
15.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
4-119
TM 10-3930-643-34
ENGINE, FUEL, EXHAUST AND COOLING TROUBLESHOOTING AND MAINTENANCE. (cont)
Fan and Clutch. (Sheet 4 of 4)
4-19.
ASSEMBLY
16.
Press bearing (17) into disk (15).
17.
Press hub (14) into bearing (17).
18.
Install ring (16).
19.
Apply Loctite 262 to four bolts (12).
20.
Using a 3/8” open end wrench, install
disk (15), hub (14), clutch (13) and
four bolts (12).
21.
Install ring (11).
22.
Install two spacers (10).
23.
Install shim (7) in armature.
24.
Install bearing sleeve (9).
25.
Press bearing (8) into housing (5).
26.
Press sleeve (6) into bearing (8).
27.
Apply Loctite 262 to four bolts (3).
28.
Using a 3/8” open end wrench and
internal snap ring pliers, install
housing (5), disk (4), four bolts (3)
and rings (2 and 1).
29.
Assemble field and rotor, items 17
thru 10 as an assembly and armature,
items 9 thru 1 as an assembly in
fan clutch. Use 0.0179 inch spacers
(10) as required to obtain 0.035 to
0.055 inch gap between clutch (13)
and clutch disk (4).
END OF TASK
4-120
TM 10-3930-643-34
CHAPTER 5
ELECTRICAL SYSTEM
MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized direct support level
maintenance procedures on the M10A Forklift.
INDEX
Title
Starting Motor
Instrument Panel Wiring Harness
Main Wiring Harness
Intermediate Wiring Harness
(S/N 2001 and above)
Intermediate Wiring Harness
(S/N 2000 and below)
Fork Control Wiring Harness
Front Lights Wiring Harness
Paragraph
Page
5-1
5-2
5-3
5-2
5-17
5-26
5-4
5-41
5-5
5-6
5-7
5-45
5-49
5-53
5-1
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-1.
Starting Motor. (Sheet 1 of 15)
This task covers:
a. Disassembly
c. Assembly
b.
d.
Cleaning/Inspection
Adjustment
INITIAL SETUP
Tools
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, Less Power
NSN 4910-00-754-0714
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, MAP only
NSN 4910-00-919-0083
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Torque Wrench
NSN 5120-00-247-2536
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Oil, Grade 3(App. C, Item 13)
Insulating tape (App. C, Item 29)
Locknut
Preformed packing (5)
Casket (3)
Cap (3)
Wick (3)
Seal
Plug
No. 00 grit sandpaper
Torques
Bolts (35 and 36) to 13-17 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
5-2
Condition Description
Right side engine cover removed.
Solenoid removed.
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-1.
Starting Motor. (Sheet 2 of 15)
DISASSEMBLY
1.
Using a flat tip screwdriver, remove
plug (1), gasket (2) and locknut (3)
from starting motor housing (70).
Discard gasket (2) and locknut (3).
Hold plunger (10) when turning
locknut (3).
2.
Using slip joint pliers, remove items
4 thru 10 as an assembly.
3.
Compress spring (6) and remove
retaining ring (4), recessed washer
(5), spring (6), recessed washer (7),
bellows (8) and washer (9) from
plunger (10).
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to pintype or socket-type connector.
4.
Using a 3/4” open end wrench, remove
nut (11) and lead assembly (12) from
starting motor housing (70).
5.
Using a flat tip screwdriver, remove
plug (13), gasket (14), plug (15) and
gasket (16). Discard gaskets (14 and
16).
6.
Remove two screws (17). Screws (17)
may be reached through ports of plugs
(13 and 15).
Go to sheet 3
5-3
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE, (cont)
5-1.
Starting Motor. (Sheet 3 of 15)
DISASSEMBLY (cont)
NOTE
Starting motor frame and housings
must be match marked before disassembly.
7.
Using a 7/16” socket and socket
wrench handle, remove four bolts
(18).
8.
Remove items 19 thru 33 as an
assembly. Use suitable driver and
hammer to tap around circumference of
frame (29).
9.
Using a 3/4” open end wrench, remove.
nut (19), lock-washer (20), washer
(21) and bushing (22).
10.
Using a flat tip screwdriver, remove
three screws (23).
11.
Separate frame (29), element holder
(33) and preformed packing (24).
Discard preformed packing (24).
12.
Remove two insulators
element holder (33).
13.
Using an electric drill, drill hole
to pry out cap (26) and wick (27)
from frame (29). Discard cap (26)
and wick (27).
(25) from
Removal of bearing from frame will
cause destruction of bearing.
Remove only if
inspection
indicates removal is necessary.
14.
Inspect bearing (28).
Replace if
cracked, broken, grooved or scored.
Go to sheet 4
5-4
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-1.
Starting Motor. (Sheet 4 of 15)
DISASSEMBLY
15.
If necessary, press out bearing (28)
using a suitable driver and press.
16.
Using a flat tip screwdriver, remove
four screws (30) and brushes (31)
from element holder (33).
17.
Remove four springs (32).
18.
Remove washer (34) from starting
motor housing (70).
19.
Using a 1/4” socket head screw key,
remove bolt (35), five bolts (36) and
housing (37).
20.
Remove and discard preformed packing
(38) from housing (37).
21.
Using an electric drill, drill hole
to pry out cap (39) and wick (40)
from housing (37). Discard cap (39)
and wick (40).
Removal of bushing from housing
will cause destruction of bushing.
inspection
Remove only if
indicates removal is necessary.
22.
Replace if
Inspect bushing (41).
cracked, broken, grooved or scored.
23.
If necessary, press out bushing (41)
using suitable driver and press.
Go to sheet 5
5-5
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-1.
Starting Motor. (Sheet 5 of 15)
DISASSEMBLY (cont)
24.
Using snap ring pliers, remove
retaining ring (42), preformed
packing (43), shaft (44) and
preformed packing (45) from starting
motor housing (70).
Discard
preformed packings (43 and 45).
25.
Remove armature (46).
26.
Remove drive (47), lever (48) and
washer (49).
27.
Using long round nose pliers, remove
plug (50).
28.
Using a 7/16” open end wrench, remove
five bolts (51).
29.
Separate items 52 thru 58 as an
assembly.
30.
Using a flat tip screwdriver, remove
preformed packing (52), seal (53) and
washer (54) from lever housing (58).
Discard preformed packing (52) and
seal (53).
31.
Using an electric drill, drill hole
to pry out cap (55) and wick (56).
Discard cap (55) and wick (56).
Removal of bearing from lever
housing will cause destruction of
bearing.
Remove only if
inspection indicates removal is
necessary.
32.
Inspect bearing (57).
Replace if
cracked, broken, grooved or scored.
33.
If necessary, press out bearing (57)
using suitable driver and press.
Go to sheet 6
5-6
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-1.
Starting Motor. (Sheet 6 of 15)
DISASSEMBLY
NOTE
Remove coil only if testing and
inspection indicate replacement is
necessary.
34.
Using a 3/4” open end wrench, remove
nut (59), washer (60) and washer (61)
from starting motor housing (70).
NOTE
In steps 35 thru 37, support coil
by hand or use pole spreader to
prevent distortion.
remove
35.
Using cross tip screwdriver,
eight screws (62).
36.
Bend up
of coil
of coil
housing
37.
If necessary, remove coil (63),
insulator (64), four shoes (65) and
two plates (66).
38.
Remove washer (67) and insulator
bushing (68) from coil (63).
39.
Using diagonal cutting pliers, cut
leads and remove terminal stud (69).
Remove only if stud is bent or
threads are damaged.
three tabs on commutator end
(63) and pull lead assembly
(63) through starting motor
(70).
Go to sheet 7
5-7
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-1.
Starting Motor. (Sheet 7 of 15)
CLEANING/INSPECTION
40.
Wipe bellows (8). insulator (68),
four brushes (31), drive (47) and two
plates (66) with a clean, lint-free
cloth. Do not use cleaning solvent.
41.
Clean coil (63) and starting motor
housing (70) with mineral spirits and
brush. Dry with clean cloth.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
42.
Clean armature (46) with mineral
spirits and brush.
Dry with
compressed air. Commutator can be
cleaned with No. 00 grit sandpaper.
Wipe commutator with a clean,
lint-free cloth to remove all
particles from between commutator
bars. Do not use emery cloth.
Go to sheet 8
5-8
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-1.
Starting Motor. (Sheet 8 of 15)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
solvent,
get
immediately.
43.
Wipe frame (29) and housings (37 and
58) with clean cloth moistened with
cleaning solvent P-D-680.
Dry
thoroughly with compressed air.
44.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
45.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 9
5-9
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-1.
Starting Motor. (Sheet 9 of 15)
TESTING
46.
Use growler and steel blade to test
for shorted windings in armature
Replace if steel blade
(46).
vibrates.
47.
Test to check for accumulation of
brush material between commutator
Replace
bars in armature (46).
armature (46) if brush material has
been cleaned out from in between
commutator bars and if testing device
shows short circuit between two
commutator bars.
NOTE
Coil must be installed in starting
housing and grounds must be
disconnected for grounds and opens
test.
48.
Test coil (63) for grounds with
multimeter. Replace if grounds are
indicated.
49.
Test coil (63) for opens with
multimeter. Replace if opens are
indicated.
Go to sheet 10
5-10
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-1.
Starting Motor. (Sheet 10 of 15)
ASSEMBLY
50.
Install terminal stud (69), if
removed, in coil (63). Use soldering
gun and insulating tape.
51.
Install insulator bushing (68) and
washer (67).
52.
Using a cross tip screwdriver,
position two plates (66) and four
shoes (65). Shoes (65) must be
assembled on coil (63) with long lip
in the direction of armature
rotation. Long lip must be the
trailing edge of the shoe, not the
leading edge.
53.
Wrap insulator (64) around coil (63).
54.
Install coil (63) in starting motor
housing (70). Support coil (63) by
hand or use pole shoe spreader.
Careful
Do not tear insulator.
installation of coil is necessary
to prevent shorting or grounding
of the coil as shoes are tightened
into place.
55.
Using a cross tip screwdriver,
install eight screws (62) through
starting motor housing (70) into
shoes (65) to secure coil (63).
Tighten screws (62) evenly.
56.
Using a 3/4” open end wrench, install
washers (61 and 60) and nut (59).
Go to sheet 11
5-11
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-1.
Starting Motor. (Sheet 11 of 15)
ASSEMBLY (cont)
57.
If removed, press new bearing (57)
into lever housing (58). Prior to
installation, soak bearing in oil,
Grade 3.
58.
Soak wick (56) in oil, Grade 3. Then
install new wick (56) and new cap
(55).
59.
Lubricate bore of seal (53) lightly
with oil, Grade 3, then install
washer (54), new seal (53) and new
preformed packing (52).
60.
Position items 58 thru 52 as an
assembly in starting motor housing
(70). Aline match marks on lever
housing (58) and starting motor
housing (70).
61.
Using a 7/16” open end wrench,
install five bolts (51).
62.
Using long round nose pliers, install
plug (50).
63.
Install washer (49), lever (48) and
drive (47).
64.
Install armature (46).
65.
Install new preformed packing (45),
shaft (44), new preformed packing
(43) and retaining ring (42).
Go to sheet 12
5-12
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-1.
Starting Motor. (Sheet 12 of 15)
ASSEMBLY
66.
If removed, press new bushing (41)
Prior to
into housing (37).
installation, soak bushing in oil,
Grade 3.
67.
Soak new wick (40) and new cap (39)
in oil, Grade 3, then install.
68.
Lubricate new preformed packing (38)
lightly with oil, Grade 3, then
install.
69.
Using a 1/4” socket head screw key,
install housing (37), five bolts (36)
and bolt (35) in starting motor
housing (70). Tighten bolts to 13 to
17 lb-ft.
70.
Install washer (34).
71.
Install four springs (32) in element
holder (33).
72.
Using a flat tip screwdriver, install
four brushes (31) and screws (30).
Check that brushes (31) ride freely
in holder.
73.
Soak new bearing (28) in oil, Grade
3.
74.
If removed, press new bearing (28)
into frame (29) with suitable driver
and press.
75.
Soak new wick (27) and new cap (26)
in oil, Grade 3, then install.
Go to sheet 13
5-13
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-1.
Starting Motor. (Sheet 13 of 15)
ASSEMBLY (cont)
(25) in
76.
Install two insulators
element holder (33).
77.
Install new preformed packing (24) in
frame (29).
78.
Position items 33 thru 30 as an
assembly.
79.
Using a flat tip screwdriver, install
three screws (23).
80.
Using a 3/4” open end wrench, install
bushing (22), washer (21), lock
washer (20) and nut (19).
NOTE
Terminals of two brush leads
connected to coil must be in
alinement with ports of plugs in
starting motor housing.
81.
Install items 33 thru 19 as an
assembly in starting motor housing
(70). Aline match marks on frame
(29) and starting motor housing (70).
Pull armature (46) out just far
enough to compress brushes for
Slide
installation on commutator.
assembly back into position.
82.
Using a 7/16” socket and socket
wrench handle, install four bolts
(18).
Go to sheet 14
5-14
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-1.
Starting Motor. (Sheet 14 of 15)
ASSEMBLY
83.
Using a flat tip screwdriver, install
two screws (17). Secure coil (63)
leads to element holder (33). Access
through ports of plugs (13 and 15).
84.
Install new gasket (16), plug (15),
new gasket (14) and plug (13).
85.
Using a 3/4” open end wrench, install
lead assembly (12) and nut (11).
86.
Install washer (9), bellows (8),
recessed washer (7), spring (6),
recessed washer (5) and retaining
Compress
ring (4) in plunger (10).
spring (6) to install retaining ring
(4) on groove of plunger (10) shaft.
87.
Install items 10 thru 4 as
assembly in starting motor
(70).
88.
Using a 1/2” open end wrench, install
new locknut (3). Do not tighten.
NOTE
Following this assembly procedure
for starting motor, install
motor
solenoid on starting
housing, refer to TM 10-3930643-20.
89.
Disconnect lead assembly (12) from
solenoid mounted on starting motor
housing (70).
90.
Position starting motor and solenoid
assembly in soft-jawed vise.
91.
Connect starting motor to 24 volt
battery as shown, using two jumper
leads. Do not connect battery
negative to MTR terminal at this
time.
92.
Connect jumper lead A to battery
negative or terminal G, as shown.
Go to sheet 15
5-15
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-1.
Starting Motor. (Sheet 15 of 15)
ADJUSTMENT
Only personnel with training and
experience in handling potentially
hazardous electrical
testing
procedures may perform the next
procedure. An insulating glove
and/or insulated tool should be
used.
93.
Momentarily touch jumper lead A from
battery negative to MTR terminal.
Drive will shift into cranking
position.
94.
Push on drive to take up movement.
95.
Measure pinion clearance. It should
be 0.36 inches.
96.
Adjust pinion clearance, if required,
by turning locknut.
97.
Remove three jumper leads.
98.
Connect lead assembly (12) to
starting motor solenoid.
99.
Install new gasket (2) and plug (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
5-16
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-2.
Instrument Panel Wiring Harness. (Sheet 1 of 9)
This task covers:
a. Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Small tag (App. C, Item 28)
Anti-corrosive varnish
(App. C, Item 30)
Tie strap
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Battery negative disconnected.
Go to sheet 2
5-17
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-2.
Instrument Panel Wiring Harness. (Sheet 2 of 9)
REMOVAL
NOTE
For the following procedure,
disconnect is used to indicate
the separation of
plugs ,
connectors or terminals and the
removal of all
attaching
hardware. To prevent loss,
reinstall attaching hardware in
its original position.
All wire must be tagged when
removed
from
connector.
Indicate whether wire is
connected to pin-type or
socket-type connector.
Quantity of tie straps used to
secure harness is variable.
1.
Disconnect harness assembly (1) at
connector from intermediate harness
in operator’s compartment.
2.
Using a flat tip screwdriver, remove
four screws (2) and washers (3).
3.
Lift instrument panel assembly
out of housing.
4.
Disconnect wire assemblies (5 thru 7)
at connectors from front lights
harness.
5.
Disconnect wire assembly (8) at
connector from heater harness.
6.
Disconnect wire assemblies (9 and 10)
at connectors from front lights cable
assembly.
7.
Using diagonal cutting pliers, cut
and discard tie straps (11).
GO to sheet 3
5-18
(4)
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-2.
Instrument Panel Wiring Harness. (Sheet 3 of 9)
REMOVAL
8.
Disconnect harness assembly (12) at
connector from blackout switch (13).
9.
Disconnect four wire assemblies (14)
at connectors and lead assemblies
(15) from diode assembly (16).
10.
Using a flat tip screwdriver,
disconnect four wire assemblies (17)
at connector and lead assembly (18)
from diode assembly (19).
11.
Disconnect wire assembly (20) at
connector from instrument panel (21).
NOTE
The following are differences
between M10A Forklift models. The
removal/installation procedures
are identical.
12.
Disconnect two lead assemblies (22)
and lead assembly (23) from circuit
breaker assembly (25), from vehicles
S/N 2001 and above or disconnect
seven lead assemblies (24) from
circuit breaker assembly (25), from
vehicles S/N 2000 and below.
Go to sheet 4
5-19
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-2.
Instrument Panel Wiring Harness. (Sheet 4 of 9)
REMOVAL (cont)
13.
Disconnect wire assemblies (26 and
27) at connectors from fan clutch
relay (28).
14.
Disconnect seven wire assemblies (29)
and wire assembly (30) at connectors
from start switch (31).
15.
Remove socket (32) and lamp (33) from
oil pressure gage (35).
16.
Disconnect two lead assemblies
from oil pressure gage (35).
17.
Remove socket (36) and lamp (37) from
air pressure gage (38).
18.
Disconnect lead assemblies (39 and
40) from hourmeter (41).
19.
Disconnect two lead assemblies (42,
43, 44 and 45), from connector (46).
20.
Disconnect lead assemblies (47 thru
50) from lead assemblies (51 thru
54).
Go to sheet 5
5-20
(34)
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-2.
Instrument Panel Wiring Harness. (Sheet 5 of 9)
REMOVAL (cont)
21.
Disconnect lead assemblies (55 and
56) from fan clutch relay (28).
22.
Disconnect two lead assemblies
from alarm signal (58).
(57)
23.
Disconnect two lead assemblies
from bulb check switch (60).
(59)
24.
Disconnect two lead assemblies
from ether start switch (62).
(61)
25.
Disconnect lead assembly (63) from
air pressure switch (64).
26.
Disconnect lead assemblies (65 and
66) from front light switch (67).
27.
Disconnect lead assemblies (68 thru
70) from rear light switch (71).
28.
Disconnect two lead assemblies
from fan switch (73).
29.
Remove harness assembly (74) from
instrument panel assembly (4).
(72)
NOTE
Refer to paragraph 2-13 for
electrical repair procedures for
terminals and connectors.
Go to sheet 6
5-21
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-2.
Instrument Panel Wiring Harness. (Sheet 6 of 9)
30.
Position harness assembly (74) on
instrument panel (4).
31.
Using a flat tip screwdriver, connect
two lead assemblies (72) to fan
switch (73).
32.
Connect lead assemblies (70 thru 68)
to rear light switch (71).
33.
Connect lead assemblies (66 and 65)
to front light switch (67).
34.
Connect lead assembly (63) to air
pressure switch (64).
35.
Connect two lead assemblies (61) to
ether start switch (62).
36.
Connect two lead assemblies (59) to
bulb check switch (60).
37.
Connect two lead assemblies (57) to
alarm signal (58).
38.
Connect lead assemblies (56 and 55)
to neutral start relay (28).
Go to sheet 7
5-22
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-2.
Instrument Panel Wiring Harness. (Sheet 7 of 9)
INSTALLATION (cont)
39.
Connect lead assemblies (54 thru 51)
to lead assemblies (50 thru 47).
40.
Connect two lead assemblies (45, 44,
43 and 42) to connector (46).
41.
Connect lead assemblies (40 and 39)
to hourmeter (41).
42.
Install lamp (37) and socket (36) in
air pressure gage (38).
43.
Connect two lead assemblies (34) to
oil pressure gage (35).
44.
Install lamp (33) and socket (32) in
oil pressure gage (35).
45.
Connect wire assembly (30) and seven
wire assemblies (29) at connectors to
start switch (31).
46.
Connect wire assemblies (27 and 26)
at connectors to fan clutch relay
(28).
Go to sheet 8
5-23
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-2.
Instrument Panel Wiring Harness. (Sheet 8 of 9)
INSTALLATION (cont)
47.
Connect seven lead assemblies (24) to
circuit assembly (25), from vehicles
S/N 2000 and below or connect lead
assembly (23) and two assemblies (22)
to circuit breaker assembly (25),
from vehicles S/N 2001 and above.
48.
Connect wire assembly (20) at
connector to instrument panel (21).
49.
Connect lead assembly (18) and four
wire assemblies (17) at connector to
diode assembly (19).
50.
Connect four lead assemblies (15) and
wire assemblies (14) at connectors to
diode assembly (16).
51.
Connect harness assembly (12) at
connector to blackout switch (13).
Go to sheet 9
5-24
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-2.
Instrument Panel Wiring Harness. (Sheet 9 of 9)
INSTALLATION
52.
Install a suitable number of new tie
straps (11) to secure harness leads
together.
53.
Position instrument panel assembly
(4) in operator’s compartment; do not
install in housing.
54.
Connect wire assemblies (10 and 9) at
connectors to front lights cable
assembly.
55.
Connect wire assembly (8) at
connector to heater harness.
56.
Connect wire assemblies (7 thru 5) at
connectors to front lights harness.
57.
Spray all instrument panel electrical
with anti-corrosive
connections
varnish.
58.
Position instrument panel assembly
(4) in housing.
59.
Install four washers (3) and screws
(2).
60.
Connect harness assembly (1) at
connector to intermediate harness.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
5-25
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 1 of 15)
This task covers:
a. Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Silicone sealant (App. C, Item 27)
Small tag (App. C, Item 28)
Tie strap
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
5-26
Condition Description
Engine side access covers removed.
Battery negative disconnected.
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-3.
Main Wiring Harness. (Sheet 2 of 15)
REMOVAL
NOTE
For the following procedure,
disconnect is used to indicate
the separation of
plugs ,
connectors or terminals and the
removal of all
attaching
hardware. To prevent loss,
reinstall attaching hardware in
its original position.
All electrical connections,
except those on the instrument
panel are sealed
against
moisture with silicone sealant.
Remove all silicone sealant
before performing maintenance on
electrical connections.
All wire must be tagged when
removed
from
connector.
Indicate whether wire is
connected to pin-type or
socket-type connector.
Quantity of tie straps used to
secure harness is variable.
1.
Using diagonal cutting pliers,
and discard tie strap (1).
2.
Using a 9/16” socket and socket
wrench handle, remove four bolts (2),
nuts (3), washers (4) and clamps (5)
from rear of vehicle.
cut
Go to sheet 3
5-27
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 3 of 15)
REMOVAL (cont)
3.
Using a flat tip screwdriver,
disconnect three wire assemblies (6)
at terminals from right stop light
and taillight.
4.
Disconnect two wire assemblies (7 and
8) at connectors from blackout
lights.
5.
Disconnect three wire assemblies (9)
at terminals from left stop light and
taillight.
NOTE
The following is a difference
between M10A Forklift models.
6.
Disconnect two wire assemblies (10)
at terminals, from vehicles S/N 2001
and above, from backup alarm.
7.
Disconnect three wire assemblies (11)
at terminals from right work light
and frame.
8.
Disconnect two wire assemblies (12)
at terminals from left work light.
Go to sheet 4
5-28
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-3.
Main Wiring Harness. (Sheet 4 of 15)
REMOVAL
9.
Remove two screws (13), washers (14)
and cover (15) from left side of
engine.
10•
Using a 1/2” open end wrench and a
flat tip screwdriver, disconnect wire
assemblies (16 and 17) at terminals
and wire assembly (18) at connector
from alternator.
11.
Using a 3/8” open end wrench,
disconnect wire assembly (19) at
terminal from
engine
water
temperature sender.
12.
Pull back boot (20).
13.
Using a flat tip screwdriver,
disconnect wire assembly (21) at
terminal from fan clutch.
Go to sheet 5
5-29
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 5 of 15)
REMOVAL (cont)
14.
Disconnect three wire assemblies (22)
at terminal from oil pressure switch
in left side of engine.
15.
Using a 3/8” open end wrench,
disconnect terminal (23) from sensor.
NOTE
The following is a difference
between M10A Forklift models.
16.
Using a 9/16” socket and socket
wrench handle, remove four bolts
(24), washers (25) and plate (26),
from vehicles S/N 2001 and above,
from left side of vehicle, underneath
battery compartment.
17.
Disconnect wire assembly (27) at
connector (28) in front, left side of
hydraulic tank.
18.
Using a cross tip screwdriver, remove
four screws (29) and washers (30).
Go to sheet 6
5-30
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-3.
Main Wiring Harness. (Sheet 6 of 15)
REMOVAL
19.
Using a 3/8” open end wrench,
disconnect two wire assemblies (31)
at terminal from torque converter
temperature sender in rear, left side
of engine.
20.
Using a 9/16” socket and socket
wrench handle, remove bolt (32),
washer (33) and clamp (34) from rear,
left side of engine compartment at
torque converter.
Go to sheet 7
5-31
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 7 of 15)
REMOVAL (cont)
21.
Remove bolt (35), washer (36) and
clamp (37) from right side of engine
compartment at torque converter.
NOTE
The following is a difference
between M10A Forklift models.
22.
Using a 9/16” open end wrench, remove
b o l t 38), washer (39) and cl amp
(40), from vehicles S/N 2000 and
below
23.
Discon nect wire assembly (41) at
connector from ether start valve.
Go to sheet 8
5-32
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-3.
Main Wiring Harness. (Sheet 8 of 15)
REMOVAL
24.
Using a flat tip screwdriver,
disconnect three wire assemblies (42)
at terminals from engine water
temperature switch.
25.
Using a 9/16” socket and socket
wrench handle, remove bolt (43),
washer (44) and clamp (45).
26.
Disconnect two wire assemblies (46
and 47) at connectors from starter
lockout relays.
27.
Using 1/2” and 3/8” open end
wire
wrenches, disconnect two
assemblies (48) at terminals and
three wire assemblies (49) at
terminals from magnetic switch.
28.
Using a 7/16” open end wrench,
disconnect wire assembly (50) at
terminal from mounting bracket.
29.
Using a flat tip screwdriver,
disconnect two wire assemblies (51)
at terminals and wire assembly (52)
at terminal from hydraulic filter
head.
Go to sheet 9
5-33
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 9 of 15)
REMOVAL (cont)
30•
Pull back boot (53).
31.
Using a 3/4” open end wrench,
disconnect three wire assemblies (54)
at terminals from starter solenoid.
32.
Pull back boot (55).
33.
Using a 3/8” open end wrench,
disconnect wire assembly (56) at
terminal from top of fuel level
sending unit.
34.
Pull back boot (57).
35.
Using a flat tip screwdriver,
disconnect wire assembly (58) at
terminal from fuel solenoid.
36.
Remove harness (59) from vehicle.
NOTE
Refer to paragraph 2-13 for
electrical repair procedures for
terminals and connectors.
Go to sheet 10
5-34
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-3.
Main Wiring Harness. (Sheet 10 of 15)
INSTALLATION
37.
Position harness (59) throughout
vehicle.
38.
Using a flat tip screwdriver, connect
wire assembly (58) at terminal to
fuel solenoid.
39.
Position boot (57).
40.
Apply silicone sealant over entire
connection.
41.
Using a 3/8” open end wrench, connect
wire assembly (56) at terminal to top
of fuel level sending unit.
42.
Position boot (55).
43.
Apply silicone sealant over entire
connection.
44.
Using a 3/4” open end wrench, connect
three wire assemblies (54) at
terminals to starter solenoid.
45.
Position boot (53).
46.
Apply silicone sealant over entire
connection.
Go to sheet 11
5-35
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 11 of 15)
INSTALLATION (cont)
47.
Using a flat tip screwdriver, connect
wire assembly (52) at terminal and
two wire assemblies (51) at terminals
to hydraulic filter head.
48.
Apply silicone sealant over entire
connection.
49.
Using a 7/16” open end wrench,
connect wire assembly (50) at
terminal to mounting bracket.
50.
Apply silicone sealant over entire
connection.
51.
Using 1/2” and 3/8” open end
wire
wrenches, connect three
assemblies (49) at terminals and two
wire assemblies (48) at terminals to
magnetic switch.
52.
Apply silicone sealant over entire
connection.
53.
Connect two wire assemblies (47 and
46) at connectors to starter lockout
relays.
54.
Apply silicone sealant over entire
connection.
55.
Using a 9/16” socket and socket
wrench handle, install clamp (45),
washer (44) and bolt (43).
56.
Using a flat tip screwdriver, connect
three wire assemblies (42) at
terminals to engine water temperature
switch.
57.
Apply silicone sealant over entire
connection.
Go to sheet 12
5-36
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-3.
Main Wiring Harness. (Sheet 12 of 15)
INSTALLATION
58.
Connect wire assembly (41) at
connector to ether start valve.
59.
Apply silicone sealant over entire
connection.
NOTE
The following is a difference
between M10A Forklift models.
60.
Using a 9/16” open end wrench,
install clamp (40), washer (39) and
bolt (38), from vehicles S/N 2000 and
below.
61.
Install clamp (37), washer (36)
bolt (35).
62.
Install clamp (34), washer (33) and
bolt (32) in front, left side of
engine.
63.
Using a 3/8” open end wrench, connect
two wire assemblies (31) at terminals
to torque converter temperature
sender.
64.
Apply silicone sealant over
connection.
and
entire
Go to sheet 13
5-37
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 13 of 15)
INSTALLATION (cont)
65.
Position wire assembly (28) in front,
left side of hydraulic tank,
66.
Using a flat tip screwdriver, install
four washers (30) and screws (29).
67.
Connect wire assemblies
connectors.
68.
Apply silicone sealant over entire
connection.
(27) at
NOTE
The following is a difference
between M10A Forklift models.
69.
Using a 9/16” socket
wrench handle, install
four washers (25) and
from vehicles S/N 2001
left side of vehicle,
battery compartment.
70.
Using a flat tip screwdriver, connect
wire assembly (23) at terminal to
sensor in left side of engine.
71.
Apply silicone sealant over entire
connection.
72.
Connect three wire assemblies (22) at
terminals to oil pressure switch.
73.
Apply silicone sealant over entire
connection.
Go to sheet 14
5-38
and socket
plate (26),
bolts (24),
and above, in
underneath
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-3.
Main Wiring Harness. (Sheet 14 of 15)
INSTALLATION
74.
Connect terminal (21) to fan clutch.
75.
Position boot (20).
76.
Apply silicone sealant over
connection.
77.
Using a 3/8” open end wrench, connect
wire assembly (19) at terminal to
engine water temperature sender.
78.
Apply silicone sealant over entire
connection.
79•
Using a 1/2” open end wrench, connect
wire assemblies (18,17 and 16) at
terminals to alternator.
80.
Apply silicone sealant over entire
connection.
81.
Using a flat tip screwdriver, install
cover (15), two washers (14) and
screws (13).
82.
Connect two wire assemblies (12) at
terminals to left work light.
83.
Apply silicone sealant over entire
connection.
84.
Connect three wire assemblies (11) at
terminals to right work light and
frame.
85.
Apply silicone sealant over entire
connection.
entire
Go to sheet 15
5-39
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-3.
Main Wiring Harness. (Sheet 15 of 15)
INSTALLATION (cont)
NOTE
The following is a difference
between M10A Forklift models.
86.
Connect two wire assemblies (10) at
terminals to backup alarm, from
vehicles S/N 2001 and above.
87.
Apply silicone sealant over entire
connection.
88.
Connect three wire assemblies (9) at
terminals to left stop light and
taillight.
89.
Apply silicone sealant over entire
connection.
90.
Connect two wire assemblies (8 and 7)
at connectors to blackout lights.
91.
Apply silicone sealant over entire
connection.
92.
Connect three wire assemblies (6) at
terminals to right stop light and
taillight.
93.
Apply silicone sealant over entire
connection.
94.
Using a 9/16” socket and socket
wrench handle, install four clamps
(5), washers (4), nuts (3) and bolts
(2).
95.
Install a suitable number of tie
straps (1) to secure harness to
vehicle.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
5-40
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-4.
Intermediate Wiring Harness (S/N 2001 and above). (Sheet 1 of 4)
This task covers:
a.
Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Silicone sealant (App. C, Item 27)
Small tag (App. C, Item 28)
Tie strap
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Battery negative disconnected.
Go to sheet 2
5-41
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-4 l
Intermediate Wiring Harness (S/N 2001 and above). (Sheet 2 of 4)
REMOVAL
NOTE
For the following procedures,
disconnect is used to indicate
the separation of plugs,
connectors or terminals and the
removal of all attaching
hardware. To prevent loss,
reinstall attaching hardware in
its original position.
All electrical connections,
except those on the instrument
panel are sealed against
moisture with silicone sealant.
Remove all silicone sealant
before performing maintenance on
electrical connections.
All wire must be tagged when
removed from connector.
Indicate whether wire is
connected to pin-type or
socket-type connector.
Quantity of tie straps used to
secure harness is variable.
1.
Cut and discard tie straps (l).
2.
Disconnect lead assembly (11) from
pressure converter under right side
of cab.
Go to sheet 3
5-42
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-4.
Intermediate Wiring Harness (S/N 2001 and above). (Sheet 3 of 4)
REMOVAL
3.
Disconnect harness assembly (16) from
main harness in left, front of
hydraulic tank.
40
Using a 9/16” socket and socket
wrench handle, remove nut (2), washer
(3) and clamp (4) under left side of
cab.
5.
Disconnect lead assembly (5) from
ground driven steering pump switch.
6.
Pull back boot (6).
7.
Using a 9/16” open end wrench,
disconnect lead assembly (7) from
transmission.
8.
Using a 10” adjustable wrench, remove
nut (8), washer (9) and clamp (10).
9.
Disconnect lead assembly (11) from
pressure converter.
10.
Pull back two boots (12).
11.
Using a 3/8” open end wrench,
disconnect two lead assemblies (13)
from pressure converter.
12.
Using a flat tip screwdriver, remove
four screws (14) and washers (15)
from operator’s compartment.
13.
Remove harness assembly (16) from
vehicle.
NOTE
Refer to paragraph 2-13 for
electrical repair procedures to
terminals and connectors.
Go to sheet 4
5-43
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-4.
Intermediate Wiring Harness (S/N 2001 and above). (Sheet 4 of 4)
INSTALLATION
14.
Position harness assembly (16)
throughout vehicle.
15.
Using a flat tip screwdriver, install
four washers (15) and screws (14) in
operator’s compartment.
16.
Connect two lead assemblies (13) to
pressure converter under left side
of cab. Apply silicone sealant over
entire connection.
17.
Pull two boots (12) over terminals.
18.
Connect lead assembly (11) to
pressure converter.
19.
Using a 10” adjustable wrench,
install clamp (10), washer (9) and
nut (8).
20.
Using a flat tip screwdriver, connect
lead assembly (7) to transmission.
Apply silicone sealant over entire
connection.
21.
Pull boot (6) over terminal.
22.
Connect lead assembly (5) to ground
driven steering pump switch.
23.
Using a 9/16” socket and socket
wrench handle, install clamp (4),
washer (3) and nut (2).
24.
Connect harness assembly (16) to main
harness in left, front of hydraulic
tank.
25.
Connect lead assembly (11) to
pressure converter under right side
of cab.
26.
Install a suitable number of new tie
straps (1) to secure harness to
vehicle.
NOTE
Return M10A Forklift to original
equipment condition.
5-44
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-5.
Intermediate Wiring Harness (S/N 2000 and below). (Sheet 1 of 4)
This task covers:
a. Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Silicone sealant (App. C, Item 27)
Small tag (App. C, Item 28)
Tie strap
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
Condition Description
Battery negative disconnected.
References
TM 10-3930-643-20
REMOVAL
NOTE
For the following procedures,
disconnect is used to indicate
plugs ,
the separation of
connectors or terminals and the
attaching
removal of all
hardware. To prevent loss,
reinstall attaching hardware in
its original position.
All electrical connections,
except those on the instrument
against
panel are sealed
moisture with silicone sealant.
Remove all silicone sealant
before performing maintenance on
electrical connections.
Quantity of tie straps used to
secure harness is variable.
Go to sheet 2
5-45
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-5.
Intermediate Wiring Harness (S/N 2000 and below). (Sheet 2 of 4)
REMOVAL (cont)
1.
Using diagonal cutting pliers,
and discard tie straps (1).
cut
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to
pin-type or socket-type connector.
2.
Disconnect lead assembly (11) from
power cluster under right side of
cab.
3.
Disconnect harness assembly (16) from
main harness in left, front of
hydraulic tank.
4.
Using a 9/16” open end wrench, remove
nut (2), washer (3) and clamp (4)
under left side of cab.
5.
Using a 3/8” open end wrench,
disconnect lead assembly (5) from
ground driven steering pump switch.
6.
Pull back boot (6).
7.
Using a flat tip screwdriver,
disconnect lead assembly (7) from
transmission.
Go to sheet 3
5-46
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-5.
Intermediate Wiring Harness (S/N 2000 and below). (Sheet 3 of 4)
REMOVAL
8.
Using a 9/16” open end wrench, remove
nut (8), washer (9) and clamp (10).
9.
Disconnect lead assembly (11) from
power cluster.
10.
Pull back two boots (12).
11.
Using a 3/8” open end wrench,
disconnect two lead assemblies (13)
from power cluster.
12.
Using a flat tip screwdriver, remove
four screws (14) and washers (15)
from operator’s compartment.
13.
Remove harness assembly (16) from
vehicle.
NOTE
Refer to paragraph 2-13 for
electrical repair procedures to
terminals and connectors.
INSTALLATION
14.
Position harness assembly (16)
throughout vehicle.
15.
Using a flat tip screwdriver, install
four washers (15) and screws (14) in
operator’s compartment.
16.
Connect two lead assemblies (13) to
power cluster under left side of cab.
Apply silicone sealant over entire
connection.
17.
Pull two boots (12) over terminals.
18.
Connect lead assembly (11) to power
cluster.
19.
Using 9/16” open end wrench, install
clamp (10), washer (9) and nut (8).
Go to sheet 4
5-47
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
Intermediate Wiring Harness (S/N 2000 and below). (Sheet 4 of 4)
5-5.
INSTALLATION (cont)
20.
Using a flat tip screwdriver, connect
lead assembly (7) to transmission.
Apply silicone sealant over entire
connection.
21.
Pull boot (6) over terminal.
22.
Using a 3/8" open end wrench, connect
lead assembly (5) to ground driven
steering pump switch.
23.
Using a 9/16" open end wrench,
install clamp (4), washer (3) and nut
(2).
24.
Connect harness assembly (16) to main
harness in left, front hydraulic
tank.
25.
Connect lead assembly (11) to power
cluster under right side of cab.
26.
Install a suitable number of new tie
straps (1) to secure harness assembly
(16) to vehicle.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
5-48
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-6.
Fork Control Wiring Harness. (Sheet 1 of 4)
This task covers:
a.
Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Silicone sealant (App. C, Item 27)
Small tag (App. C, Item 28)
Tie strap
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Fork control switch removed.
Go to sheet 2
5-49
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-6.
Fork Control Wiring Harness. (Sheet 2 of 4)
REMOVAL
NOTE
For the following procedures,
disconnect is used to indicate
the separation of plugs,
connectors or terminals and the
removal of all attaching
hardware. To prevent loss,
reinstall attaching hardware in
its original position.
All electrical connections,
except those on the instrument
panel are sealed against
moisture with silicone sealant.
Remove all silicone sealant
before performing maintenance on
electrical connections.
The quantity of tie straps used
to secure harness is variable.
1.
Using diagonal cutting pliers, cut
and discard tie straps (1) in
operator’s compartment.
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to
pin-type or socket-type connector.
2*
Using a 1/2” socket and socket wrench
handle, remove clamp (2) from harness
assembly (13) in left side of
operator’s compartment.
GO to sheet 3
5-50
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-6.
Fork Control Wiring Harness. (Sheet 3 of 4)
REMOVAL
Disconnect lead assembly (3) from
intermediate harness right side of
cab.
4.
Using diagonal cutting pliers, cut
and discard tie straps (4) from
right, front of vehicle.
5.
Using a 1/2” socket and socket wrench
handle, remove three bolts (5),
washers (6) and clamps (7).
6.
Using a 9/16” open end wrench, remove
bolt (8) and washer (9).
7.
Using a flat blade screwdriver,
disconnect lead assembly (10) from
fork control valve.
8.
Remove wire
connector.
9.
Using diagonal cutting pliers,
and discard tie straps (12).
10.
Remove harness assembly (13).
assembly (11) at
cut
NOTE
Refer to paragraph 2-13 for
electrical repair procedures for
harness terminals and connectors.
Go to sheet 4
5-51
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-6. Fork Control Wiring Harness. (Sheet 4 of 4)
INSTALLATION
11.
Position harness assembly (13) on
right, front of vehicle.
12•
Install new tie straps (12).
13.
Connect wire assembly (11) at
connector to fork control valve.
14.
Position lead assembly (10) on fork
control valve.
15.
Using a 9/16” open end wrench,
install washer (9) and bolt (8).
16.
Apply silicone sealant over entire
connection.
17.
Using a 1/2” socket and socket wrench
handle, install three clamps (7),
washers (6) and bolts (5).
18.
Install new tie straps (4).
19.
Connect lead assembly (3) to
intermediate harness under right side
of cab.
20.
Install clamp (2) on harness assembly
(13) in left side of operator’s
compartment.
21.
Install new tie straps (l).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
5-52
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-7.
Front Lights Wiring Harness. (Sheet 1 of 7)
This task covers:
a.
Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Silicone sealant (App. C, Item 27)
Small tag (App. C, Item 28)
Tie strap
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Battery negative disconnected.
Go to sheet 2
5-53
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
Front Lights Wiring Harness. (Sheet 2 of 7)
5-7.
REMOVAL
1.
Remove two access covers (1) from
instrument panel housing, refer to
TM 10-3930-643-20.
NOTE
For the following procedure,
disconnect is used to indicate
the separation of plugs,
connectors or terminals and the
removal of all attaching
hardware. To prevent loss,
reinstall attaching hardware in
its original position.
All electrical connections,
except those on the instrument
panel are sealed against
moisture with silicone sealant.
Remove all silicone sealant
before performing maintenance on
electrical connections.
Quantity of tie straps used to
secure harness is variable.
2.
Using diagonal cutting pliers, cut
and discard four tie straps (2) from
front, left side of vehicle.
3.
Using a 9/16” socket and socket
wrench handle, remove nut (3), washer
(4) and clamp (5).
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to pintype or socket-type connector.
4.
Disconnect wire assemblies 6, 7 and
8) at connectors.
Go to sheet 3
5-54
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-7
●
Front Lights Wiring Harness. (Sheet 3 of 7)
REMOVAL
5.
Using a 3/8” open end wrench, remove
two screws (9) and washers (10).
6.
Disconnect wire assemblies (11) at
terminals.
7.
Remove nut (12) and washer (13).
8.
Disconnect wire assemblies (14 and
15) at terminal and shell.
9.
Remove terminal (16) and washer (17).
10.
Remove insulator (18).
11.
Disconnect wiring harness
terminal.
12.
Remove insulator (20).
13.
Disconnect wire assembly (21) at
terminal.
14.
Remove two plugs (22).
(19) at
Go to sheet 4
5-55
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-7.
Front Lights Wiring Harness. (Sheet 4 of 7)
REMOVAL (cont)
15.
Disconnect wire assembly (23) at
connector in front, right side of
vehicle.
16.
Remove insulator (24).
17.
Disconnect wire assembly (23) at
terminal and remove.
18.
Disconnect cable assembly
connector.
19.
Remove insulator (26).
20.
Disconnect wire assembly
terminal and remove.
21*
Using a flat tip screwdriver, remove
two plugs (27).
22.
Remove harness (28) from vehicle.
(25) at
(25) at
NOTE
Refer to paragraph 2-13 for
electrical repair procedures for
terminals and connectors.
Go to sheet 5
5-56
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-7.
Front Lights Wiring Harness. (Sheet 5 of 7)
INSTALLATION
23.
Position harness (28) throughout
vehicle.
24.
Install two plugs (27).
25.
Connect wire
terminal.
26.
Apply silicone sealant over
connection.
27.
Install insulator (26).
28.
Connect wire
connector.
29.
Apply silicone sealant over entire
connection.
30.
Connect wire
terminal.
31.
Apply silicone sealant over entire
connection.
32.
Install insulator (24).
33.
Connect wire
connector.
34.
Apply silicone sealant over entire
connection.
assembly (25) at
entire
assembly (25) at
assembly (23) at
assembly (23) at
Go to sheet 6
5-57
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE. (cont)
5-7.
Front Lights Wiring Harness. (Sheet 6 of 7)
INSTALLATION (cont)
35.
Install two plugs (22) in front, left
side of vehicle.
36.
Connect wire assembly (21) at
terminal.
37.
Apply silicone sealant over entire
connection.
38.
Install insulator (20).
39•
Connect wire
terminal.
40.
Apply silicone sealant over entire
connection.
41.
Install insulator (18).
42.
Using slip joint pliers, install
washer (17) and terminal (16).
43.
Connect wire assemblies (15 and 14)
at shell and terminal.
44.
Apply silicone sealant over entire
connection.
45.
Using a 3/8” open end wrench, install
washer (13) and nut (12).
46.
Connect wire assemblies (11) at
terminals.
47.
Apply silicone sealant over entire
connection.
48.
Install two washers (10) and screws
(9).
Go to sheet 7
5-58
assembly (19) at
TM 10-3930-643-34
ELECTRICAL SYSTEM MAINTENANCE.
5-7.
Front Lights Wiring Harness. (Sheet 7 of 7)
INSTALLATION
49.
Connect wire assemblies (8, 7 and 6)
at connectors.
50.
Apply silicone sealant over
connection.
51.
Using a 9/16” socket and socket
wrench handle, install clamp (5),
washer (4) and nut (3).
52.
Using slip joint pliers, install four
new tie straps (2).
53.
Install two access covers (1) in
instrument panel housing, refer to
TM 10-3930-643-20.
entire
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
5-59/(5-60 blank)
TM 10-3930-643-34
CHAPTER 6
TRANSMISSION
TROUBLESHOOTING AND MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently troubleshoot
and repair malfunctioning equipment and to perform authorized direct support
level maintenance procedures on the M10A Forklift transmission system.
INDEX
Title
Torque Converter Troubleshooting
Transmission Troubleshooting
Torque Converter
Torque Converter Charging Pump
Torque Converter and Transmission
Hoses, Lines and Fittings
Transmission Assembly
Transmission Oil Filter Base
Scheduling Valve and Control Valve
Transmission Oil Cooler
Paragraph
Page
6-1
6-2
6-3
6-4
6-2
6-6
6-11
6-20
6-5
6-6
6-7
6-8
6-9
6-26
6-36
6-48
6-54
6-58
6-1
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-1.
Torque Converter Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
a.
HIGH TORQUE CONVERTER OIL TEMPERATURE.
Step 1.
Transmission sump oil level too high or too low.
Add or drain to proper level, refer to LO 10-3930-643-12.
If oil level is correct, proceed to Step 2.
Step 2.
Check for foam in oil. If there is evidence of foam, check for
leaks in torque converter lines, refer to paragraph 6-5.
If there is no leakage in lines, proceed to Step 3.
Step 3.
Test for torque converter pressure.
If pressure is low, check pump for wear.
If torque converter pressure is accurate, proceed to Step 4.
Step 4 .
Check for low oil flow through torque converter.
Replace torque converter charging pump, refer to paragraph 6-4.
Step 5. Check regulating valve for operation.
If not operating properly, refer to paragraph 4-10.
Step 6.
Check for clogged transmission oil cooler.
Remove and clean, refer to paragraph 6-9.
6-2
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-1.
Torque Converter Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
b.
HIGH TORQUE CONVERTER "IN" PRESSURE.
Step 1.
Check for stuck torque converter or lubrication pressure
regulator valve.
Clean, replace or repair as necessary, refer to paragraph 6-3.
Step 2. Check for clogged transmission oil cooler.
Remove and clean, if necessary, refer to paragraph 6-9.
c. LOW TORQUE CONVERTER “IN” PRESSURE.
Step 1. Check for low transmission sump oil level.
Add oil to proper level, refer to LO 10-3930-643-12.
If oil level is correct, proceed to Step 2.
Step 2.
Low clutch pressure, refer to Transmission Troubleshooting,
If clutch pressure is correct, proceed to Step 3.
Step 3.
Check external transmission and torque converter oil lines for
leaks.
Replace as necessary, refer to paragraph 6-5.
If there is no sign of leakage, proceed to Step 4.
6-3
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-1.
Torque Converter Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
c.
LOW TORQUE CONVERTER “IN” PRESSURE. (cont)
Step 4.
Check for internal leakage in torque converter.
If leakage is suspected, contact General Support.
d.
LOSS OF POWER.
Check for low engine output, refer to Engine Troubleshooting.
e. HIGH ENGINE SPEED AT TORQUE CONVERTER STALL.
Step 1.
Check for low transmission sump oil level.
Add or drain oil as necessary, refer to LO 10-3930-643-12.
If oil level is correct, proceed to Step 2.
Step 2.
Check for foam in oil,
If foam is present, check connections on inlet side of charging pump,
refer to paragraph 6-4.
If no foam is present, proceed to Step 3.
6-4
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-1.
Torque Converter Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
e. HIGH ENGINE SPEED AT TORQUE CONVERTER STALL.
Step 3. Check for defective torque converter.
Replace, refer to paragraph 6-3.
f.
LOW ENGINE SPEED AT TORQUE CONVERTER STALL.
Check for low engine output, refer to Engine Troubleshooting.
6-5
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-2.
Transmission Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
a. HIGH OIL TEMPERATURE.
Refer to Torque Converter Troubleshooting.
b.
SLOW OR ERRATIC CLUTCH ENGAGEMENT.
Step 1.
Check for clogged oil filter or oil filter screens, refer to
LO 10-3930-643-12.
If transmission continues to shift roughly or erratically,
to Step 2.
Step 2.
Test for low clutch pressure.
in this section.
proceed
Refer to “low clutch pressure”
If clutch pressure is correct, proceed to Step 3.
Step 3.
Check to see if neutral knock down valve or
regulator valve sticking.
clutch pressure
Replace control and scheduling valve assembly, refer to paragraph
6-8.
If shifting is still erratic, proceed to Step 4.
Step 4.
Internal oil leaks. Shift through all gears to determine if
one or all clutches are malfunctioning.
Replace transmission, refer to paragraph 6-6.
c.
HIGH CLUTCH PRESSURE.
Check for improper main pressure regulator valve operation.
Replace or repair as necessary, refer to paragraph 6-8.
6-6
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-2.
Transmission Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
LOW CLUTCH PRESSURE.
Step 1.
Check for clogged oil filter or transmission screens.
Clean or replace as necessary, refer to LO 10-3930-643-12.
If filter and screens are operating, proceed to Step 2.
Step 2.
Check for foamed oil.
Tighten, replace or repair any external leaks in gaskets, lines or
fittings.
If no leaks are found, proceed to Step 3.
Step 3.
Improper clutch pressure regulator valve or neutral knock down
valve operation.
Replace control and scheduling valve assembly, refer to paragraph
6-8.
If clutch pressure is still low, proceed to Step 4.
Step 4. Pressure test while shifting transmission to determine internal
leakage.
Replace transmission if internal leakage is determined,
paragraph 6-6.
e.
refer to
HIGH OR LOW TORQUE CONVERTER “IN” PRESSURE.
Refer to Torque Converter Troubleshooting.
f.
LOSS OF POWER.
Step 1. Check engine, refer to Engine Troubleshooting.
If engine is running properly, proceed to Step 2.
Step 2.
Check torque converter, refer to Torque Converter Troubleshooting.
If torque converter is operating, proceed to Step 3.
6-7
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-2.
Transmission Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
f.
LOSS OF POWER. (cont)
Step 3.
Check for improper control of scheduling valve operation.
Replace, refer to paragraph 6-8.
If valve is functioning, proceed to Step 4.
Step 4.
Check for slipping clutches.
this section.
Refer to “Low Clutch Pressure” in
If transmission is fully operational, and loss of power continues,
check parking and vehicle brakes.
g.
VEHICLE DRIVES IN ONE DIRECTION AND CREEPS IN THAT DIRECTION IN NEUTRAL
BUT STALLS WHEN SHIFTED TO THE OPPOSITE DIRECTION.
Failed range clutch.
Replace transmission, refer to paragraph 6-6.
h.
VEHICLE DRIVES IN ONE RANGE, BUT STALLS WHEN SHIFTED TO ANOTHER RANGE.
Failed range clutch.
Replace transmission, refer to paragraph 6-6.
i. ALL RANGE PRESSURES NORMAL IN ONE DIRECTION BUT ALL LOW IN OPPOSITE
DIRECTION.
Internal oil leaks in forward or reverse clutch.
Replace transmission, refer to paragraph 6-6.
j .
LOW CLUTCH PRESSURE IN ONE RANGE (CLUTCH IN EITHER DIRECTION).
Internal oil leaks in clutch.
Replace transmission, refer to paragraph 6-6.
6-8
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
Transmission Troubleshooting.
6-2.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
k.
CLUTCH PRESSURE CHECK AT FULL POWER STALL.
When performing test with vehicle at full power stall, apply brakes
before engaging transmission and clear all personnel from the
immediate area. Failure to follow this procedure could result in
SEVERE INJURY and DEATH.
During full power stall, do not engage steering system, do not exceed
15 seconds per stall check and do not allow torque converter to exceed
normal operating temperature.
NOTE
Full stall is the speed of engine with throttle at maximum, vehicle in
highest gear with brakes applied and hydraulic control valve
activated to demand maximum hydraulic relief pressure.
Step 1.
Locate pressure tap at right side center of vehicle,
operator’s compartment.
under
6-9
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-2.
Transmission Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
k.
CLUTCH PRESSURE CHECK AT FULL POWER STALL. (cont)
Step 2.
Remove cap from pressure tap and attach pressure gage, as
shown.
Step 3.
Run engine and transmission until normal operating temperatures
are obtained, refer to TM 10-3930-643-10.
Step 4. Operate vehicle under full power stall. Read pressure gage.
Clutch pressure should be 270-310 psi.
Step 5. Place vehicle in park, apply parking brake and shut engine off.
Step 6.
6-10
Remove pressure gage and install cap on pressure tap.
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-3.
Torque Converter. (Sheet 1 of 9)
This task covers:
a. Testing
b. Removal
c. Cleaning/Inspection d. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Hoist and sling, capacity of
216 lbs.
1 inch eyebolt
Pressure gage set
NSN 4940-01-086-8756
References
TM 9-4910-571-12&P
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item S)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Small tag (App. C, Item 28)
Preformed packing (5)
Tie strap (2)
Torques
Bolts (22) to 20 lb-ft.
Bolts (27) to 33 to 37 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 12-19
Condition Description
Hydraulic reservoir removed.
Paragraph 12-2
Hydraulic pump removed.
Go to sheet 2
6-11
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-3.
Torque Converter. (Sheet 2 of 9)
TESTING
1.
Using an 11/16” open end wrench,
install pressure gage at clutch
pressure tap in transmission and
torque converter.
2.
Using a 3/4” open end wrench, install
pressure gage at torque converter
charge pressure tap.
3.
Operate engine.
NOTE
Engine, torque converter and
transmission should be at normal
operating temperature.
4.
Accelerate engine to 1000 to 1200 rpm
with transmission in neutral for not
longer than three minutes. Do not
exceed 1200 rpm.
5.
Using a pressure gage, check clutch
pressure. Clutch pressure should be
270 to 310 psi. If a minimum clutch
pressure of 160 psi is not reached
within 30 seconds after engine is
operating at low idle (675 to 700
rpm), shut down engine. Do not
perform stall check test.
6.
Using a pressure gage, check torque
converter charge pressure.
Charge
pressure should be 25 to 35 psi.
Go to sheet 3
6-12
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-3.
Torque Converter. (Sheet 3 of 9)
TESTING
7.
Perform stall check:
NOTE
Perform stall check using tachometer transducer tester for
vehicles 2001 and above.
Use
electronic tachometer for vehicles
2000 and below.
a. Apply parking brake.
b.
Install tachometer transducer
tester, refer to VTM-General
Setup and Checkout Instructions
in TM 9-4910-571-12&P.
c.
Increase engine speed to be sure
it will operate at high idle
(2650 to 2750 rpm).
d.
Shift transmission to forward and
third gear.
e. Depress accelerator to its
maximum position and record
engine rpm. Engine rpm should be
2300 to 2550 rpm.
Do not exceed 15 seconds per stall
check. Do not allow torque
normal
converter to exceed
operating temperature.
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
8.
Using 1-1/2” and 718” open end
wrenches, disconnect hose
assemblies (1, 2 and 3) in front
of engine.
Go to sheet 4
6-13
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-3.
Torque Converter. (Sheet 4 of 9)
REMOVAL (cont)
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to
pin-type or
socket-type
connector.
9.
Using a flat tip screwdriver and
a 3/8" open end wrench, disconnect wire assemblies (4 and 5) at
terminals.
10.
Using a 9/16” socket and socket
wrench handle, remove four bolts (6)
and two flange halves (7).
11.
Disconnect hose assembly (8).
12.
Using long round nose pliers, remove
and discard preformed packing (9).
13.
Using a 9/16” socket and socket
wrench handle, remove four bolts (10)
and two flange halves (11).
14.
Disconnect hose assembly (12).
15.
Using long round nose pliers, remove
and discard preformed packing (13).
16.
Using a 9/16” socket and socket
wrench handle, remove four bolts (14)
and two flange halves (15).
17.
Disconnect hose assembly (16).
18.
Using long round nose pliers, remove
and discard preformed packing (17).
Go to sheet 5
6-14
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-3.
Torque Converter. (Sheet 5 of 9)
REMOVAL
19.
Using a 9/16” socket and socket
wrench handle, remove four bolts (18)
and two flange halves (19).
20•
Disconnect hose assembly (20).
21.
Using long round nose pliers, remove
and discard preformed packing (21).
22.
Using a 1/2” open end wrench,
remove four bolts (22) and locknuts
(23).
23.
Using a flat blade screwdriver or pry
bar, disconnect drive shaft (24).
24.
Using a 1-1/2" open end wrench, remove
plug (25) and preformed packing (26).
Discard preformed packing (26).
25.
Using side cutting pliers, cut and
discard two tie straps and separate
hoses for easier access to torque
converter (28).
Weight of torque converter is
Use
approximately 180 lbs.
adequate hoist and sling for
Keep
removal and installation.
unnecessary
clear
of
area
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
26.
Install one inch eyebolt in plug
mounting hole; attach hoist and
sling.
27.
Using a 9/16” socket and socket
wrench handle, remove 12 bolts (27)
and torque converter (28). Use two
bolts (27) as pusher bolts near top
and bottom.
to sheet 6
6-15
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-3.
Torque Converter. (Sheet 6 of 9)
CLEANING/INSPECTION
28.
Wipe hose assemblies (1, 2, 3, 8, 12,
16 and 20) with clean cloth moistened
with detergent and water solution.
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
• COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
29.
Wipe outer surface of torque
converter (28) with clean cloth
dampened with cleaning solvent
P-D-680. Allow to air dry.
30.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
31.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 7
6-16
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-3.
Torque Converter. (Sheet 7 of 9)
INSTALLATION
32.
Position torque converter (28) on
flywheel housing.
33.
Using a 9/16” socket, socket wrench
handle, and 1/2” torque wrench,
install torque converter (28) and 12
bolts (27). Tighten bolts (27) to 33
then to 37 lb-ft.
34.
Install two new tie straps on
hoses, removed to gain easier
access to torque converter (28).
35.
Using a 1-1/2" open end wrench,
install new preformed packing (26)
and plug (25).
36.
Position drive shaft (24).
37.
Using a 1/2” socket, socket wrench
handle and 1/2” torque wrench,
install four locknuts (23) and bolts
(22). Tighten bolts (22) to 20
lb-ft.
38.
Install new preformed packing (21).
39.
Position hose assembly (20).
40.
Using a 9/16” socket and socket
wrench handle, install two flange
halves (19) and four bolts (18).
to sheet 8
6-17
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-3.
Torque Converter. (Sheet 8 of 9)
INSTALLATION (cont)
41.
Install new preformed packing (17).
42.
Position hose assembly (16).
43.
Using a 9/16” socket and socket
wrench handle, install two flange
halves (15) and four bolts (14).
44.
Install new preformed packing (13).
45.
Position hose assembly (12).
46.
Install two flange halves (11) and
four bolts (10).
47.
Install new preformed packing (9).
48.
Position hose assembly (8).
49.
Install two flange halves
four bolts (6).
Go to Sheet 9
6-18
(7) and
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-3.
Torque Converter. (Sheet 9 of 9)
INSTALLATION
50.
Using a flat tip screwdriver and a
3/8" open end wrench, connect wire
assemblies (5 and 4) at terminals.
51.
Using 1-1/2" and 7/8" open end
wrenches, connect hose assemblies
(3, 2 and 1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
6-19
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-4.
Torque Converter Charging Pump. (Sheet 1 of 6)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Small tag (App. C, Item 28)
Preformed packing (5)
Torques
Bolts (17) to 33 to 37 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
6-20
Condition Description
Engine top and side access covers
removed.
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-4.
Torque Converter Charging Pump. (Sheet 2 of 6)
REMOVAL
1.
Using a 9/16” socket and socket
wrench handle, remove four bolts (1)
and two flange halves (2) from
charging pump (18).
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
2.
Disconnect hose assembly (3).
3.
Using long round nose pliers, remove
and discard preformed packing (4).
4*
Using a 9/16” socket and socket
wrench handle, remove four bolts (5)
and two flange halves (6).
5.
Disconnect hose assembly (7).
6.
Using long round nose pliers, remove
and discard preformed packing (8).
Go to sheet 3
6-21
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-4.
Torque Converter Charging Pump. (Sheet
REMOVAL (cont)
7.
Using a 9/16" socket and socket
wrench handle, remove four bolts (9)
and two flange halves (10).
8.
Disconnect hose assembly (11).
9.
Using long round nose pliers, remove
and discard preformed packing (12).
10.
Using a 9/16" socket and socket
wrench handle, remove four bolts (13)
and two flange halves (14).
11.
Disconnect hose assembly (15).
12.
Using long round nose pliers, remove
and discard preformed packing (16).
13.
Using a 9/16" socket and socket
wrench handle, remove two bolts (17),
charging pump (18) and preformed
packing (19).
Discard preformed
packing (19).
Go to sheet 4
6-22
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-4.
Torque Converter Charging Pump. (Sheet 4 of 6)
CLEANING/INSPECTION
14.
Wipe hose assemblies (3, 7, 11 and
15) with clean cloth moistened with
detergent and water solution.
•TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
15.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
16.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
6-23
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-4.
Torque Converter Charging Pump. (Sheet 5 of 6)
INSTALLATION
17.
Using a 9/16" socket, socket wrench
handle and 1/2” torque wrench,
install new preformed packing (19),
charging pump (18) and two bolts (17)
in torque converter. Tighten bolts
(17) to 33 to 37 lb-ft.
18.
Install new preformed packing (16).
19. Connect hose assembly (15).
20,
Using a 9/16" socket and socket
wrench handle, install two flange
halves (14) and four bolts (13).
Go to sheet 6
6-24
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-4.
Torque Converter Charging Pump. (Sheet 6 of 6)
INSTALLATION
21.
Install new preformed packing (12).
22.
Connect hose assembly (11).
23.
Using a 9/16" socket and socket
wrench handle, install two flange
halves (10) and four bolts (9).
24.
Install new preformed packing (8).
25.
Connect hose assembly (7).
26.
Install two flange halves
four bolts (5).
27.
Install new preformed packing (4).
28.
Connect hose assembly (3).
29.
Install two flange halves
four bolts (l).
(6) and
(2) and
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
6-25
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 1 of
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic's
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Small tag (App. C, Item 28)
Preformed packing (11)
Tie strap (3)
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
6-26
Condition Description
Transmission oil drained.
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 2 of
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a 1-1/2" open end wrench,
disconnect hose assembly (3) from
torque converter.
2.
Remove union
packing (2).
packing (2).
3.
Remove hose assembly (3), elbow (4)
and preformed packing (5) from torque
Discard
converter oil filter.
preformed packing (5).
4.
Using a 5/8" open end wrench,
disconnect hose assembly (8) from
torque converter.
5.
Remove union
packing (7).
packing (7).
6.
Remove hose assembly (8), union (9)
and preformed packing (10) from
Discard preformed
transmission.
packing (10).
(1) and preformed
Discard preformed
(6) and preformed
Discard preformed
Go to sheet 3
6-27
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 3 of
-
REMOVAL (cont)
7.
Using a 1-1/2” open end wrench,
disconnect hose assembly (13) from
torque converter.
8.
Using slip joint pliers, remove elbow
(11) and preformed packing (12).
Discard preformed packing (12).
9.
Using a 1-1/2” open end wrench,
remove hose assembly (13) and elbow
(14) from transmission oil cooler.
10.
Using a 9/16” socket and socket
wrench handle, remove four bolts
(15), two flange halves (16) and
preformed packing (17) from torque
converter. Discard preformed packing
(17).
11.
Disconnect hose assembly (18).
12.
Using 1-3/8” and 1-1/2” open end
wrenches, remove hose assembly (18)
and adapter (19) from transmission.
13.
Using a 9/16” socket and socket
wrench handle, remove four bolts
(20), two flange halves (21) and
preformed packing (22) from torque
converter. Discard preformed packing
(22).
14.
Disconnect hose assembly (23).
15.
Using 1-3/8” and 1-1/2” open end
wrenches, remove hose assembly (23)
and adapter (24) from transmission.
Go to sheet 4
6-28
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 4 of
REMOVAL
16.
Using a 9/16” socket and socket
wrench handle, remove four bolts
(25), two flange halves (26) and
preformed packing (27) from torque
converter. Discard preformed packing
(27).
17.
Disconnect hose assembly (28).
18.
Using a 1-1/2" open end wrench,
remove hose assembly (28) and elbow
(29) from transmission.
19.
Using a 9/16" socket and socket
wrench handle, remove four bolts
(30), two flange halves (31) and
preformed packing (32) from torque
converter. Discard preformed packing
(32).
20.
Disconnect hose assembly (33).
21.
Using 1-1/2" and 3/4" open end
wrenches, remove hose assembly (33),
elbow (34) and preformed packing (35)
from torque converter oil filter.
Discard preformed packing (35).
Go to sheet 5
6-29
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 5 of
REMOVAL (cont)
22.
Using side cutting pliers, cut and
discard three tie straps (36).
23.
Using 9/16" and 3/4" open end
wrenches, remove nut (37), insert
(38), elbow (39) and reducer (40).
24.
Disconnect tube assembly (42).
25.
Remove nut (41), tube (42), insert
(43), elbow (44) and adapter (45)
from flywheel housing.
26.
Using a flat tip screwdriver and
1-3/8" open end wrench, remove clamp
(46) and elbow
transmission.
27.
Disconnect hose assembly (52)
28.
Using a 3/4" socket and socket wrench
handle, remove bolt (48), washer (49)
and clamp (50) from frame under
cradle.
29.
Using a flat tip screwdriver and
1-3/8” open end wrench, remove clamp
(51), hose (52) and nipple (53).
30,
Using a 9/16" socket and socket
wrench handle, remove locknut (54),
washer (55), clamp (56) and washer
(57) from frame under converter.
31.
Disconnect hose assembly (60).
32.
Using a 1-1/2" open end wrench,
remove union (58) and preformed
Discard preformed
packing (59).
packing (59).
33.
Remove hose assembly (60) from
transmission oil cooler.
Go to sheet 6
6-30
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 6 of
CLEANING/INSPECTION
34.
Wipe hose assemblies (3, 8, 13, 18,
23, 28, 33, 52 and 60) with clean
cloth moistened with detergent and
water solution.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
air
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
35.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
36.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 7
6-31
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 7 of
INSTALLATION
37.
Using a 1-1/2” open end wrench,
install hose assembly (60) in
transmission oil cooler.
38.
Install new preformed packing (59)
and union (58) in transmission.
39•
Using a 7/8” open end wrench, connect
hose assembly (60).
40.
Using a 9/16” socket and socket
wrench handle, install washer (57),
clamp (56), washer (55) and locknut
(54).
41.
Using a 1-3/8” open end wrench and a
flat tip screwdriver, install nipple
(53), hose (52) and clamp (51) on
frame.
42.
Using a 3/4” socket and socket wrench
handle, install clamp (50), washer
(49) and bolt (48).
43.
Connect hose
transmission.
44.
Using a 3/8” open end wrench and flat
tip screwdriver, install elbow (47)
and clamp (46).
45*
Using 9/16” and 3/4” open end
wrenches, install adapter (45), elbo
(44), insert (43), tube (42) and nut
(41) in flywheel housing.
46.
Connect tube (42) in transmission.
47.
Install reducer (40), elbow (39),
insert (38) and nut (37).
48.
Install three new tie straps (36).
Go to sheet 8
6-32
assembly (52) in
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 8 of
INSTALLATION
49.
Using 1-1/2" and 1-3/4" open end
wrenches, install new preformed
packing (35), elbow (34) and hose
assembly (33) in torque converter oil
filter.
50.
Connect hose assembly (33) to torque
converter.
51.
Using a 9/16" socket and socket
wrench handle, install new preformed
packing (32), two flange halves (31)
and four bolts (30).
52.
Using a 1-1/2" open end wrench,
install elbow (29) and hose assembly
(28) in transmission.
53.
Connect hose assembly (28) in torque
converter.
54.
Using a 9/16" socket and socket
wrench handle, install new preformed
packing (27), two flange halves (26)
and four bolts (25).
Go to sheet 9
6-33
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 9 of
INSTALLATION (cont)
55.
Using 1-3/8" and 1-1/2" open end
wrenches, install adapter (24) and
hose assembly (23) in transmission.
56
Connect hose assembly (23) in torque
converter.
❑
57.
Using a 9/16" socket and socket
wrench handle, install new preformed
packing (22), two flange halves (21)
and four bolts (20).
58.
Using 1-3/8" and 1-1/2" open end
wrenches, install adapter (19) and
hose assembly (18) in transmission.
59•
Connect hose assembly (18) in torque
converter.
600
Using a 9/16" socket and socket
wrench handle, install new preformed
packing (17), two flange halves (16)
and four bolts (15).
61.
Using a 1-1/2" open end wrench,
install elbow (14) and hose assembly
(13) in transmission oil cooler.
62.
Using slip joint pliers, install new
preformed packing (12) and elbow (11)
in torque converter.
63.
Using a 1-1/2" open end wrench,
connect hose assembly (13).
Go to sheet 10
6-34
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-5.
10)
Torque Converter and Transmission Hoses, Lines and Fittings. (Sheet 10 of
INSTALLATION
64.
Using a 5/8" open end wrench, install
new preformed packing (10), union (9)
and hose assembly
(8) in
transmission.
65.
Install new preformed packing (7) and
union (6) in torque converter.
66.
Connect hose assembly (8).
67.
Using 1-1/2" and 1-5/16" open end
wrenches, install new preformed
packing (5), elbow (4) and hose
assembly (3) in torque converter oil
filter.
68.
Install new preformed packing (2) and
union (1) in torque converter.
69.
Connect hose assembly (3).
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
6-35
TM 10-3930-643-34
TRANSMISSION
6-6
●
TROUBLESHOOTING AND MAINTENANCE. (cont)
Transmission Assembly. (Sheet 1 of 12)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Lifting eye, capacity of 730 lbs.
Hoist and cable, capacity of
730 lbs.
1-1/2” open end off set wrench (45)
NSN
Personnel Required
Three
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Small tag (App. C, Item 28)
Lifting eye (App. D, Item D-9)
Hexnut and washer
Preformed packing (2)
Cotter pin (2)
Gasket
Torques
Bolts (7 and 10) to 80 lb-ft.
Bolts (3 and 2) to 34 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Vehicle frames locked in straight-ahead
position.
TM 10-3930-643-20
Ground driven steering pump removed.
Propeller shaft-torque converter to
transmission removed.
Seat assembly removed.
Transmission fluid drained.
Go to sheet 2
6-36
TM
TRANSMISSION
6-6.
10-3930-643-34
TROUBLESHOOTING AND MAINTENANCE.
Transmission Assembly. (Sheet 2 of 12)
REMOVAL
1.
Using floor jack, raise vehicle 16”
inches off floor and support with
four jack stands.
2.
Drill a hole through floor plate (1)
of cab directly above tapped hole in
top of transmission. Make hole large
enough for a lifting eye capable of
supporting at least 4,000 lbs.
3.
Install lifting eye in hole in floor
of cab and secure with washer and
hexnut.
4.
Using a 9/16" open and box end
wrench, remove eight bolts (2)
disconnecting propeller shaft from
transmission rear output yoke to
rear axle.
5.
Using a 9/16" socket and socket
wrench handle, remove four bolts
(3) disconnecting transmission to
hanger bearing propeller shaft from
transmission front output yoke.
Go to sheet 3
6-37
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-6.
Transmission Assembly. (Sheet 3 of 12)
REMOVAL (cont)
6.
Using a flat tip screwdriver, loosen
clamp (19).
7.
Disconnect hose assembly (20).
8.
Using a 1-3/8" open end wrench,
remove elbow (21).
9.
Using a pipe wrench, remove gage (4),
nipple (5) and elbow (6) from right
side of transmission (53).
10.
Using a 3/4" socket and socket wrench
handle, remove two bolts (7), washers
(8) and plate (9) from right side of
transmission (53).
11.
Remove two bolts (10), washers (11)
and plate (12) from left side of
transmission (53).
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
12.
Using a 1-1/2" open end wrench,
disconnect hose assembly (13) from
underneath transmission (53).
13.
Using a 1-3/8" open end wrench,
remove adapter (14).
GO to sheet 4
6-38
TM 10-3930-643-34
TRANSMISSION
6-6.
TROUBLESHOOTING AND MAINTENANCE.
Transmission Assembly. (Sheet 4 of 12)
REMOVAL
14.
Using a 1-1/2" open end wrench,
disconnect hose assembly (15).
15.
Using a 1-3/8" open end wrench,
remove adapter (16).
16.
Using a 1-1/2" open end wrench,
disconnect hose assembly (17) from
front, right side of transmission
(53).
Using a 5/8" open end wrench,
disconnect hose assembly (17a).
17.
18.
Using a pipe wrench, remove elbow
(18).
19.
Using a 1-1/4" open end wrench,
disconnect hose assembly (22).
20.
Using a 1-1/16" open end wrench,
remove elbow (23).
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to
pin-type or socket-type connector.
21.
Disconnect two wire assemblies
at terminals.
22.
Using a 1" open and box end wrench,
remove switch (25), coupling (26)
and nipple (27).
23.
Using a 9/16" socket and socket
wrench handle, remove two bolts (28),
washers (29) and bracket (30).
(24)
24.
Using a 5/8" open end wrench,
disconnect tube assembly (31).
25.
Using 3/4" and 9/16" open end
wrenches, remove elbow (32) and
reducer (33).
Go to sheet 5
6-39
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-6.
Transmission Assembly. (Sheet 5 of 12)
REMOVAL (cont)
26.
Using a 7/16" open end wrench,
disconnect hose assembly (34) from
transmission (53).
27.
Using a 1-1/2" open end off set wrench
disconnect hose assembly (34a).
28.
Remove union (35) and preformed
packing (36). Discard preformed
packing (36).
29.
Using a 7/8” open end wrench,
disconnect hose assembly (37) from
control and scheduling valve on
transmission (53).
30.
Using a 13/16" open end wrench,
remove union (38) and preformed
Discard preformed
packing (39).
packing (39).
31.
Using long round nose pliers, remove
cotter pin (40) and pin (41).
Discard cotter pin (40).
32.
Disconnect clevis (42).
33.
Using a 9/16" socket and socket
wrench handle, remove four nuts (45a)
and bolts (45b). Slide grommet (45c)
forward, away from bracket (50).
34.
Remove cotter pin (43) and pin (44).
Discard cotter pin (43).
35.
Disconnect clevis (45).
36.
Using a 3/4" socket and socket wrench
handle, remove two bolts (46),
washers (47), bolts (48) and washers
(49) from top of transmission (53).
37.
Remove bracket (50).
Go to sheet 6
6-40
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-6.
Transmission Assembly. (Sheet 6 of 12)
REMOVAL
38.
Using a 1-1/8" socket and socket
wrench handle, remove plug (51) and
gasket (52). Discard gasket (52).
Remove all gasket material from
mounting surfaces.
WEIGHT HAZARD
Weight of transmission assembly is
approximately 730 lbs.
Use
adequate hoist and cable for
removal and installation.
Keep
unnecessary
area clear of
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
39.
Attach lifting eye to top of
transmission (53) at mounting bore
for plug (51), refer to Appendix D,
part D-9 for fabrication of lifting
eye.
40.
Attach a cable to lifting eye
installed in transmission (53) and
run cable through lifting eye
installed in floor plate (1) of cab
to a winch mounted to the side of the
vehicle.
41.
Raise transmission (53) high enough
to clear pin supports in rear vehicle
frame.
42.
Tip transmission (53) to rear of
vehicle and lower.
43.
Using a 3/4" socket and socket wrench
handle, remove eight bolts (54),
washers (55) and bracket (56) from
transmission (53).
44.
Using a 3/4" socket, socket wrench
handle and a 3/4” open end wrench,
remove seven nuts (57), washers (58),
bolts (59), washers (60) and bracket
(61).
Go to sheet 7
6-41
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-6.
Transmission Assembly. (Sheet 7 of 12)
CLEANING/INSPECTION
45.
Wipe hose and tube assemblies (13,
15, 17, 20, 22, 31, 34 and 37) with
clean cloth moistened with detergent
and water solution. Wipe dry with
clean cloth.
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
46.
Wipe gage (4) with clean cloth
moistened with cleaning solvent
P-D-680. Allow to air dry.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
47.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 8
6-42
48.
TM 10-3930-643-34
TRANSMISSION
6-6.
TROUBLESHOOTING AND MAINTENANCE.
Transmission Assembly. (Sheet 8 of 12)
INSTALLATION
49.
Using a 3/4" socket, socket wrench
handle and a 3/4" open end wrench,
install bracket (61), seven washers
(60)9 bolts (59), washers (58) and
nuts (57) in transmission (53).
50.
Using a 3/4" socket and socket wrench
handle, install bracket (56), eight
washers (55) and bolts (54) in
transmission (53).
WEIGHT HAZARD
Weight of transmission assembly
Use
is approximately 730 lbs.
adequate hoist and cable for
installation. Keep area clear of
Failure
unnecessary personnel.
to follow this procedure could
result in SEVERE INJURY.
51.
Position transmission (53) underneath
vehicle.
52.
Attach cable to lifting eye on top of
transmission (53) and lifting eye
installed in floor plate (1) of cab.
53.
Using hoist and chain, raise transmission (53) up, pushing it to rear
of vehicle, clearing the left side.
Position pins on brackets (56 and
61) into pin supports in vehicle
rear frame.
54.
Remove hoist, cable and lifting eye
from top of transmission (53).
55.
Using a 1-1/8" socket and socket
wrench handle, install new gasket
(52) and plug (51) in top of
transmission (53).
6-43
TM 10-3930-643-34
TROUBLESHOOTING AND MAINTENANCE. (cont)
TRANSMISSION
6-6.
Transmission Assembly. (Sheet 9 of 12)
INSTALLATION (cont)
56.
Install bracket (50).
57.
Using a 3/4" socket and socket wrench
handle, install two washers (49),
bolts (48), washers (47) and bolts
(46).
58.
Connect clevis (45) to control and
scheduling valve on transmission
(53).
59.
Using long round nose pliers, install
pin (44) and new cotter pin (43).
60.
Slide grommet (45c) back
bracket (50) and using a
socket and socket wrench
install four bolts (45b)
(45a) .
61.
Connect clevis (42).
62.
Using long round nose pliers,
install pin (41) and new cotter
pin (40).
63.
Using a 13/16" open end wrench,
install new preformed packing (39)
and union (38).
64.
Using a 7/8" open end wrench, connect
hose assembly (37).
65.
Using a
wrench,
packing
rear of
66.
Connect hose assembly (34a).
67.
Using a 7/16" open end wrench,
connect hose assembly (34).
1-1/2" open end off set
install new preformed
(36) and union (35) in
transmission (53).
Go to sheet 10
6-44
toward
9/16”
handle,
and nuts
TM 10-3930-643-34
TRANSMISSION
6-6.
TROUBLESHOOTING AND MAINTENANCE.
Transmission Assembly. (Sheet 10 of 12)
INSTALLATION
68. Using 3/4" and 9/16" open end
wrenches, install reducer (33) and
elbow (32) in right side of transmission (53).
69. Using a 5/8" open end wrench, connect
tube assembly (31).
70.
Using a 9/16" socket and socket wrench
handle, install bracket (30), two
washers (29) and bolts (28).
71.
Using a 1" open and box end wrench,
install nipple (27), coupling (26)
and switch (25).
72.
Connect two wire assemblies (24) at
terminals.
73.
Using a 1-1/16" open end wrench,
install elbow (23).
74.
Using a 1-1/4" open end wrench,
connect hose assembly (22).
75.
Using a pipe wrench, install elbow
(18) .
76.
Using a 5/8" open end wrench, connect
hose assembly (17a).
77.
Using a 1-1/2" open end wrench,
connect hose assembly (17) under
transmission (53).
78.
Using a 1-3/8" open end wrench,
install adapter (16).
79.
Using a 1-1/2" open end wrench,
install hose assembly (15).
Go to sheet 11
6-45
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-6.
Transmission Assembly. (Sheet 11 of 12)
INSTALLATION (cont)
80.
Using a 1-3/8" open end wrench,
install adapter (14).
81.
Using a 1-1/2" open end wrench,
connect hose assembly (13) under
transmission (53).
NOTE
Tighten bolts finger tight only.
82.
Using a 3/4" socket and socket wrench
handle, install plate (12), two
washers (11) and bolts (10).
NOTE
Tighten bolts finger tight only.
83.
Install plate (9), two washers
and bolts (7).
(8)
NOTE
Clearance should be 1/16 inch.
If clearance is less, plate must
be replaced. If clearance is
1/16 inch, torque bolts to 80
lb-ft .
84.
Using a feeler gage, measure
clearance between plates (9 and 12)
and support block.
85.
Using pipe wrench, install elbow (6),
nipple (5) and gage (4) at right side
of transmission (53).
86.
Using a 1-3/8" open end wrench,
install elbow (21).
87.
Connect hose assembly (20).
88.
Using a flat tip screwdriver,
tighten clamp (19).
89.
Position hanger bearing propeller
shaft from transmission front output yoke to rear of transmission (53).
Go to sheet 12
6-46
TM 10-3930-643-34
TRANSMISSION
6-6.
TROUBLESHOOTING AND MAINTENANCE.
Transmission Assembly. (Sheet 6 of 12)
INSTALLATION
90.
Using a 9/16" socket, socket wrench
handle and torque wrench, install
four bolts (3) connecting propeller
shaft to transmission (53). Tighten
bolts (3) to 34 lb-ft.
91.
Position propeller shaft from rear
output yoke to rear axle.
92.
Using a 9/16" open and box end wrench,
install four bolts (2) connecting
propeller shaft to transmission (53).
Tighten bolts (2) to 34 lb-ft.
93.
Remove hexnut, washer and lifting
eye from floor plate (1) of cab.
94.
Using floor jack, remove four jack
stands and lower vehicle to the
ground.
END OF TASK
6-47
TM
10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-7.
Transmission Oil Filter Base. (Sheet 1 of 6)
This task covers:
a.
c.
e.
Removal
Cleaning/Inspection
Installation
b.
d.
Disassembly
Assembly
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2" Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Preformed packing (2)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
6-48
Condition Description
Transmission oil filter
element removed.
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-7.
Transmission Oil Filter Base. (Sheet 2 of 6)
REMOVAL
NOTE
● Tag all hose and tube assemblies
before disconnecting to aid in
installation.
The following are differences
between M1OA Forklift models.
The removal/installation
procedures are identical.
1.
Using a 1-1/2” open end wrench,
disconnect hose assembly (l).
2.
Using a 9/16” open end wrench,
disconnect hose assembly (2) on
inside, left of frame, from vehicles
S/N 2001 and above.
3.
Remove elbow (3) from vehicles S/N
2001 and above.
4.
Using a 1-1/2” open end wrench,
disconnect hose assembly (4).
5.
Remove elbow
packing (6).
packing (6).
(5) and preformed
Discard preformed
Go to sheet 3
6-49
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-7.
Transmission Oil Filter Base. (Sheet 3 of 6)
REMOVAL (cent)
6.
Using a 1-1/2" open end wrench,
remove elbow (7) and preformed
packing (8).
Discard preformed
packing (8).
7.
using a 9/16" socket and socket
wrench handle, remove four bolts (9),
washers (10) and base (11).
8.
Using a 3/4" socket, socket wrench
handle and a 3/4" open end wrench,
remove three bolts (12), nuts (13),
washers (14) and bracket (15).
DISASSEMBLY
9.
Using internal snap ring pliers,
remove retaining ring (16), washer
(17), spring (18) and valve (19) from
base (11).
10.
Using a 1/4" socket head screw key,
remove plug (20) from base (11).
11.
Remove plug (21) from vehicles S/N
2000 and below.
Go to sheet 4
6-50
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-7.
Transmission Oil Filter Base. (Sheet 4 of 6)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
•
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
12.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
13.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
6-51
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-7.
Transmission Oil Filter Base. (Sheet 5 of 6)
ASSEMBLY
14.
Using a 1/4" socket head screw key,
install plug (21) on vehicles S/N
2000 and below.
15.
Install plug (20).
16.
Using internal snap ring pliers,
install valve (19), spring (18),
washer (17) and retaining ring (16).
INSTALLATION
17.
Using a 3/4" socket, socket wrench
handle and a 3/4" open end wrench,
install bracket (15), three washers
(14), nuts (13) and bolts (12) on
inside, left of frame.
18.
Using a 9/16" socket and socket
wrench handle, install base (11),
four washers (10) and bolts (9).
19.
Using a 1-1/2" open end wrench,
install new preformed packing (8) and
elbow (7).
GO to sheet 6
6-52
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-7.
Transmission Oil Filter Base. (Sheet 6 of 6)
INSTALLATION
20.
Using a 1-1/2" open end wrench,
install new preformed packing (6) and
elbow (5).
21.
Connect hose assembly (4).
22.
Using a 9/16” open end wrench,
install elbow (3) on
2001 and above.
vehicles S/N
23.
Connect hose assembly (2) on vehicles
S/N 2001 and above.
24.
Using a 1-1/2” open end wrench,
connect hose assembly (l).
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
6-53
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-8.
Scheduling Valve and Control Valve. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Detergent (App. C, Item 33)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Preformed packing (13)
Cotter pin (2)
Plug (2)
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Vehicle frames locked in straight ahead
position.
TM 10-3930-643-20
Transmission fluid drained.
Go to sheet 2
6-54
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-8.
Scheduling Valve and Control Valve. (Sheet 2 of 4)
REMOVAL
1.
Using long round nose pliers, remove
cotter pin (1), pin (2), cotter pin
(3) and pin (4) from transmission.
Discard cotter pins (1 and 3).
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
2.
Using a 7/8" open end wrench,
disconnect tube (5).
3.
Remove union (6) from tee (19).
4.
Using a 7/16" open end wrench,
disconnect tube (7).
NOTE
Plug all ports in valves to
prevent entry of foreign material
or dirt.
5*
Using 1/2" and 5/8" open end
wrenches, remove elbow (8) and air
cylinder (9) from control valve (14).
Go to sheet 3
6-55
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cent)
6-8.
Scheduling Valve and Control Valve. (Sheet 3 of 4)
REMOVAL (cont)
6.
Using a 9/16” socket and socket
wrench handle, remove three bolts
(10), washers (11), scheduling valve
(12), six preformed packings (13),
control valve (14) and six preformed
packings (15). Discard six preformed
packings (13 and 15).
7.
Using a 1“ open end wrench, remove
items 16 thru 19 as an assembly,
coupling (20) and preformed packing
(21) from scheduling valve (12).
Discard preformed packing (21).
8.
Using 9/16” and 11/16" open end
wrenches, remove cap (16), coupling
(17) and adapter (18) from tee (19).
CLEANING/INSPECTION
9.
10•
Clean all parts with mild detergent
and wipe dry with clean cloth. Refer
to paragraph 2-8.
Inspect all parts. Refer to paragraph 2-9.
INSTALLATION
11.
Using 9/16" and 11/16" open end
wrenches, install adapter (18),
coupling (17) and cap (16) to tee
(19).
12.
Using a 1" open end wrench, install
new preformed packing (21), coupling
(20) and items 16 thru 19 as an
assembly to scheduling valve (12).
Go to sheet 4
6-56
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-8.
Scheduling Valve and Control Valve. (Sheet 4 of 4)
INSTALLATION
13.
Using a 9/16" socket and socket
wrench handle, install six new
preformed packings (15), control
valve (14), six new preformed
packings (13), scheduling valve (12),
three washers (11) and bolts (10).
14.
Using 1/2" and 5/8” open end
wrenches, install air cylinder (9)
and elbow (8) into control valve
(14).
15.
Using a 7/16" open end wrench,
connect tube (7) to elbow (8).
16.
Using a 7/8" open end wrench, install
union (6) to tee (19).
17. Connect tube (5) to union (6).
18.
Using long round nose pliers, install
pin (4), new cotter pin (3), pin (2)
and new cotter pin (l).
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
6-57
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cent)
6-9.
Transmission Oil Cooler. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
1-1/2” Open end wrench
NSN 5120-00-184-8438
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Detergent (App. C, Item 33)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Left engine side access cover
removed.
Paragraph 4-9
Engine oil cooler removed.
Go to sheet 2
6-58
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-9.
Transmission Oil Cooler. (Sheet 2 of 4)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a flat tip screwdriver,
disconnect hose assemblies (1 and 2)
from left side of engine.
2.
Using a 1-1/2" open end wrench,
disconnect hose assemblies (3 and 4).
3.
Using a flat tip screwdriver, remove
clamp (5), tube (6), clamp (7) and
hose (8).
4.
Disconnect hose assembly (9).
NOTE
The difference between oil cooler
(12) and oil cooler assembly (13)
is removable clamps on the oil
cooler assembly (13).
5.
Using a 1/2" socket and socket wrench
handle, remove four nuts (lo),
washers (11), oil cooler (12) or oil
cooler assembly (13) and four washers
(14).
6.
Using two 3/4" open end wrenches,
remove two nuts (15), washers (16),
bolts (17) and clamps (18) from oil
cooler assembly (13), if removed.
Go to sheet 3
6-59
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE. (cont)
6-9.
Transmission Oil Cooler. (Sheet 3 of 4)
CLEANING/INSPECTION
7.
Wipe hoses (1, 2, 3, 4, 8 and 10)
with clean cloth moistened with
detergent and water solution.
Dry
with clean cloths.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
8.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
9.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
6-60
TM 10-3930-643-34
TRANSMISSION TROUBLESHOOTING AND MAINTENANCE.
6-9.
Transmission Oil Cooler. (Sheet 4 of 4)
INSTALLATION
10.
Using two 3/4" open end wrenches,
install two clamps (18), bolts (17),
washers (16) and nuts (15) on oil
cooler assembly (13), if removed.
11.
Using a 1/2" socket and socket wrench
handle, install four washers (14),
oil cooler assembly (13) or oil
cooler (12), four washers (11) and
nuts (10).
12.
Using a flat tip screwdriver, connect
hose assembly (9).
13.
Install hose (8), clamp (7), tube (6)
and clamp (5).
14.
Using a 1-1/2" open end wrench,
connect hose assemblies (4 and 3).
15.
Using a flat tip screwdriver, connect
hose assemblies (2 and 1).
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
6-61/(6-62 blank)
TM 10-3930-643-34
CHAPTER 7
FRONT AND REAR AXLES
TROUBLESHOOTING AND MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently troubleshoot
and repair malfunctioning equipment and to perform authorized direct support
level maintenance procedures on the M1OA Forklift front and rear axles.
INDEX
Title
Front and Rear Axles Troubleshooting
Front Axle Assembly (S/N 2001 to 2903)
Front Axle Assembly (S/N 2000 and below/and
S/N 2904 and above)
Front Differential Carrier Assembly
Front and Rear Planetary
Rear Drive Axle (S/N 2001 and above)
Rear Axle Assembly (S/N 2000 and below)
Rear Differential Carrier Assembly
Paragraph
Page
7-1
7-2
7-2
7-5
7-3
7-4
7-5
7-6
7-7
7-8
7-11
7-20
7-24
7-32
7-39
7-46
7-1
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-1.
Front and Rear Axles Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
a.
NOISE WHEN DRIVING.
Step 1.
Check lubricant level.
If level is low, inspect for leaks.
If leak exists, take necessary corrective action.
If level is low and no leaks exist, refill lubricant to proper
level, refer to LO 10-3930-643-12.
Step 2. Inspect for scored or damaged wheel bearings.
If wheel bearings are satisfactory, install and check for
possibility of improper adjustment of wheel bearing, refer to
paragraph 7-5 for wheel bearing inspection, replacement or
adjustment.
If wheel bearings are operating, proceed to Step 3.
Step 3.
Check for bent shaft or worn or damaged gear teeth on axle
shaft.
Replace, refer to paragraph 7-2 or 7-3 for front axle and 7-6 or 7-7
for rear axle.
If axles are satisfactory, proceed to Step 4.
Step 4.
Inspect ring gear and bearings in planetary.
If damaged, replace, refer to paragraph 7-5.
If damage is to planetary carrier assembly, contact General Support.
If planetary is functioning, proceed to Step 5.
Step 5. Differential pinion and ring gear adjustment too tight.
Contact General Support.
7-2
TM
10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-1.
Front and Rear Axles Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
b.
NOISE ON TURNS.
Differential side gears or pinion gears defective.
Contact General Support.
c.
NOISE WHILE VEHICLE IS COASTING.
Defective or misadjusted differential.
Contact General Support.
d.
e.
DIFFERENTIAL OVERHEATS.
Step 1.
Check for correct lubricant level, refer to LO 10-3930-643-12.
Step 2.
Defective differential, refer to paragraph 7-4 for front
paragraph 7-8 for rear differential replacement.
and
LOSS OF LUBRICANT.
Step 1. Check for correct level of lubricant, refer to LO 10-3930643-12.
If lubricant level is correct, proceed to Step 2.
Step 2.
Check for leaks.
Leak at planetary cover gasket, refer to paragraph 7-5.
Leak at differential, refer to paragraph 7-4 for front and paragraph
7-8 for rear.
7-3
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-1.
Front and Rear Axles Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
e.
LOSS OF LUBRICANT. (cont)
If leak is at differential drive yoke, contact General Support.
If no external leaks exist, proceed to Step 3.
Step 3.
Check for oil behind wheel in brake compartments.
If oil is leaking into brake compartment,
housing oil seal, refer to paragraph 7-5.
f.
replace
DIFFERENTIAL OIL LEVEL RISES.
Replace drive axle oil seal, refer to paragraph 7-5.
7-4
axle
spindle
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-2.
Front Axle Assembly (S/N 2001 to 2903). (Sheet 1 of 6)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Shop Equipment, Automotive
Maintenance and Repair:
Organizational Maintenance,
Common No. 2, Less Power
NSN 4910-00-754-0650
Jack stand (2)
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Preformed packing (2)
Wood block (2)
Bolts (29) to 680 lb-ft.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Front axle drained.
TM 10-3930-643-20
Front wheels removed.
Paragraph 7-5
Front planetaries removed.
Paragraph 8-4
Front service brakes removed.
Go to sheet 2
7-5
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-2.
Front Axle Assembly (S/N 2001 to 2903). (Sheet 2 of 6)
REMOVAL
NOTE
Vehicle must be raised off the
ground and supported with jack
stands under the frame for the
following procedure.
1.
Using a 9/16" socket and socket
wrench handle, disconnect propeller
shaft (1) from under front of
vehicle, refer to TM 10-3930-643-20.
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
2.
Using a 1/2" box and open end wrench,
disconnect tube assembly (2).
3.
Using a 7/16" socket, socket wrench
handle and a 7/16" open end wrench,
remove nut (3), washer (4), bolt (5)
and washer (6).
4.
Using a 9/16" socket, socket wench
handle and a 9/16" open end wrench,
remove nut (7), washer (8), bolt (9),
washer (10) and clamp (11) from right
side of axle assembly.
5.
Using a 9/16" socket and socket
wrench handle, remove two bolts (12),
washers (13) and access cover (14).
Go to sheet 3
7-6
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-2.
Front Axle Assembly (S/N 2001 to 2903). (Sheet 3 of 6)
REMOVAL
6.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove nut (15), washer (16), bolt
(17), washer (18) and clamp (19).
7.
Using a 9/16” socket and socket
wrench handle, remove two bolts (20),
washers (21) and access cover (22).
8.
Using two 7/16" box and open end
wrenches, remove tube assemblies (23).
9.
Using a 3/4” socket and socket wrench
handle, remove bolt (24), washer (25)
and clamp (26).
WEIGHT HAZARD
Use transmission and differential
lift for removal and installation.
Keep area clear of unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
10.
Position transmission and differential
lift under front axle assembly.
11.
Using a 1-1/2” socket, socket wrench
handle and a 1-1/2” open end wrench,
remove eight nuts (27), washers (28),
bolts (29), washers (30) and front
axle assembly.
12.
Place front axle assembly on wood
blocks and remove transmission and
differential lift.
13.
Using a 7/16” socket and socket
wrench, remove plug (31).
14.
Using a 1-1/4” socket and socket
wrench handle, remove plug (32),
preformed packing (33), plug (34)
and preformed packing (35). Discard
preformed packings (33 and 35).
Go to sheet 4
7-7
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-2.
Front Axle Assembly (S/N 2001 to 2903). (Sheet 4 of 6)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
solvent,
get
immediately.
15.
Wipe front axle assembly with clean
cloth moistened with cleaning solvent
P-D-680. Allow to air dry.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
16.
Clean all other parts with clean
cloths moistened with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
17.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
7-8
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-2.
Front Axle Assembly (S/N 2001 to 2903). (Sheet 5 of 6)
INSTALLATION
18.
Using a 1-1/4” socket and socket
wrench handle, install new preformed
packing (35), plug (34), new
preformed packing (33) and plug (32).
19.
Using an 11/16” socket and socket
wrench handle, install plug (31).
20.
Using a transmission and differential
lift, position front axle assembly
under front of vehicle.
21.
Using a 1-1/2” socket, socket wrench
handle and a 1-1/2” open end wrench,
install eight washers (30), bolts
(29), washers (28) and nuts (27).
Using a 3/4” torque wrench, tighten
bolts (29) to 680 lb-ft.
22.
Using a 3/4” socket and socket wrench
handle, install clamp (26), washer
(25) and bolt (24).
23.
Using two 7/16” box and open end
wrenches, position and install tube
assemblies (23).
Go to sheet 6
7-9
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-2.
Front Axle Assembly (S/N 2001 to 2903). (Sheet 6 of 6)
INSTALLATION (cont)
24.
Using a 9/16” socket and socket
wrench handle, and install access
cover (22), two washers (21) and
bolts (20).
25.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
install clamp (19), washer (18), bolt
(17), washer (16) and nut (15).
26.
Using a 9/16” socket and socket
wrench handle, install access cover
(14), two washers (13) and bolts
(12).
27.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
install clamp (11), washer (10), bolt
(9), washer (8) and nut (7).
28.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
install washer (6), bolt (5), washer
(4) and nut (3).
29.
Using 3/4” and 13/16” box and open
end wrenches, connect tube assembly
(2).
30.
Using a 1/2” socket, socket wrench
handle and a 1/2” open end wrench,
connect propeller shaft (l), refer
to TM 10-3930-643-20.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
7-10
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 1
of 9)
This task covers:
a.
c*
Removal
Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Transmission and Differential Lift
NSN 4910-00-585-3622
Jack stands (2)
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Preformed packing (7)
Wood block (2)
Torques
Nuts (19) to 680 lb-ft.
Nuts (25) to 270 to 300 lb-ft.
Nuts (33) to 270 to 300 lb-ft.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Front axle drained.
TM 10-3930–643–20
Front wheels removed.
Paragraph 7-5
Front planetaries removed.
Paragraph 8-4
Front service brakes removed.
Go to sheet 2
7-11
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 2
of 9)
REMOVAL
Vehicle must be raised off the
ground and supported with jack
stands under the frame for the
following procedure.
1.
Using 7/16” and 1/2” open end
wrenches, disconnect tube assembly
(1) from front, underside of vehicle.
2.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
remove nut (2), washer (3), bolt (4)
and washer (5).
3.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove nut (6), washer (7), bolt (8)
and clamp (9) from right side of axle
assembly.
4.
Remove nut (10), washer (11), bolt
(12) and clamp (13) from left side of
axle assembly.
Go to sheet 3
7-12
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 3
of 9)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
5.
Using 7/16” and 13/16” box and open
end wrenches, remove tube assemblies
(14).
6.
Using a 3/4” socket and socket wrench
handle, remove bolt (15), washer (16)
and clamp (17).
7.
Disconnect propeller shaft (18), refer
to TM 10-3930-643-20.
Use transmission and differential
lift for removal and installation.
Keep area clear of unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
8.
Position transmission and differential lift under front of vehicle to
remove axle items 23 thru 47 as an
assembly.
9.
Using a 1-1/2” socket, socket wrench
handle and a 1-1/2” open end wrench,
remove eight nuts (19), washers (20),
bolts (21) and washers (22).
Go to sheet 4
7-13
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 4
of 9)
REMOVAL (cont)
10.
Using a transmission and differential
lift, remove axle items 23 thru 47 as
an assembly.
11.
Place front axle assembly on wood
blocks and remove transmission and
differential lift.
12.
Remove two shafts (23).
13.
Using a 3/4” socket, socket wrench
handle and transmission and differential lift, remove differential
(24), refer to paragraph 7-4.
14.
Using a 1-1/8” socket, socket wrench
handle and a 1-1/8” open end wrench,
remove 16 nuts (25), washers (26),
bolts (27), washers (28), spindle
(29) and preformed packing (30) from
bowl (47) on right side.
Discard
preformed packing (30).
15.
Using a 1-1/4” socket and socket
wrench handle, remove plug (31) and
preformed packing (32) from spindle
(29). Discard preformed packing
(32).
Go to sheet 5
7-14
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 5
of 9)
REMOVAL
16.
Using a 1-1/8” socket, socket wrench
handle and 1-1/8” open end wrench,
remove 16 nuts (33), washers (34),
bolts (35), washers (36), spindle
(37) and preformed packing (38) from
Discard
bowl (47) on left side.
preformed packing (38).
17.
Using a 1-1/4” socket and socket
wrench handle, remove plug (39) and
preformed packing (40) from spindle
(37). Discard preformed packing
(40).
18.
Remove plug (41), preformed packing
(42), plug (43), preformed Packing
(44), plug (45) and preformed packing
Discard
(46) from bowl (47).
preformed packings (42,44 and 46).
Go to sheet 6
7-15
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 6
of 9)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
solvent,
get
immediately.
19.
Wipe differential (24) and front axle
assembly with clean cloth moistened
with cleaning solvent P-D-680. Allow
to air dry.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
20.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
21.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 7
7-16
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 7
of 9)
INSTALLATION
NOTE
One-piece axle assembly is no
longer available.
22.
Using a 1-1/4” socket and socket
wrench handle, install new preformed
packing (46), plug (45), new
preformed packing (44), plug (43),
new preformed packing (42) and plug
(41) in bowl (47).
23.
Install new preformed packing (40)
and plug (39) in spindle (37).
24.
Using a 1-1/8” socket, socket wrench
handle and a 1/2” torque ‘wrench,
install new preformed packing (38),
spindle (37), 16 washers (36), bolts
(35), washers (34) and nuts (33) in
bowl (47). Tighten nuts (33) to 270
to 300 lb-ft.
Go to sheet 6
7-17
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 8
of 9)
INSTALLATION (cont)
25.
Using a 1-1/4” socket and socket
wrench handle, install new preformed
packing (32) and plug (31) in spindle
(29).
26.
Using a 1-1/8” socket, socket wrench
handle, 1–1/8” open end wrench and
torque wrench, install new preformed
packing (30), spindle (29), 16
washers (28), bolts (27), washers
(26) and nuts (25) in bowl (47).
Tighten nuts (25) to 270 to 300
lb-ft.
27.
Using a 9/16” socket, socket wrench
handle and transmission and differential lift, install differential
(24), refer to paragraph 7-4.
28.
Install two shafts (23).
29.
Using a transmission and differential
lift, position axle under front of
vehicle to install front axle
assembly items 47 through 23 as an
assembly.
30•
Using a 1-1/2” socket, socket wrench
handle, 1-1/2” open end wrench and
torque wrench, install eight washers
(22), bolts (21), washers (20) and
nuts (19). Tighten nuts (19) to 680
lb-ft.
Go to sheet 9
7-18
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-3. Front Axle Assembly (S/N 2000 and below and S/N 2904 and above). (Sheet 9
of 9)
INSTALLATION
31.
Connect propeller shaft (18), refer
to TM 10-3930-643-20.
32.
Using a 9/16” socket and socket
wrench handle, install clamp (17),
washer (16) and bolt (15).
33.
Using 3/4” and 13/16” box and open
end wrenches, install tube assemblies
(14).
34.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
install clamp (13), bolt (12), washer
(11) and nut (10).
35.
Install clamp (9), bolt (8),
(7) and nut (6).
36.
Install washer (5), bolt (4), washer
(3) and nut (2).
37.
Using 3/4” and 13/16” box and open
end wrenches, connect tube assembly
(1).
washer
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
7-19
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-4.
Front Differential Carrier Assembly. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(APP. C, Item 5)
Clean cloth (App. C, Item 24)
Loctite 262 (App. C, Item IS)
Wood block (2)
Torques
Bolts (5) to 75 to 85 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Front wheels and tires removed.
Propeller shaft - hanger bearing to
front axle removed.
LO 10-3930-643-12
Planetary lubricant drained.
Axle lubricant drained.
Paragraph 7-5
Front planetaries removed.
Go to sheet 2
7-20
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-4.
Front Differential Carrier Assembly. (Sheet 2 of 4)
REMOVAL
Use transmission and differential
lift for removal and installation.
Keep area clear of unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
NOTE
The procedures for the left and
right side axles are identical.
1.
Support and secure differential (8)
in rear, center, front axle with
transmission and differential lift.
2.
Using 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove nut (1), washer (2), bolt (3)
and block (4) and move brake lines to
one side.
3.
Using a 3/4” socket and socket wrench
handle, remove 14 bolts (5), washers
(6), bracket (7) and differential
(8).
4.
Using transmission and differential
lift, remove differential (8) from
front axle assembly.
5.
Remove differential (8) from transmission and differential lift and
support between two wood blocks.
Go to sheet 3
7-21
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
Front Differential Carrier Assembly. (Sheet 3 of 4)
7-4.
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
6.
Wipe differential with clean cloth
moistened with cleaning solvent
P-D-680. Allow to air dry.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
7.
Clean all other parts with clean
cloths moistened with cleaning
solvent P-D-680.
Dry thoroughly
with compressed air.
Refer to
paragraph 2-8.
8.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
7-22
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-4.
Front Differential Carrier Assembly. (Sheet 4 of 4)
INSTALLATION
Apply Loctite 262 to mounting flange
in differential (8) in rear, center,
front axle. Position and secure
differential (8) on transmission and
differential lift and install into
front axle assembly.
10.
Using a 5/8” socket, socket wrench
handle and torque wrench, install
bracket (7), 14 washers (6) and bolts
(5). Tighten bolts (5) to 75 to 85
lb-ft.
11.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
install block (4), bolt (3), washer
(2) and nut (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
7-23
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-5.
Front and Rear Planetary. (Sheet 1 of 8)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic's
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling, capacity of
216 lbs.
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Loctite 262 (App. C, Item IS)
Shim (2)
Seal
Ring
Gasket
Torques
Bolts (1) to 24 to 26 lb-ft.
Bolts (2) to 34 to 37 lb-ft.
Bolts (8) to 30 lb-ft. and 40 to
45 lb-ft.
Bolts (12) to 20 to 23 lb-ft.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Planetary lubricant drained.
TM 10-3930-643-20
Wheel removed.
Paragraph 8-4
Service brakes removed.
Go to sheet 2
7-24
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-5.
Front and Rear Planetary. (Sheet 2 of 8)
REMOVAL
NOTE
The following is a procedure for
removal/installation of left side
rear planetary carrier assembly.
The procedure for right rear and
front left and right planetary
assemblies is identical.
1.
Using a 9/16” open and box end
wrench, remove two bolts (1) from
rear, left side of axle assembly.
2.
Using a 9/16” socket, socket wrench
handle and a putty knife, remove
eight bolts (2), washers (3), cover
(4) and gasket (5). Discard gasket
(5). Remove all gasket material from
mounting surfaces.
Weight of planetary carrier assembly is approximately 180 lbs. Use
adequate hoist and sling for
Keep
removal and installation.
area clear of
unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY.
3.
Attach hoist and sling to planetary
carrier assembly (6) and remove.
Place securely on ground.
Go to sheet 3
7-25
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-5.
Front and Rear Planetary. (Sheet 3 of 8)
REMOVAL (cont)
4.
Remove hoist and sling.
5.
Remove axle shaft (7).
6.
Using a 9/16” socket and socket
wrench handle, remove 12 bolts (8),
retainer (9), shims (10 and 11) and
items 12 thru 16 as an assembly.
Discard shims (10 and 11).
NOTE
Weight of ring and hub assembly is
approximately 60 lbs.
7.
Using a 1/2” socket and socket wrench
handle, remove eight bolts (12),
four bars (13) and ring (14) from
hub (15).
8.
Using an arbor press and bearing
adapter, remove bearing (16).
9.
Using a ball peen hammer and a flat
tip screwdriver, remove items 17 thru
27 as an assembly from left side of
rear axle assembly.
Go to sheet 4
7-26
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-5.
Front and Rear Planetary. (Sheet 4 of 8)
REMOVAL
NOTE
The following is a difference
between M10A Forklift models.
10.
Remove retainer (17), seal (18) and
bearing (20) from wheel hub (27),
from vehicles S/N 2001 and above or
remove retainer (17), seal (18), ring
(19) and bearing (20) from wheel hub
(27), from vehicles S/N 2000 and
below. Discard seal (18).
11.
Mark position of disc (23) and wheel
hub (27). Then using a 1-1/8” socket
and socket wrench handle, remove 18
bolts (21), washers (22) and disc
(23) .
12.
Remove cups (24 and 25).
13.
Using a putty knife, remove and
discard ring (26).
Go to sheet 5
7-27
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-5.
Front and Rear Planetary. (Sheet 5 of 8)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
14.
Wipe planetary carrier assembly (6)
with clean cloth moistened with
cleaning solvent P-D-680. Allow to
air dry.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
15.
Clean all parts except bearing (20)
with cleaning solvent P-D-680. Dry
thoroughly with compressed air.
Refer to paragraph 2-8.
16.
Inspect all parts.
graph 2-9.
Go to sheet 6
7-28
Refer to para-
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-5.
Front and Rear Planetary. (Sheet 6 of 8)
INSTALLATION
17.
Lubricate new ring (26) with clean
oil and install in wheel hub (27).
18.
Install cups (25 and 24).
19.
Using a 1-1/8” socket and socket
wrench handle, install disc (23),
18 washers (22) and bolts (21).
Aline location marks with wheel
hub (27) during installation.
NOTE
The following is a difference
between M10A Forklift models.
20.
Install bearing (20), new seal (18)
and retainer (17) on vehicles S/N
2001 and above or install bearing
(21), ring (19), new seal (18) and
retainer (17) in vehicles S/N 2000
and below.
21.
Apply Loctite 290 to lips of new
seal (18) before installation,
then install items 27 thru 17 as
an assembly on left side of rear
axle assembly.
22.
Install bearing (16).
23.
Apply Loctite 262 to threads on eight
bolts (12). Using a 1/2” socket and
a torque wrench, install ring (14),
four bars (13) and eight bolts (12)
to hub (15). Tighten eight bolts
(12) to 20 to 23 lb-ft.
GO to sheet 7
7-29
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-5.
Front and Rear Planetary. (Sheet 7 of 8)
INSTALLATION (cont)
24.
Install items 16 thru 12 as an
assembly in rear left side of rear
axle assembly.
25.
Using a 9/16” socket, socket wrench
handle and torque wrench, install
retainer (9) and four of 12 bolts
(8). Tighten four of 12 bolts (8) to
30 lb-ft while rotating wheel
assembly.
26.
Using a feeler gage, measure gap
between retainer (9) and end of
spindle at two points and install.
Average two measurements to determine
shim pack thickness. Use shim pack
equal to, but not less than, average
gap dimension.
27.
Using a 9/16” socket, socket wrench
handle and torque wrench, remove four
bolts (8) and retainer (9).
28.
Apply Loctite 262 to threads on 12
bolts (8). Using a 1/2” socket and
torque wrench, install new shims (11
and 10), retainer (9) and bolts (8).
Tighten bolts (8) to 40 to 45 lb-ft
while rotating wheel assembly.
29.
Install axle shaft (7).
Go to sheet 8
7-30
..
.-..
-.
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-5.
Front and Rear Planetary. (Sheet 8 of 8)
INSTALLATION
30.
Attach hoist and sling to planetary
carrier assembly (6) and install.
31.
Remove hoist and sling.
32.
Apply Loctite 262 to threads of eight
bolts (2). Using a 9/16” socket and
torque wrench, install new gasket
(5), cover (4), eight washers (3) and
bolts (2). Tighten eight bolts (2)
to 34 to 37 lb-ft.
33.
Using 9/16” open end wrench, install
two bolts (1) to left side of axle
assembly. Tighten two bolts (1) to
24 to 26 lb-ft.
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
7-31
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-6.
Rear Drive Axle (S/N 2001 and above). (Sheet 1 of 7)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenancet Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Jack stand (2)
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Preformed packing (3)
Wood block (2)
Torques
Bolts (28) to 680 lb-ft.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Rear axle drained.
TM 10 3930-643-20
Rear wheels removed.
Paragraph 7-5
Rear planetaries removed.
Paragraph 8-16
Parking brake removed.
Paragraph 8-4
Rear service brakes removed.
Go to sheet 2
7-32
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-6.
Rear Drive Axle (S/N 2001 and above). (Sheet 2 of 7)
REMOVAL
NOTE
Vehicle must be raised off the
ground and supported with jack
stands under the frame for the
following procedure.
1.
Using a 1/2” box and open end wrench,
disconnect, tube assembly (1) from
under rear of vehicle.
2.
Using a 7/16” socket, socket wrench
handle and a 7/16” open end wrench,
remove nut (2), washer (3), bolt (4)
and washer (5).
3.
Remove nut (6), washer (7), bolt (8),
washer (9) and clamp (10) from left
side of rear axle assembly.
4.
Using a 9/16” socket and socket
wrench handle, remove two bolts (11),
washers (12) and access cover (13).
Go to sheet 3
7-33
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
Rear Drive Axle (S/N 2001 and above). (Sheet 3 of 7)
7-6.
REMOVAL (cont)
5. Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove nut (14), washer (15), bolt
(16), washer (17) and clamp (18) from
right side of rear axle assembly.
6.
Using a 9/16” socket and socket
wrench handle, remove two bolts (19),
washers (20) and access cover (21).
7.
Using a 7/16” box and open end
wrench, remove tube assemblies (22).
8.
Using a 3/4” socket and socket wrench
handle, remove bolt (23), washer (24)
and clamp (25).
Use transmission and differential
lift for removal and installation.
Keep area clear of unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
9.
Position transmission and differential lift under rear of vehicle to
remove rear axle, items 30 thru 37 as
an assembly.
Go to sheet 4
7-34
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-6.
Rear Drive Axle (S/N 2001 and above). (Sheet 4 of 7)
REMOVAL
10.
Using a 1-1/2” socket, socket wrench
handle and a 1-1/2” open end wrench,
remove eight nuts (26), washers (27),
bolts (28) and washers (29)0
11.
Using a transmission and differential lift, remove rear axle, items
30 thru 37 as an assembly.
12.
Place rear axle, items 30 thru 37 as
an assembly, on wood blocks and
remove transmission and differential
lift.
13.
Remove differential (30), refer to
paragraph 7-9.
14.
Using a 1-1/4” socket and socket
wrench handle, remove plug (31),
preformed packing (32), plug (33),
preformed packing (34), plug (35) and
Discard
preformed packing (36).
preformed packings (32, 34 and 36).
Go to sheet 5
7-35
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
Rear Drive Axle (S/N 2001 and above). (Sheet 5 of 7)
7-6.
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
Wipe rear axle (37) and differential
(30) with clean cloth moistened with
cleaning solvent P-D-680. Allow to
air dry.
15.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
16.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
17.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 6
7-36
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-6.
Rear Drive Axle (S/N 2001 and above). (Sheet 6 of 7)
INSTALLATION
18.
Using a 1-1/4” socket and socket
wrench handle, install new preformed
packing (36), plug (35), new
preformed packing (34), plug (33),
new preformed packing (32) and plug
(31) in axle (37).
19.
Install differential (30), refer to
paragraph 7-9.
20.
Using a transmission and differential lift, position rear axle
assembly items 37 thru 30 under rear
of vehicle and install.
21*
Using a 1-1/2” socket, socket wrench
handle and a 1-1/2” open end wrench,
install eight washers (29), bolts
(28), washers (27) and nuts (26).
Tighten eight bolts (28) to 680
lb-ft.
22.
Using a 9/16” socket and socket
wrench handle, install clamp (25),
washer (24) and bolt (23).
23.
Using a 7/16” box and open end
wrench, position and install tube
assemblies (22).
24.
Using a 9/16” socket and socket
wrench handle, install access cover
(21), two washers (20) and bolts (19)
to right side of rear axle assembly.
25.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
install clamp (18), washer (17), bolt
(16), washer (15) and nut (14).
Go to sheet 7
7-37
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
Rear Drive Axle (S/N 2001 and above). (Sheet 7 of 7)
7-6.
INSTALLATION (cent)
26.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
install access cover (13), two
washers (12) and bolts (11) to left
side of rear axle assembly.
27.
Install clamp (10), washer (9), bolt
(8), washer (7) and nut (6).
28.
Using a 7/16” socket, socket wrench
handle and a 9/16” open end wrench,
install washer (5), bolt (4), washer
(3) and nut (2).
29.
Using 1/2” and 13/16” box and open
end wrenches, connect tube assembly
(1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
7-38
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-7.
Rear Axle Assembly (S/N 2000 and below). (Sheet 1 of 7)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Jack stand (2)
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloths (App. C, Item 24)
Small tag (App. C, Item 28)
Preformed packing (7)
Wood block (2)
Nuts (18) to 680 lb-ft.
Nuts (23) to 270 to 300 lb-ft.
Nuts (31) to 270 to 300 lb-ft.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Rear axle drained.
TM 10-3930-643-20
Rear wheels removed.
Paragraph 8-16
Parking brake removed.
Paragraph 7-5
Rear planetaries removed.
Paragraph 8-4
Rear service brakes removed.
Go to sheet 2
7-39
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
Rear Axle Assembly (S/N 2000 and below). (Sheet 2 of 7)
7-7.
REMOVAL
NOTE
Vehicle must be raised off the
ground and supported with jack
stands under the frame for the
following procedure.
1.
Using a 1/2” open end wrench,
disconnect tube assembly (1) from
under rear of vehicle.
2.
Using a 7/16” open end wrench, 7/16”
socket and socket wrench handle,
remove nut (2), washer (3), bolt (4)
and washer (5).
3.
Using a 9/16” open end wrench, 9/16”
socket and socket wrench handle,
remove nut (6), washer (7), bolt (8)
and clamp (9) from left side of axle
assembly.
4.
Remove nut (10), washer (11), bolt
(12) and clamp (13) from right side
of axle assembly.
Go to sheet 3
7-40
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-7.
Rear Axle Assembly (S/N 2000 and below). (Sheet 3 of 7)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
5.
Using a 7/16” open end wrench, remove
tube assemblies (14).
6.
Using a 3/4” socket, socket wrench
handle and a 3/4” open end wrench,
remove bolt (15), washer (16) and
clamp (17).
Use transmission and differential
lift for removal and installation.
Keep area clear of unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY.
7.
Position transmission and differential lift under rear axle assembly
items 22 thru 45.
8.
Using a 1-1/2” open end wrench,
1-1/2” socket and socket wrench
handle, remove eight nuts (18),
washers (19), bolts (20) and washers
(21).
9.
Using a transmission and differential
lift, a hammer and flat tip screwdriver, remove rear axle assembly
items 22 thru 45.
10.
Place rear axle assembly items 22
thru 45 on wood blocks and remove
transmission and differential lift.
11.
Remove differential (22), refer to
paragraph 7-9.
GO to sheet 4
7-41
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
Rear Axle Assembly (S/N 2000 and below). (Sheet 4 of 7)
7-7.
REMOVAL (cont)
12.
Using a 1-1/8” open end wrench,
1-1/4” socket and socket wrench
handle, remove 16 nuts (23), washers
(24), bolts (25), washers (26),
spindle (27) and preformed packing
Discard
(28) from bowl (45).
preformed packing (28).
13.
Using a 1-1/4” open end wrench,
remove plug (29) and preformed
Discard
packing (30) from spindle.
preformed packing (30).
14.
Using a 1-1/8” open end wrench,
1-1/8”socket and socket wrench
handle, remove 16 nuts (31), washers
(32), bolts (33), washers (34),
spindle (35) and preformed packing
Discard
(36) from bowl (45).
preformed packing (36).
15.
Using a 1-1/4” open end wrench,
remove plug (37) and preformed
packing (38) from spindle (35).
Discard preformed packing (38).
16.
Remove plug (39), preformed packing
(40), plug (41), preformed packing
(42), plug (43) and preformed packing
Discard
(44) from bowl (45).
preformed packings (40, 42 and 44).
GO
to sheet 5
7-42
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-7.
Rear Axle Assembly (S/N 2000 and below). (Sheet 5 of 7)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
17. Wipe spindles (27 and 35) and bowl
(45) with clean cloth moistened with
cleaning solvent P-D-680. Allow to
air dry.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
18.
Clean all other parts with cleaning
Dry thoroughly
solvent P-D–680.
with compressed air. Refer to paragraph 2-8.
19.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 6
7-43
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-7.
Rear Axle Assembly (S/N 2000 and below). (Sheet 6 of 7)
INSTALLATION
20.
Using a 1-1/4 open end wrench,
install new preformed packing (44),
plug (43), new preformed packing
(42), plug (41), new preformed
packing (40) and plug (39) from bowl
(45)*
21.
Install new preformed packing (38)
and plug (37) in spindle (35).
22.
Using 1-1/8” open end wrench, 1/8”
socket, socket wrench handle and
torque wrench, install new preformed
packing (36), spindle (35), 16
washers (34), bolts (33), washers
(32) and nuts (31) in bowl (45).
Tighten 16 nuts (31) to 270 to 300
lb-ft.
23.
Using a 1-1/4” open end wrench,
install new preformed packing (30)
and plug (29) in spindle (27).
24.
Using a 1-1/8” open end wrench,
1-1/8” socket, socket wrench handle
and torque wrench, install new
preformed packing (28), spindle (27),
16 washers (26), bolts (25), washers
(24) and nuts (23) in bowl (45).
Tighten 16 nuts (23) to 270 to 300
lb-ft.
25.
Using a transmission and differential lift, install differential
(22) in items 45 thru 23 as an
assembly, refer to paragraph 7-9.
26.
Position rear axle assembly items 45
through 22 under rear of vehicle.
Go to sheet 7
7-44
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-7.
Rear Axle Assembly (S/N 2000 and below). (Sheet 7 of 7)
INSTALLATION
27.
Using a 1-1/2” open end wrench,
1-1/2” socket, socket wrench handle
and torque wrench, install eight
washers (21), bolts (20), washers
(19) and nuts (18). Tighten eight
nuts (18) to 680 lb-ft.
28.
Using a 1-1/2” adjustable wrench,
install clamp (17), washer (16) and
bolt (15)0
29.
Using a 1-1/8” socket and socket
wrench handle, connect tube assemblies (24).
30•
Using a 9/16” open end wrench, 9/16”
socket and socket wrench handle,
install clamp (13), bolt (12), washer
(11) and nut (10).
31•
Install clamp (9), bolt (8),
(7) and nut (6).
32.
Using a 7/16” open end wrench, 7/16”
socket and socket wrench handle,
install washer (5), bolt (4), washer
(3) and nut (2).
33.
Using 1-1/2” open end wrench, connect
tube assembly (l).
washer
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
7-45
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cont)
7-8.
Rear Differential Carrier Assembly. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Loctite 262, Grade N
(App. C, Item 15)
Gasket
Seal
Wood block (2)
Torques
Bolts (5) to 75 to 85 lb-ft.
EQUIPMENT CONDITION
References
LO 10-3930-643-12
Condition Description
Planetary lubricant drained.
Axle lubricant drained.
TM 10-3930-643-20
Rear wheels and tires removed.
Paragraph 7-5
Rear planetaries removed.
Paragraph 8-16
Parking brake removed.
Go to sheet 2
7-46
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-8.
Rear Differential Carrier Assembly. (Sheet 2 of 4)
REMOVAL
1.
Using a transmission and differential lift, support and secure
differential (8) in front, center of
rear axle.
2.
Using a 7/16” open and box end
wrench, remove nut (l), washer
(2), bolt (3) and block (4).
Move brake lines to one side.
3.
Using a 3/4” socket and socket
wrench handle, remove 14 bolts (5),
washers (6) and bracket (7).
4.
Using a transmission and differential
lift, remove differential (8).
5.
Remove differential (8)
from
transmission and differential lift
and support between two wood blocks.
Go to sheet 3
7-47
TM 10-3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE. (cent)
7-8.
Rear Differential Carrier Assembly. (Sheet 3 of 4)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680,
used for cleaning parts, is toxic
and flammable. Use only in well
Wear
ventilated areas.
protective goggles and gloves.
Do not smoke or allow open flames
or sparks in areas where cleaning
solvent is used or stored. Avoid
contact with eyes, skin or
clothing. If contact with eyes
is made, flush with cold water
and seek medical attention
immediately. If contact with
skin or clothing is made, flush
with cold water. If you become
dizzy while using cleaning
fresh
air
solvent, get
immediately.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
(goggles/shield,
equipment
gloves, etc.).
6.
Clean all parts with clean cloth
moistened with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
7.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
7-48
TM 10–3930-643-34
FRONT AND REAR AXLES TROUBLESHOOTING AND MAINTENANCE.
7-8.
Rear Differential Carrier Assembly. (Sheet 4 of 4)
INSTALLATION
8.
Apply Loctite 262 to mounting flange
in differential (8).
9.
Using a transmission and differential
lift, position differential (8) and
install into axle on rear of vehicle.
10.
Using a 3/4” socket, socket wrench
handle and torque wrench, install
bracket (7), 14 washers (6) and bolts
(5). Tighten bolts (5) to 75 to 85
lb-ft.
11.
Using a 7/16” open and box end
wrench, install block (4), bolt
(3), washer (2) and nut (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
7-49 (7-50 blank)
TM 10-3930-643-34
CHAPTER 8
BRAKE
TROUBLESHOOTING AND MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently troubleshoot
and repair malfunctioning equipment and to perform authorized direct support
level maintenance procedures on the M10A Forklift brake system.
INDEX
Title
Service Brake Troubleshooting
Parking Brake Troubleshooting
Parking Brake Air Cylinder
Service Brake Assembly
Power Cluster (S/N 2000 and below)
Power Cluster Reservoir
(S/N 2000 and below)
Pressure Converter (S/N 2001 and above)
Pressure Converter Reservoir
(S/N 2001 and above)
Treadle Two Way Valve
(S/N 2000 and below)
Treadle Check Valve (S/N 2001 and above)
Parking Brake Control Valve
Treadle Valve (S/N 2000 and below)
Treadle Valve (S/N 2001 and above)
Air Compressor
Governor Assembly
Parking Brake Assembly
Paragraph
Page
8-1
8-2
8-3
8-4
8-5
8-2
8-5
8-6
8-11
8-17
8-6
8-7
8-21
8-26
8-8
8-31
8-9
8-10
8-11
8-12
8-13
8-14
8-15
8-16
8-37
8-40
8-43
8-47
8-54
8-62
8-75
8-80
8-1
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-1.
Service Brake Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
a.
BRAKES DO NOT ENGAGE.
Check brake calipers for evidence of oil leakage.
Leakage indicates a faulty seal, refer to paragraph 8-4 for repair
procedures.
b.
BRAKES DO NOT RELEASE.
Check treadle and treadle valves for proper operation.
If repair is necessary, refer to paragraphs 8-9, 8-10, 8-12 and
8-13.
c. BRAKES SQUEAL OR SCRAPE.
Check for wear of brake liners.
To repair service brakes, refer to paragraph 8-4.
8-2
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-1.
Service Brake Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
LOW AIR PRESSURE.
Step 1. Check air compressor belt.
Adjust or replace if necessary, refer to paragraph 8-14.
If belt is good, go to Step 2.
Step 2. Inspect governor.
Repair or replace governor, refer to paragraph 8-15.
If governor is good, go to step 3.
Step 3. Inspect air compressor discharge valves to determine if valves
are leaking.
If valves are faulty, repair or replace, refer to paragraph 8-14.
If valves are good, go to Step 4.
Step 4. Inspect for a restriction in discharge line or in discharge
cavity of air compressor.
Remove and clean cylinder head, refer to paragraph 8-14.
If no restriction is found, go to Step 5.
Step 5.
Inspect for restriction in inlet valves.
Remove cylinder head and clean inlet valves, guides,
inlet ports, refer to paragraph 8-14.
springs
and
If no restriction is found, go to Step 6.
Step 6. Inspect air compressor inlet valves for faulty operation or
worn parts.
Repair or replace inlet valve if necessary, refer to paragraph 8-14.
If valve is good, go to Step 7.
8-3
TN 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-1.
Service Brake Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
LOW AIR PRESSURE. (cent)
Step 7.
Inspect air compressor parts for wear.
Repair compressor, refer to paragraph 8-14.
e. HIGH AIR PRESSURE.
Inspect governor for proper operation.
If necessary, repair, refer to paragraph 8-15.
f.
NOISY COMPRESSOR.
Check oil supply line for restriction.
If restriction is found, check for damage. Repair or replace if
necessary.
Inspect crankshaft and connecting rod bearings for burns or wear.
Replace if necessary, refer to paragraph 8-14.
8-4
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-2. Parking Brake Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
a. PARKING BRAKE DRAGS.
Step 1.
Check for low air pressure and check lines for restrictions.
If restriction is found, check for damage.
Repair or replace, if necessary.
Step 2. If parking brakes do not apply, check linkage.
Adjust linkage, refer to TM 10-3930-643-20.
Step 3.
b.
Replace return springs, refer to paragraph 8-16.
PARKING BRAKE SLIPS.
Apply parking brake. With engine running and transmission in the
forward third gear position, fully accelerate engine. If vehicle moves
and parking brake is properly adjusted, check for oil on linings or worn
linings. If linings are worn below 1/8”, replace brake shoe assembly,
refer to paragraph 8-16.
8-5
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-3.
Parking Brake Air Cylinder. (Sheet 1 of 5)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean-cloth (App. C, Item 24)
Emery cloth (App. C, Item 4)
Pneumatic grease (App. C, Item 32)
Air cylinder kit 930480C92
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Air pressure vented.
TM 10-3930-643-20
Parking brake air cylinder removed.
Go to sheet 2
8-6
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-3.
Parking Brake Air Cylinder. (Sheet 2 of 5)
DISASSEMBLY
Spring is under pressure from
plate. Use suitable press to
Failure to
release spring.
follow this procedure could
result in SEVERE INJURY. If you
are injured, seek medical aid
immediately.
10
Position air cylinder (1) securely in
press.
2.
Using a 1/2” socket and socket wrench
handle, remove eight screws (2).
3.
Release press slowly to relieve
pressure on spring (3).
4.
Remove air cylinder (l).
5.
Remove spring (3) and plate (4).
6.
Using a flat tip screwdriver, remove
four screws (5) and plate (6).
7.
Using a 7/8” open end wrench, remove
nuts (7 and 8).
8.
Remove shaft (9).
Go to sheet 3
8-7
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-3.
Parking Brake Air Cylinder. (Sheet 3 of 5)
DISASSEMBLY (cont)
NOTE
Remove nuts from shaft only if
inspection proves replacement of
nuts or shaft is necessary.
9.
Remove nuts (10 and 11) from shaft
(9).
10.
Remove piston (12).
11.
Remove and discard felt (13) and ring
(14).
12.
Remove and discard ring
bushing (16).
Go to sheet 4
8-8
(15) and
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-3.
Parking Brake Air Cylinder. (Sheet 4 of 5)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
Flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
13.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
14.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
8-9
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
Parking Brake Air Cylinder. (Sheet 5 of 5)
8-3.
ASSEMBLY
15.
Lubricate inner diameters of new
bushing (16) and new ring (15) with
clean grease and install.
16.
Lubricate inner diameter of air
cylinder (1) with clean grease.
17.
Install new ring (14) and new felt
(13) in piston (12).
18.
Using a 7/8” open end wrench, install
shaft (9) with nuts (11 and 10) in
piston (12).
19.
Install piston (12) to air cylinder
(l).
20.
Using a 7/8” open end wrench, install
nuts (8 and 7).
21.
Using a flat tip screwdriver, install
plate (6) and four screws (5) to
plate (4).
22•
Position plate (4) and spring (3) on
air cylinder (l).
23.
Position air cylinder (1) in press
and compress spring (3).
24.
Using a 1/2” socket and socket wrench
handle, install eight screws (2).
25.
Remove air cylinder (1) from press.
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-10
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-4.
Service Brake Assembly. (Sheet 1 of 6)
This task covers:
b. Disassembly
a. Removal
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Brake fluid (App. C, Item 2)
Clean cloth (App. C, Item 24)
Small tags (App. C, Item 28)
Preformed packing (12)
Boot (4)
Backup packing (4)
Bolt (1) to 7 lb-ft.
Bolts (5) to 290 lb-ft.
Bolts (7) to 285 lb-ft.
Bolts (16) to 40 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Tire and wheel assembly removed.
Go to sheet 2
8-11
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-4.
Service Brake Assembly. (Sheet 2 of 6)
REMOVAL
NOTE
The following is a maintenance
procedure for one service brake
assembly. The maintenance procedure for the remaining service
brake assemblies is identical.
1.
Disconnect tube assembly (25)
tee pipe (3).
from
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
2.
Using a 3/4” socket and socket wrench
handle, remove bolt (1) and washer
(2).
3.
Remove tee pipe (3) and washer (4).
4.
Remove ten bolts (5) and washers (6).
5.
Remove items 10 thru 24 as an
assembly from disc (9).
6.
Remove axle planetary hub, refer to
paragraph 7-5.
7.
Using a 1-1/8” socket and socket
wrench handle, remove 18 bolts (7),
washers (8) and disc (9) from axle
planetary hub.
Go to sheet 3
8-12
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-4.
Service Brake Assembly. (Sheet 3 of 6)
REMOVAL
8.
Using a 9/16” socket and socket
wrench handle, remove plug (10) and
preformed packing (11) from cap (18).
Discard preformed packing (11).
DISASSEMBLY
9.
Remove four bolts (12).
10.
Remove four pins (13).
11.
Remove two linings (14).
12.
Install plug (10).
13.
Force four pistons (20) out of
housing (24) with compressed air.
Apply air to port of cap (18)
(without plug).
14.
Remove plug (10).
15.
Remove and discard four boots (15).
16.
Remove eight bolts (16), washers
(17), two caps (18) and preformed
packings (19). Discard two preformed
packings (19).
17.
Remove and discard four preformed
packings (21) from pistons (20).
18.
Using a 3/8” open end wrench, remove
two bleeder screws (23) from housing
(24).
Go to sheet 4
8-13
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-4. Service Brake Assembly. (Sheet 4 of 6)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves . Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
fresh
get
air
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
19. Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
20.
Inspect disc (9) for cracks, scoring,
grooves, glazing or wear less than
0.4375 inches thick.
21.
Inspect two linings (14) for cracks,
scoring, grooves or wear less than
0.125 inch thick.
22.
Inspect four pistons (20) for cracks,
breaks, burrs, scoring or grooves.
23.
Inspect housing (24) for cracks,
breaks, grooves or scoring in piston
bores, bores blocked or threads
damaged.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 5
24.
8-14
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-4.
Service Brake Assembly. (Sheet 5 of 6)
ASSEMBLY
25.
Using a 3/8” open end wrench, install
two bleeder screws (23) in housing
(24).
26.
Lubricate with clean brake fluid and
install new preformed packings (21)
in grooves of bores in housing (24).
27.
Install four new boots (15) in bores
of housing (24).
28.
Lubricate four pistons (20) with
clean brake fluid and install
partially into housing
(24).
Position lips of four new boots (15)
in groove of four pistons (20), as
shown.
29.
Check four new boots (15) and pistons
(20) to make sure proper seating has
been obtained and install four new
boots (15) using a dust boot installing tool.
30•
Using a 9/16” socket and torque
wrench, install two new preformed
packings (19), caps (18), eight
washers (17) and bolts (16). Tighten
eight bolts (16) to 40 lb-ft.
31.
Install four pins (13).
32.
Install four bolts (12) loosely.
33.
Position two linings (14).
34.
Adjust four pins (13) with two
linings (14), as shown.
35.
Tighten four bolts (12), securing
pins (13) in housing (24).
Go to sheet 6
8-15
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-4.
Service Brake Assembly. (Sheet 6 of 6)
INSTALLATION
36.
Using a 9/16” socket and socket
wrench handle, install new preformed
packing (11) and plug (10) in two
caps (18).
37.
Position disc (9) on axle planetary
hub .
38.
Using a 1-1/8” socket and torque
wrench, install 18 washers (8) and
bolts (7). Tighten 18 bolts (7) to
285 lb-ft.
39•
Install axle planetary hub, refer to
paragraph 7-5.
40•
Position items 24 thru 10 as an
assembly on disc (9).
41.
Using a 3/4” socket and socket wrench
handle, install ten washers (6) and
bolts (5). Tighten ten bolts (5) to
290 lb-ft.
42.
Position washer (4) and tee pipe (3).
43.
Using a 3/4” socket and torque
wrench, install washer (2) and bolt
(l). Tighten bolt (1) to 7 lb-ft.
44.
Using a 10” adjustable wrench,
connect tube assembly (25) to tee
pipe (3).
45. Install tire and wheel assembly,
refer to TM 10-3930-643-20.
46.
Bleed air in brake hydraulic system,
refer to TM 10-3930-643-20.
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-16
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-5.
Power Cluster (S/N 2000 and below). (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Gasket
Wood block (4)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Air pressure vented.
Go to sheet 2
8-17
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-5.
Power Cluster (S/N 2000 and below). (Sheet 2 of 4)
REMOVAL
Make sure that vehicle will not
roll or shift. Secure with wood
blocks .
DEATH
or serious injury may result by
your failure to follow this
procedure.
NOTE
The following is a maintenance
procedure for the right side
power cluster. The maintenance
procedure for the left side
power cluster is identical.
• Tag all tube assemblies before
disconnecting to aid in
installation.
1.
Using a 3/4” or a 1/2” open end wrench
disconnect tube assembly (1) from
power cluster at front, underside
of vehicle.
2.
Using 5/8" and 11116” open end
wrenches, disconnect tube assemblies
(2, 3 and 4).
3.
Using a 1/2" socket and socket wrench
handle, remove four locknuts (5) and
power cluster (6).
4.
Using an 11/16" open end wrench,
remove fitting (7) and gasket (8).
Discard gasket (8). Remove all
gasket material from mounting
surfaces.
5.
Using a 9/16" open end wrench,
remove elbow (9).
6.
Using an 8“ pipe wrench, remove
coupling (10) and nipple (11).
7.
Using 9/16” and 11/16” open end
wrenches, remove elbows (12 and
13).
Go to sheet 3
8-18
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-5. Power Cluster (S/N 2000 and below). (Sheet 3 of 4)
CLEANING/INSPECTION
● TOXIC\FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves, Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If y o u
flush with cold water.
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
8.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
9.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
8-19
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cent)
Power Cluster (S/N 2000 and below). (Sheet 4 of 4)
8-5.
INSTALLATION
10.
Using 9/16" and 11/16” open end
wrenches, install elbows (13
and 12) on power cluster (6).
11.
Using an 8“ pipe wrench, install
nipple (11) and coupling (10).
12.
Using a 9/16” open end wrench,
install elbow (9).
13.
Using an 11/16" open end wrench,
install new gasket (8) and fitting
(7).
14.
Using a 1/2" socket and socket
wrench handle, install power
cluster and four locknuts.
15.
Using 5/8" and 11/16" open end
wrenches, connect tube assemblies
(4, 3 and 2) to power cluster (6).
16.
Using a 3/4” or a 1/2" open end
wrench, connect tube assembly (l).
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-20
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-6
●
Power Cluster Reservoir (S/N 2000 and below). (Sheet 1 of 5)
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Gasket (3)
Nut
Torques
Except for special torques shown,
all fasteners are tightened by a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Left side front frame access cover
removed.
Go to sheet 2
8-21
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
Power Cluster Reservoir (S/N 2000 and below). (Sheet 2 of 5)
8-6.
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a 3/4” open end wrench,
disconnect tube assemblies (1 and 2)
from inner, left side of front frame.
2.
Using a 5/8” socket and socket wrench
handle, remove tee (3).
3.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove four nuts (4), bolts (5),
eight washers (6) and items 7 thru 21
as an assembly.
DISASSEMBLY
4.
Using a 5/8” socket, socket wrench
handle and vise grips, remove plug
(7), coupling (8), nipple (9),
adapter (10), gasket (11), cap (12)
and gasket (13). Discard gaskets (11
Remove all gasket material
and 13).
from mounting surfaces.
5.
Using a 1/2” socket, socket wrench
handle, and a 1/2” open end wrench,
remove nut (14), lock washer (15) and
bolt (16).
6.
Separate clamp (17) and tank (21).
7.
Using a 3/4” open end wrench, hold
nut (18) on inside of tank (21).
8.
Remove adapter (19) and gasket (20).
Discard gasket (20). Remove all
gasket material from mounting surfaces
9.
Remove and discard nut (18).
GO
to sheet 3
8-22
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-6.
Power Cluster Reservoir (S/N 2000 and below). (Sheet 3 of 5)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
10.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
11.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
8-23
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-6.
Power Cluster Reservoir (S/N 2000 and below). (Sheet 4 of 5)
ASSEMBLY
12.
Install new gasket (20) on adapter
(19) .
13.
Using a 3/4” open end wrench,
position and hold new nut (18) in
tank (21)0
14.
Install adapter (19).
15.
Position clamp (17) on tank (21).
16.
Using a 1/2” socket, socket wrench
handle and a 1/2” open end wrench,
install bolt (16), lock washer (15)
and nut (14).
17.
Using a 5/8” socket, socket wrench
handle and vise grips, install new
gasket (13), cap (12), new gasket
(11), adapter (10), nipple (9),
coupling (8) and plug (7).
Go to sheet 5
8-24
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-6.
Power Cluster Reservoir (S/N 2000 and below). (Sheet 5 of 5)
INSTALLATION
18.
Using a 9/16”
handle, and a
install items
assembly with
bolts (5) and
19.
Using a 5/8” socket and socket wrench
handle, install tee (3).
20.
Using a 3/4” open end wrench, connect
tube assemblies (2 and 1).
21.
Using a 5/8” socket and socket wrench
handle, remove plug (7).
22•
Refill tank (21) to proper level,
refer to LO 10-3930-643-12.
23.
Install plug (7).
24.
Bleed air in brake hydraulic system,
refer to TM 10-3930-643-20.
socket, socket wrench
9/16” open end wrench,
21 thru 7 as an
eight washers (6), four
four nuts (4).
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-25
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-7.
Pressure Converter (S/N 2001 and above). (Sheet 1 of 5)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App.
C,
Item
5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Detergent (App. C, Item 33)
Silicone sealant (App. C, Item 27)
Wood block (4)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
Go to sheet 2
8-26
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-7. Pressure Converter (S/N 2001 and above). (Sheet 2 of 5)
REMOVAL
Make sure that vehicle will not
roll or shift. Secure with wood
blocks .
DEATH
or serious injury may result by
your failure to follow this
procedure.
NOTE
● The following is a maintenance
procedure for the rear brake
(left hand) pressure converter.
The maintenance procedure for
the front brake (right hand)
pressure converter is identical,
except as noted.
● All electrical connections,
except those on the instrument
panel, are sealed against
moisture with silicone sealant.
Remove all silicone sealant
before performing maintenance on
electrical connections.
. Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Disconnect wire assembly (1) at
terminal and using 1/2”, 7/8” and 5/8”
open end wrenches, disconnect hose
assemblies (2 and 3) and tube
assemblies (4 and 5) from pressure
converter on front of vehicle.
2.
Using a 3/8” open end wrench, remove
two nuts (6), washers (7) and wire
assemblies (8) from left side of
pressure converter (13) only.
Go to sheet 3
8-27
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cent)
8-7. Pressure Converter (S/N 2001 and above). (Sheet 3 of 5)
REMOVAL (cent)
3.
Using a 3/4” socket, socket wrench
handle and a 3/4" box end wrench,
remove two nuts (9), washers (10),
bolts (11), washers (12) and
pressure converter (13).
4.
Using a 5/8” open end wrench, remove
adapter (15), elbow (16) and nipple
(17).
5.
Using a 9/16” and 7/8” open end
wrench, remove elbows (18 and 19).
6.
Using a 13/16” open end wrench, remove
tee (20 from left side pressure
converter (13) only.
Go to sheet 4
8-28
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-7.
Pressure Converter (S/N 2001 and above). (Sheet 4 of 5)
CLEANING/INSPECTION
8.
Wipe all hose assemblies (2 and 3),
tube assemblies (4 and 5) and wire
assemblies (1 and 6) with detergent
and water solution.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
9.
10.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
8-29
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
Pressure Converter (S/N 2001 and above). (Sheet 5 of 5)
8-7.
INSTALLATION
11.
Using a 13/16” open end wrench install
tee (20) on left side pressure
converter (13) only.
12.
Using a 9/16” and 7/8” open end
wrenches , install elbows (19 and 18).
13.
Using a 5/8” open end wrench, install
nipple (17), elbow (16) and adapter
(15).
14.
Using a 3/4” socket, socket wrench
handle, and a 3/4” box end wrench,
install pressure converter (13),
two washers (12), bolts (11),
washers (10), nuts (9) under front
of vehicle.
15.
Connect two wire assemblies (8) at
terminals on left side pressure
converter (13) only. Apply silicone sealant over entire connection.
16. Using a 3/8” open end wrench, install
two washers (7) and nuts (6) on
terminals of left side pressure
converter (13) only.
17.
Using 5/8”, 1/2” and 7/8” open end
wrenches, connect tube assemblies (5
and 4) and hose assemblies (3 and 2).
18.
Connect wire assembly (1) at
terminal. Apply silicone sealant
over entire connection.
SERVICE
19.
If after servicing brake system the
brake warning light goes on and
stays on, reset indicator rod back
in place with a length of wire.
Indicator rod has no resistance and
light will go off.
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-30
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-8
●
Pressure Converter Reservoir (SIN 2001 and above). (Sheet 1 of 6)
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00–177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Suitable container
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Air pressure vented.
Go to sheet 2
8-31
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-8.
Pressure Converter Reservoir (S/N 2001 and above). (Sheet 2 of 6)
REMOVAL
NOTE
●
The following is a maintenance
procedure for the left pressure
converter reservoir. The maintenance
procedure for the right pressure
converter reservoir is identical.
●
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
10
Using a 7/8” open end wrench, loosen
tube assembly (1) at elbow (11) on
left side of front frame.
2.
Position suitable container at end of
tube assembly (l).
3.
Using a 7/8” open end wrench,
disconnect tube assembly (1) from
pressure converter.
4.
Using a 3/4” open end wrench, remove
breather (2).
5.
Drain pressure converter.
6.
Using a 7/8” open end wrench, remove
tube assembly (l).
7*
Using a 5/8” open end wrench, remove
connectors (3 and 4).
8.
Disconnect items 5 thru 9 as an
assembly from connector (10).
Go to sheet 3
8-32
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-8.
Pressure Converter Reservoir (S/N 2001 and above). (Sheet 3 of 6)
REMOVAL
9.
Using a 5/8” open end wrench, remove
ferrule (5), nut (6), ferrule (7) and
nut (8) from tube (9).
10.
Remove connector (10) from cover
(15).
11.
Using a 5/8” open end wrench, remove
elbow (11) from reservoir (18).
12.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench,
remove four nuts (12), eight washers
(13) and four bolts (14).
13.
Remove items 15 thru 18 as an
assembly from frame weldment.
DISASSEMBLY
14.
Using a flat tip screwdriver, pry off
retainer (17) from cover (15).
15.
Remove cover (15).
16.
Using a flat tip screwdriver,
separate diaphragm (16) from cover
(15).
17•
Remove retainer (17) from reservoir
(18).
Go to sheet 4
8-33
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-8.
Pressure Converter Reservoir (S/N 2001 and above). (Sheet 4 of 6)
CLEANING/INSPECTION
Wipe diaphragm (16) with dry, clean
cloth .
18.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
19.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
20.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
8-34
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-8
●
Pressure Converter Reservoir (S/N 2001 and above). (Sheet 5 of 6)
ASSEMBLY
21•
Using a flat tip screwdriver, install
retainer (17) on reservoir (18).
22.
Install diaphragm (16) in cover (15).
23.
Install items 16 and 15 as an
assembly on reservoir (18) and secure
in place with retainer (17).
INSTALLATION
24.
Position items 18 thru 15 as an
assembly on frame weldment on left
side of front frame.
25.
Using a 9/16" socket, socket wrench
handle and a 9/16” open end wrench,
install four bolts (14), eight
washers (13) and four nuts (12).
26.
Using 5/8” open end wrench,
elbow (11).
27.
Install connector (10) in cover (15).
install
Go to sheet 6
8-35
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-8.
Pressure Converter Reservoir (S/N 2001 and above). (Sheet 6 of 6)
INSTALLATION (cont)
28.
Position nuts (6 and 8) on tube (9).
29.
Install ferrules (7 and 5) in nuts (8
and 6). Ferrules (7 and 5) ❑ ust fit
tightly in tube (9).
30•
Connect items 9 thru 5 as an assembly
to connector (10). Tube (9) must
point straight up.
31•
Using 5/8” and 3/4” open end
wrenches, install connectors (4 and
3) and breather (2).
32.
Using a 7/8" open end wrench, connect
tube assembly (1) to elbow (11) and
install on pressure converter.
33.
Using a flat tip screwdriver, pry
retainer (17) off cover (15).
34.
Remove cover (15).
35.
Refill pressure converter to proper
level, refer to LO 10-3930-643-12.
36.
Install and secure cover (15) with
retainer (17).
37.
Bleed air from brake hydraulic
system, refer to TM 10-3930-643-20.
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-36
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-9.
Treadle Two-Way Valve (S/N 2000 and below). (Sheet 1 of 3)
This task covers:
b.
a. Disassembly
c. Assembly
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Gasket
Torques
Cap (2) to 45 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Two-way valve removed from righthand
treadle valve.
DISASSEMBLY
10 Using a 3/4” socket and socket wrench
handle, remove plug (l).
2.
Remove cap (2).
3.
Remove retainer and seat assembly (3)
from body (5).
4.
Remove and discard gasket (4).
Remove all gasket material from
mounting surfaces.
to sheet 2
8-37
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
Treadle Two-Way Valve (S/N 2000 and below)._ (Sheet 2 of 3)
8-9.
CLEANING/INSPECTION
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
5*
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
6.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 3
8-38
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-9.
Treadle Two-Way Valve (S/N 2000 and below). (Sheet 3 of 3)
ASSEMBLY
7.
Install new gasket (4) on cap (2).
8.
Install retainer and seat
(3) in body (5).
9.
Using a 3/4” socket, socket wrench
handle and torque wrench, install cap
(2). Tighten cap (2) to 45 lb-ft.
10.
Using a 3/4” socket and socket wrench
handle, install plug (l).
assembly
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
8-39
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-10.
Treadle Check Valve (S/N 2001 and above). (Sheet 1 of 3)
This task covers:
b.
a. Disassembly
c. Assembly
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Torques
Seat (1) to 45 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Check valve removed from
treadle valve.
DISASSEMBLY
1.
Using a 1-1/8” open end wrench,
remove seat (l).
2.
Remove and discard diaphragm (2) and
ring (3) from body (5).
3.
Remove and discard preformed packing
(4).
Go to sheet 2
8-40
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-10.
Treadle Check Valve
(S/N 2001 and above). (Sheet 2 of 3)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
4.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
5.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 3
8-41
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cent)
8-10.
Treadle Check Valve (S/N 2001 and above). (Sheet 3 of 3)
ASSEMBLY
6.
Install new preformed packing (4) on
seat (l).
7.
Install new ring (3) and new
diaphragm (2) on body (5).
8.
Using a 1-1/8” socket, socket wrench
handle and torque wrench, install
seat (l). Tighten seat (1) to 45
lb-ft .
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-42
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-11.
Parking Brake Control Valve. (Sheet 1 of 4)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Locknut (5) to 35 in-lb.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Parking brake control valve removed.
Go to sheet 2
8-43
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-11.
Parking Brake Control Valve. (Sheet 2 of 4)
DISASSEMBLY
1.
Using a 7/16” socket and socket
wrench handle, remove two screws (1)
and lock washers (2).
2.
Using a flat brass punch, separate
cover (3) and seal ring (4) from body
(11). Discard seal ring (4).
3.
Hold plunger (7).
4.
Using a 9/16” socket and socket
wrench handle, remove and discard
locknut (5) and washer (6)0
5.
Remove plunger (7), valve (8) and
Discard
spring (9) from body (11).
valve (8).
6.
Remove and discard preformed packing
(10).
Go to sheet 3
8-44
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-11.
Parking Brake Control Valve. (Sheet 3 of 4)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
7.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
8.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
8-45
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-11.
Parking Brake Control Valve. (Sheet 4 of 4)
ASSEMBLY
Install new preformed packing (10)
and spring (9) on plunger (7).
9.
10. Install plunger (7) in body (11).
11.
Install new valve (8).
12.
Using a 5/8” socket, socket wrench
handle and torque wrench, install new
washer (6) and locknut (5). Tighten
locknut (5) to 35 in-lb.
13.
Position new seal ring (4) and cover
(3)0
14.
Using a 9/16” socket and socket
wrench handle, install two lock
washers (2) and screws (l).
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-46
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-12.
Treadle Valve (S/N 2000 and below). (Sheet 1 of 7)
This task covers:
b.
a. Disassembly
c. Assembly
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent ( App. C, Item 33)
Grease (App. C, Item 11)
Valve (2)
Preformed packing (3)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Treadle valve removed.
Go to sheet 2
8-47
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-12.
Treadle Valve (S/N 2000 and below). (Sheet 2 of 7)
DISASSEMBLY
1.
Using a flat brass punch, depress
piston (7) to compress spring (2).
2.
Remove retainer (l).
3.
Remove items 2 thru 7 as an assembly
from body (17).
4.
Remove spring (2) from piston (7).
5.
Remove and discard preformed packing
(3) from piston (7).
6.
Using a flat brass punch, depress
retainer (5) in piston (7).
7.
Using snap ring pliers, remove ring
(4).
8.
Remove retainer (5) and spring (6)
from piston (7).
NOTE
Use scribe or punch to aid in
assembly.
9.
Matchmark body (17), cover (18) and
body (33).
10.
Using a 9/16” socket and socket
wrench handle, remove four bolts (8)
and lock washers (9).
11.
Using a flat tip screwdriver,
separate body (17) and cover (18).
Go to sheet 3
8-48
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-12.
Treadle Valve (S/N 2000 and below). (Sheet 3 of 7)
DISASSEMBLY
12•
Remove and separate guide (10) and
push rod (11).
13.
Remove valve guide (12).
14.
Using a small flat tip screwdriver,
remove and discard seals (13 and 14)
from valve guide (12).
15.
Remove and separate spring (15) and
Discard
valve (16) from body (17).
valve (16).
16.
Separate cover (18) and body (33).
17.
Remove and discard preformed packing
(19).
18.
Remove items 20 thru 24 as an
assembly from body (33).
19.
Remove spring (21), seals (22 and 23)
and preformed packing (24) from
piston (20). Discard seals (22 and
23) and preformed packing (24).
20.
Using snap ring pliers, remove ring
(25) and shield (26).
21.
Remove items 27 thru 32 as an
assembly from body (33).
22.
Remove valve (27), spring (28), valve
guide (29) and items 30 thru 32 as an
assembly. Discard valve (27).
23.
Remove and discard seals (31 and 32)
from retainer (30).
Go to sheet 4
8-49
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-12.
Treadle Valve (S/N 2000 and below). (Sheet 4 of 7)
CLEANING/INSPECTION
24.
Wipe all rubber and plastic parts
with a clean cloth moistened with
mild detergent and water solution.
● TOXICIFLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
air
get
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
25.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
26.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
8-50
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-12.
Treadle Valve (S/N 2000 and below). (Sheet 5 of 7)
ASSEMBLY
27.
Lubricate new seals (32 and 31) with
clean grease.
28.
Install new seals (32 and 31) in
retainer (30).
29.
Install valve guide (29).
30.
Install spring (28) and new valve
(27).
31.
Lubricate center bore of body (33)
with clean grease.
32.
Using internal snap ring pliers,
install items 32 thru 27 as an
assembly, shield (26) and ring (25).
33.
Install new preformed packing (24)
and new seals (23 and 22) on piston
(20).
34.
Lubricate piston (20) with clean
grease.
35.
Install spring (21) and piston
in body (33).
(20)
Go to sheet 6
8-51
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-12.
Treadle Valve (S/N 2000 and below). (Sheet 6 of 7)
ASSEMBLY (cont)
36.
Install new preformed packing (19) in
cover (18).
37•
Position cover (18) with ❑ atchmarks
on body (33).
38.
Lubricate center bore of body (17)
with clean grease.
39•
Install new valve (16) in spring
(15).
40.
Lubricate new seals (14 and 13) with
clean grease and install.
41.
Install new seal (14) in valve guide
(12).
42.
Install new seal (13) on valve guide
(12).
43.
Install new valve (16) in valve guide
(12).
44•
Install items 16 thru 12 as an
assembly in body (17).
45.
Install push rod (11) in guide (10).
Go to sheet 7
8-52
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-12.
Treadle Valve (S/N 2000 and below). (Sheet 7 of 7)
ASSEMBLY
46.
Install guide (10) in new valve (16).
47•
Position body (17) with matchmarks on
cover (18).
48.
Using a 9/16” socket and socket
wrench handle, install four lock
washers (9) and bolts (8).
49•
Lubricate bore of piston (7) with
clean grease.
50.
Using a flat brass punch, position
spring (6) and retainer (5) in piston
(7). Depress retainer (5).
51.
Using internal snap ring pliers,
install ring (4).
52.
Lubricate outer diameter of new
preformed packing (3) with clean
grease and install.
53.
Install spring (2) on piston (7).
54.
Install items 7 thru 2 as an assembly
in body (17). Depress to compress
spring (2).
55.
Install retainer (l).
NOTE
Return M1OA Forklift to original
equipment condition.
END OF TASK
8-53
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-13.
Treadle Valve (S/N 2001 and above). (Sheet 1 of 8)
This task covers:
a.
c*
Disassembly
Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Grease (App. C, Item 10)
Thread sealant (App. C, Item 25)
Preformed packing (8)
Spring (4)
Valve (2)
Studs (10) to 25 in-lb.
Screws (11) to 15 in-lb.
Screw (25) to 7 in-lb.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
GO to
8-54
sheet 2
Condition Description
Treadle valve removed.
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-13.
Treadle Valve (S/N 2001 and above). (Sheet 2 of 8)
DISASSEMBLY
1.
Using a flat brass punch, depress
piston (9) to compress spring (2).
2.
Using internal snap ring pliers,
remove ring (l).
3.
Remove spring (2) and items 3 thru 9
as an assembly. Discard spring (2).
4.
Using a flat brass punch, depress
retainer (4).
5.
Using internal snap ring pliers,
remove ring (3).
6.
Remove retainer (4), ring (5), spring
(6), shims (7) and preformed packing
Discard
(8) from piston (9).
preformed packing (8).
Go to sheet 3
8-55
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-13.
Treadle Valve (S/N 2001 and above). (Sheet 3 of 8)
DISASSEMBLY (cont)
NOTE
Remove studs from body only if
inspection indicates replacement
is necessary.
7. Using a vise grip, remove three
studs (10), if necessary.
NOTE
Use scribe or punch to aid in
assembly.
8.
Matchmark bodies (13 and 34).
9.
Using a 7/16” socket and socket
wrench handle, remove four screws
(11) and tag (12).
10.
Separate bodies (13 and 34).
11.
Remove and discard preformed packing
(14).
12.
Using a flat brass punch, depress
body (18).
13.
Remove ring (15).
14.
Separate valve (16), spring (17),
body (18) and preformed packing (19).
Discard valve (16), spring (17) and
preformed packing (19).
15.
Remove and discard preformed packings
(20 and 21).
16.
Remove disk (22) and spring (23).
Discard spring (23).
Go to sheet 4
8-56
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-13.
Treadle Valve (S/N 2001 and ab+ove). (Sheet 4 of 8)
DISASSEMBLY
17.
Using a small flat tip screwdriver,
remove and discard preformed packing
(24).
18.
Remove screw (25), washer (26) and
diaphragm (27).
19.
Using a flat brass punch, depress
body (31).
20.
Remove ring (28).
21.
Remove items 29 thru 33 as an
assembly from body (34).
22.
Separate valve (29), spring (30),
body (31) and preformed packing (32).
Discard valve (29), spring (30) and
preformed packing (32).
23.
Remove and discard preformed packing
(33).
Go to sheet 5
8-57
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-13.
Treadle Valve (S/N 2001 and above). (Sheet 5 of 8)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek q edical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
solvent,
get
immediately.
l COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
24.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
25.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 6
8-58
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-13.
Treadle Valve (S/N 2001 and above). (Sheet 6 of 8)
ASSEMBLY
26.
Lubricate new preformed packings (33
and 32) with clean grease and
install.
27.
Install new spring (30) and new
valve (29) in valve body (31).
28.
Lubricate center bore of body (34)
with clean grease and install.
29.
Install items 33 thru 29 as an
assembly and ring (28) in body (34).
30.
Using flat tip screwdriver, install
diaphragm (27), washer (26) and screw
(25). Tighten screw (25) to 7 in-lb.
Go to sheet 7
8-59
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-13.
Treadle Valve (S/N 2001 and above). (Sheet 7 of 8)
ASSEMBLY (cont)
31.
Lubricate new preformed packing (24)
and install.
32.
Install new spring (23) and disc (22)
in body (34).
33.
Lubricate new preformed packing (21
and 20) with clean grease and
install.
34.
Lubricate new preformed packing (19)
with clean grease and install with
new spring (17).
35.
Install new valve (16), ring (15) and
new preformed packing (14) in body
(18).
36.
Lubricate center bore of body
with clean grease.
37.
Install items 21 thru 16 as an
assembly in body (13).
38.
Position body (13) with matchmark on
body (34).
39.
Using a 7/16” socket, socket wrench
handle and torque wrench, install tag
Tighten
(12) and four screws (11).
four screws (11) to 55 in-lb.
40.
Coat threads of three studs (10) with
thread sealant and install, if removed. Tighten three studs (10) to
25 in-lb.
Go to sheet 8
8-60
(13)
.
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-13.
Treadle Valve (S/N 2001 and above). (Sheet 8 of 8)
ASSEMBLY
41.
Lubricate center bore of piston (9)
with clean grease.
42.
Lubricate new preformed packing (8)
with clean grease and install.
43.
Position shims (7), spring (6), ring
(5) and retainer (4) in piston (9).
44.
Using a flat brass punch, depress
retainer (4).
45.
Using internal snap ring pliers,
install ring (3).
46.
Install new spring (2) on piston (9).
47.
Install items 9 thru 2 as an assembly
in body (13).
48.
Using internal snap ring pliers,
install ring (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
8-61
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-14.
Air Compressor. (Sheet 1 of 13)
This task covers:
a.
c.
Disassembly
Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, Less Power
NSN 3470-00-754-0708
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, MAP only
NSN 3470-00-919-0068
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Micrometer
Feeler gage
Piston ring compressor
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Plastigage (App. C, Item 22)
Quick drying paint
(App. C, Item 6)
Casket (4)
Preformed packing
Seal (2)
Bushing
Bushing (2)
Torques
Bolts (1) to 18 lb-ft.
Bolts (4 and 14) to 15 lb-ft,
Two bolts (20) to 8 lb-ft. and
9 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
8-62
Condition Description
Air Compressor removed.
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-14.
Air Compressor. (Sheet 2 of 13)
DISASSEMBLY
1.
Using a 7/16” socket and socket wrench
handle, remove two bolts (1), valve
(2) and two cups (3) from cylinder
head (5).
2.
Using snap ring pliers, remove two
cages (7), springs (8), washers (9),
valves (10) and seats (11) from valve
(2).
3.
Using a drift punch and hammer,
matchmark cylinder head (5) and
cylinder block (15) with punch in
crankcase (41).
4.
Using a 1/2” socket and socket
wrench handle, remove five bolts (4),
cylinder head (5) and gasket (6).
Discard gasket (6).
5.
Using a gasket scraper, scrape carbon
accumulations from under cylinder
head (5).
6.
Using a small flat tip screwdriver,
pry off two guards (12) and valves
(13) on cylinder head (5).
GO
to sheet 3
8-63
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-14.
Air Compressor. (Sheet 3 of 13)
DISASSEMBLY (cont)
7.
Using a drift punch and hammer,
matchmark cylinder block (15) and
crankcase (41) with punch.
8.
Using a 1/2” open end wrench, remove
six lock bolts (14), cylinder block
(15) and gasket (16) from crankcase
(41). Discard gasket (16).
9.
Lift cylinder block (15) straight up
until clear of pistons.
10,
Position crankcase (41) on one side.
11.
Rotate crankshaft (38) to bring one
connecting rod (26) to bottom of
stroke.
12.
Using a 1/4” socket, socket wrench
handle and a open end wrench, remove
two locknuts ((17), rod cap (18),
bearing half (19), two bolts (20),
items 22 thru 28 as an assembly and
bearing half (21). Discard bearing
halves (19 and 21).
13.
for
Repeat procedure
second
connecting rod and piston assembly.
14.
Replace two rod caps
connecting rods (26).
15.
Using a 1/4” socket and socket wrench
handle, install four bolts (20) and
locknuts (17).
16.
Identify connecting rods (26) as
matched assemblies by marking with
quick dry paint.
17.
Using a small flat tip screwdriver,
remove ring sets (22 and 23) from
connecting rod and piston assembly.
Go to sheet 4
8-64
(18) on
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-14.
Air Compressor. (Sheet 4 of 13)
DISASSEMBLY
18.
Clamp piston (27) bottom side up in
soft-jawed vise.
19.
Insert pointed tool in hole on bottom
side of pin (25).
20•
Press downward to force end of
lockwire (24) out of hole.
21•
Using long round nose pliers, remove
lockwire (24) through bore of piston
(27).
22.
Using a flat punch and hammer, remove
pin (25) and connecting rod (26).
23.
Using a flat punch and hammer, remove
and discard bushing (28) from
connecting rod (26).
NOTE
Disassembly procedure for second
connecting rod and piston assembly
is identical.
Go to sheet 5
8-65
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-14.
Air Compressor. (Sheet 5 of 13)
DISASSEMBLY (cont)
24.
Using a 1/2” socket and socket
wrench handle, remove four lock bolts
(29) and bearing cap (33).
25.
Remove and discard seal (30).
preformed packing (31) and gasket
Remove
(32) from bearing cap (33).
all gasket material from mounting
surfaces.
26.
Remove four lock bolts (34), bearing
cap (35) and gasket (36) from
crankcase (41). Discard gasket (36).
27.
Using a small flat tip screwdriver,
remove and discard seal (37) in
bearing cap (35).
28.
Aline front connecting rod bearing
journal of crankshaft (38) in
crankcase (41) with cut-out portion
of crankshaft (38) bearing bore in
front end of crankcase (41).
29.
Using a soft faced hammer against
rear end of crankshaft (38), drive
bearing (39) free from supporting
bore of crankshaft (38) in crankcase
(41)*
30,
Remove crankshaft (38) from crankcase
(41).
31.
Using a press, remove bearing (39)
from crankshaft (38).
32.
Using a small flat tip screwdriver,
remove key (40).
Go to sheet 6
8-66
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-14.
Air Compressor. (Sheet 6 of 13)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Near protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored. Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
•COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
33.
Clean all parts with cleaning solvent
P-D-680. If necessary, run wire or
wire brush through oil passages in
crankshaft (38) to remove oil
deposits.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 7
8-67
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-14.
Air Compressor. (Sheet 7 of 13)
CLEANING/INSPECTION (cont)
34.
Using a micrometer, measure front
bearing journal (threaded end) of
crankshaft (38). Dimension must be
1.3779 to 1.3784 inches.
35.
Using a micrometer, measure rear
bearing journal of crankshaft (38).
Standard dimension: 1.3779 to 1.3784
inches .
0.010 U/S dimension: 1.3684 to 1.3689
inches.
0.020 U/S dimension: 1.3584 to 1.3589
inches .
0.030 U/S dimension: 1.3484 to 1.3489
inches .
NOTE
If necessary, grind rear bearing
journal to next lower undersize
dimension and replace bearing cap
with appropriate undersize bearing
cap.
36.
Using a micrometer, measure two
connecting rod bearing journals.
Standard dimension: 1.1230 to 1.1235
inches.
0.020 U/S dimension: 1.1040 to 1.1035
inches.
0.030 U/S dimension: 1.0940 to 1.0935
inches.
Go to sheet 8
8-68
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-14. Air Compressor. (Sheet 8 of 13)
CLEANING/INSPECTION
NOTE
If necessary, grind connecting rod
bearing journals to next lower
undersize dimension and replace
with
appropriate
bearings
undersize bearings.
37.
Inspect threads and keyway of
crankshaft (38). Replace if keyway
is chipped or misshaped or threads
are stripped.
38.
Using a micrometer, measure cylinder
diameter of cylinder block (15).
Cylinder diameter should be 1.995 to
2.000 inches.
39.
Inspect cylinder block (15) for
cracks, scoring, pitting or damage.
If severe scoring or pitting of
cylinder walls is evident, cylinders
may be bored to 2.015 to 2.020 inches
and pistons (27) replaced with
oversize pistons.
40.
Inspect piston (27) for cracks.
Light scoring or abrasion marks can
be removed with a stone.
41.
Install ring sets (22 and 23).
42.
Using a feeler gage, measure
clearance of rings in grooves.
Clearance should be 0.005 to 0.0025
inches.
Go to sheet 9
8-69
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-14.
Air Compressor. (Sheet 9 of 13)
CLEANING/INSPECTION (cont)
43.
Using a feeler gage, measure ring
gap. Gap should be 0.003 to 0.010
inches.
44.
Using a feeler gage, check clearance
of pin (25) in bushing (28).
Clearance should be 0.0002 to 0.0006
inches .
NOTE
Ensure that all match marks on
connecting rods and rod caps are
alined and connecting rods are
installed on journal from which
they were removed.
45.
Using a 1/2” socket, socket wrench
handle, torque wrench, install
connecting rod (26), new bearing
halves (19 and 21), two rod caps
(18), bolts (20) and locknuts (17) on
crankshaft (38) with Plastigage.
Tighten four bolts (20) to 9 lb-ft.
46.
Remove Plastigage and measure bearing
clearance. Bearing clearance must be
0.0005 to 0.0020 inches.
47.
Using a feeler gage, measure
connecting rod (26) to crankshaft
side clearance. Clearance must be
0.003 to 0.008 inches.
Go to sheet 10
8-70
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-14.
Air Compressor. (Sheet 10 of 13)
CLEANING/INSPECTION
48.
Inspect bearing cap (35) for cracks
or damage. Replace if cracked or
damaged.
49.
Inspect cylinder head (5) for
Carbon
deposits or foreign matter.
deposits in air inlet and exhaust
Heavy
cavities must be removed.
accumulations of rust or foreign
matter in water passage must be
removed. A light coating of rust is
acceptable.
50•
Inspect valve seat surfaces for
scratches, burrs or imperfections.
Slight imperfections may be removed
with a stone.
51.
Inspect valves (2,8 and 13), two
guards (12) cages (11) and seats (7)
for nicks, burrs, pitting or
roughness. Minor defects may be
removed with lapping equipment. Pin
in two guards (12) must be a tight
fit in pin hole.
52.
Using a micrometer, measure free
length of two springs (10). Free
length should be 0.97 inch. Apply
load of 3.5 lbs to two springs (10).
Using hydraulic pliers, measure test
length. Test length should be 0.73
inches.
Go to sheet 11
8-71
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-14.
Air Compressor. (Sheet 11 of 13)
ASSEMBLY
53.
Using a hydraulic press or soft jawed
vise, install new bushing (28) on
connecting rod (26).
54.
Using a soft jawed vise, install
connecting rod (26) and pin (25) in
piston (27).
NOTE
Ensure that lockwire holes in
pistons and pin are alined during
installation.
55.
Using long round nose pliers, install
lockwire (24).
56.
Install ring sets (23 and 22).
Position gap in rings 180 degrees
apart.
57.
Using a small hammer, install key
(40) in crankshaft (38).
58.
Press bearing (39) onto crankshaft
(38).
59.
Position crankshaft (38) in crankcase (41). Press bearing (39) in
bore into crankcase (41).
60.
Using a soft jawed vise, install new
seal (37) in bearing cap (35).
61.
Using a 1/2” socket and socket
wrench handle, install new gasket
(36), bearing cap (35) and four lock
bolts (34) in crankcase (41).
Go to sheet 12
8-72
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-14.
Air Compressor. (Sheet 12 of 13)
ASSEMBLY
Install new preformed packing (31)
and new seal (30) in bearing cap
(33).
Using a 1/2” socket and socket
wrench handle, install new gasket
(32), new preformed packing (31), new
seal (30), bearing cap (33) and four
lock bolts (29) in crankcase (41).
64.
Using a piston ring compressor,
install items 28 thru 22 as an
assembly in cylinder block (15).
65.
Install new gasket (16) and cylinder
block (15) with items 28 thru 22 as
an assembly in crankcase (41). Guide
lower ends of connecting rods onto
journals on crankshaft.
66.
Using a torque wrench and square
drive to hex adapter, install six
lock bolts (14). Tighten six lock
bolts (14) to 15 lb-ft.
67.
Using a 1/4” socket, socket wrench
handle, torque wrench and a open end
wrench, install new bearing halves
(21 and 19), rod cap (18), two bolts
(20) and locknuts (17). Tighten two
bolts (20) to 8 lb-ft.
NOTE
Ensure match marks on connecting
rod and rod cap are alined.
68.
Repeat procedure
for
second
connecting rod and piston assembly.
Go to sheet 13
8-73
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-14.
Air Compressor. (Sheet 13 of 13)
ASSEMBLY (cont)
69.
Install two valves (13) and guards
(12) in cylinder head (5).
Guards
must be staked and flush with
cylinder head (5).
70.
Using a 1/2” socket, socket wrench
handle and torque wrench, install new
gasket (6) , cylinder head (5) and five
bolts (4) in crankcase (41). Tighten
five bolts (4) to 15 lb-ft.
71.
Using snap ring pliers, install two
seats (11), valves (10), washers (9),
springs (8) and cages (7) in valve
(2).
72.
Using a 7/16” socket, socket wrench
handle and torque wrench, install two
cups (3), valve (2) and two bolts (1)
in cylinder head (5). Tighten two
bolts (1) to 18 lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
8-74
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-15.
Governor Assembly. (Sheet 1 of 5)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Shop Equipment, Automotive
Maintenance and Repair:
Organizational Maintenance,
Common No. 1, Less Power
NSN 4910-00-754-0654
Shop Equipment, Automotive
Maintenance and Repair:
Organizational Maintenance,
Common No. 2, Less Power
NSN 4910-00-754-0650
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Thread sealant (App. C, Item 31)
Grease, Type 2 (APP. C, Item 32)
Preformed packing (2)
Grommet
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Governor removed.
Go to sheet 2
8-75
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-15.
Governor Assembly. (Sheet 2 of 5)
DISASSEMBLY
1.
Using internal snap ring pliers,
remove cover (1), retaining ring (2)
and items 3 thru 9 as an assembly
from body (27).
2.
Using a 1/2” socket, socket wrench
handle and flat tip screwdriver,
remove nut (3), spring seat (4),
spring (5), spring seat (6), guide
(7) and spring seat (8) from screw
(9).
3.
Remove exhaust stem (10) and spring
(11) from body (27).
4.
Remove items 12 thru 20 as an
assembly from body (27).
5.
Using a small flat tip screwdriver,
remove and discard preformed packings
(12 and 13) from piston (20).
6.
Using internal snap ring pliers,
remove retaining ring (14), spring
(15) and valve (16).
7.
Remove retaining ring (17), washer
(18) and grommet (19).
Discard
grommet (19).
8.
Using long round nose pliers, remove
filters (21 and 22) in body (27).
9.
Using a socket head screw key, remove
plugs (23 thru 26).
Go to sheet 3
8-76
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-15.
Governor Assembly. (Sheet 3 of 5)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
If
with eyes, skin or clothing.
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
get
air
solvent,
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
10.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
11.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
8-77
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-15.
Governor Assembly. (Sheet 4 of 5)
ASSEMBLY
NOTE
Apply thread
installation.
sealant before
12.
Using a socket head screw key,
install plugs (26 thru 23).
13.
Using long round nose pliers, install
filters (22 and 21) in body (27).
NOTE
Before further assembly, lubricate
lower bore of body, top of piston,
piston grooves, preformed packings, guide, grommet and screw
with grease.
14.
Using internal snap ring pliers,
install new grommet (19) in piston
(20).
15.
Using internal snap ring pliers,
install washer (18) and retaining
ring (17).
16.
Using internal snap ring pliers,
install valve (16), spring (15) and
retaining ring (14). Small end of
spring must be toward valve (16).
17.
Install new preformed packings
and 12).
18.
Install spring (11) and exhaust stem
(10) in piston (20).
19.
Install items 12 thru 20 as an
assembly in body (27).
Go to sheet 5
8-78
(13
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-15.
Governor Assembly. (Sheet 5 of 5)
ASSEMBLY
20.
Using a 1/2” socket and socket wrench
handle, install spring seat (8),
guide (7), spring seat (6), spring
(5), spring seat (4) and nut (3).
Tighten spring seat (4) until
dimension between head of screw (9)
and spring seat (4) is as shown.
21.
Using internal snap ring pliers,
install items 3 thru 9 as an
assembly, retaining ring (2) and
cover (1) in body (27).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
8-79
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-16.
Parking Brake Assembly. (Sheet 1 of 6)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Cotter pin
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
8-80
Condition Description
Parking brake linkage removed.
Propeller shaft (transmission to rear
axle) removed.
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-16.
Parking Brake Assembly . (Sheet 2 of 6)
REMOVAL
NOTE
l Hold flange yoke while removing
nut from vehicle S/N 2000 and
below.
l The following are differences
between M10A Forklift models.
The
removal/installation
procedures are identical.
1.
Using a 1-5/16” socket and socket
wrench handle, remove nut (1) and
washer (4) from vehicles S/N 2000 and
below or remove cotter pin (2),
locknut (3) and washer (4) from
vehicles S/N 2001 and above from rear
axle under vehicle.
2.
Using a suitable puller, remove items
5 thru 9 as an assembly.
3.
Using a 9/16” socket and socket
wrench handle, remove eight bolts
(5), lock washers (6) and flange yoke
(8) from brake drum (9) on vehicles
S/N 2000 and below or washers (7) and
flange yoke (8) on vehicles S/N 2001
and above from brake drum (9).
Go to sheet 3
8-81
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-16.
Parking Brake Assembly. (Sheet 3 of 6)
REMOVAL (cont)
4.
Using brake spring pliers, remove two
springs (10), shoe assemblies (11),
lever (12) and roller (13) from rear
axle, under vehicle.
5.
Using a 3/4” socket and socket wrench
handle, remove six bolts (14),
washers (15) and plate (16).
NOTE
● Inspect
shoe assemblies for wear
of linings. If worn below 1/8”,
replace brake shoe assembly.
● Brake
shoe assemblies must be
replaced in pairs.
Go to sheet 4
8-82
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-16.
Parking Brake Assembly. (Sheet 4 of 6)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680,
used for cleaning parts, is toxic
and flammable. Use only in well
Wear
ventilated areas.
protective goggles and gloves.
Do not smoke or allow open flames
or sparks in areas where cleaning
solvent is used or stored. Avoid
contact with eyes, skin or
clothing. If contact with eyes
is made, flush with cold water
and seek medical attention
immediately. If contact with
skin or clothing is made, flush
with cold water. If you become
dizzy while using cleaning
fresh
solvent, get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield,
gloves, etc.).
6.
Clean all parts with cleaning solvent
P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
NOTE
If necessary,
drum.
resurface brake
7.
Measure inside diameter of brake
drum (9). If measurement exceeds
13.410 inches, replace drum.
8.
Inspect brake drum (9) for scoring
or cracks. Replace if necessary.
9.
Inspect all parts.
graph 2-9.
Refer to paraGo to sheet 5
8-83
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE. (cont)
8-16.
Parking Brake Assembly. (Sheet 5 of 6)
INSTALLATION
10.
Using a 13/16” socket and socket
wrench handle, install plate (16),
six washers (15) and bolts (14) in
rear axle under vehicle.
11.
Lubricate and install roller (13),
contact points and lever (12). Lever
(12) must be positioned on left hand
brake pawl. Roller (13) on right
hand brake pawl must ride on upper
edge of lever (12).
12.
Lubricate shoe (17) to bracket
contact point. Install two shoe
assemblies (11).
Web of shoe
assemblies (11) must be positioned
under guide brackets on plate (16).
13.
Using brake spring pliers, install
two springs (10). Springs (10)
must be installed in holes nearest plate (16).
Go to sheet 6
8-84
TM 10-3930-643-34
BRAKE TROUBLESHOOTING AND MAINTENANCE.
8-16.
Parking Brake Assembly. (Sheet 6 of 6)
INSTALLATION
NOTE
The following are differences
between M10A Forklift models.
14.
Using a 9/16” socket and a socket
wrench, install flange yoke (8),
eight washers (7) and bolts (5) in
vehicles S/N 2001 in brake drum (9)
and above or flange yoke (8), eight
lock washers (6) and bolts (5) in
vehicles S/N 2000 and below in brake
drum (9).
15.
Install items 9 thru 5 as an assembly
in rear axle, under vehicle.
16.
Using a 1-5/16” socket and socket
wrench handle, install washer (4),
locknut (3) and new cotter pin (2) in
vehicles S/N 2001 and above or washer
(4) and nut (1) in vehicles S/N 2000
and below. Tighten locknut (1) to
300-400 lb-ft.
17.
Using an adjustable wrench, adjust
parking brake linkage, refer to
TM 10-3930-643-20.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
8-85 (8-86 blank)
TM 10-3930-643-34
CHAPTER 9
STEERING
TROUBLESHOOTING AND MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently troubleshoot
and repair malfunctioning equipment and to perform authorized direct support
level maintenance procedures on the M10A Forklift steering system.
INDEX
Title
Steering Troubleshooting
Steering Gear Assembly
Ground Driven Steering Pump (S/N 2000 and below)
Ground Driven Steering Pump (S/N 2001 and above)
Steering Cylinder
Control Valve and Check Valve
Steering Circuit Relief Valve
Paragraph
Page
9-1
9-2
9-3
9-4
9-5
9-6
9-7
9-2
9-6
9-14
9-24
9-32
9-37
9-52
9-1
TN 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-1.
Steering Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
a.
SLOW STEERING AT LOW ENGINE RPM AND SLOW BOOM HYDRAULICS AT HIGH ENGINE
RPM .
Step 1.
Check operation of hydraulic pump for malfunction or worn
parts.
Replace hydraulic pump, refer to paragraph 12-2.
Step 2.
Check steering circuit relief valve pressure, refer to
paragraph 9-7.
Adjust to correct pressure setting.
Step 3.
Check steering circuit relief valve for leaks or defective
operation.
Repair steering circuit relief valve, refer to paragraph 9-7.
b.
SLOW STEERING.
Step 1.
Check steering cylinder assembly for worn or scored piston
rings or seals, refer to paragraph 9-5.
Step 2. Check inside diameter of steering cylinder for nicks and
grooves too deep to be polished out.
Replace defective parts. Install repair kit.
For disassembly and inside inspection of cylinder assembly, refer to
paragraph 9-5.
For replacement of cylinder assembly, refer to TM 10-3930-643-20.
9-2
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-1.
Steering Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
c. NOISY OPERATION.
Step 1.
Check steering circuit relief valve for possible chattering,
refer to paragraph 9-7.
Repair as necessary.
Step 2.
d.
Refer to TM 10-3930-643-20 for other malfunctions
gear noise). Also, refer to paragraph 12-1.
(steering
HYDRAULIC OIL HEATING UP.
Step 1.
Check steering circuit relief valve for insufficient valve
pressure or pressure too high, refer to paragraph 9-7.
Adjust to correct pressure setting.
Step 2.
Check steering circuit relief valve to determine if defective,
refer to paragraph 9-7.
Repair steering circuit relief valve.
e.
INSUFFICIENT STEERING PRESSURE.
Check steering circuit relief valve pressure, refer to paragraph 9-7.
Adjust to correct pressure setting.
9-3
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-1.
Steering Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
f.
STICKING CONTROL VALVE PLUNGER.
Step 1. Check control valve plunger bore for burrs or scoring, refer to
paragraph 9-6.
Replace control valve.
Step 2. Check valve plunger in steering control valve to see if it is
warped. Also, check for dirt or foreign matter, refer to
paragraph 9-6.
Clean steering control valve.
Step 3.
Replace plunger if necessary.
Check control valve for damaged, broken or distorted springs,
refer to paragraph 9-6.
Replace springs if damaged, broken or distorted.
g.
PLAY IN STEERING GEAR.
Check for worn gear teeth in steering gear housing, refer to paragraph
9-2.
Repair steering gear.
9-4
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
Steering Troubleshooting.
9-1.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
h.
HARD STEERING WHILE DRIVING.
Check oil pressure, if pressure is low, adjust to correct pressure
setting, refer to paragraph 9-6.
Check frame hinge pins for frozen bushings, refer to paragraph 10-2.
Replace frame hinge pin bushings.
NOTE
Since the procedure for replacing frame hinge pin bushings requires so
much time, other causes for malfunctions “h.” should be thoroughly
investigated, refer to TM 10-3930-643-20.
9-5
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-2.
Steering Gear Assembly. (Sheet 1 of 8)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tool S
Tool Kit, General Mechanic's
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Leas Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Feeler gage
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean-cloth (App . C, Item 24)
Multi-purpose gear grease
(App; C; Item 10)
Gasket
Seal (2)
Torques
Nut (3) to 22 lb-ft.
Locknut (4) to 90 lb-ft.
Bolts (9) to 30 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
9-6
Condition Description
Steering gear removed.
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-2.
Steering Gear Assembly. (Sheet 2 of 8)
DISASSEMBLY
NOTE
Scribe a mark on flange and shaft
of ballnut and worm assembly to
aid in installation.
1.
Using a 9/16” open end wrench, remove
bolt (1) and flange (2).
2.
Using a 3/4” socket and socket wrench
handle, remove nut (3).
3.
Turn setscrew (12) counterclockwise
several times to relieve load from
bearings (6 and 23).
4.
Using a spanner wrench, remove
locknut (4) and items 5 thru 8 as an
assembly.
5.
Using a cotter pin extractor, remove
seat (5), bearing (6) and ring (7)
from adjuster (8).
6.
Using a 9/16” socket and socket
wrench handle, remove three bolts
(9), washers (10) and items 11 thru
15 as an assembly.
7.
Using a large rubber mallet, remove
gearshaft (11).
8.
Using a flat tip screwdriver, remove
setscrew (12), shim (13) and gasket
(15) from cover (14). Discard gasket
(15).
9.
Using a large rubber mallet, remove
items 16 thru 23 as an assembly from
housing (26).
GO to sheet 3
9-7
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-2.
Steering Gear Assembly. (Sheet 3 of 8)
DISASSEMBLY (cont)
10.
Using a 3/8” socket and socket wrench
handle, remove bolt (16), washer (17)
and clamp (18).
11.
Using long round nose pliers, remove
four guides (19) and 54 balls (20)
from ballnut and worm assembly (21),
ring (22) and bearing (23).
12.
Using a cotter pin extractor, remove
and discard seals (24 and 25).
Go to sheet 4
9-8
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-2.
Steering Gear Assembly. (Sheet 4 of 8)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
solvent,
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
13.
Soak bearings (6 and 23) in cleaning
solvent P-D-680 to loosen dirt then
rinse in clean cleaning solvent
P-D-680. Wipe dry.
14.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 5
9-9
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-2.
Steering Gear Assembly. (Sheet 5 of 8)
CLEANING/INSPECTION (cont)
15.
Inspect 54 balls (20) for flat spots
or wear. Balls (20) should be same
size within 0.0001 inch.
16.
Inspect all other parts.
paragraph 2-9.
Refer to
ASSEMBLY
NOTE
All parts must be clean and free
of abrasive dirt.
All moving
parts must be lubricated with
multi-purpose gear grease.
17.
Using a wooden dowel and hammer,
install new seals (25 and 24),
bearing (23) and ring (22).
18.
Position ballnut and worm assembly
(21) with return guide holes facing
up.
19.
Aline grooves in ballnut and worm
assembly (21).
20,
Using pliers, insert 27 balls (20)
into any return guide hole.
21.
Slowly rotate worm away from guide
holes while inserting balls (20).
22.
Continue inserting balls (20) until
circuit is filled from the bottom of
one hole to the bottom of the other
or until stopped by reaching end of
worm.
Go to sheet 6
9-10
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-2.
Steering Gear Assembly. (Sheet 6 of 8)
ASSEMBLY
NOTE
If balls are stopped by reaching
end of worm, hold down balls
already installed with rod or
punch. Rotate shaft in a reverse
direction a few turns. Filling of
circuit may then be continued.
23.
Place remaining balls (20) in groove
of one guide (19). Then cover with
another guide (19).
24.
Plug both ends of guides (19) with
multi-purpose grease to prevent balls
when
(20) from falling out
installing.
25.
Using long round nose pliers, install
items 20 and 19 as an assembly in
ballnut and worm assembly (21).
NOTE
Install remainder of balls by
repeating steps 18 thru 25.
26.
Install 27 of 54 balls (20) in
ballnut and worm assembly (21).
27.
Using a 3/8” socket and socket wrench
handle, install clamp (18), washer
(17) and bolt (16).
NOTE
Do not allow ballnut to rotate to
end of worm threads. Temporarily
tape exposed threads until ready
for assembly.
28.
Test items 23 thru 16 as an assembly
by rotating ballnut on worm. Ballnut
and worm assembly (21) must move
freely.
Go to sheet 7
9-11
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-2.
Steering Gear Assembly. (Sheet 7 of 8)
ASSEMBLY (cont)
29.
Using a large rubber mallet, install
items 23 thru 16 as an assembly in
housing (26).
30.
Position new gasket (15) on cover
(14).
31.
Using long round nose pliers, install
shim (13) on setscrew (12).
32.
Using a flat tip screwdriver, install
items 13 and 12 as an assembly in
gearshaft (11).
33.
Using a feeler gage, measure
clearance between head of setscrew
(12) and gearshaft (11). If
clearance exceeds 0.002 inch, install
thicker shim (13).
34.
Thread cover (14) onto setscrew (12).
35.
Rotate worm until ballnut is in
center of worm assembly (21).
36.
Using a large rubber mallet, install
items 14 thru 11 as an assembly in
housing (26).
Center tooth of
gearshaft (11) must enter center
tooth space of ballnut on ballnut and
worm assembly (21).
37.
Rotate setscrew (12) to pull cover
(14) over end of gearshaft (11).
38.
Back off to permit clearance between
gear on gearshaft (11) and ballnut
and worm assembly (21).
Go to sheet 8
9-12
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-2.
Steering Gear Assembly. (Sheet 8 of 8)
ASSEMBLY
39.
Using a 9/16” socket and socket
wrench handle, install three washers
(10) and bolts (9). Tighten bolts
(9) to 30 lb-ft.
40.
Using a wooden dowel and hammer,
install ring (7), bearing (6) and
seat (5) in adjuster (8).
41.
Using a spanner wrench, install items
8 thru 5 as an assembly and locknut
(4). Tighten locknut (4) to 90
lb-ft.
42.
Using a 3/4” socket and socket wrench
handle, install nut (3). Tighten nut
(3) to 22 lb-ft.
43.
Using a 9/16” open-end wrench,
install flange (2) and bolt (1). Use
matchmarks made before step 1.
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
9-13
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 1 of 10)
This task covers:
a.
c.
Disassembly
Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tags (App. C, Item 28)
Loctite 262, Grade N
(App. C, Item 15)
Lubricating oil (App. C, Item 19)
Preformed packing (17)
Seal (2)
Torques
BOltS (1) to 24 lb-ft.
Bolts (9 and 10) to 34 lb-ft.
Bolts (32 and 33) to 18 lb-ft.
Bolts (45) to 20 lb-ft.
Plug (49) to 30 lb-ft.
Plugs (51) to 60 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
9-14
Condition Description
Ground driven steering pump removed.
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 2 of 10)
DISASSEMBLY
1.
Using a 7/16” socket and socket
wrench handle, remove three bolts (1)
and items 2 thru 8 as an assembly.
2.
Using retaining ring pliers, remove
seal (2), ring (3) and seal (4).
Discard seals (2 and 4).
3.
Using a scribe, remove preformed
packing (5) and locating ring (6).
Discard preformed packing (5).
4.
Using a flat tip screwdriver, remove
plug (7) from adapter (8).
5.
Using a 9/16” socket and socket
wrench handle, remove four bolts (9
and 10).
6.
Using retaining ring pliers, remove
two rings (11).
7.
Using a plastic mallet, separate
items 12 thru 19 as an assembly.
Go to sheet 3
9-15
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 3 of 10)
DISASSEMBLY (cont)
8.
Using a scribe, remove and discard
preformed packing (12).
9*
Using a small punch, remove two pins
(13), bearings (14) and body (15).
10.
Using a small punch and flat blade
screwdriver, remove two pins (16),
screws (17), plate (18) and body
(19).
11.
Using a plastic mallet, remove two
gears (20) and pins (21) from shafts
(23 and 24).
12.
Using retaining ring pliers,
two rings (22).
13.
Using a plastic mallet, remove shafts
(23 and 24).
14.
Using a scribe, remove preformed
packing (25) and two bearings (26).
Discard preformed packing (25).
15.
Using a 9/16” socket and socket
wrench handle, remove two nuts (27)
and washers (28).
16.
Using slip joint pliers, remove two
studs (29) and block (30).
17.
Using a scribe, remove and discard
two preformed packings (31).
18.
Using a 1/4” socket head screw key,
remove two bolts (32) and four bolts
(33).
19.
Using a 1-1/4” open end wrench,
remove plug (34), preformed packing
(35) and plug (36).
Discard
preformed packing (35).
20.
Using slip joint pliers, remove plug
(37).
Go to sheet 4
9-16
remove
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 4 of 10)
DISASSEMBLY
Exercise care when removing
retainer.
Retainer is under
Failure to
spring pressure.
follow this procedure could result
in SEVERE INJURY.
21.
Using a 1-1/8” open end wrench,
remove retainer (38) and preformed
Discard preformed
packing (39).
packing (39).
22.
Using a wooden dowel, remove spring
(40), seat (41), spool (42) and valve
(43).
23.
Using a scribe, remove and discard
two preformed packings (44).
24.
Using a 1/2” socket and socket wrench
handle, remove two bolts (45).
25.
Using a plastic mallet, separate body
(46) from items 47 thru 55 as an
assembly.
Go to sheet 5
9-17
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 5 of 10)
DISASSEMBLY (cont)
26.
Using a scribe, remove and discard
two preformed packings (47) and
preformed packing (48).
27.
Using a 1/4” open end wrench, remove
plug (49) and preformed packing (50)
Discard preformed packing (50).
Exercise care when removing plugs.
Plugs are under spring pressure.
Failure to follow this procedure
could result in SEVERE INJURY.
28.
Using a 1-1/4” open end wrench,
remove four plugs (51) and preformed
packings (52).
Discard four
preformed packings (52).
NOTE
Tag location of pistons in body to
aid in installation.
29.
Remove four springs (53) and pistons
(54) from body (55).
Go to sheet 6
9-18
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 6 of 10)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
30.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
Go to sheet 7
9-19
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 7 of 10)
CLEANING/INSPECTION (cont)
31.
Inspect two bearings (14 and 26).
Check inside diameter for scoring.
Replace if scored, grooved or badly
pitted.
32.
Inspect two gears (20). Replace if
teeth are worn or gears are pitted or
scored.
33.
Inspect shafts (23 and 24). Replace
if splines are worn or shafts are
pitted or scored.
34•
Inspect all other parts. Refer to
paragraph 2-9.
ASSEMBLY
NOTE
All moving parts, seals and preformed packings must be lubricated
before installation.
35.
Install four pistons (54) and springs
(53) in body (55).
36.
Using a 1-1/4” socket, socket wrench
handle and torque wrench, install
four new preformed packings (52) and
four plugs (51). Tighten plugs (51)
to 60 lb-ft.
37.
Install new preformed packing (50)
and plug (49). Tighten plug (49) to
30 lb-ft.
38.
Install new preformed packing (48)
and two new preformed packings (47).
Go to sheet 8
9-20
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 8 of 10)
ASSEMBLY
39.
Position body (46) against items 55
thru 47 as an assembly.
40.
Using a 1/2” socket, socket wrench
handle and torque wrench, install two
bolts (45). Tighten to 20 lb-ft.
41.
Install two new preformed packings
(44).
42.
Using a wooden dowel, install spool
(42), seat (41) and spring (40) in
valve (43).
43.
Using a 12” adjustable wrench,
install new preformed packing (39)
and retainer (38).
Go to sheet 9
9-21
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 9 of 10)
ASSEMBLY (cont)
44.
Using slip joint pliers, install plug
(37) in retainer (38).
45.
Using a 1/4" socket and socket wrench
handle, install plug (36), new
preformed packing (35) and plug (34).
46.
Using a 1/4" socket head screw key,
1/4" socket, socket wrench handle and
torque wrench, install four bolts
(33), two bolts (32) and block (30).
Tighten bolts (33 and 32) to 18
lb-ft.
47.
Install two new preformed packings
(31) in block (30).
48.
Using slip joint pliers, install two
studs (29).
49.
Using a 9/16" socket and socket
wrench handle, install two washers
(28) and nuts (27).
50.
Install two bearings (26) and new
preformed packing (25).
51.
Install shafts (24 and 23).
52.
Using retaining ring pliers, install
two rings (22).
Go to sheet 10
9-22
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-3.
Ground Driven Steering Pump (S/N 2000 and below). (Sheet 10 of 10)
ASSEMBLY
53.
Using a hammer and small punch,
install two pins (21) and gears (20).
54.
Using a flat tip screwdriver and
small punch, install plate (18), two
screws (17), pins (16) and body (15).
55.
Using a hammer and small punch,
install two bearings (14) and pins
(13).
56.
Using retaining ring pliers, install
two rings (11).
57.
Install new preformed packing (12).
58.
Position items 19 thru 12 as an
assembly.
59.
Apply Loctite 262 under bolt heads
only. Using a 9/16" socket, socket
wrench handle and torque wrench,
install four bolts (10 and 9).
Tighten bolts (10 and 9) to 34 lb-ft.
60.
Using a flat tip screwdriver, install
adapter (8) and plug (7).
61.
Install locating ring (6) and new
preformed packing (5).
62.
Using retaining ring pliers, install
new seal (4), ring (3) and new seal
(2).
63.
Position items 8 thru 2 as an
assembly.
64.
Apply Loctite 262 under bolt heads
only. Using a 7/16" socket, socket
wrench handle and torque wrench,
Tighten
install three bolts (1).
three bolts (1) to 24 lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
9-23
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-4.
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 1 of 8)
This task covers:
a.
c.
Disassembly
Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basict
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Small tag (App. C, Item 28)
Preformed packing (19)
Seal (2)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
9-24
Condition Description
Ground driven steering pump removed.
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-4.
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 2 of 8)
DISASSEMBLY
1.
Using a plastic mallet, separate
plate (1) from flange (10).
2.
Using a scribe, remove and discard
preformed packing (2).
3.
Using a cotter pin extractor, remove
seal (3), snap ring (4) and seal (5).
Discard seals (3 and 5).
4.
Using a 1/4” socket head screw key,
remove eight bolts (6) and items 7
thru 10 as an assembly.
5.
Using a drift pin and scribe, remove
two dowels (7), preformed packing (8)
and plug (9) from flange (lo).
Discard preformed packing (8).
6.
Using a 9/16" socket and socket
wrench handle, remove two bolts (11),
washers (12), four bolts (13) and
washers (14).
7.
Using a plastic mallet, remove items
15 thru 19 as an assembly.
8.
Using a scribe, remove preformed
packing (15), seat (16), piston (17)
and retainer (18) from plate (19).
Discard preformed packing (15).
9.
Using a scribe, remove and discard
preformed packing (20) from valve
body (39).
Go to sheet 3
9-25
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 3 of 8)
9-4.
DISASSEMBLY (cont)
10•
Using a 1/4" socket head screw key,
remove two bolts (21) and washers
(22).
11.
Using a plastic mallet, separate
plate (26) and valve body (39) from
body (59).
NOTE
Tag all pistons to aid in
installation.
12.
Remove two pistons (23) and springs
(24) from valve body (39).
13.
Using a plastic mallet, remove two
spacers (25), plate (26) and
preformed packing (27). Discard
preformed packing (27).
14.
Remove two pistons (28), springs (29),
preformed packings (30) and preformed
packing (31) from body (59). Discard
two preformed packings (30) and preformed packing (31).
15.
Using a scribe, remove and discard
two preformed packings (32) from
valve body (39).
16.
Using a 9/16" socket and socket
wrench handle, remove four bolts
(33), washers (34), plate (35) and
preformed packing (36). Discard
preformed packing (36).
17.
Using a plastic mallet, remove spring
(37) and sleeve (38) from valve body
(39) .
18.
Using a scribe, remove two preformed
packings (40) and preformed packing
(41) from body (59). Discard
preformed packings (40 and 41).
19.
Using a plastic mallet, remove items
42 thru 52 as an assembly from body
(59).
Go to sheet 4
9-26
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-4.
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 4 of 8)
DISASSEMBLY
20.
Separate items 45 thru 48 as an
assembly from items 49 thru 52
as an assembly.
21.
Using long round nose pliers, remove
four pins (42) and balls (43).
22.
Remove two pins (44).
23.
Using a scribe, remove two rings (45),
preformed packings (46) and bushings
(47) from gear (48). Discard two
preformed packings (46).
24.
Using a scribe, remove two rings
(49), preformed packings (50) and
bushing (51) from gear (52).
Discard two preformed packings
(50) .
25.
Remove plug (53) and preformed
packing (54). Discard preformed
packing (54).
26.
Using a scribe, remove two preformed
packings (55), seats (56), balls (57)
and retainers (58) from body (59).
Discard two preformed packings (55).
Go to sheet 5
9-27
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-4.
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 5 of 8)
CLEANING/INSPECTION
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
air
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
27.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
28.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 6
9-28
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-4.
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 6 of 8)
ASSEMBLY
NOTE
All moving parts, seals and preformed packings must be lubricated
before installing.
29.
Install two retainers (58), balls
(57), seats (56) and new preformed
packings (55) in body (59). Seats
(56) must be flush with face of
body (59).
30.
Install new preformed packing (54)
and plug (53).
31.
Install two bushings (51), new
preformed packings (50) and rings
(49) on gear (52).
32.
Install two bushings (47), new
preformed packings (46) and rings
(45) on gear (48).
33.
Install two pins (44).
34.
Install four balls (43) and pins
(42) .
35.
Position items 48 thru 45 as an
assembly on items 52 thru 49 as
an assembly.
36.
Install items 52 thru 42 as an
assembly in body (59).
Go to sheet 7
9-29
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 7 of 8)
9-4.
ASSEMBLY (cont)
37.
Install new preformed packing (41)
and two new preformed packings (40)
in body (59).
38.
Install sleeve (38) and spring (37)
in valve body (39).
39.
Install new preformed packing (36),
plate (35), four washers (34) and
bolts (33).
40.
Install two new preformed packings
(32) in valve body (39).
41.
Install new preformed packing (31),
two new preformed packings (30),
springs (29) and pistons (28) in
body (59).
42.
Install new preformed packing (27),
plate (26) and two spacers (25).
43.
Install two springs (24) and pistons
(23).
44.
Position valve body (37) and plate
(26) against body (57).
45.
Using an socket head screw key,
install two washers (22) and bolts
(21).
GoO to sheet 8
9-30
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-4.
Ground Driven Steering Pump (S/N 2001 and above). (Sheet 8 of 8)
ASSEMBLY
46.
Install new preformed packing (20) in
valve body (39).
47.
Install retainer (18), piston (17),
seat (16) and new preformed packing
(15) in plate (19).
48.
Position items 19 thru 15 as an
assembly.
49.
Using a 9/16" socket and socket
wrench handle, install four washers
(14), bolts (13), two washers (12)
and bolts (11).
50.
Using a flat tip screwdriver, install
plug (9) and new preformed packing
(8) and two dowels (7) in flange
(10).
51.
Using 1/4" socket head screw key and
plastic mallet, install items 10 thru
7 as an assembly and eight bolts (6).
52.
Install new seal (5), snap ring (4)
and new seal (3).
53.
Install new preformed packing (2).
54.
Position plate (1) on flange (10).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
9-31
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-5.
Steering Cylinder. (Sheet 1 of 5)
This task covers:
a.
c.
Disassembly
Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Emery cloth (App. C, Item 4)
Lubricating oil (App. C, Item 19)
Loctite 592 (App. C, Item 17)
Preformed packing (3)
Seal (3)
Washer
Ring (2)
Torques
Nut (1) to 370 lb-ft.
Cap (12) to 950 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Co to sheet 2
9-32
Condition Description
Steering cylinder removed.
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-5.
Steering Cylinder. (Sheet 2 of 5)
DISASSEMBLY
1.
Using a cylinder cap tool, unscrew
cap (13).
2.
Using a large rubber mallet, remove
items 1 thru 13 as an assembly from
cylinder (15).
3.
Using a 1-13/16" socket and socket
wrench handle, remove nut (1).
Hold rod (13) eye in suitable
holding device when removing nut (1).
4.
Remove 2 thru 5 as an assembly from
rod (13).
5.
Remove two rings (2) from piston (5).
6.
Using a scribe, remove and discard
seal (3) and preformed packing (4).
7.
Using a large rubber mallet, remove
items 6 thru 11 as an assembly.
8.
Using a scribe, remove washer (6)
from gland (11).
9.
Remove and discard preformed packings
(7 and 8).
10.
Remove and discard seals (9 and 10)
from gland (11).
11.
Remove cap (12) from rod (13).
12.
Using a hammer and punch, remove
bushing (14) from cylinder (15).
Go to sheet 3
9-33
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Steering Cylinder. (Sheet 3 of 5)
9-5.
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
13.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
14.
Inspect all parts. Refer to paragraph 2-9.
GO to sheet 4
9-34
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-5.
Steering Cylinder. (Sheet 4 of 5)
ASSEMBLY
NOTE
All moving parts, seals and preformed packings must be lubricated
with hydraulic fluid before
installing.
15.
Using a rubber mallet, install
bushing (14) on cylinder (15).
16.
Install cap (12) on rod (13).
17.
Install new seal (10) in gland (11)
with larger end of seal (10) facing
inward.
18.
Install new seal (9) in gland (11)
with open end of seal (9) facing
outward.
19.
Install new preformed packings (8 and
7) and washer (6) on gland (11).
20.
Lubricate rod (13).
21.
Using a large rubber mallet,
install items 11 thru 6 as an
assembly on rod (13).
Go to sheet 5
9-35
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-5
Steering Cylinder. (Sheet 5 of 5)
●
ASSEMBLY (cont)
22.
Install new preformed packing (4)
on piston (5).
23.
Install one of two rings (2), closest
to gland (11) on piston (5).
24.
Place seal (3) in hot water 180-200
degrees F to soften and install over
preformed packing (4).
25.
Using a ring compressor, compress
seal (3) and ring (2) onto piston (5).
26.
Using a rubber mallet, install items
5 thru 2 as an assembly on rod (13),
keeping items 3 and 2 compressed.
27.
Apply Loctite 592 to threads of rod
(13) and using a 1-13/16" socket,
socket wrench handle and torque
wrench, install nut (1). Tighten
nut (1) to 370 lb-ft.
28.
Using a lint free cloth, lubricate
items 11 thru 6 as an assembly and
items 5 thru 2 as an assembly.
29.
Tap items 13 thru 2 as an assembly
into cylinder (15), until seal (3)
is inserted in barrel.
30.
Apply Loctite 592 across width of
cylinder (15) housing threads.
31.
Using a cylinder cap tool and torque
wrench, tighten cap (12) to 950
lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
9-36
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 1 of 15)
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection d. Assembly
e. Installation
f. Adjustment
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling, capacity of
100 lbs.
Personnel Required
Two (Adjustment only)
Torques
Plug (45) to 100 lb-ft.
Plug (47) to 45 lb-ft.
Plug (48) to 30 lb-ft.
Nut (50) to 50 lb-ft.
Plug (55) to 110 lb-ft.
Bolts (56) to 15 lb-ft.
Screws (60) to 25 lb-ft.
Screw (64) to 7.5 lb-ft.
Plug (76) to 7.5 lb-ft.
Nut (82) to 10 lb-ft.
Locknut (84) to 10 lb-ft.
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Small tag (App. C, Item 28)
Crocus cloth (App. C, Item 3)
Lubricating oil (App. C, Item 19)
Preformed packing (22)
Seal (3)
Wiper (2)
Tie strap
EQUIPMENT CONDITION
References
Paragraph 9-7
Condition Description
Steering circuit relief valves removed.
Go to sheet 2
9-37
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-6.
Control Valve and Check Valve. (Sheet 2 of 15)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a 9/16" socket and socket
wrench handle, remove two bolts (1)
and two flange halves (2) from under
right side of cab.
2.
Disconnect hose assembly (3) from
check valve (11).
NOTE
The following is a difference
between M10A Forklift models.
3.
Using a scribe, remove preformed
packing (4) and plate (5) from
vehicles S/N 2001 and above. Discard
preformed packing (4).
4.
Remove and discard preformed packing
(6).
5.
Using a 9/16” socket and socket
wrench handle, remove four bolts (7)
and two flange halves (8).
6.
Disconnect hose assembly (9).
7.
Remove preformed packing (10) and
check valve (11). Discard preformed
packing (10).
Go to sheet 3
9-38
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 3 of 15)
REMOVAL
8.
Using a 1/2" socket and socket wrench
handle, remove bolt’ (12) and strap
(13) from right front of engine
compartment.
9.
Using diagonal cutting pliers, cut
and discard tie strap (14) from under
right side of cab.
10.
Using a 9/16" open end wrench,
disconnect hose assembly (15)
from connector (16).
11.
Using a 3/4" open end wrench and
a scribe, remove connector (16) and
preformed packing (17). Discard
preformed packing (17).
12.
Using a 9/16" socket and socket
wrench handle, remove four bolts
(18) and two flange halves (19).
13.
Disconnect hose assembly (20).
140
Using a scribe, remove and discard
preformed packing (21).
15.
Using a 1" open end wrench,
disconnect hose assembly (22).
16.
Using a 1-1/4" open end wrench,
loosen locknut on elbow (23).
17.
Using a 1-1/8" open end wrench,
remove elbow (23) and preformed
packing (24). Discard preformed
packing (24).
Go to sheet 4
9-39
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Control Valve and Check Valve. (Sheet 4 of 15)
9-6.
REMOVAL (cont)
18.
Using a 15/16" open end wrench,
disconnect hose assembly (25).
19.
Using a 1-1/8" open end wrench,
remove connector (26) and preformed
packing (27). Discard preformed
packing (27).
20.
Using a 15/16" open end wrench,
disconnect hose assembly (28).
21.
Using a 1-1/4" open end wrench,
loosen locknut on elbow (29).
22.
Using a 1-1/8" open end wrench,
remove elbow (29) and preformed
packing (30). Discard preformed
packing (30).
23.
Using a 15/16" socket, socket wrench
handle and a 1-1/8" open end wrench,
remove nut (31), washer (32) and
bolt (33).
24.
Move pin (34) aside.
25.
Using a 1-1/8" open end wrench,
loosen locknut (35).
26.
Using a 10" adjustable wrench, remove
link assembly (36). Unscrew from
plunger on valve assembly (42).
27.
Remove washer (37).
Go to sheet 5
9-40
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 5 of 15)
REMOVAL
WEIGHT HAZARD
Weight of valve assembly is
approximately 95 lbs.
Use
adequate hoist and sling for
removal and installation.
Keep
area clear of
unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY .
28.
Attach hoist and sling to valve
assembly (42) on right side, under
cab.
29.
Using a 3/4" socket and socket wrench
handle, remove three nuts (38),
washers (39), bolts (40), washers
(41) and valve assembly (42).
30.
Remove hoist and sling.
DISASSEMBLY
31.
Using a 1-3/8" socket and socket
wrench handle, remove plug (43),
preformed packing (44), plug (45),
preformed packing (46) and plug (47).
Discard preformed packings (44 and
46) .
32.
Using a 5/8" socket and socket wrench
handle, remove three plugs (48) and
preformed packings (49).
Discard
three preformed packings (49).
33.
Using a 1-1/2" socket and socket
wrench handle, remove nut (50).
34.
Using a scribe, remove items 51 thru
55 as an assembly.
Go to sheet 6
9-41
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Control Valve and Check Valve. (Sheet 6 of 15)
9-6.
DISASSEMBLY (cont)
35.
Remove washer (51), preformed packing
(52) and rings (53 and 54) from plug
(55). Discard preformed packing
(52).
36.
Using a 9/16" socket and socket
wrench handle, remove two bolts (56),
cap (57), body (58) and seal (59).
Discard seal (59).
37.
Using a flat tip screwdriver, remove
two screws (60), plate (61), wiper
(62) and seal (63). Discard wiper
(62) and seal (63).
38.
Remove screw (64), preformed packing
(65), seat (66), spring (67) and seat
(68). Discard preformed packing
(65).
NOTE
Same quantity and size of shims
must be installed during assembly.
39.
Using a scribe, remove plate (69) and
shims (70).
40.
Remove spacer (71), spring (72) and
poppet (73).
41.
Remove items 74 thru 76 as an
assembly.
Go to sheet 7
9-42
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 7 of 15)
DISASSEMBLY
42.
Using a scribe, remove retainer (74)
and preformed packing (75) from plug
(76). Discard preformed packing
(75).
43.
Remove spring (77) and poppet (78).
44.
Remove plunger (79).
45.
Remove and discard wiper (80) and
seal (81).
46.
Using an 11/16" open end wrench,
remove nut (82) and preformed packing
(83). Discard preformed packing
(83).
47.
Using an 11/16" open end wrench,
remove locknut (84), preformed
packing (85), adjusting screw (86),
spring (87) and poppet (88). Discard
preformed packing (85).
48.
Using a 1-3/8" open end wrench,
remove plug (89), preformed packing
(90), retainer (91) and Preformed
Discard preformed
packing (92).
packings (90 and 92).
49.
Remove spring (93), shims (94) and
plunger (95) from valve (96).
Go to sheet 8
9-43
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Control Valve and Check Valve. (Sheet 8 of 15)
9-6.
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
50.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
51.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 9
9-44
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 9 of 15)
ASSEMBLY
NOTE
All moving parts, preformed packings,
plungers and seal counterbores in
valve must be lubricated before
assembling.
52.
Install plunger (95), shims (94) and
spring (93) in valve (96).
53.
Install new preformed packing (92),
retainer (91), new preformed packing
(90) and plug (89).
54.
Using an 11/16" socket, socket wrench
handle and torque wrench, install
poppet (88), spring (87), adjusting
screw (86), new preformed packing
Tighten
(85) and locknut (84).
locknut (84) to 10 lb-ft.
55.
Install new preformed packing (83)
and nut (82). Tighten nut (82) to 10
lb-ft .
56.
Install new seal (81) and new
(80).
57.
Install plunger (79).
58.
Install poppet (78) and spring (77).
59.
Install new preformed packing (75)
and retainer (74) on plug (76).
60.
Using a flat tip bit in adapter
socket and torque wrench, install
items 76 thru 74 as an assembly.
Tighten plug (76) to 7.5 lb-ft.
wiper
Go to sheet 10
9-45
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-6.
Control Valve and Check Valve. (Sheet 10 of 15)
ASSEMBLY (cont)
61.
Install poppet (73), spring (72) and
spacer (71).
62.
Install shims (70) and plate (69).
63.
Using a flat tip bit in adapter
socket and torque wrench, install
seat (68), spring (67), seat (66),
new preformed packing (65) and screw
(64). Tighten screw (64) to 7.5
lb-ft .
64.
Install new seal (63), new wiper
(62), plate (61) and two screws (60).
Tighten screws (60) to 25 lb-ft.
65.
Using a 9/16” socket, socket wrench
handle and torque wrench, install
new seal (59), body (58), cap (57)
and two bolts (56). Tighten bolts
(56) to 15 lb-ft.
66.
Using a flat tip screwdriver, install
rings (54 and 53), new preformed
packing (52) and washer (51) on plug
(55).
Go to sheet 11
9-46
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 11 of 15)
ASSEMBLY
67.
Using a flat tip ‘bit in adapter
socket and torque wrench, install
items 55 thru 51 as an assembly.
Tighten plug (55) to 110 lb-ft.
68.
Using a 1-1/2" socket, socket wrench
handle and torque wrench, install nut
(50). Tighten nut (50) to 50 lb-ft.
69.
Using a 5/8" socket, socket wrench
handle and torque wrench, install
three new preformed packings (49) and
plugs (48). Tighten plugs (48) to 30
lb-ft.
70.
Using a 1-3/8" socket, socket wrench
handle and torque wrench, install
plug (47), new preformed packing
(46), plug (45), new preformed
packing (44) and plug (43). Tighten
plug (47) to 45 lb-ft and plug (45)
to 100 lb-ft.
Go to sheet 12
9-47
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-6.
Control Valve and Check Valve. (Sheet 12 of 15)
INSTALLATION
71.
Attach hoist and sling to valve
assembly (42) and install under
right side of cab.
72.
Using a 3/4" socket, socket wrench
handle and a 3/4" open end wrench,
install three washers (41), bolts
(40), washers (39) and nuts (38).
73.
Remove hoist and sling.
74.
Using a 10" adjustable wrench,
install washer (37) and link
assembly (36).
75.
Using a 1-1/8" open end wrench,
tighten locknut (35).
76.
Position pin (34).
77.
Using a 15/16" socket, socket wrench
handle and a 1-1/8" open end wrench,
install bolt (33), washer (32) and
nut (31).
78.
Using a 1-1/8" open end wrench,
install new preformed packing (30)
and elbow (29).
79.
Using a 1-1/4" open end wrench,
tighten locknut on elbow (29).
80.
Using a 15/16" open end wrench,
connect hose assembly (28) to
elbow (29).
81.
Using a 1-1/8" open end wrench,
install new preformed packing (27)
and connector (26).
82.
Using a 15/16" open end wrench,
connect hose assembly (25).
Go to sheet 13
9-48
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 13 of 15)
INSTALLATION
83.
Using a 1-1/8" open end wrench,
install new preformed packing (24)
and elbow (23).
84.
Using a 1-1/4" open end wrench,
tighten locknut on elbow (23).
85.
Using a 1" open end wrench,
connect hose assembly (22).
86.
Using a 9/16" socket and socket
wrench handle, install new preformed
packing (21), hose assembly (20), two
flange halves (19) and four bolts
(18).
87.
Using a 3/4" open end wrench,
install new preformed packing (17)
and connector (16).
88.
Using a 9/16" open end wrench,
connect hose assembly (15).
89.
Install new tie strap (14).
90.
Using a 1/2" socket and socket wrench
handle, install strap (13) and bolt
(12) on right front of engine
compartment.
91.
Position check valve (11) on valve
assembly (42) under right side of
cab.
92.
Position new preformed packing (10)
and hose assembly (9) on check valve
(11).
93.
using a 9/16" socket and socket
wrench handle, install two flange
halves (8) and four bolts (7).
94.
Install new preformed packing (6).
Go to sheet 14
9-49
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-6.
Control Valve and Check Valve. (Sheet 14 of 15)
INSTALLATION (cont)
NOTE
The following is a difference
between M10A Forklift models.
95.
Install plate (5) and new preformed
packing (4) on vehicles S/N 2001 and
above.
96.
Position hose assembly (3) and two
flange halves (2).
97.
Using a 9/16" socket and socket
wrench handle, install four bolts
(l).
ADJUSTMENT
98.
Check fluid level of hydraulic fluid
reservoir, refer to LO 10-3930643-12. Fill to proper level.
99.
Check fluid filter, refer to TM 103930-643-20. Clean or replace as
necessary.
100.
Using a 10" adjustable wrench,
install relief valves, refer to TM
10-3930- 643-20.
101.
Using a 5/8" socket and socket wrench
handle, remove one plug (48) and
Discard
preformed packing (49).
preformed packing (49).
102.
Using a 10" adjustable wrench,
install hydraulic pressure gage
(0-3000 psi).
Go to sheet 15
9-50
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-6.
Control Valve and Check Valve. (Sheet 15 of 15)
ADJUSTMENT
103.
Using an 11/16" socket and socket
wrench handle, remove nut (82) and
preformed packing (83).
Discard
preformed packing (83).
104.
Loosen locknut (84).
105.
Using a flat tip screwdriver, back
off adjusting screw (86) until no
tension is felt.
106.
Start engine and run at high idle.
Turn steering wheel fully right or
left. Hydraulic fluid must be at
normal operating
temperature.
Pressure gage should read 2000 psi.
107.
Using a flat tip screwdriver, turn
adjusting screw (86) clockwise to
increase pressure, counterclockwise
to decrease pressure, as necessary.
108.
Using an 11/16" socket, socket
wrench handle and torque wrench,
tighten locknut (84) to 10 lb-ft.
109.
Stop engine.
110.
Install new preformed packing
and nut (82).
111.
Remove hydraulic pressure gage.
112.
Using a 5/8" socket, socket wrench
handle and torque wrench, install
new preformed packing (49) and one
plug (48). Tighten plug (48) to 30
lb-ft.
(83)
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
9-51
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-7.
Steering Circuit Relief Valve. (Sheet 1 of 7)
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection d. Assembly
e. Installation
f. Adjustment
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Preformed packing (7)
Torques
Nuts (2 and 4) to 10 lb-ft.
Body (13) to 75 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
9-52
Condition Description
Hydraulic system vented.
Vehicle turned left.
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-7.
Steering Circuit Relief Valve. (Sheet 2 of 7)
REMOVAL
NOTE
This task is for maintenance of
the left steering relief valve.
Procedure for maintenance of the
right steering relief valve is
identical.
1.
Using a 1-1/4" open end wrench,
remove items 2 thru 19 as an assembly
from steering control valve under
cab, on right side of vehicle.
2*
Using a scribe, remove and discard
preformed packing (1).
3.
Plug valve port on items 2 thru 19 as
an assembly to prevent contamination
from entering hydraulic system.
DISASSEMBLY
4.
Using a 1-1/16" socket, socket wrench
handle, machinist scribe and flat tip
(2),
screwdriver, remove nut
preformed packing (3), nut (4),
preformed packing (5) and screw (6).
Discard preformed packings (3 and 5).
5.
Using a 1-1/4" open end wrench,
remove items 7 thru 12 as an assembly
from body (13).
Go to sheet 3
9-53
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
9-7.
Steering Circuit Relief Valve. (Sheet 3 of 7)
DISASSEMBLY (cont)
6.
Using a scribe, remove and discard
preformed packing (7).
7.
Remove spring (8), poppet (9),
preformed packing (10) and retainer
Discard
(11) from plug (12).
preformed packing (10).
8.
Remove items 14 thru 19 as an
assembly from body (13).
9.
Remove spring (14), piston (15) and
items 17 thru 19 as an assembly from
poppet (16).
10,
Using a scribe, remove ring (17) and
preformed packing (18) from poppet
(19). Discard preformed packing
(18).
Go to sheet 4
9-54
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-7
●
Steering Circuit Relief Valve. (Sheet 4 of 7)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
11.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
12.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
9-55
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Steering Circuit Relief Valve. (Sheet 5 of 7)
9-7.
ASSEMBLY
NOTE
All preformed packings must be
lubricated with hydraulic fluid
before installing.
13.
Install new preformed packing
and ring (17) on poppet (19).
14.
Install items 19 thru 17 as an
assembly, piston (15) and spring (14)
in poppet (16).
15.
Install items 19 thru 14 as an
assembly in body (13).
16.
Install retainer (11), new preformed
packing (10), poppet (9) and spring
(8) in plug (12).
17.
Install new preformed packing (7).
18.
Using a 1-1/4" socket and socket
wrench handle, install items 12 thru
7 as an assembly in body (13).
19.
Using a flat tip screwdriver, 11/16”
socket, socket wrench handle and
torque wrench, install screw (6), new
preformed packing (5), nut (4), new
preformed packing (3) and nut (2).
Tighten nut (4) to 10 lb-ft while
holding screw (6). Tighten nut (2)
to 10 lb-ft.
Go to sheet 6
9-56
(18)
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE.
9-7.
Steering Circuit Relief Valve. (Sheet 6 of 7)
INSTALLATION
20.
Using 15/16" socket, socket wrench
handle and torque wrench, install
items 19 thru 2 as an assembly and
new preformed packing (1) in steering
control valve. Tighten items 19 thru
2 to 75 lb-ft.
ADJUSTMENT
21.
Using a 5/8" socket and socket wrench
handle, remove plug (20) and
preformed packing (21).
Discard
preformed packing (21).
22.
Install pressure gage.
23.
Operate and observe at what pressure
valve releases. Valve should open at
3500 psi.
24.
Using an 11/16" socket and socket
wrench handle, remove nut (2) and new
preformed packing (3), if necessary.
25.
Using an 11/16" open end wrench and
flat tip screwdriver, loosen nut (4)
while holding screw (6).
Go to sheet 7
9-57
TM 10-3930-643-34
STEERING TROUBLESHOOTING AND MAINTENANCE. (cont)
Steering Circuit Relief Valve. (Sheet 7 of 7)
9-7.
ADJUSTMENT (cont)
NOTE
Turn screw clockwise to increase
pressure: counterclockwise to
decrease as necessary.
26.
Using an 11/16" socket, socket wrench
handle, torque wrench and flat tip
screwdriver, tighten nut (4) to 10
lb-ft while holding screw (6), after
obtaining proper pressure setting.
27.
Using an 11/16" open end wrench,
install new preformed packing (3) and
nut (2).
28.
Remove pressure gage.
29.
Using a 5/8" socket and socket wrench
handle, install new preformed packing
(21) and plug (20).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
9-58
TM 10-3930-643-34
CHAPTER 10
FRAME AND TOWING ATTACHMENTS
MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized direct support level
maintenance procedures on the M10A Forklift frame.
INDEX
Title
Bolster
Frame Hinge Pin and Frame Assembly
Counterweights
Roll Over Protective Structure
(S/N) 2000 and below)
Paragraph
Page
10-1
10-2
10-3
10-2
10-6
10-19
10-4
10-23
10-1
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-1.
Bolster. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Multi-purpose grease
(App. C, Item 12)
Preformed packing (4)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
Hoist and two slings, capacity
of 350 lbs.
EQUIPMENT CONDITION
References
Paragraph 7-8
Condition Description
Rear differential removed.
Paragraph 8-3
Parking brake air cylinder removed.
Go to sheet 2
10-2
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
Bolster. (Sheet 2 of 4)
10-1.
REMOVAL
WEIGHT HAZARD
Weight of bolster is approximately
350 lbs. Use adequate hoist and
two slings for removal and
installation. Keep area clear of
unnecessary personnel. Failure to
follow this procedure could result
in SEVERE INJURY.
1.
Attach two slings to bolster (6) in
rear of frame. With hoist suspended
above center, rear of vehicle, take
up slack in slings.
2.
Using a 3/4" socket and socket wrench
handle, remove two bolts (1) and
washers (2).
Bolster will be suspended by
slings when pins are removed.
Keep even tension on slings after
one pin has been removed to keep
other pin from binding.
3.
Using a flat brass punch and hammer,
remove two pins (3), four preformed
packings (4) and spacers (5).
Discard preformed packings (4).
4.
Lower bolster (6) onto dollies to
make removing from under vehicle
easier. Remove slings.
5.
Using a flat brass punch and hammer,
remove two bushings (7).
Go to sheet 3
10-3
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-1.
Bolster. (Sheet 3 of 4)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
air
get
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
6.
Wipe bolster (6) clean with clean
cloth moistened with cleaning solvent
P-D-680. Dry throughly.
7.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
8.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
10-4
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-1.
Bolster. (Sheet 4 of 4)
INSTALLATION
9.
Lubricate bushings (7) with clean
grease. Using a-flat brass punch and
hammer, install bushings (7) in
bolster (6). Groove in bushing (7)
must be in alinement with bore in
bolster (6).
10,
Using dollies, position bolster (6)
under vehicle.
11.
Attach slings to bolster (6).
12.
Using a hoist and sling, position
bolster (6) to frame.
13.
Lubricate spacers (5) and four new
preformed packings (4) with clean
grease and install on bolster (6).
14.
Lubricate two pins (3) with clean
grease and using a flat brass punch
and hammer, install.
15.
Measure clearance between spacers (5)
and frame. Clearance must be 0.0625
inch. Remove pins (3) and add
spacers as necessary if clearance
exceeds requirements.
16.
Using a 3/4" socket and socket wrench
handle, install two washers (2) and
bolts (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
10-5
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 1 of 13)
This task covers:
a. Checking Hinge Pin Wear b. Adjustment
c. Removal
d. Cleaning/Inspection
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Grease (App. C, Item 8)
Bushing Removal Tool (App. D, Item 12)
Seal (2)
Torques
Nut (4) to 190 lb-ft. and 220 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Wheels blocked.
TM 10-3930-643-20
Lubrication lines and fittings removed
from upper and lower frame hinge pins.
Go to sheet 2
10-6
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 2 of 13)
CHECKING HINGE PIN WEAR
1.
Position vehicle on level ground.
NOTE
Place the dial indicator in a
position that will allow another
person to observe the readings
from the side of the vehicle at a
safe distance.
2.
Position dial indicator as close as
possible to the hitch pin at the
lower frame hitch and zero dial
indicator.
Only a qualified operator may
perform the next step. All other
personnel, with the exception of
an observer for reading the dial
the
indicator, must clear
immediate area. Failure to follow
this procedure could result in
SEVERE INJURY or DEATH.
3.
Power forklift down until front
wheels are off ground.
4.
Read dial indicator.
5.
Raise forklift to full height.
6.
If readings
Read dial indicator.
indicate an up and down movement of
more than 0.010 inch, adjustment or
replacement is necessary.
7.
Install safety lock bar, refer to TM
10-3930-643-10.
8.
Lower forklift to ground.
9.
Stop engine.
Go to sheet 3
10-7
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 3 of 13)
ADJUSTMENT
NOTE
During adjustment, lock plates on
shafts must be kept from moving by
frame stop blocks and spacers.
10.
Center hinge alinement. Using feeler
gage, measure at points A. The front
frame tongues should be centered
between rear frame ears so that the
dimensions at points A are the same.
11.
Using feeler gage, measure at points
B. The dimensions at points B must
be the same. Dimensions will not
necessarily be the same as the point
A measurements.
NOTE
Dimensions at points A and B must
be spaced so that no part of the
front frame tongues comes in
contact with the rear frame ears.
12.
Using a 15/16" socket and socket
wrench handle, remove two bolts (1),
washers (2) and retainer plate (3)
from lower hitch.
13.
Using a 3-1/16" socket and socket
wrench handle, remove nut (4).
14.
Using a 15/16" socket and socket
wrench handle, remove two bolts (5),
washers (6) and retainer plate (7)
from upper hitch.
15.
Using a 3-1/16" socket and socket
wrench handle, adjust points A and
B clearance of front and rear frame.
If front frame tongues are too high,
loosen nut (8). If front frame
tongues are too low, tighten nut (8),
refer to step (10 and 11) for proper
dimensions.
Go to sheet 4
10-8
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 4 of 13)
ADJUSTMENT
16.
Using a feeler gage, measure
clearance between lock plates and
frame ears. Shafts (11 and 15) and
their lock plates must not make
contact with frame ears. A minimum
of 0.0625 inch must exist between
lock plate and frame. If clearance
is incorrect, refer to step 29 for
shim installation.
17.
Using a 15/16" socket and socket
wrench handle, install retainer plate
(7), two washers (6) and bolts (5).
Retainer plate (7) can be turned over
if it does not aline with nut (8).
If retainer plate (7) still does not
aline with nut (8), loosen or tighten
nut (8). Do not turn nut more than
30 degrees.
18.
Using a 3-1/16" socket, socket wrench
handle and torque wrench, install nut
(4) and tighten to 190 lb-ft. Tap
head of shaft (15) solidly with hammer
while tightening nut (4) to seat shaft
(15).
19.
Loosen nut (4).
20.
Tighten nut (4) by hand with retainer
plate (3).
21.
Raise forklift to maximum height and
lower in jerky increments. This will
help to seat mating components.
22.
Recheck vertical frame movement with
dial indicator, refer to step 6. If
dial indicator reading still exceeds
0.010 inch, determine if movement is
all up and down. If movement is
anything but vertical, replacement of
worn parts is necessary. If measure
exceeds 0.010 inch and is all up and
down, repeat steps 18 and 19.
Increase tightening of nut (4) to 220
lb-ft.
Go to sheet 5
10-9
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-2.
Frame Hinge Pin and Frame Assembly.
(Sheet 5 of 13)
ADJUSTMENT (cont)
23.
Using a 15/16" socket and socket
wrench handle, install retainer plate
(3), two washers (2) and bolts (1).
Retainer plate (3) can be turned over
if it does not aline with nut (4).
If retainer plate (3) still does not
aline with nut (4), do not turn more
than 30 degrees.
NOTE
The following step is the procedure used to acquire 0.0625 inch
gap between shafts lock plates and
frame ears.
24.
Using bottle jacks, support frames to
allow removal of shaft (15) or shaft
(11).
Do not remove both shafts from
frame at the same time. If both
shafts need adjustment, remove one
at a time.
NOTE
The following steps are for
adjusting lower hitch shaft.
Adjustment of upper hitch shaft
is identical, except as noted.
25.
Remove steering linkage before
removal of upper hitch shaft, refer
to TM 10-3930-643-20.
26.
Using a 15/16" socket and socket
wrench handle, remove two bolts (1),
washers (2) and retainer plate (3).
27.
Using a 3-1/16" socket and socket
wrench handle, remove nut (4).
Go to sheet 6
10-10
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 6 of 13)
ADJUSTMENT
29.
Using a flat brass punch and hammer,
remove spacer (16) from shaft (15).
30.
Install shims (17) and spacer (16)
on shaft (15). Each shim is 0.010
inch thick.
31.
Lubricate shaft (15) with clean
grease, using a flat punch and
hammer, install shaft (15).
32.
Using a 3-1/16" socket and socket
wrench handle, install nut (4) and
adjust, refer to Adjustment procedures.
33.
Using a 15/16" socket and socket
wrench handle, install retainer plate
(3), two washers (2) and bolts (1).
REMOVAL
34.
Remove transmission to bearing hanger
TM
propeller shaft, refer to
10-3930-643-20.
35.
Remove steering linkage, refer to TM
10-3930-643-20.
36.
Use four ten-ton bottle jacks to
support front and rear frames.
Go to sheet 7
10-11
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 7 of 13)
REMOVAL (cont)
NOTE
The following procedure is for
removal of the top hitch shaft
and bushings. Removal of lower
hitch shaft and bushings is
identical, except for positioning of a suitable puller or
ports-power.
Nut and bolt are provided for
replacing seal, without removing
shafts.
37.
Using a 1/2" socket, socket wrench
handle and a 1/2" open end wrench,
remove two nuts (18), bolts (19)
and seals (20). Discard two seals
(20) .
38.
Using a 15/16" socket and socket
wrench handle, remove two bolts (5),
washers (6) and retainer plate (7).
39.
Using a 3-1/16" socket and socket
wrench handle, remove nut (8).
40.
Using a 1-1/8" socket and socket
wrench handle, remove bolt (9) and
spacer (10).
41.
Using a large rubber mallet, remove
shaft (11). If necessary, drive
shaft (11) from frame with hammer and
drift.
42. Using a hammer and drift punch,
remove spacer (12).
43. Remove bushing (23).
Go to sheet 8
10-12
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
Frame Hinge Pin and Frame Assembly. (Sheet 8 of 13)
10-2.
REMOVAL
Do not remove both upper and lower
shafts at the same time. Do one
at a time, only.
NOTE
surrounding
Repositioning of
lines, cables or hoses may be
necessary to accommodate use of
equipment.
44.
Using a bushing removal tool, a 7/16”
socket, socket wrench handle and a
7/16” open end wrench, remove bushing
(21). Install two side pieces of
bushing removal tool in bushing (21)
so the lips of the tool grasp the lower
edge of the bushing (21).
45.
Install the center piece of the
bushing removal tool over the shaft
of the ports-power and between the
two side pieces of the bushing
removal tool.
46.
Install a nut to lock the assembly
together on the ports-power shaft.
Activate the ports-power and push
out bearing (21).
47.
Using a hammer and drift punch,
remove bushing (22).
48.
Remove two bushings (24) from left
and right side of rear frame.
Go to sheet 9
10-13
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cent)
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 9 of 13)
REMOVAL
49.
Using 3/4" socket, socket wrench
handle and an open end wrench, remove
two nuts (25), bolts (26) and
fittings (27) from lift cylinders on
each side of vehicle. Refer to
paragraph 12-12.
50.
Using a hoist and slings, disconnect
two lift cylinders assemblies and
secure on boom assembly.
51.
Using a 3/4 socket, socket wrench
handle and an open end wrench, remove
nut (28) two washers (29) and bolt
(30) from rod (31) under rear front
frame assembly.
52.
Using a hammer and drift punch,
remove rod (31). Drive rod (31)
through the front frame assembly and
remove from the other side of
vehicle.
53.
Using a 9/16" socket, socket wrench
handle and a open end wrench, remove
two bolts (32), spacers (33), nuts
(34) and washers (35) from access
cover (40).
54.
Remove six bolts (36), rollers (37),
nuts (38), washers (39) and access
cover (40).
Go to sheet 10
10-14
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 10 of 13)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
If
with eyes, skin or clothing.
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
●
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
55.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
56.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 11
10-15
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 11 of 13)
INSTALLATION
57.
Using a 9/16" socket, socket wrench
handle and a open end wrench, install
access cover (40), six washers (39),
nuts (38), rollers (37) and bolts
(36) to front frame assembly.
58.
Install two washers (35), nuts (34),
spacers (33) and bolts (32) to access
cover (40).
59.
Using a hammer and drift punch,
install rod (31).
60.
Using a 3/4 socket, socket wrench
handle and an open end wrench,
install bolt (30), two washers (29),
and nut (28) to rod (31) under rear
front frame assembly.
61.
Using a hoist and slings, connect two
lift cylinders assemblies. Refer to
paragraph 12-12.
62.
Using 3/4" socket, socket wrench
handle and an open end wrench,
install two fittings (27), bolts (26)
and nuts (25) to lift cylinders on
each side of vehicle.
Go to Sheet 12
10-16
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 12 of 13)
INSTALLATION
63.
Lubricate bores with clean grease.
Using a hammer and drift punch,
install two bushings (24) on left and
rights sides of rear frame.
64.
Lubricate bore with clean grease.
Install bushing (21), refer to step
44. Use ports-power or equivalent
to push bushing (21) into front frame
tongue until bushing seats against
counterbore of tongue.
65.
Lubricate bore with clean grease.
Install bushing (23) until flush
with frame ear surfaces.
66.
Lubricate bore with clean grease.
Install bushing (22) until flush
with frame ear surfaces.
67.
Using a 1/2” socket, socket wrench
handle and a 1/2” open end wrench,
position two new seals (20). One
seal goes on top of upper front
frame tongue and one goes below
tongue. Cutting of new seals is
not necessary if shafts (15 or 11)
have been removed. If shafts are
already in place, then cut new
seals and use bolts (19) and nuts
(18) to secure seals (20).
Go to Sheet 13
10-17
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-2.
Frame Hinge Pin and Frame Assembly. (Sheet 13 of 13)
INSTALLATION (cont)
68.
Using a hammer and drift, install
spacer (12).
69.
Using a large rubber mallet, install
shaft (11). If necessary, drive
shaft (11) into frame with hammer
and drift.
70.
Using a 1-1/8" socket and socket
wrench handle, install spacer (10)
and bolt (9).
71.
Using a 3-1/16" socket and socket
wrench handle, install nut (8).
72.
Using a 15/16" socket and socket
wrench handle, install retainer
plate (7), two washers (6) and
bolts (5).
NOTE
The following step must be done
after upper and lower hitch
bearings have been replaced.
73.
Adjust front and rear frames, refer
to Adjustment procedure.
74.
Install steering linkage, refer to
TM 10-3930-643-20.
75.
Install transmission to bearing
hanger propeller shaft, refer to
TM 10-3930-643-20.
76.
Lubricate with clean grease. Install
lubrication lines and fittings.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
10-18
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-3.
Counterweights. (Sheet 1 of 4)
This task covers:
a. Removal
b.
Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2" Open end wrench
NSN 5120-00-184-8489
Hoist and sling, capacity of
2562 lbs.
Torques
Bolts (4 and 18) to 280 lb-ft.
Bolt (8) to 680 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Pintle hook and drawbar removed.
Go to sheet 2
10-19
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
Counterweights. (Sheet 2 of 4)
10-3.
REMOVAL
WEIGHT HAZARD
The weight of the heaviest
Use
counterweight is 2135 lbs.
adequate hoist and sling for
removal and installation.
Keep
area clear of
unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY.
1.
Attach hoist and sling to one weight
(1) in rear of vehicle.
2.
Using a hoist and sling, remove three
weights (1), one at a time, from
vehicle.
3.
Remove hoist and sling.
NOTE
The following step is for removal
of side weights on the right side.
Removal and installation of left
side weights is identical.
4.
Attach hoist and sling to weight (10)
on right side of rear frame.
5.
Using a 1-1/8" socket, socket wrench
handle and 1-1/8" open end wrench.
remove two nuts (2), washers (3),
bolts (4), washers (5), nut (6),
washer (7), bolt (8), washer (9) and
weight (10). Bolts (4) may have to
be driven from frame and weights (10
and 15) with a hammer and drift.
Go to sheet 3
10-20
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
Counterweights. (Sheet 3 of 4)
10-3.
REMOVAL
6.
Attach hoist and sling to weight
(15).
7.
Using a 1-1/2" socket, socket wrench
handle and a 1-1/2" open end wrench,
remove two nuts (11), washers (12),
bolts (13), washers (14) and weight
(15).
8. Remove hoist and sling from weight
(15).
9.
10.
Attach hoist and sling to weight
(20).
Using a 1-1/2" socket, socket wrench
handle and a 1-1/2” open end wrench,
remove four nuts (16), washers (17),
bolts (18), washers (19) and weight
(20).
INSTALLATION
11.
Position weight (20) on frame.
12.
Using a 1-1/8" socket, socket wrench
handle and a 1-1/8” open end wrench,
install four washers (19), bolts
(18), washers (17) and nuts (16).
Tighten bolts (18) to 280 lb-ft.
13.
Remove hoist and sling from weight
(20).
14.
Attach hoist and sling to weight
(15).
15.
Position weight (15) on rear of
frame.
16.
Using a 1-1/2" socket, socket wrench
handle and a 1-1/2" open end wrench,
install two washers (14), bolts (13),
washers (12) and nuts (11).
17.
Remove hoist and sling from weight
(15).
Go to sheet 4
10-21
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-3.
Counterweights. (Sheet 4 of 4)
INSTALLATION (cont)
18.
Attach hoist and sling to weight
(10).
19.
Using a 1-1/8” socket, socket wrench
handle and 1-1/8” open-box wrench,
position weight (10) on weight (15).
20.
Install washer (9), bolt (8), washer
(7) and nut (6). Tighten bolt (8) to
680 lb-ft.
21.
Install two washers (5), bolts (4),
washers (3) and nuts (2).
Tighten
two bolts (4) to 280 lb-ft.
22.
Remove hoist and sling from weight
(10).
23.
Attach hoist and sling to three
weights (1), one at a time.
24.
Install three weights (1) on rear of
vehicle.
25.
Remove hoist and sling from weight
(1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
10-22
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-4.
Roll Over Protective Structure. (S/N 2000 and below). (Sheet 1 of 6)
This task covers:
b.
a. Disassembly
c. Assembly
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Strips (3)
Channel (4)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Roll over protective structure removed.
DISASSEMBLY
1.
Using a putty knife, remove seal (1)
from front window frame in cab.
2.
Using a 9/16" socket and socket
wrench handle, remove two bolts (2),
washers (3), support (4), two strips
(5) and strip (6) in front of cab.
Discard strips (5 and 6).
3.
Using a putty knife, remove seal (7)
from left side of door frame in cab.
Go to sheet 2
10-23
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
Roll over protective Structure.
10-4.
(S/N 200 and below). (Sheet 2 of 6)
DISASSEMBLY (cont)
NOTE
The following steps
of items from the
window. Removal of
from the right rear
cover removal
rear left
these items
is identical.
4.
Using a putty knife, remove seal (8)
from inner lip of protector (9) from
left rear window of cab.
5.
Locate break in seal and pry tab “A”
free of tab “B” in seal (10).
6.
Remove protector (9) from seal (10).
7.
Remove seal (10) from window frame.
8.
Remove seal (11) from protector (12)
from rear center window of cab.
9.
Locate break in seal (13) and pry tab
"A" free of tab “B”.
10.
Remove protector (12) from seal (13).
11.
Remove seal (13) from window frame.
12.
Using a 7/16" box and open end
wrench, remove six nuts (14) from
upper left and right sides of inside,
rear of cab.
Go to sheet 3
10-24
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-4.
Roll Over Protective Structure. (S/N 2000 and below). (Sheet 3 of 6)
DISASSEMBLY
13.
Using a 7/16" socket and socket
wrench handle, remove six bolts (15),
washers (16) and two bars (17) from
outer cab.
14.
Using a putty knife, remove seal (18)
from right side of window frame on
right side of cab.
15.
Using a 9/16" socket and socket
wrench handle, remove eight bolts
(19), washers (20), panel (21) and
channels (22 thru 25) on right side
of cab.
16.
Remove two screws (26) and plate (27)
from lower front, inner right side of
cab.
Go to sheet 4
10-25
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-4.
Roll Over Protective Structure. (S/N 2000 and below). (Sheet 4 of 6)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
17.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
18.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
10-26
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE.
10-4.
Roll Over Protective Structure. (S/N 2000 and below). (Sheet 5 of 6)
ASSEMBLY
19.
Using a 9/16" socket and socket
wrench handle, install plate (27) and
two screws (26) on front, right side,
inside of cab.
20.
Install new channels (25 thru 22) in
right side of cab. Apply adhesive
backing of channels (25 thru 22) to
clean, dry surface.
21.
Install panel (21), eight
(20) and bolts (19).
22.
Install seal (18) on
window frame in cab.
23.
Using a 7/16" socket and socket
wrench handle, install two bars (17),
six washers (16), bolts (15) and nuts
(14) in rear, upper left and right
sides of cab.
24.
Install seal (13) on window frame in
rear center window in cab.
25.
Install protector (12) in seal (13).
26.
Press seal (13) in tab "A" into tab
“B”. A mild soap solution on tab "A"
will help to make installation
easier.
27.
Install seal (11) on protector (12).
right
washers
side
Go to sheet 6
10-27
TM 10-3930-643-34
FRAME AND TOWING ATTACHMENTS MAINTENANCE. (cont)
10-4.
Roll Over Protective Structure. (S/N 2000 and below). (Sheet 6 of 6)
ASSEMBLY (cont)
NOTE
The following step covers installation of items from the rear left
Installation of
side window.
these items in the right side is
identical.
28.
Install seal (10) on window frame in
left rear window of cab.
29.
Install protector (9) in seal (10).
30.
Press tab "A" into tab “B” in seal
(10). A mild soap solution on tab
“A” will help to make installation
easier.
31.
Install seal (8) on protector (9).
32.
Install seal (7) in left side door
frame of cab.
33.
Install new strip (6) and two new
strips (5) on support (4) in front of
cab.
34.
Install support (4), two washers (3)
and bolts (2).
35.
Install seal (1) in front window
frame of cab.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
10-28
TM 10-3930-643-34
CHAPTER 11
BODY, CHASSIS AND HULL ACCESSORY ITEMS
MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized direct support level
maintenance procedures on the M10A Forklift body, chassis cab and hull
accessory items.
INDEX
Title
Heater (S/N 2001 and above)
Paragraph
11-1
Page
11-2
11-1
TM 10-3930-643-34
BODY, CHASSIS AND HULL ACCESSORY ITEMS. (cont)
11-1.
Heater Assembly (S/N 2001 and above). (Sheet 1 of 6)
This task covers:
a. Disassembly
c. Assembly
c. Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
11-2
Condition Description
Heater assembly removed.
TM 10-3930-643-34
BODY, CHASSIS AND HULL ACCESSORY ITEMS.
11-1
●
Heater Assembly (S/N 2001 and above). (Sheet 2 of 6)
DISASSEMBLY
1.
Using a flat tip screwdriver, remove
four screws (1) and cover (2).
2.
Remove knob (3).
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to
pin-type or socket-type connector.
3.
Disconnect four wire assemblies (4)
at connector (5) and switch (7).
4.
Using a 9/16" open end wrench, remove
nut (6) and switch (7).
5.
Using a flat tip screwdriver, remove
plate (8), two screws (9) and plate
(10).
6.
Remove two cups (11) from plate (10).
7.
Remove two screws (12) and plate (13)
from heater (14).
8.
Remove two cups (15) from plate (13).
9.
Remove screw (16), clamp (17) and
resistor (18) from heater (14).
10.
Remove items 19 thru 22 as an assembly from heater (14).
Go to sheet 3
11-3
TM 10-3930-643-34
BODY, CHASSIS AND HULL ACCESSORY ITEMS. (cont)
11-1.
Heater Assembly (S/N 2001 and above). (Sheet 3 of 6)
DISASSEMBLY (cont)
11.
Using a flat tip screwdriver, loosen
four clamps (19), remove two hoses
(20), clamps (19) and valve (21) from
two cores (22).
12.
Using a 1/2" socket and socket wrench
handle, remove three nuts (23) and
items 24 thru 29 as an assembly from
heater (14).
13.
Using a flat tip screwdriver, remove
screw (24) and fan (25) from motor
(29).
14.
Using a 1/2" socket and socket wrench
handle, remove two nuts (26), plate
(27) and spacer (28).
15.
Remove two nuts (30) and grommet (31)
from heater (14).
Go to sheet 4
11-4
TM 10-3930-643-34
BODY, CHASSIS AND HULL ACCESSORY ITEMS.
11-1.
Heater Assembly (S/N 2001 and above). (Sheet 4 of 6)
CLEANING/INSPECTION
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
If
with eyes, skin or clothing.
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
get
fresh
air
solvent,
immediately.
16.
Wipe all parts except two hoses (17)
and connector (5) with clean cloth
moistened with cleaning solvent
P-D-680. Do not apply cleaning
solvent to wire lead on motor (26).
17.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
11-5
TM 10-3930-643-34
BODY, CHASSIS AND HULL ACCESSORY ITEMS .(cont)
11-1.
Heater Assembly (S/N 2001 and above). (Sheet 5 of 6)
ASSEMBLY (cont)
18.
Using a 1/2” socket and socket wrench
handle, install grommet (31) and two
nuts (30) in heater (14).
19.
Install spacer (28), plate (27) and
two nuts (26) on motor (29).
20.
Using a flat tip screwdriver, install
fan (25) and screw (24).
21.
Using a 1/2” socket and socket wrench
handle, install items 29 thru 24 as
an assembly and three nuts (23) in
heater (14).
22.
Using a flat tip screwdriver, install
valve (21), two-hoses (20) and four
clamps (19) in two cores (22).
23.
Install items 22 thru 19 as an
assembly in heater (14).
24.
Install two cups (15) in plate (13).
Go to sheet 6
11-6
TM 10-3930-643-34
BODY, CHASSIS AND HULL ACCESSORY ITEMS.
11-1.
Heater Assembly (S/N 2001 and above). (Sheet 6 of 6)
ASSEMBLY
25.
Using a flat tip screwdriver, install
resistor (18), clamp (17) and screw
(16) to heater (14).
26.
Install plate (13) and two screws (12)
in heater (14).
27.
Install two cups (11) in plate (10).
28.
Install plate (10), two screws
and plate (8) in heater (14).
29.
Using a 1/2” socket and socket wrench
handle, install switch (7) and nut
(6).
30.
Connect four wire assemblies (4) to
connector (5) and switch (7).
31.
Using a flat tip screwdriver, install
knob (3).
32.
Using a 5/16” socket and socket
wrench handle, install cover (2) and
four screws (1).
(9)
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
11-7/(11-8 blank)
TM 10-3930-643-34
CHAPTER 12
HYDRAULIC SYSTEM
TROUBLESHOOTING AND MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently troubleshoot
and repair malfunctioning equipment and to perform authorized direct support
level maintenance procedures on the M10A Forklift hydraulic system.
INDEX
Title
Hydraulic System Troubleshooting
Hydraulic Pump
Loader Control Valve
Inlet Valve Assembly
Fork Valve Assembly
Tilt Valve Assembly
Boom Assembly Valve
Fork Control Valve
Tilt Cylinder
Boom Assembly
Lifting Forks and Carriage Assembly
Lift Cylinder
Sideshift Cylinder (S/N 2000 and below)
Sideshift Cylinder (S/N 2001 and above)
Fork Position Cylinders (S/N 2000 and below)
Fork Position Cylinders (S/N 2001 and above)
Oscillation Cylinder (S/N 2000 and below)
Oscillation Cylinder (S/N 2001 and above)
Hydraulic Reservoir and Filter
Paragraph
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8
12-9
12-10
12-11
12-12
12-13
12-14
12-15
12-16
12-17
12-18
12-19
Page
12-2
12-9
12-13
12-27
12-33
12-42
12-50
12-56
12-65
12-75
12-86
12-101
12-111
12-121
12-132
12-142
12-152
12-160
12-170
12-1
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-1.
Hydraulic System Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
NOTE
Before using this procedure, check all hydraulic connections and lines
for damage or external leakage and correct where necessary.
Check the hydraulic hoses for leaks and loose fittings. Apply soap and
water solution over length of hoses and observe. If a hydraulic hose
fitting is loose, tighten it. If a hose is damaged or defective,
replace it.
Also check the hydraulic fluid level as described in the Operator’s
Manual TM 10-3930-643-10.
a. ALL IMPLEMENTS FAIL TO OPERATE.
Check hydraulic pump to determine if it is malfunctioning or worn out.
Replace hydraulic pump, refer to paragraph 12-2.
b.
ALL CYLINDER ASSEMBLIES OPERATE SLOWLY.
Step 1.
Check hydraulic pump to determine if it is malfunctioning or
worn.
Replace hydraulic pump, refer to paragraph 12-2.
Step 2. Check loader control valve spools to determine if they are
stuck between galleries, blocking passages, refer to paragraph
12-3.
Test loader control valve per paragraph 12-3. Repair loader control
valve, refer to paragraphs 12-3, 12-4, 12-5, 12-6 and 12-7.
NOTE
This procedure refers to cylinders which are not involved in steering.
For steering system malfunctions, refer to paragraph 9-1.
12-2
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-1.
Hydraulic System Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
b.
ALL CYLINDER ASSEMBLIES OPERATE SLOWLY.
Step 3.
Check loader control valve to determine if relief valves are
stuck or if valve spring(s) are broken, allowing hydraulic
fluid under pressure to dump back to reservoir, refer to
paragraphs 12-3, 12-4, 12-5, 12-6 and 12-7.
Repair system relief valve and/or circuit relief valve and adjust to
correct pressure setting.
c. A PARTICULAR CYLINDER ASSEMBLY OPERATES SLOWLY.
Step 1. Check for worn or scored cylinder piston rings and/or seals.
Refer to the paragraph covering the cylinder malfunctioning.
Non-steering cylinders have disassembly procedures in Chapter
12.
Step 2.
Check inside diameter of cylinder housings to determine if
badly scored or nicked. Refer to the paragraph covering the
Non-steering cylinders have
cylinder malfunctioning.
disassembly procedures in Chapter 12.
Replace cylinders which have nicks and/or scoring which cannot be
removed with fine emery cloth.
Replace seals and piston rings prior to assembly.
12-3
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-1.
Hydraulic System Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
d.
LOSS OF CYLINDER MOTION DURING OPERATION.
Step 1.
Check hydraulic pressure.
If pressure is low, go to step 2.
Step 2.
Check hydraulic pump outlet to determine if it is operating
correctly, refer to paragraph 12-2.
If necessary, clean the hydraulic line, refer to TM 10-3930-643-20.
Step 3. Check loader control valve relief valve(s) to determine if any
are leaking and/or defective, refer to paragraph 12-3 for tests
and adjustments.
If necessary, replace hydraulic pump, refer to paragraph 12-2.
Step 4. Check loader control valve relief valve(s) to determine if any
are leaking and/or defective, refer to paragraph 12-3 for tests
and adjustments.
If necessary to repair system relief valve, refer to paragraph 12-3.
If necessary to repair or replace circuit relief valve(s), refer to
paragraphs 12-4, 12-5 and 12-6.
Step 5. Check loader control valve system relief valve for broken
spring, refer to paragraph 12-3.
Replace spring, refer to paragraph 12-3.
12-4
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-1.
Hydraulic System Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
e. LOAD SLOWLY DROPS WITH LIFT CONTROL LEVER IN “HOLD”.
Step 1.
Check loader control valve spool to determine if hydraulic
fluid is leaking past it, refer to paragraph 12-3.
Repair or replace loader control valve, refer to paragraph 12-3.
If hydraulic fluid is leaking by the valve spool in the fork valve
assembly, refer to paragraph 12-5.
If hydraulic fluid is leaking by the valve spool in boom assembly
valve, refer to paragraph 12-7.
Step 2. Check to determine if hydraulic fluid is passing from hold side
to opposite side of hydraulic lift cylinder piston, refer to
paragraph 12-12.
Repair hydraulic lift cylinder, refer to paragraph 12-12.
f.
MOMENTARY DROP OF LOAD WHEN LIFT CONTROL LEVER IS MOVED FROM ‘HOLD” TO
“RAISE” OR “RAISE” TO “HOLD”.
Step 1. Check for scored or worn check valve poppet or seat in loader
control valve, refer to paragraphs 12-3, 12-5 and 12-7.
Replace appropriate valves.
Step 2. Check for valve poppet held off its seat in loader control
valve, refer to paragraphs 12-3, 12-4, 12-5 and 12-6.
Clean system.
Check for foreign matter after cleaning.
Step 3. Inspect for broken check valve spring, refer to paragraphs
12-3, 12-4, 12-5 and 12-7.
Replace any broken or defective spring.
12-5
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-1.
Hydraulic System Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
g.
NOISY OPERATION.
Step 1.
Check hydraulic pump to determine if it is worn out or malfunctioning.
Replace hydraulic pump, refer to paragraph 12-2.
Step 2.
Check system relief valve spring or circuit relief valve
spring(s) for possible chattering in loader control valve,
refer to paragraphs 12-3, 12-4, 12-5, 12-6 and 12-7.
Replace spring(s).
h.
HYDRAULIC OIL HEATING UP,
Step 1.
Check loader control valve relief valve(s) for insufficient
valve pressure or pressure too high, refer to paragraph 12-3.
Adjust to correct pressure setting.
Step 2.
Check loader control valve system relief valve to determine if
defective, refer to paragraphs 12-3, 12-4, 12-5 and 12-6.
Repair loader control valve and/or relief valve(s).
Step 3. Check hydraulic pump to determine if it is worn out or malfunctioning.
Replace hydraulic pump, refer to paragraph 12-2.
i.
INSUFFICIENT PUMP PRESSURE BUILD-UP.
Step 1.
Check hydraulic pump to determine if it is malfunctioning or
worn out.
Replace pump, refer to paragraph 12-2.
Step 2.
Check valve pressure on loader control valve and relief
valve(s), refer to paragraphs 12-3, 12-4, 12-5, 12-6 and 12-7.
Adjust to correct pressure setting.
12-6
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-1.
Hydraulic System Troubleshooting.
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
j.
STICKING LOADER CONTROL VALVE SPOOL(S).
NOTE
Steps below should be taken after
temperature.
Step 1.
system is heated to proper
Check loader control valve to determine if housing has been
distorted by improperly tightened mounting bolts, refer to
paragraph 12-3.
Loosen and retighten mounting bolts to proper torque.
Step 2.
Check individual circuit valves to determine if there is
distortion of valve housing by improperly tightened bolts,
refer to paragraphs 12-4, 12-5, 12-6 and 12-7.
Loosen and retighten bolts to proper torque.
Step 3. Check control valve plunger bore(s) for burrs or scoring, refer
to paragraphs 12-3, 12-4, 12-5, 12-6 and 12-7.
Replace loader control valve.
Step 4. Check valve spools in loader control valve to see if any are
warped. Also check for dirt or foreign matter, refer to
paragraphs 12-3, 12-4, 12-5, 12-6 and 12-7.
Clean loader control valve.
Step 5.
Replace spool(s) if necessary.
Check loader control valve for damaged, broken or distorted
springs, refer to paragraph 12-3. Also refer to paragraphs
12-4, 12-5, 12-6 and 12-7 as applicable.
Replace springs if damaged, broken or distorted.
12-7
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-1.
Hydraulic System Troubleshooting. (cont)
MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION
k.
HYDRAULIC PUMP NOT DELIVERING OIL.
Step 1. Check hydraulic pump to determine if it is rotating.
If necessary, replace hydraulic pump, refer to paragraph 12-2.
Step 2.
Check hydraulic pump to determine if it is malfunctioning or
worn out.
Replace pump, refer to paragraph 12-2.
l.
OIL LEAKAGE AT HYDRAULIC PUMP.
Step 1.
Check for worn or damaged oil seals or preformed packing(s),
refer to paragraph 12-2.
Replace seals and preformed packings prior to installation of pump.
Step 2.
Check for defective mounting of preformed packing(s), refer to
paragraph 12-2.
Replace preformed packings prior to reinstallation of pump.
12-8
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
Hydraulic Pump. (Sheet 1 of 4)
12-2.
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Small tag (App. C, Item 28)
Preformed packing (4)
Seal (2)
Torques
Bolts (12) to 55 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Hydraulic reservoir drained.
REMOVAL
1.
Using a 9/16” socket and socket
wrench handle, remove four bolts (1)
and two flange halves (2) from right
side of vehicle.
Go to sheet 2
12-9
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-2.
Hydraulic Pump. (Sheet 2 of 4)
REMOVAL (cont)
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
2.
Disconnect hose assembly (3).
3.
Using a machinist’s scribe, remove
and discard preformed packing (4).
4.
Using a 9/16” socket and socket
wrench handle, remove four bolts (5)
and two flange halves (6).
5.
Using a 10” adjustable wrench,
disconnect hose assembly (7).
6.
Using a machinist’s scribe, remove
and discard preformed packing (8).
7.
Using a 5/8” open end wrench,
disconnect hose assembly (9) from tee
assembly (10).
8.
Cap tee assembly (10).
9.
Using an 11/16” open end wrench,
remove tee assembly (10) from
hydraulic pump (18).
10.
Using a machinist’s scribe, remove
and discard preformed packing (11).
11.
Using a 3/4” socket and socket wrench
handle, remove two bolts (12), lock
washers (13) and pump (18) from
torque converter.
12.
Using a machinist’s scribe, remove
and discard preformed packing (14).
13.
Using snap ring pliers, remove seal
(15), snap ring (16) and seal (17)
from hydraulic pump (18).
Discard
seals (15 and 17).
Go to sheet 3
12-10
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-2.
Hydraulic Pump. (Sheet 3 of 4)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
14.
Wipe pump (18) and hose assemblies (3
and 7) with clean cloth moistened
with detergent. Dry with compressed
air.
15. Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
16.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
12-11
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Hydraulic Pump. (Sheet 4 of 4)
12-2.
INSTALLATION
17.
Using snap ring pliers, install new
seal (17), snap ring (16) and new
seal (15) in hydraulic pump (18).
18.
Install new preformed packing (14).
19.
Using a 3/4” socket and torque
wrench, install items 18 thru 14 as
an assembly, two lock washers (13)
and bolts (12). Tighten two bolts
(12) to 55 lb-ft.
20.
Using an 11/16” adjustable wrench,
install new preformed packing (11)
and tee assembly (10) to hydraulic
pump (18).
21.
Using a 5/8” open end wrench, connect
hose assembly (9) to tee assembly
(10).
22.
Position new preformed packing (8)
and hose assembly (7).
23.
Using a 9/16” socket and socket
wrench handle, install two flange
halves (6) and four bolts (5).
24.
Position new preformed packing (4)
and hose assembly (3).
25.
Install two flange halves
four bolts (1).
26.
Fill hydraulic reservoir to proper
level, refer to LO 10-3930-643-12.
(2) and
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-12
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-3.
Loader Control Valve. (Sheet 1 of 14)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Testing/Adjusting
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2" Open end wrench
NSN 5120-00-184-8489
Pressure tester hand pump
NSN 4940-01-036-5784
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Small tag (App. C, Item 28)
Sandwich test block (App. D, Item 13)
Preformed packing (16)
Y bolt (4)
Torques
Nuts (39) to 74 lb-ft.
Nuts (41) to 48 lb-ft.
Acorn nut (51 and 61) to 10 lb-ft.
Jam nut (52 and 62) to 10 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Condition Description
Hydraulic pressure vented.
TM 10-3930-643-20
Right frame access cover removed.
Go to sheet 2
12-13
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-3.
Loader Control Valve. (Sheet 2 of 14)
REMOVAL
1.
Using pliers, remove three cotter
pins (1) and pins (2) from under
right side of cab. Discard cotter
pins (2).
2.
Using a 9/16” socket and socket
wrench handle, remove two bolts (3)
and clamp (4).
3.
Using a 9/16” socket, socket wrench
handle and a 9/16” open end wrench.
remove bolt (5), wasfier (6), nut (7),
washer (8) and clamp (9).
4.
Using a 9/16" socket and socket
wrench handle, remove four bolts
(10), two flange halves (11) and
preformed packing (12).
Discard
preformed packing (12).
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
5.
Using 1-3/8”, 1-9/16” and 1" open end
wrenches, disconnect tube assemblies
(13 thru 17).
Go to sheet 3
12-14
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
Loader Control Valve. (Sheet 3 of 14)
12-3.
REMOVAL
6.
Using a 1-1/2" open end wrench,
disconnect hose assemblies (18 thru
20) .
7.
Using a 3/4” socket, socket wrench
handle and a open end wrench, remove
three bolts (21), washers (22), nuts
(23), washers (24) and items 25 thru
36 as an assembly from vehicle.
8.
Using a 1-3/8" open end wrench,
remove three connectors (25) and
preformed packings (26). Discard
three preformed packings (26).
9.
Using a 1“ open end wrench, remove
elbow (27), preformed packing (28),
connector (29) and preformed Packing
(30). Discard preformed packings (28
and 30).
10.
Using a 1-9/16” open end wrench,
remove two elbows (31 and 32) and
preformed packings (33). Discard two
preformed packings (33).
11.
Using a 10” adjustable wrench, remove
elbow (34) and preformed packing (35)
from loader control valve (36).
Discard preformed packing (35).
Go to sheet 4
12-15
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-3.
Loader Control Valve. (Sheet 4 of
DISASSEMBLY
12.
Using a 1-1/2” socket and socket
wrench handle, remove plug (37) and
preformed packing (38) from outlet
housing (43).
Discard preformed
packing (38).
13.
Using a 3/4” socket and socket wrenc
handle, remove two nuts (39), rod
(40), four nuts (41) and two rods
(42).
NOTE
When separating outlet housing and
valve assemblies be extremely
careful not to damage sealing
surfaces.
14.
Separate outlet housing (43), inlet
valve assembly (44), fork valve
assembly (45), tilt valve assembly
(46) and boom valve assembly (47).
15.
Using a scribe, remove and discard
four preformed packings (48).
NOTE
For repair of valve assemblies,
refer to paragraphs 12-4 thru
12-7.
Go to sheet 5
12-16
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-3.
Loader Control Valve. (Sheet 5 of 14)
CLEANING/INSPECTION
16.
Wipe hose assemblies (18 thru 20)
with clean cloth moistened with
detergent. Wipe dry with clean
cloth.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protecive
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
17.
Clean all other parts except valve
assemblies (44 thru 47) with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
18.
Inspect all parts except valve
assemblies (44 thru 47). Refer to
paragraph 2-9.
Go to sheet 6
12-17
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-3.
Loader Control Valve. (Sheet 6 of 14)
ASSEMBLY
19.
Install four new preformed packings
(48).
20.
Position boom valve assembly (47),
tilt valve assembly (46), fork valve
assembly (45), inlet valve assembly
(44) and outlet housing (43).
21.
Using a 3/4” socket and torque
wrench, install two rods (42), four
nuts (41), rod (40) and two nuts
(39)0 Tighten nuts (41) to 48 lb-ft
and nuts (39) to 74 lb-ft.
22.
Using a 1-1/2” socket and socket
wrench handle, install new preformed
packing (38) and plug (37) in outlet
housing (43).
23.
Using a 3/4” socket, socket wrench
handle and a open end wrench, install
loader control valve (36), three
washers (24), nuts (23), washers (22)
and bolts (21).
Go to sheet 7
12-18
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-3.
Loader Control Valve. (Sheet 7 of 14)
ASSEMBLY
24.
Using a 1-1/2” open end wrench,
connect hose assemblies (20 thru 18).
25.
Using a 1-9/16” open end wrench,
connect tube assemblies (17 and 16).
26.
Using a 9/16” socket and socket
wrench handle, install new preformed
packing (12), two flange halves (11)
and four bolts (10).
27.
Using a 3/4” socket, socket wrench
handle and a open end wrench, install
clamp (9), washer (8), nut (7),
washer (6) and bolt (5).
28.
Using a 9/16” socket and socket
wrench handle, install clamp (4) and
two bolts (3).
29.
Using long round nose pliers, install
three pins (2) and new cotter pins (1).
INSTALLATION
30.
Using a 10” adjustable wrench,
install new preformed packing (35)
and elbow (34) on loader control
valve (36).
31.
Using a 1-9/16” open end wrench,
install two new preformed packings
(33) and two elbows (32 and 31).
32.
Using a 1“ open end wrench, install
new preformed packing (30), connector
(29), new preformed packing (28) and
elbow (27).
33.
Using a 1-3/8” open end wrench,
install three new preformed packings
(26) and connectors (25).
Go to sheet 8
12-19
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Loader Control Valve. (Sheet 8 of 14)
12-3.
TESTING/ADJUSTING - RELIEF VALVES
34.
Vent hydraulic system, refer to
TM 10-3930-643-10.
35.
Using a 11/16” socket and socket
wrench handle, remove plug (49) and
preformed packing (50) from loader
control valve (36) and inlet valve
Discard preformed
assembly (44).
packing (50).
36.
Using a 10” adjustable wrench,
install 3000 psi hydraulic pressure
gage in plug (49) port.
37.
Start engine in operator’s compartment.
38.
Operate tilt and fork controls
through four loading cycles, refer to
TM 10-3930-643-10.
39.
Position forks in forks together
position and hold, refer to TM 103930-643-10.
40.
Accelerate engine to full throttle.
41.
Read hydraulic pressure gage. If
system does not relieve at 2755 psi,
adjust system relief valve.
42.
Using a 1-1/4” and 11/16” open end
wrenches, remove system relief valve
and acorn nut (51) from loader
control valve (36) and inlet valve
assembly (44).
43.
Using a 3/4” open end wrench, loosen
jam nut (52).
44.
Using a flat tip screwdriver, adjust
screw (53), turning clockwise to
increase
pressure
and
the
decrease
counterclockwise to
pressure.
Go to sheet 9
12-20
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-3.
Loader Control Valve. (Sheet 9 of 14)
TESTING/ADJUSTING RELIEF VALVES
45.
Hold adjustment screw when correct
pressure is obtained.
If correct
pressure cannot be obtained with
adjustment, replace or repair relief
valve as necessary, refer to
paragraph 12-5.
46.
Using a 3/4” socket and torque
wrench, tighten jam nut (52) to 10
lb-ft .
47.
Using an 11/16” socket and torque
wrench, install acorn nut (51) and
tighten to 10 lb-ft.
48.
Stop engine.
49.
Vent hydraulic system pressure, refer
to TM 10-3930-643-10.
50.
Using a 10” adjustable wrench,
disconnect hydraulic pressure gage
from loader control valve (36) and
inlet valve assembly (44).
51.
Using an 11/16” socket and socket
wrench handle, install new preformed
packing (50) and plug (49).
Go to sheet 10
12-21
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Loader Control Valve. (Sheet 10 of 14)
12-3.
TESTING/ADJUSTING - FORK CIRCUIT RELIEF VALVES
52.
Vent hydraulic system pressure, refer
to TM 10-3930-643-10.
53.
Using a 1" open end wrench
disconnect tube assembly (14) from
elbow (27) on loader control valve
(36) and fork valve assembly (45).
54.
Disconnect tube assembly (15) from
connector (29).
55.
Connect two tees to connector (29)
and elbow (27). Tees will have to
fit on connector (29) and elbow (27),
as well as tube assemblies (14 and
15) and hydraulic pressure gage.
56.
Using a 1" open end wrench and a 10”
adjustable wrench, connect tube
assemblies (15 and 14) to two tees.
57.
Using a 10” adjustable wrench,
connect two hydraulic pressure gages
to two tees.
58.
Start engine in operator’s compartment.
59.
Operate tilt and fork controls
through four loading cycles, refer to
TM 10-3930-643-10. This will bring
hydraulic fluid to normal operating
temperature.
Go to sheet 11
12-22
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-3.
Loader Control Valve. (Sheet 11 of 14)
TESTING/ADJUSTING - FORK CIRCUIT RELIEF VALVES
60.
Position forks in forks together
position and hold, refer to TM
10-3930-643-10.
61.
Read hydraulic pressure gages. Front
gage should read 1930 psi and rear
gage 30 psi.
62.
Position forks in forks apart
position and hold.
63.
Read hydraulic pressure gages. Rear
gage should read 1930 psi and front
gage 30 psi.
64.
Using a 1-9/16” open end wrench,
adjust two circuit relief valves on
loader control valve (36) and fork
valve assembly (45), front and rear.
Except for pressure, adjustment of
fork circuit relief valves is same as
main system relief valve adjustment,
step 10.
65.
Stop engine.
66.
Vent hydraulic system pressure, refer
to TM 10-3930-643-10.
67.
Using a 10” adjustable wrench,
disconnect two hydraulic gages from
fork valve assembly (45).
68.
Using a 1“ open end wrench and a 10”
adjustable wrench, disconnect tube
assemblies (15 and 14).
69.
Using a 10” adjustable wrench, remove
two tees.
70.
Using a 1" open end wrench, connect
tube assembly (15) to connector (29).
71.
Connect tube assembly (14) to elbow
(27).
Go to sheet 12
12-23
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-3.
Loader Control Valve. (Sheet 12 of 14)
TESTING/ADJUSTING - TILT BACK CIRCUIT RELIEF VALVE
72.
Vent hydraulic system pressure, refer
to TM 10-3930-643-10.
73.
Using a 9/16”
wrench handle,
and two flange
cylinder, left
74.
Disconnect hose assembly (56) from
tube assembly (58).
75.
Using a scribe, remove and discard
preformed packing (57).
76.
Position new preformed packing (57)
and sandwich test block on tube
assembly (58), refer to Appendix D
for fabrication instruction for
sandwich test block.
77.
Install new preformed packing (57) on
hose assembly (56).
78.
Connect hose assembly
sandwich test block.
79.
Using a 9/16” socket and socket
wrench handle, install two flange
halves (55) and four Y bolts.
80.
Using a 10" adjustable wrench,
install pressure tester hand pump in
sandwich test block.
81.
Start engine
compartment.
Go to sheet 13
12-24
socket and socket
remove four bolts (54)
halves (55) from tilt
side.
in
(56) to
operator’s
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-3.
Loader Control Valve. (Sheet 13 of 14)
TESTING/ADJUSTING - TILT BACK CIRCUIT RELIEF VALVE
82.
Operate hydraulic controls through
three full movements of travel to
warm hydraulic fluid.
83.
Position fork tilt control in full
tilt back position, refer to TM 103930-643-10.
84.
Position in hold (NEUTRAL) position.
85.
Stop engine.
86.
Pump pressure tester hand pump
pressure to 3000 psi on tilt
cylinder.
87.
Read gage. If pump pressure exceeds
or does not produce 3000 psi, relief
valve (60) must be adjusted.
88.
Using an 11/16” socket and socket
wrench handle, remove acorn nut (61)
from loader control valve (36) and
tilt valve assembly (46). Tilt back
relief valve (60).
89.
Using a 1“ open end wrench,
jam nut (62).
90.
Using a flat tip screwdriver, adjust
screw (63), turning clockwise to
increase pressure, counterclockwise
to decrease pressure.
91.
Hold when 3000 psi adjustment is
made.
92.
Using an 11/16” socket and torque
wrench, tighten jam nut (62) to 10
lb-ft .
loosen
Go to sheet 14
12-25
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-3.
Loader Control Valve. (Sheet 14 of 14)
TESTING/ADJUSTING - TILT BACK CIRCUIT RELIEF VALVE (cont)
93.
Using a 11/16” socket and socket
wrench handle, install and tighten
acorn nut (61) to 10 lb-ft.
94.
Vent pressure tester hand pump,
pressure on tilt cylinder, left
side.
95.
Using a 10” adjustable wrench,
disconnect pressure tester hand pump
from sandwich test block.
96.
Using a 9/16” socket and socket
wrench handle, remove four bolts
(54) and two flange halves (55).
97.
Disconnect hose assembly (56) from
sandwich test block.
98.
Inspect new preformed packing (57),
replace with new, if damaged during
test.
99.
Remove sandwich test block and
preformed packing (57). Keep second
preformed packing (57) with sandwich
test block for future testing.
100.
Install new preformed packing (57),
hose assembly (56), two flange
halves (55) and four bolts (54) to
tube assembly (58).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-26
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-4.
Inlet Valve Assembly. (Sheet 1 of 6)
This task covers:
a. Disassembly
c. Assembly
b.
d.
Cleaning/Inspection
Testing/Adjusting
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Crocus cloth (App. C, Item 3)
Preformed packing (7)
Torques
Nuts (2 and 4) to 10 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 12-3
Condition Description
Loader control valve disassembled.
Go to sheet 2
12-27
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-4.
Inlet Valve Assembly. (Sheet 2 of 6)
DISASSEMBLY
1.
Using a 1-1/4” open end wrench,
remove relief valve items 2 thru 19
as an assembly from housing (22).
2.
Using a scribe, remove and discard
preformed packing (l).
3.
Using an 11/16” socket and socket
wrench handle, remove nut (2) and
preformed packing (3).
Discard
preformed packing (3).
4.
Using an 11/16” socket, socket wrench
handle and a flat tip screwdriver,
remove nut (4), preformed packing (5)
and adjusting screw (6). Discard
preformed packing (5).
5.
Using a 1-1/4” socket, socket wrench
handle and a open end wrench. remove
items 7 thru 12 as an assembly from
body (13).
Go to sheet 3
12-28
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-4.
Inlet Valve Assembly. (Sheet 3 of 6)
DISASSEMBLY
6.
Using a scribe, remove and discard
preformed packing (7).
7.
Remove spring (8), poppet (9),
preformed packing (10) and ring (11)
from plug (12). Discard preformed
packing (10).
8.
Remove items 14 thru 19 as an
assembly from body (13).
9.
Remove spring (14), piston (15) and
items 17 thru 19 as an assembly from
poppet (16).
10.
Remove ring (17) and preformed
packing (18) from poppet (19).
Discard preformed packing (18).
11.
Using a 1-1/2” open end wrench,
remove plug (20) and preformed
packing (21) from housing (22).
Discard preformed packing (21).
Go to sheet 4
12-29
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-4.
Inlet Valve Assembly. (Sheet 4 of 6)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
12.
Wipe all parts with clean cloth
moistened with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. All grooves and
passages in housing (22) must be free
of foreign matter.
13.
Inspect housing (22) surfaces for
burrs, scratches, nicks or scores.
Stone or lap all burrs. Use crocus
cloth on small scores.
14.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 5
12-30
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-4.
Inlet Valve Assembly. (Sheet 5 of 6)
ASSEMBLY
NOTE
Lubricate all preformed packings,
and housing before installing.
15.
Using a 1-1/2” open end wrench,
install new preformed packing (21)
and plug (20) in housing (22).
16.
Install new preformed packing (18)
and ring (17) on poppet (19).
17.
Install items 19 thru 17 as an
assembly, piston (15) and spring (14)
on poppet (16).
18.
Install items 19 thru 14 as an
assembly in body (13).
19.
Install ring (11), new preformed
packing (10), poppet (9) and spring
(8) in plug (12).
20.
Install new preformed packing (7) on
plug (12).
Go to sheet 6
12-31
TN 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Inlet Valve Assembly. (Sheet 6 of 6)
12-4.
ASSEMBLY (cont)
21.
Using a 1-1/4” socket and socket
wrench handle, install items 12 thru
7 as an assembly in body (13).
22.
Using a flat tip screwdriver, 11/16”
socket and torque wrench, install
adjusting screw (6), new preformed
packing (5) and nut (4). Tighten nut
(4) to 10 lb-ft.
23.
Using an 11/16” socket and torque
wrench, install new preformed packing
(3) and nut (2). Tighten nut (2) to
10 lb-ft.
24. Install new preformed packing (l).
25.
Using a 1-1/4” socket and socket
wrench handle, install relief valve
items 19 thru 2 as an assembly.
TESTING/ADJUSTING
26.
Adjust relief valve items 19 thru 2
as an assembly, refer to paragraph
12-3.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-32
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-5.
Fork Valve Assembly. (Sheet 1 of 9)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Crocus cloth (App. C, Item 3)
Preformed packing (12)
Wiper (2)
Seal (2)
Torques
Bolts (6) to 5 lb-ft.
Screw (9) to 4 lb-ft.
Plug (25) to 75 lb-ft.
Nut (38) to 10 lb-ft
Nut (40) to 10 lb-ft
Body (49) to 75 lb-ft
EQUIPMENT CONDITION
References
Paragraph 12-3
Condition Description
Loader control valve disassembled.
Go to sheet 2
12-33
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Fork Valve Assembly. (Sheet 2 of 9)
12-5.
DISASSEMBLY
1.
Using a flat tip screwdriver and snap
ring pliers, remove guide screw (1),
retaining ring (2) and plate (3).
2.
Using a flat tip screwdriver, remove
screw (4) and plate (5).
3.
Using a 1/4” socket head screw key,
remove two bolts (6), cap (7) and
plate (8).
4.
Remove items 9 thru 16 as an
assembly.
5.
Using a flat tip screwdriver and
s tribe, remove screw (9) and
preformed packing (10).
Discard
preformed packing (10).
6.
Remove seat (11), spring (12) and
Note
seat (13) from spool (14).
position of spool to aid in
installation.
7.
Using a scribe, remove and discard
two wipers (15) and seals (16).
Go to sheet 3
12-34
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-5.
Fork Valve Assembly. (Sheet 3 of 9)
DISASSEMBLY
8.
Using an 11/16” socket and socket
wrench handle, remove items 17 thru
20 as an assembly.
9.
Using a scribe, remove preformed
packing (17), ring (18) and preformed
packing (19) from plug (20). Discard
preformed packings (17 and 19).
10.
Using an 11/16” socket and socket
wrench handle, remove items 21 thru
25 as an assembly.
11.
Using a scribe, remove washer (21),
preformed packing (22), ring (23) and
preformed packing (24) from plug
(25). Discard preformed packings (22
and 24).
12.
Remove spring (26) from housing (37).
13.
Using long round nose pliers, remove
retainer (27) from plug (31). Rotate
plug (31) counterclockwise to remove.
14.
Remove items 28 thru 35 as an
Note
assembly from housing (37).
position of spool (28) to aid in
installation.
Go to sheet 4
12-35
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Fork Valve Assembly. (Sheet 4 of 9)
12-5.
DISASSEMBLY (cont)
15.
Remove items 29 thru 35 as an
assembly from spool (28).
16.
Using a flat tip screwdriver, remove
items 29 thru 31 as an assembly from
poppet (35).
17.
Using a scribe, remove preformed
packing (29) and ring (30) from plug
(31). Discard preformed packing
(29).
18.
Remove spring (32).
19.
Using snap ring pliers, remove
retaining-ring (33) and washer (34)
from poppet (35).
NOTE
There are two relief valves in the
fork valve assembly. The maintenance procedure for both relief
valves is identical.
20.
Using a 1-1/4” open end wrench,
remove relief valve items 38 thru 55
as an assembly.
Go to sheet 5
12-36
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-5.
Fork Valve Assembly. (Sheet 5 of 9)
DISASSEMBLY
21.
Using a scribe, remove and discard
preformed packing (36) from housing
(37).
22.
Using an 11/16” socket and socket
wrench handle, remove nut (38) and
preformed packing (39).
Discard
preformed packing (39).
23.
Using a flat tip screwdriver, remove
nut (40), preformed packing (41) and
adjusting screw (42). Discard
preformed packing (41).
24.
Remove items 43 thru 48 as an
assembly from body (49).
25.
Using a scribe, remove and discard
preformed packing (43).
26.
Remove spring (44), poppet (45),
preformed packing (46) and ring (47)
from plug (48). Discard preformed
packing (46).
27.
Remove items 50 thru 55 as an
assembly from body (49).
28.
Remove spring (50), piston (51) and
items 53 thru 55 as an assembly from
poppet (52).
29.
Remove ring (53) and preformed
packing (54) from poppet (55).
Discard preformed packing (54).
Go to sheet 6
12-37
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-5.
Fork Valve Assembly. (Sheet 6 of 9)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
30.
Wipe all parts with clean cloth
moistened with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8. All grooves and passages in
housing (37) must be free of foreign
matter.
31.
Inspect housing (37) surfaces for
burrs, scratches, nicks or scores.
Stone or lap all burrs. Use crocus
cloth on small scores.
32.
Inspect all other parts.
paragraph 2-9.
Go to sheet 7
12-38
Refer to
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-5.
Fork Valve Assembly. (Sheet 7 of 9)
ASSEMBLY
NOTE
Lubricate all preformed packings,
wipers, seals. sliding parts and
housing before installing.
33.
Install new preformed packing (54)
and ring (53) on poppet (55).
34.
Install items 55 thru 53 as an
assembly, piston (51) and spring (50)
on poppet (52).
35.
Install items 55 thru 50 as an
assembly in body (49).
36.
Install ring (47), new preformed
packing (46), poppet (45) and spring
(44) in plug (48).
37.
Install new preformed packing (43).
38.
Using a 1-1/4” socket and socket
wrench handle, install items 48 thru
43 as an assembly in body (49).
39.
Using a flat tip screwdriver, install
adjusting screw (42), new preformed
Tighten
packing (41) and nut (40).
nut (40) to 10 lb-ft.
40.
Using an 11/16” socket and torque
wrench, install new preformed packing
(39) and nut (38). Tighten nut (38)
to 10 lb-ft.
41.
Install new preformed packing (36) in
housing (37).
Go to sheet 8
12-39
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-5.
Fork Valve Assembly. (Sheet 8 of 9)
ASSEMBLY (cont)
42.
Using a 1-1/4” socket and torque
wrench, install relief valve items 55
thru 38 as an assembly. Tighten body
(49) to 75 lb-ft.
43.
Using snap ring pliers, install
washer (34) and retaining ring (33)
in poppet (35).
44.
Install spring (32).
45.
Install ring (30) and new preformed
packing (29) on plug (31). -
46.
Using a flat tip screwdriver, install
items 31 thru 29 as an assembly on
poppet (35).
47.
Install items 33 thru 29 as an
assembly in spool (28).
48.
Install items 35 thru 28 as an
assembly in housing (37).
49.
Using long round nose pliers, install
retainer (27) in plug (31).
Rotate
plug (31) clockwise to install.
50.
Install spring (26).
51.
Install new preformed packing (24),
ring (23), new preformed packing (22)
and washer (21) in plug (25).
Go to sheet 9
12-40
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-5.
Fork Valve Assembly. (Sheet 9 of 9)
ASSEMBLY
52.
Using an 11/16” socket and torque
wrench, install items 25 thru 21 as
an assembly in housing (37). Tighten
plug (25) to 75 lb-ft.
53.
Install new preformed packing (19),
ring (18) and new preformed packing
(17) in plug (20).
54.
Install items 20 thru 17 as an
assembly in housing (37).
55.
Install two new seals (16) and new
wipers (15) on spool (14).
56.
Position seat (13), spring (12) and
seat (11) on spool (14)0
57.
Install new preformed packing (10) on
screw (9).
58.
Using a flat tip screwdriver, install
items 16 thru 9 as an assembly.
Tighten screw (9) to 4 lb-ft.
59.
Using a 1/4” socket and torque
wrench, install plate (8), cap (7)
and two bolts (6). Tighten two bolts
(6) to 5 lb-ft.
60.
Using a flat tip screwdriver, install
plate (5) and screw (4).
60.
Using a flat tip screwdriver and a
snap ring pliers, install plate (5),
screw (4), plate (3), retaining ring
(2) and guide screw (l).
61.
Adjust relief valve items 55 thru 38
as an assembly, refer to paragraph
12-3.
NOTE
Return M1OA Forklift to
equipment condition.
original
END OF TASK
12-41
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cent)
12-6.
Tilt Valve Assembly. (Sheet 1 of 8)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic's
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Crocus cloth (App. C, Item 3)
Preformed packing (10)
Seal (2)
Wiper (2)
Screw (8) to 4 lb-ft
Plug (17) and nut (26) to 75
EQUIPMENT CONDITION
References
Paragraph 12-3
Go to sheet 2
12-42
Condition Description
Loader control valve disassembled.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-6.
Tilt Valve Assembly. (Sheet 2 of 8)
DISASSEMBLY
1.
Remove spring (1) and poppet (2).
2.
Using a flat tip screwdriver, remove
two screws (3) and plate (4).
3.
Using a 1/4” socket head screw key,
remove two bolts (5), cap (6) and
plate (7).
4.
Remove items 8 thru 15 as an
assembly. Note position of spool
(13) to aid in installation.
5.
Using a flat tip screwdriver, remove
screw (8).
6.
Remove seat (9), spring (10) and
seat (11) from spool (12).
7.
Using a machinists scribe, remove
and discard two wipers (13) and seals
(14).
8.
Using a 1-1/4” socket and socket
wrench handle, remove items 15 thru
23 as an assembly from housing (25).
Go to sheet 3
12-43
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-6.
Tilt Valve Assembly. (Sheet 3 of 8)
DISASSEMBLY (cont)
9.
Using a machinists scribe, remove
plug (15) and preformed packing (16).
Discard preformed packing (16).
10.
Remove spring (17) from items 18 thru
23 as an assembly.
11.
Using a 7/8” socket and socket wrench
handle , remove nut (18) and items 19
thru 21 as an assembly from poppet
(23).
12.
Using a machinists scribe, remove
spacer (19), preformed packing (20)
and ring (21). Discard preformed
packing.
13.
Remove preformed packing (22) from
poppet (23). Discard preformed
packing (22).
14.
Using a 1-1/4” open end wrench,
remove relief valve items 26 thru 43
as an assembly.
15.
Using a machinists scribe, remove
preformed packing (24) from housing
(25). Discard preformed packing (24).
Go to sheet 4
12-44
TN 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-6.
Tilt Valve Assembly. (Sheet 4 of 8)
DISASSEMBLY
16.
Using an 11/16” socket and socket
wrench handle, remove nut (26) and
preformed packing (27). Discard
preformed packing (27).
17.
Using an 11/16” open end wrench and
a flat tip screwdriver, remove nut
(28), preformed packing (29) and
adjusting screw (30). Discard
preformed packing (29).
18.
Using a 1-1/4” socket, socket wrench
handle and vise, remove items 31 thru
36 as an assembly from body (37).
19.
Using a scribe, remove and discard
preformed packing (31).
20.
Remove spring (32), poppet (33),
preformed packing (34) and ring (35)
from plug (36). Discard preformed
packing (34).
21.
Remove items 38 thru 43 as an
assembly from body (37).
22.
Remove spring (38), piston (39) and
items 41 thru 43 as an assembly from
poppet (49).
23.
Remove ring (41) and preformed packing
(42) from poppet (43). Discard
preformed packing (42).
Go to sheet 5
12-45
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-6.
Tilt Valve Assembly. (Sheet 5 of 8)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
24.
Wipe all parts with clean cloth
moistened with cleaning solvent P-D680. Dry thoroughly with compressed
air. Refer to paragraph 2-8. All
grooves and passages in housing (25)
must be free of foreign matter.
Go to sheet 6
12-46
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-6. Tilt Valve Assembly. (Sheet 6 of 8)
CLEANING/INSPECTION
25.
Inspect housing (25) surfaces for
burrs, scratches and nicks or scores.
Stone or lap all burrs. Use crocus
cloth on small burrs.
26.
Inspect all other parts. Refer to
paragraph 2-9.
ASSEMBLY
NOTE
Lubricate all preformed packings,
wipers, seals, sliding parts and
housing before installing.
27.
Install new preformed packing (42)
and ring (41) on poppet (43).
28.
Install items 43 thru 41 as an
assembly, piston (39) and spring
(38) in poppet (40).
29.
Install items 43 thru 38 as an
assembly in body (37).
30.
Install ring (35), new preformed
packing ((34), poppet (33) and spring
(32) in plug (36).
31,
Install new preformed packing (31).
Go to sheet 7
12-47
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cent)
12-6.
Tilt Valve Assembly. (Sheet 7 of 8)
ASSEMBLY (cont)
32.
Using a 1-1/4” socket and socket
wrench handle, install items 36 thru
31 as an assembly in body (37).
33.
Using an 11/16” socket, socket wrench
handle and flat tip screwdriver,
install adjusting screw (30), new
preformed packing (29) and nut (28).
34.
Using an 11/16” socket and torque
wrench, install new preformed packing
((27) and nut (26). Tighten nut (26)
to 10 lb-ft.
35.
Install new preformed packing (24) in
housing (25).
36.
Using a
wrench,
thru 26
(26) to
37.
Install new preformed packing (22) on
poppet (23).
38.
Install ring (20) and new preformed
packing (19) on spacer (21).
39.
Install items 21 thru 19 as an
assembly and nut (18) in poppet (23).
40.
Using a 7/8” socket and socket wrench
handle, install spring (17) and items
23 thru 18 as an assembly in plug
(17).
41.
Install new preformed packing (16) in
plug (15).
Go to sheet 8
12-48
1-1/4” socket and torque
install relief valve items 43
as an assembly. Tighten nut
75 lb-ft.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-6.
Tilt Valve Assembly. (Sheet 8 of 8)
ASSEMBLY
42.
Using a 1-1/4” socket and torque
wrench, install items 23 thru 15 as
an assembly in housing (25).
43.
Install two seals (14) and new wipers
(13).
44.
Position seat (11), spring (10) and
seat (9) on spool (12).
45.
Using a flat tip screwdriver, install
screw (8). Tighten screw (8) to 4
lb-ft .
46.
Install items 14 thru 8 as an
assembly.
47.
Using a 1/4” socket head screw key and
torque wrench, install plate (7), cap
(6) and two bolts (5). Tighten bolts
(5) to 5 lb-ft.
48.
Using a flat tip screwdriver, install
plate (4) and two screws (3).
49.
Install poppet (2) and spring (l).
50.
Adjust relief valve items 43 thru 26
as an assembly, refer to paragraph
12-3.
NOTE
Return M10A Forklift to
original equipment condition.
END OF TASK
12-49
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-7.
Boom Assembly Valve. (Sheet 1 of 6)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Crocus cloth (App. C, Item 3)
Preformed packing (4)
Seal (2)
Wiper (2)
Torques
Bolts (5) to 5 lb-ft
Screw (8) to 4 lb-ft
Plug (19) to 75 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 12-3
Go to sheet 2
12-50
Condition Description
Loader control valve disassembled.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-7.
Boom Assembly Valve. (Sheet 2 of 6)
DISASSEMBLY
1.
Remove spring (1) and poppet (2).
2.
Using a flat tip screwdriver, remove
two screws (3) and plate (4).
3.
Using a 1/4” socket head screw key,
remove two bolts (5), cap (6) and
plate (7).
4.
Remove items 8 thru 15 as an assembly
from housing (16). Note position of
spool (13) to aid in installation.
5.
Using a flat tip screwdriver, remove
screw (8) and preformed packing (9).
Discard preformed packing (9).
6.
Remove seat (10), spring (11) and
seat (12) from spool (13).
Remove and discard two wipers (14)
and seals (15) from housing (16).
Using a 1-1/4” socket and socket
wrench handle, remove items 17 thru
25 as an assembly from housing (16).
Go to sheet 3
12-51
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Boom Assembly Valve. (Sheet 3 of 6)
12-7.
DISASSEMBLY (cont)
9.
Using a scribe, remove preformed
packing (17) from plug (19). Discard
preformed packing (17).
10.
Remove items 20 thru 25 as an
assembly and spring (18) from plug
(19).
11.
Using an 11/16” box and open end
wrench, remove nut (20) and items 21
thru 23 as an assembly from poppet
(25).
12.
Using a scribe, remove preformed
packing (21) and ring (22) from
Discard preformed
spacer (23).
packing (21).
13.
Remove preformed packing (24) from
Discard preformed
poppet (25).
packing (24).
Go to sheet 4
12-52
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-7.
Boom Assembly Valve. (Sheet 4 of 6)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
14.
Wipe all parts with clean cloth
moistened with cleaning solvent P-D680. Dry thoroughly with compressed
air. Refer to pararaph 2-8.
Go to sheet 5
12-53
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-7. Boom Assembly Valve. (Sheet 5 of 6)
CLEANING/INSPECTION (cont)
NOTE
All grooves and passages in
housing must be free of foreign
matter.
15. Inspect all parts. Refer to paragraph 2-9.
ASSEMBLY
NOTE
Lubricate all preformed packings,
wipers, seals. sliding parts and
housing before installing.
16.
Install new preformed packing (24) on
poppet (25).
17.
Install ring (22) and new preformed
packing (21) on spacer (23).
18.
Using an 11/16” box and open end
wrench, install items 23 thru 21 as
an assembly and nut (20) on poppet
(25).
19.
Install spring (18) and items 25 thru
20 as an assembly in plug (19).
Go to sheet 6
12-54
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-7.
Boom Assembly Valve. (Sheet 6 of 6)
ASSEMBLY
20.
Install new preformed packing (17) on
plug (19).
21.
Using a 1-1/4” socket and torque
wrench, install items 25 thru 17 as
an assembly in housing (16). Tighten
plug (19) to 75 lb-ft.
22.
Install two new seals (15) and new
wipers (14) in housing (16).
23.
Position seat (12), spring (11) and
seat (10) on spool (13).
24.
Using a flat tip screwdriver, install
new preformed packing (9) and screw
(8). Tighten screw (8) to 4 lb-ft.
25.
Install items 13 thru 8 as an
assembly.
26.
Using a 1/4” hex head adapter and
torque wrench, install plate (7), cap
(6) and two bolts (5). Tighten two
bolts (5) to 5 lb-ft.
27.
Using a flat tip screwdriver, install
plate (4) and two screws (3).
28.
Install poppet (2) and spring (l).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-55
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-8.
Fork Control Valve. (Sheet 1 of 9)
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Detergent (App. C, Item 33)
Small tag (App. C, Item 28)
Preformed packing (10)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
12-56
Condition Description
Hydraulic pressure vented.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
Fork Control Valve. (Sheet 2 of 9)
12-8.
REMOVAL
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to
socket-type
pin-type or
connector.
1.
Using slip joint pliers, disconnect
cable assembly (1) at connector from
front of vehicle.
2.
Using a 1/2” socket and socket wrench
handle, remove bolt (2) and washer
(3).
3.
Disconnect wire assembly (4).
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
4.
Using a 7/8” open end wrench,
disconnect hose assembly (5) at
connector (6).
5.
Remove connector (6) and preformed
Discard preformed
packing (7).
packing (7).
6.
Disconnect hose assembly (8) a elbow
(9).
Go to sheet 3
12-57
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-8.
Fork Control Valve. (Sheet 3 of 9)
REMOVAL (cont)
7.
Using a 7/8” open end wrench, remove
elbow (9) and preformed packing (10).
Discard preformed packing (10).
8.
Disconnect hose assembly (11) at
connector (12).
9.
Remove connector (12) and preformed
packing (13).
Discard preformed
packing (13).
10.
Disconnect hose assembly
elbow (15).
11.
Remove elbow (15) and preformed
packing (16).
Discard preformed
packing (16).
12.
Disconnect hose assembly
elbow (18).
13.
Remove elbow (18) and preformed
packing (19).
Discard preformed
packing (19).
14.
Disconnect two hose assemblies
at two elbows (21).
15.
Remove two elbows (21) and preformed
packings (22). Discard two preformed
packings (22).
Go to sheet 4
12-58
(14) at
(17) at
(20)
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-8. Fork Control Valve. (Sheet 4 of 9)
REMOVAL
16.
Using a 7/8” open end wrench,
disconnect hose assembly (23) at
connector (24).
17.
Remove connector (24) and preformed
packing (25). Discard preformed
packing (25).
18.
Using a 1/2” socket, socket wrench
handle and a 1/2” box and open end
wrench, remove four bolts (26) , nuts
(27), washers (28) and fork control
valve assembly (29).
19.
Remove four nuts (30) and two
brackets (31).
DISASSEMBLY
20.
Using a 7/8” open end wrench, remove
three nuts (32) and sleeves (33).
21.
Disconnect three wire assemblies
(34) from wire assemblies (35)
lifting up connector assembly (38)
for access.
22.
Using a 3/8” open end wrench, remove
nut (36) pulling back boot (39) for
access.
Go to sheet 5
12-59
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Fork Control Valve. (Sheet 5 of 9)
12-8.
DISASSEMBLY (cont)
23.
Disconnect three wire assemblies (37)
at terminals.
24.
Remove connector assembly (38).
25.
Remove boot (39).
26.
Remove three coils (40) and six shims
(41).
27.
Using a 7/8” open end wrench, remove
two plugs (42) and preformed packings
(43). Discard preformed packings
(43).
28.
Using a 1/2” socket and socket wrench
handle, remove two nuts (44), washers
(45) and three studs (46).
29.
Separate three valves (47).
Go to sheet 6
12-60
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-8.
Fork Control Valve. (Sheet 6 of 9)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
get
air
solvent,
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
30.
Wipe cable assembly (l), wire
assemblies (4, 34, 35 and 37),
connector assembly (38), coils (40)
and shims (41) with clean dry cloth.
Go to sheet 7
12-61
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-8. Fork Control Valve. (Sheet 7 of 9)
CLEANING/INSPECTION (cont)
31.
Wipe hose assemblies (5, 8, 11, 14,
17, 20 and 23) and boot (39) with
clean cloth moistened with detergent.
Dry with compressed air.
32.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
33.
Inspect all parts. Refer to paragraph 2-9.
ASSEMBLY
34.
Position three valves (47).
35.
Using a 1/2” socket and socket wrench
handle, install three studs (46), two
washers (45) and nuts (44).
36.
Using a 7/8” open end wrench, install
two new preformed packings (43) and
plugs (42).
37.
Install six shims (41) and three
coils (40).
38.
Install boot (39).
39.
Install connector assembly (38).
40.
Position three wire assemblies (37).
Go to sheet 8
12-62
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-8.
Fork Control Valve. (Sheet 8 of 9)
ASSEMBLY
41.
Using a 3/8” open end wrench, install
nut (36).
42.
Connect three wire assemblies (35) to
wire assemblies (34).
43.
Using a 7/8” open end wrench, install
three sleeves (33) and nuts (32).
INSTALLATION
44.
Using a 1/2” socket, socket wrench
handle and a box and open end wrench,
install two brackets (31) and four
nuts (30) to front of vehicle.
45.
Install fork control valve assembly
(29), four washers (28), nuts (27)
and bolts (26).
46.
Using a 7/8” open end wrench, install
new preformed packing (25) and
connector (24).
47.
Connect hose assembly (23).
Go to sheet 9
12-63
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-8. Fork Control Valve. (Sheet 9 of 9)
INSTALLATION (cont)
48.
Using a 7/8” open end wrench, install
two new preformed packings (22) and
elbows (21).
49.
Connect two hose assemblies (20).
50.
Install new preformed packing (19)
and elbow (18).
51.
Connect hose assembly (17).
52.
Install new preformed packing (16)
and elbow (15).
53.
Connect hose assembly (14).
54.
Install new preformed packing (13)
and connector (12).
55.
Connect hose assembly (11).
56.
Install new preformed packing (10)
and elbow (9).
57.
Connect hose assembly (8).
58.
Install new preformed packing (7) and
connector (6).
59.
Connect hose assembly (5).
60.
Position wire assembly (4).
61.
Using a 3/8” socket and socket wrench
handle, install washer (3) and bolt
(2).
62.
Using slip joint pliers, connect
cable assembly (1) at connector in
front of vehicle.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-64
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-9. Tilt Cylinder. (Sheet 1 of 10)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Testing
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling, capacity of
450 lbs.
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Grease (App. C, Item 11)
Loctite 262 (App. C, Item 15)
Lubricating oil (App. C, Item 19)
Preformed packing (8)
Ring cord
Ring
Wiper
Seal (3)
Bushing (2)
Torques
Bolts (21) to 80 lb-ft
Go to sheet 2
12-65
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Tilt Cylinder. (Sheet 2 of 10)
12-9.
REMOVAL
1.
Lower forks to the ground and shut
down engine.
2.
Operate tilt control lever several
times to relieve pressure in
cylinder.
WEIGHT HAZARD
Weight of cylinder assembly is
approximately 450 lbs.
Use
adequate hoist and sling for
removal and installation.
Keep
area clear of
unnecessary
personnel. Failure to follow this
procedure could result in SEVERE
INJURY.
3.
Attach hoist and sling to cylinder
assembly (20).
4.
Using a 3/4” socket and socket wrench
handle, remove two bolts (1), washers
(2) and bracket assembly (3) from
cylinder assembly (20).
5.
Using a 5/16” socket and head screw
key, remove two bolts (4 and 5).
There might be some hydraulic
pressure still remaining in the
cylinder. Use caution when
disconnecting tube assemblies.
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
6.
Disconnect tube assembly (6).
Go to sheet 3
12-66
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
Tilt Cylinder. (Sheet 3 of 10)
12-9.
REMOVAL
7.
Remove and discard preformed packing
(7).
8.
Using a 9/16” socket and socket
wrench handle, remove four bolts (8)
and two flange halves (9).
9.
Disconnect hose assembly (10).
10.
Remove and discard preformed packing
(11).
11.
Using a 1-1/8” socket and socket
wrench handle, remove bolt (12),
washer (13) and pin (14).
12.
Using a 9/16” open end wrench,
disconnect hose assembly (15).
13.
Using a 1/2” open and box end
wrench, remove adapter (16) from
vehicles S/N 2000 and below, only.
Using a 1-1/8” socket and socket
wrench handle, remove bolt (17),
washer (18) and pin (19).
14.
15.
Using hoist and sling, remove
cylinder assembly (20) and shims
(20a) from vehicle.
16.
Place cylinder assembly (20) on a
suitable work bench and remove hoist
and sling.
Go to sheet 4
12-67
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Tilt Cylinder. (Sheet 4 of 10)
12-9.
DISASSEMBLY
170
Extend rod (53) half way and drain
remaining hydraulic fluid.
18.
Using a 1/2” socket and socket wrench
handle, remove six bolts (21), and
washers (22) from retainer (23).
19.
Loosen retainer (23), and ring cord
(24) from cylinder (55). The
retainer (23) and ring cord (24) will
stay loosely on upper portion of rod
(53) for removal later.
20.
Using a brass punch, drive items 25
thru 52 into cylinder (55) to loosen
three lock rings (26).
21.
Using a pick, remove shim (25) and
three lock rings (26). Discard lock
rings (26) .
22.
Using hoist and sling, remove items
27 thru 53 as an assembly from
cylinder (55).
23.
Using a 15/16” socket and socket
wrench handle, remove eight bolts
(28), washers (29), piston (30) and
two hubs (31) from rod (53).
24.
Remove ring (32) seal (33), and
preformed packing (34) from piston
(30). Discard seal (33) and
preformed packing (34).
25.
Using a scribe, remove ring (35),
preformed packing (36), and ring (37)
from rod (53). Discard preformed
packing (36).
26.
Remove piston (38).
27.
Remove ring buffer (39), preformed
packing (40), back up ring (41), ring
(42), seal (43) and preformed packing
(44) from piston (38). Discard
preformed packings (40 and 44).
Go to sheet 5
12-68
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-9.
Tilt Cylinder. (Sheet 5 of 10)
DISASSEMBLY
28.
Remove ring (45), preformed packing
(46), ring (47), from rod (53).
Discard preformed packing (46).
29.
Remove items 48 thru 52 as an
assembly, ring cord (24) and retainer
(23) from rod (53). Discard ring
cord (24).
30.
Remove and discard wiper (27) from
retainer (23).
31.
Using a scribe, remove seal (48),
preformed packing (49), washer (50)
and wear ring (51) from piston (52).
Discard seal (48) preformed packing
(49).
32.
Using an arbor press, remove and
discard bushing (54) from rod (53).
33.
Remove and discard bushing (56) from
cylinder (55).
Go to sheet 6
12-69
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cent)
12-9.
Tilt Cylinder. (Sheet 6 of 10)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
34.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
35.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 7
12-70
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-9. Tilt Cylinder. (Sheet 7 of 10)
ASSEMBLY
NOTE
Lubricate all preformed packings,
wipers, seals, rod and cylinder
before installing.
36.
Using an arbor press, install new
bushing (56) on cylinder (55).
37.
Install new bushing (54) on rod (53).
38.
Install wear ring (51), washer (50),
new preformed packing (49) and new
seal (48) on piston (52).
39.
Install new wiper (27) on retainer
(23).
40.
Install retainer (23), new ring cord
(24) and items 52 thru 48 as an
assembly on rod (53).
41.
Install ring (47), new preformed
packing (46) and ring (45) on rod
(53)
●
42.
Install new preformed packing (44),
seal (43), ring (42), back UP ring
(41), new preformed packing (40), and
ring buffer (39) on piston (38).
43.
Install piston (38) on rod (53).
GO to sheet 8
12-71
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Tilt Cylinder. (Sheet 8 of 10)
12-9.
ASSEMBLY (cont)
44.
Install ring (37), new preformed
packing (36) and ring (35) on rod
(53) .
45.
Install new preformed packing (34),
new seal (33) and ring (32) on piston
(30)
●
46.
Using a 15/16” socket and socket
wrench handle, install two hubs (31),
piston (30), eight washers (29) and
bolts (28).
47.
Using hoist and sling, install items
53 thru 27 as an assembly half way
into cylinder (55).
48.
Install three new lock rings (26) and
shim (25).
49.
Slide ring cord (24) and retainer
(23) down and position on cylinder
(55).
50.
Using a 1/2” socket and torque
wrench, install six washers (22) and
bolts (21). Tighten six bolts (21)
to 80 lb-ft.
INSTALLATION
51.
Attach hoist and sling to cylinder
assembly (20) on top of boom
assembly.
52.
Position cylinder assembly (20),
53.
Coat pin (19), washer (18) and bolt
(17) with grease.
54.
Using a 1/2” open and box end
wrench, install adapter (16) on
vehicles S/N 2000 and below, only.
55.
Using a 9/16” open end wrench,
connect hose assembly (15).
Go to sheet 9
12-72
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-9.
Tilt Cylinder. (Sheet 9 of 10)
INSTALLATION
56.
Coat pin (14), washer (13) and bolt
(12) with grease.
57.
Using a 1-1/8” socket and socket
wrench handle, install pin (14),
washer (13) and bolt (12).
58.
Install new preformed packing (11).
59.
Connect hose assembly (10).
60.
Using a 9/16” socket and socket
wrench handle, install two flange
halves (9) and four bolts (8).
61.
Install new preformed packing (7).
62.
Connect tube assembly (6).
63.
Using a 5/16” socket head screw key,
install two bolts (5 and 4).
64.
Using a 3/4” socket and socket wrench
handle, install bracket assembly (3),
two washers (2) and bolts (l).
65.
Remove hoist and sling from cylinder
assembly (20).
66.
Operate engine until hydraulic fluid
is at normal operating temperature.
67.
Move tilt control lever to tilt back
position until rod is fully extended.
68.
Apply Loctite 262 to three washers
(22) and bolts (21).
Go to sheet 10
12-73
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-9.
Tilt Cylinder. (Sheet 10 of 10)
TESTING
69.
Using a 1-1/8” socket and socket
wrench handle, disconnect rod end of
cylinder from vehicle.
70.
Start engine and move tilt control
lever to tilt forward position until
rod is fully retracted.
71.
Using a 9/16” open end wrench,
disconnect rear hose from cylinder.
and cap hose.
72.
Operate engine at 2625 to 2750 rpm
and ❑ ove tilt control lever to tilt
forward position.
73.
Observe rear port. Continuous fluid
flow from port indicates defective
packing or deformed cylinder.
74.
Connect rear hose.
75.
Using a 1-1/8” socket and socket
wrench handle, connect rod end to
vehicle.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-74
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-10. Boom Assembly. (Sheet 1 of 11)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling, capacity of
2100 lbs.
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Detergent (App. C, Item 33)
Seal (16)
Cotter pin
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Front work light, headlight and blackout
light assemblies removed.
Front fenders removed.
Paragraph 12-11
Vehicle carriage assembly removed.
REMOVAL
1.
Using a hydraulic jack, raise vehicle
and place two jack stands under rear
of vehicle to prevent vehicle from
tipping when boom assembly is
removed.
Go to sheet 2
12-75
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-10. Boom Assembly. (Sheet 2 of 11)
REMOVAL (cont)
NOTE
The following are differences
between M1OA Forklift models.
2.
Operate boom control lever in
operator’s compartment to raise boom
on vehicles S/N 2001 and above only.
3.
Remove pin (1) from front on vehicles
S/N 2001 and above only.
4.
Position boom support (43) under boom
assembly (40) on vehicles S/N 2001
and above only.
5.
Using a 1/2” socket and socket wrench
handle, remove six bolts (2), washers
(3), clips (4) and three clamps (5)
from front, right side of vehicle.
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
6.
Uncouple quick-coupler to disconnect
tube assembly (6) from hose assembly
(7).
7.
Cap hose assembly (7) to prevent
contamination from entering hydraulic
system.
8.
Using a 1/2” socket and socket wrench
handle, remove six bolts (8), washers
(9) and three clamps (10) from front,
left side of vehicle.
9.
Uncouple quick-coupler to disconnect
tube assembly (11) from hose assembly
(12).
10.
Using a plug, cap hose assembly (12).
GO to sheet 3
12-76
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-10. Boom Assembly. (Sheet 3 of 11)
REMOVAL
WEIGHT HAZARD
Weight of boom assembly is
Use
approximately 2100 lbs.
adequate hoist and sling for
Keep
removal and installation.
unnecessary
area clear of
personnel. Failure to follow this
procedure could result in SEVERE
INJURY.
11.
Attach hoist and sling to rod (21) at
front of vehicle.
12.
Using a 1-1/8” socket and socket
wrench handle, remove bolt (13),
washer (14) and pin (15).
13.
Using a rubber mallet, remove washers
(16 and 17) and items 18 thru 21 as
an assembly. Rod weights approximately 103 lbs. Washers (16 and 17)
are used as shims: their quantity is
variable.
14.
Remove hoist and sling.
Go to sheet 4
12-77
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-10. Boom Assembly. (Sheet 4 of 11)
REMOVAL (cont)
15.
Using a hammer and punch, a 7/16”
socket and socket wrench handle,
remove two seals (18), two bushings
(19) and lubrication fittings (20)
from rod (21). Discard seals (18).
16.
Using a safety rope, fasten tilt
cylinder to vehicle to prevent
cylinder rod end from dropping when
pin (24) is removed.
17.
Using a 1-1/8” socket and socket
wrench handle, remove bolt (22),
washer (23) and pin (24).
18.
Using a 10” long bar, attach hoist
and sling to lever (31).
19.
Using a 1-1/8” socket and socket
wrench handle, remove bolt (25),
washer (26) and pin (27).
20.
Using a hoist and sling, remove items
28 thru 31 as an assembly.
Lever
(31) weighs approximately 382 lbs.
21.
Remove hoist and sling.
Go to sheet 5
12-78
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-10. Boom Assembly. (Sheet 5 of 11)
REMOVAL
22.
Using a hammer and punch, a 7/16”
socket and socket wrench handle,
remove two seals (28), bushings (29)
and lubrication fitting (30) from
lever (31). Discard seals (28).
23.
Attach hoist and sling to boom
assembly (40) and take up slack.
24.
Using a 1-1/8” socket and socket
wrench handle. remove two bolts (32),
washers (33) and pins (34).
25.
Using a safety rope, fasten lift
cylinders to vehicle to prevent
cylinder rod ends from dropping when
boom assembly (40) is removed.
26.
Remove two bolts (35), washers (36)
and pins (37).
27.
Using a hoist and sling, remove items
38 thru 40 as an assembly and p1ace
on suitable work bench. Boom
assembly (40) weighs approximately
2100 lbs.
28.
Remove hoist and sling.
GO to sheet 6
12-79
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-10. Boom Assembly. (Sheet 6 of 11)
DISASSEMBLY
29.
Using a 7/16” socket and socket
wrench handle, remove 12 seals (38)
and six lubrication fittings (39)
from boom assembly (40). Discard
seals (38).
30.
Using a cotter pin extractor, remove
cotter pin (41), pin (42) and boom
support (43) from front of vehicles
S/N-2001 and above. Discard cotter
pin (41).
31.
Using a 3/4” socket, socket wrench
handle and 3/4” open end wrench,
remove bolt (44) and nut (45) from
vehicles S/N 2001 and above.
Go to sheet 7
12-80
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-10. Boom Assembly. (Sheet 7 of 11)
CLEANING/INSPECTION
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
32.
Wipe hose assemblies (7 and 12) with
clean cloth moistened with detergent.
Dry with compressed air.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored,
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
33. Clean all other parts with cleaning
solvent P–D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 8
12-81
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-10. Boom Assembly. (Sheet 8 of 11)
CLEANING/INSPECTION (cont)
34.
Inspect boom assembly (40).
If
bushings are worn, boom assembly (40)
must be replaced.
35.
Inspect all other parts.
paragraph 2-9.
Refer to
ASSEMBLY
NOTE
The following are differences
between M10A Forklift models.
36.
Using a 3/4” socket, socket wrench
handle and open end wrench, install t
nut (45) and bolt (44) in vehicles
S/N 2001 and above.
37.
Using a rubber mallet and slip joint
pliers, install boom support (43),
pin (42) and new cotter pin (41), in
vehicles S/N 2001 and above.
38.
Using a 7/16” socket, socket wrench
handle and rubber mallet, install six
lubrication fittings (39) and 12 new
seals (38) on boom assembly (40),
seal lips face outward.
Go to sheet 9
12-82
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-10. Boom Assembly. (Sheet 9 of 11)
INSTALLATION
39.
Attach hoist and sling to boom
assembly (40).
40.
Position items 40 thru 38 as an
assembly on vehicle.
41.
Position boom support (43) under boom
in vehicles S/N 2001 and above.
42.
Using a 1-1/8” socket and socket
wrench handle, install two pins (37),
washers (36) and bolts (35).
43.
Remove hoist and sling.
44.
Install two pins (34), washers
and bolts (32).
45.
Using a 7/16” socket, socket wrench
handle and rubber mallet, install
lubrication fitting (30), two
bushings (29) and new seals (28) in
lever (31), seal lips face outward.
(33)
Go to sheet 10
12-83
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-10. Boom Assembly. (Sheet 10 of 11)
INSTALLATION (cont)
46.
Using a 10” long bar, attach hoist
and sling to lever (31).
47.
Position items 31 thru 28 as an
assembly on vehicle.
Lever (31)
weighs approximately 382 lbs.
48.
Using a 1-1/8” socket and socket
wrench handle, install pin (27),
washer (26) and bolt (25).
49.
Remove hoist and sling.
50.
Using a 1-1/8” socket, socket wrench
handle and a rubber mallet, install
pin (24), washer (23) and bolt (22).
51.
Using a 7/16” socket, socket wrench
handle and a rubber mallet, install
two lubrication fittings (20),
bushings (19) and new seals (18) in
rod (21), seal lips face outward.
52.
Attach hoist and sling to rod (21).
Go to sheet 11
12-84
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-10. Boom Assembly. (Sheet 11 of 11)
INSTALLATION
53.
Using a 1-1/4” socket and socket
wrench handle, install items 21 thru
18 as an assembly, washers (17 and
16), pin (15), washer (14) and bolt
(13)* Use washers (17 and 16) as
shims to maintain a maximum gap of
0.031 inch between sides of rod (21)
and lever (31) and between rod (21)
and vehicle frame.
54.
Remove hoist and sling.
55.
Using a 15/16” open end wrench,
connect hose assembly (12) to tube
assembly (11).
56.
Using a 1/2” socket and socket wrench
handle, install three clamps (10),
six washers (9) and bolts (8).
57.
Using a 15/16” open end wrench,
connect hose assembly (7) to tube
assembly (6) to front, right side of
vehicle.
58.
Using a 1/2” socket and socket wrench
handle, install three clamps (5),
clips (4), six washers (3) and bolts
(2).
59.
Install pin (1) to lock boom support
(43) in place, for vehicles S/N 2001
and above.
60.
Lubricate all lubrication fittings,
refer LO 10-3930-643-12.
61.
Remove two jack stands and hydraulic
jack from rear of vehicle.
NOTE
Return M10A Forklift to
equipment condition.
original
END OF TASK
12-85
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 1 of 15)
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Two hoist and slings, capacity
of 4600 lbs.
2-9/16” socket and socket
wrench handle
NSN 5189-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Detergent (App. C, Item 33)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Preformed packing (16)
3/4 inch flat washer (7)
Tie strap (6)
Wooden block (2)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 12-13 or 12-14
Condition Description
Sideshift cylinder removed.
Paragraph 12-8
Fork control valve removed.
Paragraph 12-15 or 12-16
Fork position cylinders removed.
Paragraph 12-17 or 12–18
Oscillation cylinder removed.
Go to sheet 2
12-86
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-11.
Lifting Forks and Carriage Assembly. (Sheet 2 of 10)
REMOVAL
1.
Using diagonal cutters, cut six tie
straps (1) from harness assembly (2)
and two hose assemblies (6) in
vehicle, front right. Discard six
tie straps (l).
2.
Using a 9/16” socket and socket
wrench handle, remove bolt (3).
washer (4) and clip (5).
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
3. Uncouple quick-couplers to disconnect
two hose assemblies (6) from vehicle,
front right and left sides.
4.
Install two plugs (8) in ends of two
hose assemblies (7).
Go to sheet 3
12-87
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 3 of 15)
REMOVAL (cont)
5.
Using a safety rope, secure rod
assembly (9) to boom assembly to
prevent movement when pin (12) is
removed.
WEIGHT HAZARD
Weight of lifting forks and
carriage assembly is approximately
4600 lbs. Use adequate hoist and
for
removal
sling
and
installation. Keep area clear of
unnecessary personnel. Failure to
follow this procedure could result
in SEVERE INJURY.
6.
Attach hoist and sling to carriage
assembly (20).
7.
Using a hammer and punch, a 1-1/8”
socket, socket wrench handle, remove
bolt (10), washer (11), pin (12) and
washers (13 and 14). Washers (13
and 14) are used as shims; their
quantity is variable.
8.
Remove two bolts (15), washer (16),
pin (17) and washers (18 and 19).
Washers (18 and 19) are used as
shims; their quantity is variable.
9.
Drive vehicle straight back from
carriage assembly (20) without
bumping assembly with boom arms.
Lower carriage assembly (20) to
ground and secure with wooden blocks.
10.
Remove hoist and sling.
Go to sheet 4
12-88
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-11.
Lifting Forks and Carriage Assembly. (Sheet 4 of 15)
DISASSEMBLY
11.
Using a 3/4” socket and socket wrench
handle, remove four bolts (21),
washers (22) and two plates (23).
12.
Attach hoists and slings to forks (25
and 26) and take up slack.
13.
Using hoists and slings, rubber
mallet and a brass bar, remove two
pins (24) and forks (25 and 26).
Mark left and right forks to aid in
installation.
14.
Using an 11/16” open end wrench,
disconnect two hose assemblies (27)
from adapters (29).
15.
Using a 13/16” open end wrench,
remove two nuts (28) and adapters
(29).
NOTE
The following is a difference
between M10A Forklift models.
16.
Using a 1-1/8” socket, socket wrench
handle and a 1-1/8” box and open end
wrench, remove bolt (30), washer
(31), nut (32) and clamp (33) from
vehicles S/N 2001 and above.
17.
Using an 11/16” open end wrench,
disconnect tube assembly (34) from
elbow (37), from vehicles S/N 2001
and above.
18.
Disconnect tube assembly (34) from
elbow (38).
Go to sheet 5
12-89
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 5 of 15)
DISASSEMBLY (cont)
19.
Using an 11/16” open end wrench,
disconnect tube assembly (34) from
elbow (45), from vehicles S/N 2000
and below.
20.
Using a 13/16” open end wrench,
remove nuts (35 and 36) and elbow
(37) from vehicles S/N 2001 and
above.
21.
Using an 11/16” open end wrench,
remove elbow (38).
22.
Disconnect hose assemblies (39 and
40) from vehicles S/N 2001 and above.
23.
Using a 13/16” open end wrench,
remove tee (41).
24.
Using a 7/16” socket and socket head
screw key, remove two nuts (42),
washers (43), bolts (44) and items 45
and 46 as an assembly.
25.
Using a 13/16” open end wrench,
remove three elbows (45) from flow
divider (46).
26.
Using a socket and socket wrench
handle, remove lubrication fittings
(47 and 48).
Go to sheet 6
12-90
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-11.
Lifting Forks and Carriage Assembly.
DISASSEMBLY
27.
Attach two hoists and slings, one to
apron (60) and the other to frame
(89).
28.
Using a 2-9/16” socket and socket
wrench handle, remove two nuts (49),
cam followers (50) and pins (51).
29.
Using a hoist and sling, remove items
52 thru 60 as an assembly from frame
(82), and place securely on floor.
30.
Remove hoist and sling.
31.
Using a 1-1/8” socket and socket
wrench handle, remove seven bolts
(52), washers (53) and claw (54).
32.
Using snap ring pliers, remove two
retaining rings (55), covers (56),
retaining rings (57), rollers (58)
and retaining rings (59) from apron.
12-91
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 7 of 15)
DISASSEMBLY (cont)
33.
Attach hoists and slings to frames
(82 and 89).
34.
Using a 1-1/8” socket and socket
wrench handle, remove two bolts (61),
washers (62), plate (63) and shim
(64).
35.
Using a 3/8” socket and socket wrench
handle, remove two lubrication
fittings (65).
36.
Using a 1-1/8” socket and socket
wrench handle, remove seven bolts
(66), washers (67), plate (68) and
plate (69) and seven washers (70).
37.
Separate items 71 thru 82 and items
83 thru 89 as assemblies.
Go to sheet 8
12-92
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-11.
Lifting Forks and Carriage Assembly. (Sheet 8 of 15)
DISASSEMBLY
38.
Using a 3/8” socket and socket wrench
handle, remove three lubrication
fittings (71 thru 73).
39.
Using a drift pin and hammer, remove
two pins (74), shafts (75) and
rollers (76).
40.
Remove two washers (77) from vehicles
S/N 2001 and above.
41.
Remove four washers (78) from
vehicles S/N 2000 and below.
42.
Using a 2-9/16” socket and socket
wrench handle, remove two nuts (79)
and cam followers (80) from frame
(82).
43.
Using drift pin, remove two pins (81)
from cam followers (80).
44.
Remove hoists and slings.
45.
Remove eight strips (83), 16 preformed packings (84) and shim (85).
Discard 16 preformed packings (84).
46.
Using a 7/16” socket, socket wrench
handle and snap ring pliers, remove
lubrication fitting (86), retaining
ring (87) and bearing (88) from frame
(89).
Go to sheet 9
12-93
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 9 of 15)
CLEANING/INSPECTION
47.
Wipe hose assemblies (6, 7, 27, 39
and 40) and two plugs (8) with clean
cloth moistened with detergent. Wipe
dry.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
48.
Wipe bearing (88) with cleaning
solvent P-D-680). Air dry.
Go to sheet 10
12-94
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-11.
Lifting Forks and Carriage Assembly
CLEANING/INSPECTION
49.
Clean all other parts with cleaning
solvent P-D-680. Dry with compressed
air. Refer to paragraph 2-8.
50.
Inspect all parts.
graph 2-9.
Refer to para-
ASSEMBLY
51.
Attach hoists and slings to frames
(89 and 82).
52.
Using a 5/16” socket, socket wrench
handle and snap ring pliers, install
bearing (88), retaining ring (87) and
lubrication fitting (86).
53.
Install shim (85), 16 new preformed
packings (84) and eight strips (83).
54.
Using a plastic hammer, install two
pins (81) in cam followers (80).
55.
Using a 2-9/16” socket and socket
wrench handle, install two nuts (79)
on cam followers (80).
Go to sheet 11
12-95
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 11 of 15)
ASSEMBLY (cont)
NOTE
The following are differences
between M10A Forklift models. The
removal/installation procedure is
identical.
56.
Position four washers (78) in
vehicles S/N 2000 and below.
57.
Position two washers (77) in vehicles
S/N 2001 and above.
58.
Using a hammer and punch, install two
rollers (76), shafts (75) and pins
(74).
59.
Using a 3/8” socket and socket wrench
handle, install two lubrication
fittings (73 thru 71).
60.
Using hoists and slings, position
items 89 thru 83 on items 82 thru 71
as assemblies.
Go to sheet 12
12-96
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-11.
Lifting Forks and Carriage Assembly. (Sheet 12 of 15)
ASSEMBLY
61.
Using a 1-1/8” socket and torque
wrench, install seven washers (70),
plate (69), plates (68), seven
washers (67) and bolts (66). Tighten
seven bolts (66) to 290 lb-ft. If
interference is found between frame
(82) and plate (68), install 3/4 inch
flat washers between plates (69) and
(68). Shim to a clearance of 0.010
inch with shim (85).
62.
Using a 3/8” socket and socket wrench
handle, install two lubrication
fittings (65).
63.
Using a 1-1/8” socket and socket
wrench handle, install shim (64),
plate (63), washers (62) and two
bolts (61). Install the least amount
of shims (64) possible to obtain no
preload on bearing (68).
64.
Remove hoists and slings.
65.
Using snap ring pliers, install two
retaining rings (59), rollers (58),
retaining rings (57), covers (56) and
retaining rings (55) on apron (60).
66.
Using a 1-1/8” socket and socket
wrench handle, install claw (54),
seven washers (53) and bolts (52).
67.
Attach hoist and sling to apron (60).
Go to sheet 13
12-97
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 13 of 15)
ASSEMBLY (cont)
67.
Position items 60 thru 52 as an
assembly on frame (82).
68.
Using hoist and sling, position items
60 thru 52 as an assembly on frame
(82).
69.
Using a 2-9/16” socket and socket
wrench handle, install two pins (51),
cam followers (50) and two nuts (49).
70.
Remove hoist and sling.
71.
Using a 3/8” socket and socket wrench
handle, install lubrication fittings
(48 and 47).
72.
Using a 13/16” open end wrench,
install three elbows (45) on flow
divider (46).
73.
Using a 7/16” socket and 1/4” socket
head screw key, install items 46 and
45 as an assembly, two bolts (44),
washers (43) and nuts (42).
74.
Position tee (41).
75.
Using an 11/16” open end wrench,
connect hose assemblies (40 and 39)
in vehicles S/N 2001 and above.
76.
Install elbow (38).
77.
Using a 13/16” open end wrench,
install elbow (37) and nuts (36 and
35) in vehicles S/N 2001 and above.
Go to sheet 14
12-98
TM 10-3930-643-34
HYDRAULIC SYSTEM MAINTENANCE.
Lifting Forks and Carriage Assembly. (Sheet 14 of 15)
12-11.
ASSEMBLY
78.
Using an 11/16” open end wrench,
connect tube assembly (34) to elbow
(45) in vehicles S/N 2000 and below.
79.
Connect tube assembly (34) to elbow
(38).
80.
Connect tube assembly (34) to elbow
(37) in vehicles S/N 2001 and above.
81.
Using a 1-1/8” socket and socket
wrench handle, install clamp (33),
nut (32), washer (31) and bolt (30)
in vehicles S/N 2001 and above.
82.
Using a 13/16” open end wrench,
install two adapters (29) and nuts
(28).
83.
Using an 11/16” open end wrench,
connect two hose assemblies (27) to
adapters (29).
84.
Attach hoist and slings to forks (26
and 25).
85.
Using hoists and slings and a rubber
mallet, install forks (26 and 25) and
two pins (24).
86.
Remove hoist and slings.
87.
Using a 3/4” socket and socket wrench
handle, install two plates (23),
washers (22) and four bolts (21).
Go to sheet 15
12-99
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-11.
Lifting Forks and Carriage Assembly. (Sheet 15 of 15)
INSTALLATION
88.
Using a hoist and sling,
carriage assembly (20).
89.
Using a 1-1/8” socket and socket
wrench handle, install washers (19
and 18), pin (17), washer (16) and
two bolts (15). Use washers (19 and
18) as shims to provide a maximum gap
of 0.031 inch between boom arms and
carriage frame.
90.
Install washers (14 and 13), pin
(12), washer (11) and bolt (10).
Install pin (12) through rod assembly
(9). Use washers (14 and 13) as
shims to provide a gap of 0.031 inch
between lever (9) and carriage frame.
91.
Remove hoist and sling.
92.
Remove two plugs (8) from ends of two
hose assemblies (7).
93.
Using quick-couplers, connect two
hose assemblies (7) to two hose
assemblies (6).
94.
Using a 9/16” socket and socket
wrench handle, install clip (5),
washer (4) and bolt (3).
95.
Install six new tie straps (1) to
secure harness assembly (2).
position
NOTE
Return M10A Forklift to original
equipment condition.
12-100
END OF TASK
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-12.
Lift Cylinder. (Sheet 1 of 10)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Testing
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Hoist and sling, capacity of
260 lbs.
2-3/4” open end wrench
NSN 5120-00-081-9104
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5 )
Clean cloth (App. C, Item 24)
Grease (App. C, Item 11)
Loctite 262 (App. C, Item 15)
Small tag (App. C, Item 28)
Preformed packing (9)
Ring
Lock ring
Seal (3)
Bushing
Suitable container
Torques
Bolts (23) to 34 lb-ft.
Locknut (29) to 1900 to 2000 lb-ft.
Go to sheet 2
12-101
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-12. Lift Cylinder. (Sheet 2 of 10)
REMOVAL
NOTE
The following is a procedure for
removal/installation of right side
lift cylinder. The procedure for
left side lift cylinder is
identical.
1.
Remove fender (1) from front, right
side of vehicle, refer to TM 10-3930643-20. Remove fender and ladder for
left side lift cylinder.
2.
Position forks so boom ends are
approximately two feet off ground.
3.
Block securely in place.
Weight of lift cylinder is approximately 260 lbs. Use adequate
hoist and sling for removal and
installation. Keep area clear of
unnecessary personnel. Failure to
follow this procedure could result
in SEVERE INJURY.
4.
Position hoist and sling on cylinder
assembly (48) , making sure the sling
is rapped under tube assembly (19),
and take up slack.
5.
Using a 1-1/8” socket and socket
wrench handle, remove bolt (2),
washer (3) and pin (4) from top of
lift cylinder.
Do not attempt to retract rod if
it is bent.
6.
Start engine and move lift control
lever to LOWER position to retract
rod . Turn engine off and vent
hydraulic pressure, refer to TM 103930-643-10.
Go to sheet 3
12-102
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-12.
Lift Cylinder. (Sheet 3 of 10)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
7.
Using a 9/16” socket and socket
wrench handle, remove eight bolts
(5) and four flanges (6) from bottom
of cylinder assembly (48).
8.
Disconnect two hose assemblies (7).
9.
Remove and discard two preformed
packings (8).
10.
Using a 3/4 socket, socket wrench
handle and a open end wrench, remove
nut (9), bolt (10), fitting (11) and
shim (12) from bottom of cylinder
assembly (48).
11.
Using hoist and sling, remove
cylinder assembly (48) from vehicle
and place on suitable work bench.
12.
Remove hoist and sling.
13.
Using a 5/16” socket head screw key,
remove two bolts (13 and 14).
14.
Disconnect tube assembly (19).
15.
Remove and discard preformed packing
(15).
16.
Using a 9/16” socket and socket
wrench handle, remove two bolts (16),
washers (17), support assembly (18)
and tube assembly (19).
17.
Remove spacer (20), preformed packing
(21) and valve (22) from cylinder
(48). Discard preformed packing
(21).
Go to sheet 4
12-103
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Lift Cylinder. (Sheet 4 of 10)
12-12.
DISASSEMBLY
18.
Using hoist and sling, extend rod
(45) half way out of cylinder
assembly and drain remaining fluid.
19.
Using a 9/16” socket and socket
wrench handle, remove six bolts (23)
washers (24) from retainer (25).
20.
Loosen retainer (25) and ring (26)
from cylinder and slide up on rod
(45).
21.
Using a brass punch, drive items 29
thru 44 down into cylinder (48) to
loosen three lock rings (27).
22.
Using a pick, remove and discard
three lock rings (27).
23.
Using hoist and sling, remove items
28 thru 45 as an assembly from
cylinder (48).
24.
Using a 2-3/4” socket and socket
wrench handle, remove lock nut (28)
and items 30 thru 35 as an assembly
from rod (45).
25.
Using a scribe, remove preformed
packing (29) , wear ring (30),
preformed packing (31), seal (32),
wear ring (33) and preformed packing
(34) from piston (35). Discard seal
(32) and preformed packings (31 and
34).
26.
Remove items 36 thru 44 as an
assembly, retainer (25) and ring (26)
from rod (45). Discard preformed
packing (26).
27.
Remove and discard wiper seal (25a)
from retainer (25).
Go to sheet 5
12-104
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-12.
Lift Cylinder. (Sheet 5 of 10)
DISASSEMBLY
28.
Using a scribe, remove preformed
packing (36), ring (37) and rod seal
(37a) from piston (44).
29.
Remove and discard preformed packing
(38) and seals (39 and 40).
30.
Remove preformed packing (41) and
rings (42 and 43). Discard preformed
packing (41).
31.
Using an arbor press, a 7/16” socket
and socket wrench handle, remove
bushing (46) and fitting (47) from
cylinder (48). Discard bushing (46).
Go to sheet 6
12-105
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-12.
Lift Cylinder. (Sheet 6 of 10)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
32.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
33.
Inspect piston (35) and retainer
(44), rod (45) and cylinder (48) for
burrs, scratches or other damage. A
small stone may be used to remove
burrs or small scratches.
Replace
parts showing damage or excessive
wear.
34.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 7
12-106
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
Lift Cylinder. (Sheet 7 of 10)
12-12.
ASSEMBLY
35.
Using an arbor press, a 7/16” socket
and socket wrench handle, install
fitting (47) and new bushing (46) in
cylinder (48).
NOTE
Lubricate all preformed packings,
wipers, seals. sliding parts and
housing before installing.
36.
Install rings (43 and 42) and new
preformed packing (41) on piston
(44).
37.
Install new seals (40 and 39) and new
preformed packing (38) on piston
(44).
38.
Install rod seal (37a), ring (37) and
new preformed packing (36) on piston
(44).
39.
Install new wiper seal (25a) on
retainer (25).
40.
Install new ring (26), retainer (25)
and items 44 thru 36 as an assembly
on rod (45).
41.
Install new preformed packing (34),
wear ring (33) , new seal (32), new
preformed packing (31), wear ring
(30) and new preformed packing (29)
on piston (35). To install outer
seal ring (32) soak in hot water
until pliable.
42.
Using a 2-3/4” socket and torque
wrench, install items 35 thru 30 as
an assembly and lock nut (28) on rod
(45). Tighten lock nut (28) to 1900
to 200 lb-ft.
Go to sheet 8
12-107
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-12.
Lift Cylinder. (Sheet 8 of 10)
ASSEMBLY
43.
Using a hoist and sling, Install
items 45 thru 28 as an assembly into
cylinder (48).
44.
Install three new lock rings (27).
45.
Slide new ring (26) and retainer (25)
down and position on cylinder (48).
46.
Apply loctite 262 on six bolts (23).
47.
Using a 9/16” socket and socket
wrench handle, install six washers
(24) and bolts (23) on retainer (25).
Tighten six bolts (23) to 34 lb-ft.
INSTALLATION
48.
Install valve (22), new preformed
packing (21) and spacer (20) in
cylinder assembly (48).
49.
Using a 9/16” socket and socket
wrench handle, install tube assembly
(19), support assembly (18), two
washers (17) and bolts (16) on lower
part of cylinder assembly (48).
50.
Install new preformed packing (15) on
upper part of cylinder assembly (48).
51.
Connect tube assembly (19).
52.
Using a 5/16” socket head screw key,
install two bolts (14 and 13).
Go to sheet 9
12-108
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-12.
Lift Cylinder. (Sheet 9 of 10)
INSTALLATION
53.
Position hoist and sling on cylinder
assembly (48), making sure the sling
is rapped under tube assembly (19)
and take up slack.
54.
Coat mounting rod on lower frame of
vehicle with grease.
55.
Using a hoist and sling, install
cylinder assembly (48) on vehicle.
56.
Using a 3/4” socket, socket wrench
handle and open end wrench, install
shim (12), fitting (11), bolt (10)
and nut (9) to lower end of cylinder
assembly (48).
57.
Install two new preformed packings
(8).
58.
Connect two hose assemblies (7).
59.
Using a 9/16” socket and socket
wrench handle, install four flanges
(6) and eight bolts (5) on hose
assemblies (7).
60.
Start engine and move lift control
lever to RAISED position to aline rod
(45) with boom assembly.
61.
Using a 1-1/8” socket and socket
wrench handle, install pin (4),
washer (3) and bolt (2) in rod end of
cylinder assembly (48).
62.
Remove hoist and sling.
63.
Install fender (1) to front, right
side of vehicle, refer to TM 10-3930643-12.
64.
Lubricate grease fittings, refer to
TM 10-3930-643-12.
Go to sheet 10
12-109
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-12.
Lift Cylinder. (Sheet 10 of 10)
INSTALLATION
65.
Check and refill hydraulic reservoir,
refer to TM 10-3930-643-12.
66.
Operate engine until hydraulic fluid
is at normal operating temperature.
67.
Move lift cylinder through at least
five full movements of travel to
bleed air from system.
68.
Check for binding in lift cylinder
operation.
69.
Stop engine.
70.
Inspect hydraulic hoses, fittings and
cylinder assemblies for leaks. -
TESTING
71.
Lower forks to the ground.
72.
Using a 9/16” socket and socket wrench
handle, disconnect hoses from left
side lift cylinder and cap hoses.
73.
Disconnect hose from lower end of right
side lift cylinder and cap hoses.
74.
Operate engine at 2625 to 2750 rpm and
move lift control lever to maximum
LOWER position.
75.
Observe lower port. Continuous fluid
flow from port indicates defective
packing. Replace packing if defective.
76.
Connect hoses.
NOTE
Return M10A Forklift to
original equipment condition.
END OF TASK
12-110
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 1 of 10)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Testing
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling
1-13/16” socket and socket
wrench handle
NSN 5120-00-199-7768
Material/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Fine emery cloth (App. C, Item 4)
Hydraulic fluid (App. C, Item 19)
Preformed packing (3)
Rod packing
Packing (2)
Wiper ring
Plug (2)
Wood block
Suitable container
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
Go to sheet 2
12-111
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 2 of 10)
REMOVAL
Only a qualified operator may
perform the next procedure.
All
other personnel must clear the
immediate area. Failure to follow
this procedure could result in
SERIOUS INJURY or DEATH. If
injured, obtain medical aid
immediately.
NOTE
Do not disconnect battery negative
ground for steps 1, 2 and 3. The
electrical system must be
operating for the engine and
hydraulic cylinders to-function.
1.
Start engine, refer to TM 10-3930643-10.
2.
Spread forks apart as far as
possible, refer to TM 10-3930-643-10.
3.
Shift vehicle carriage assembly to
extreme right, using side shift
lever, refer to TM 10-3930-643-10.
4.
Stop engine, refer to TM 10-3930-64310.
5.
Turn master disconnect switch OFF.
Go to sheet 3
12-112
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
Sideshift Cylinder (S/N 2000 and below). (Sheet 3 of 10)
12-13.
REMOVAL
6.
Attach hoist and sling to cylinder on
Remove
vehicle carriage assembly.
slack from sling.
7.
Using a 1-13/16” socket and socket
wrench handle, remove nut (1) and
washer (2).
8.
Loosen nut (7) slightly, approximately 1/2 turn.
9*
Retract rod (19) to stop. Be sure
vehicle carriage apron is not pulled
along with rod (19). Do not damage
bushing (23) unless it is being
replaced.
10•
Secure cylinder assembly (10) to
In
vehicle carriage assembly.
addition, cylinder assembly (10) must
remain securely held by hoist and
sling.
11.
Vent all hydraulic pressure, refer to
TM 10-3930-643-10.
Go to sheet 4
12-113
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 4 of 10)
REMOVAL (cont)
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
12.
Using a 7/8” open end wrench,
disconnect hose assemblies (3 and 4)
from cylinder assembly (10).
13.
Remove two unions (5) and preformed
packings (6). Discard two preformed
packings (6).
14.
Using a 1-13/16” socket and socket
wrench handle, loosen nut (7) enough
to show a small gap between nut (7)
and left mounting bracket.
15.
Using a rubber mallet, drive cylinder
assembly (10) free of pin (9).
Use
soft hammer and protect cylinder
assembly (10) with wood block.
16.
Using a 1-13/16” socket and socket
wrench handle and long round nose
pliers, remove nut (7), washer (8)
and pin (9). Observe position of
washer (8) to aid in installation.
NOTE
Place cylinder assembly in on repair
stand with oil ports down to avoid
contamination.
17.
Remove cylinder assembly (10) from
mounting brackets and place on a
suitable work bench with oil ports
facing down.
18.
Using a suitable container, drain all
hydraulic fluid from cylinder
assembly (10). There should be
approximately two quarts.
19. Remove hoist and sling.
Go to sheet 5
12-114
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 5 of 10)
DISASSEMBLY
20.
Using a spanner wrench, remove
retainer (11) from cylinder shell
(12).
NOTE
Observe positioning of seals,
wipers and packings when removing
them. Record positioning, as
necessary, for proper assembly.
21.
Remove items 13 thru 19 as an
assembly from cylinder shell (12).
22.
Using a 14” adjustable wrench, remove
nut (13) from rod (19).
23.
Using a rubber mallet, remove items
14 thru 18 as an assembly from rod
(19).
24.
Remove and discard packings (15 and
16) from piston (14).
25.
Remove and discard seal (17) from
piston (14).
26.
Remove and discard preformed packing
(18), wiper ring (20) and rod packing
(21) from retainer (11). One or more
spacer rings will be removed with
these items.
27.
Remove and discard two plugs (22)
from retainer (11).
28.
Using an arbor press, remove bushing
(23) from rod (19).
Go to sheet 6
12-115
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 6 of 10)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED
AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
30.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 7
12-116
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 7 of 10)
CLEANING/INSPECTION
29.
Inspect rod (19) and inside of
cylinder shell (12) for scratches,
grooves, burrs or other damage which
Small
might cause a malfunction.
burrs and shallow scratches can be
polished out with fine emery cloth
and oil. Replace what cannot be
repaired. Threads on cylinder shell
(12) and rod (19) must not be
damaged.
Be sure residues of
abrasives and foreign matter have
been cleaned away prior to assembly.
30.
Inspect bushing (23). Replace if it
is cracked or worn enough to allow
excessive movement of rod (19).
31.
Inspect all other parts.
paragraph 2-9.
Refer to
Go to sheet 8
12-117
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 8 of 10)
ASSEMBLY
32.
Using an arbor press, install bushing
(23) on rod (19).
33.
Install two new plugs (22) in
retainer (11).
NOTE
Lubricate all preformed packings,
wipers, seals. sliding parts and
housing before installing.
34.
Using a flat tip screwdriver, install
one spacer ring in new rod packing
(21). One more spacer ring will be
used as a shim in the slots in
retainer (11).
35.
Install new rod packing (21), new
wiper ring (20) and new preformed
packing (18) on retainer (11). Make
sure the lips of new rod packing (21)
face the opposite direction from lip
of new wiper ring (20). Lip of new
wiper ring (20) should point toward
the out side of retainer (11).
36.
Install new seal (17), and new
packings (16 and 15) on piston (14).
37.
Using a 14” adjustable wrench,
install items 18 thru 14 as an
assembly and nut (13) on rod (19).
38.
Install items 19 thru 13 as an
assembly in cylinder shell (12).
39.
Install retainer (11) on rod (19).
40.
Using a spanner wrench, tighten
retainer (11) and items 19 thru 13 as
an assembly in cylinder shell (12).
Go to sheet 9
12-118
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 9 of 10)
INSTALLATION
41.
Fill cylinder assembly (10) with
approximately two quarts of hydraulic
fluid.
42.
Attach hoist and sling to cylinder
assembly (10) and position on
mounting brackets.
43.
Using a plastic hammer and 1-13/16”
socket and socket wrench handle,
install pin (9), washer (8) and nut
(7). Tighten nut (7) to a snug fit,
then back off 1/8 turn. This
procedure is necessary to allow
cylinder end movement between
mountings and cylinder assembly (10).
44.
Install two new preformed packing (6)
and two unions (5).
45.
Using a 7/8” open end wrench, connect
hose assemblies (4 and 3).
46.
Using a 1-13/16” socket and socket
wrench handle, install washer (2) and
nut (1) to cylinder assembly (10)
47.
Remove hoist and sling.
48.
Check hydraulic fluid level. Add
hydraulic fluid, refer to TM 10-3930643-12.
Go to sheet 10
12-119
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-13.
Sideshift Cylinder (S/N 2000 and below). (Sheet 10 of 10)
TESTING
Only a qualified operator may
perform the next procedure.
All
other personnel must clear the
immediate area. Failure to follow
this procedure could result in
SERIOUS INJURY or DEATH. If
injured, obtain medical aid
immediately.
49.
Turn master disconnect switch ON.
50.
Start engine.
51.
Slowly move sideshift cylinder through
at five full movements of travel to
bleed air from system.
52.
Check for binding of cylinder
assembly during operation.
53.
Stop engine.
54.
Inspect hydraulic hoses, fittings and
cylinder assemblies for leaks.
NOTE
Return M10A Forklift to
original equipment condition.
END OF TASK
12-120
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 1 of 11)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Testing
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling
1-13/16” socket and socket
wrench handle
NSN 5120-00-199-7768
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Hydraulic fluid (App. C, Item 19)
Fine emery cloth (App. C, Item 4)
Seal (4)
Preformed packing (2)
Wire
Wiper
Ring
Wood block
Suitable container
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
Go to sheet 2
12-121
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 2 of 11)
REMOVAL
Only a qualified operator may
perform the next procedure.
All
other personnel must clear the
immediate area. Failure to follow
this procedure could result in
SERIOUS INJURY or DEATH. If
injured, obtain medical aid
immediately.
NOTE
Do not disconnect battery negative
ground for steps 1, 2 and 3. The
electrical system must be
operating for the engine and
hydraulic cylinders to function.
1.
Start engine, refer to TM 10-3930643-10.
2.
Spread forks apart as far as
possible, refer to TM 10-3930-643-10.
3.
Shift vehicle carriage assembly to
extreme right, using side shift
lever, refer to TM 10-3930-643-10.
4.
Stop engine, refer to TM 10-3930-64310.
5.
Turn master disconnect switch OFF.
Go to sheet 3
12-122
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 3 of 11)
REMOVAL (cont)
6.
Attach hoist and sling to cylinder
assembly (10). Remove slack from
sling.
7.
Using a 1-13/16” socket and socket
wrench handle, remove nut (1) and
washer (2).
8.
Loosen nut (7) slightly, approximately 1/2 turn.
9.
Retract rod (19) to stop. Be sure
vehicle carriage apron is not pulled
along with rod (19). Do not damage
bushing (24) unless it is being
replaced.
10.
Vent all hydraulic pressure, refer to
TM 10-3930-643-10.
Go to sheet 4
12-123
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 4 of 11)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
11.
Using a 7/8” open end wrench,
disconnect hose assemblies (3 and 4)
from cylinder assembly (10) of
vehicle carriage assembly.
12.
Using a 7/8” open end wrench, remove
two unions (5) and preformed packings
(6). Discard preformed packings (6).
13.
Using a 1-13/16” socket and socket
wrench handle, loosen nut (7) enough
to show a small gap between nut (7)
and left mounting bracket.
14.
Using a rubber mallet, drive cylinder
assembly (10) free of pin (9). Use
soft hammer and protect cylinder
assembly with wood block.
15.
Using a 1-13/16” socket and socket
wrench handle and long round nose
pliers, remove nut (7), washer (8)
and pin (9). Observe position of
washer (8) to aid in installation.
Go to sheet 5
12-124
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 5 of 11)
REMOVAL (Cont)
NOTE
Place cylinder assembly in on repair
stand with oil ports down to avoid
contamination.
16.
Remove cylinder assembly (10) from
mounting brackets and place on a
suitable work bench with oil ports
facing down.
17.
Using a suitable container, drain
all hydraulic fluid from cylinder
assembly (10). There should be
approximately two quarts.
18.
Remove hoist and sling.
DISASSEMBLY
19.
Remove wire (11).
Go to sheet 6
12-125
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 6 of 11)
DISASSEMBLY
NOTE
Observe positioning of seals,
wipers and ring when removing
them. Record positioning, as
necessary, for proper assembly.
20.
Using a spanner wrench, loosen
retainer (13) from barrel (12).
21.
Remove items 14 thru 19 from barrel
(12). Pull items 14 thru 19 as an
assembly straight out to prevent
damage to barrel (12).
NOTE
Observe positioning of seals,
wipers and packings when removing
them. Record positioning, as
necessary, for proper assembly.
22.
Secure rod (19) in vice. Protect rod
(19) with shop cloths and/or padding
and metal protector.
23.
Using a 14” adjustable wrench and
long round nose pliers, remove pin
(14) and nut (15) from rod (19).
24.
Using a rubber mallet, remove items
16 thru 18 as an assembly from rod
(19).
25.
Using a scribe, remove and discard
seals (17 and 18) from piston (16).
26.
Remove retainer (13) from rod (19).
27.
Remove and discard seal (20), ring
(21), wiper (22) and seal (23) from
retainer (13).
28.
Using an arbor press, remove bushing
(24) from vehicle carriage assembly.
Go to sheet 7
12-126
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 7 of 11)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
get
air
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
28.
Clean all parts with cleaning solvent
P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 8
12-127
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 8 of 11)
CLEANING/INSPECTION
29.
Inspect rod (19) and inside of barrel
(13) for scratches, grooves, burrs or
other damage which might cause a
malfunction. Small burrs and shallow
scratches can be polished out with
fine emery cloth and oil.
Replace
what cannot be repaired. Threads on
barrel (13) and rod (19) must not be
Be sure residues of
damaged.
abrasives and foreign matter have
been cleaned away prior to assembly.
30.
Inspect piston (16). Replace if it
has scratches, grooves, burrs or
other damage which might cause a
malfunction.
31.
Inspect all other parts.
paragraph 2-9.
Go to sheet 9
12-128
Refer to
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 9 of 11)
ASSEMBLY
32.
Using an arbor press, install bushing
(24) on vehicle carriage assembly.
NOTE
Lubricate all preformed packings,
wipers, seals. sliding parts and
housing before installing.
33.
Install new seal (23), in retainer
(13). Make sure the lips of seal
(23) face inside barrel (12).
seal installer tool if necessary.
Use
34.
Install new wiper (22) , new ring (21)
and new seal (20 on retainer (13).
35.
Install retainer (13) on rod (19).
36.
Install new seal (18 and 17) on
piston (16) .
37.
Using a 14" adjustable wrench,
install items 18 thru 16 as an
assembly and nut (15) on rod.
38.
Aline holes in nut (15) with hole in
rod (19) and install pin (14).
39.
Install items 19 thru 13 as an
assembly in barrel (12).
40.
Using a spanner wrench, tighten
retainer (13) and items 19 thru 14 as
an assembly in barrel (12).
41.
Using slip joint pliers , install wire
(11).
Go to sheet 10
12-129
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 10 of 11)
INSTALLATION
42.
Fill cylinder assembly (10) with
approximately two quarts of hydraulic
fluid.
43.
Attach hoist and sling to cylinder
assembly (10) and position on
mounting brackets.
44.
Using a plastic hammer and 1-13/16"
socket and socket wrench handle,
install pin (9), washer (8) and nut
(7). Tighten nut (7) to a snug fit,
then back off 1/8 turn. This
procedure is necessary to allow
cylinder end movement between
mountings and cylinder assembly (10).
45.
Install two new preformed packing (6)
and two unions (5).
46.
Using a 7/8" open end wrench, connect
hose assemblies (4 and 3).
47.
Using a 1-13/16" socket and socket
wrench handle, install washer (2) and
nut (1) to cylinder assembly (10)
48.
Remove hoist and sling.
49.
Check hydraulic fluid level. Add
hydraulic fluid, refer to TM 10-3930643-12.
Go to sheet 11
12-130
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-14.
Sideshift Cylinder (S/N 2001 and above). (Sheet 11 of 11)
TESTING
Only a qualified operator may
All
perform the next procedure.
other personnel must clear the
immediate area. Failure to follow
this procedure could result in
SERIOUS INJURY or DEATH. If
injured, obtain medical aid
immediately.
50.
Turn master disconnect switch ON.
51.
Start engine.
52.
Slowly move sideshift cylinder through
at five full movements of travel to
bleed air from system.
53.
Check for binding of cylinder
assembly during operation.
54.
Stop engine.
55.
Inspect hydraulic hoses, fittings and
cylinder assemblies for leaks.
NOTE
Return M10A Forklift to
original equipment condition.
Return M10A Forklift to original
equipment condition.
END OF TASK
12-131
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 1 of 10)
This task covers:
b. Disassembly
a. Removal
c. Cleaning/Inspection d. Assembly
f. Testing
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Hydraulic fluid (App. C, Item 19)
Emery cloth (App. C, Item 4)
Preformed packing (8)
Wiper (2)
Nylon rider (2)
Cotter pin (2)
Ring
Nuts (15 and 16) to 90 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Go to sheet 2
12-132
Condition Description
Hydraulic pressure vented.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
Fork Position Cylinders (S/N 2000 and below). (Sheet 2 of 10)
12-15.
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using an 11/16" open end wrench,
disconnect tube assemblies (1 and 2)
from tee fitting and elbows (3 and 4)
on vehicle carriage assembly.
2.
Remove elbows (3 and 4) and preformed
packings (5 and 6). Discard
preformed packings (5 and 6).
3.
Disconnect tube assembly (7) from
elbow (8) and flow divider.
4.
Remove elbow (8) and preformed
packing (9). Discard preformed
packing (9).
5.
Disconnect tube assembly (10) from
elbow (11) and from flow divider.
6.
Remove elbow (11) and preformed
packing (12). Discard preformed
packing (12).
7.
Using slip joint pliers, remove
cotter pin (13) and pin (14) from
cylinder assembly (16) and mounting
bracket. Discard cotter pin (13).
8.
Using a 1-1/8” socket and socket
wrench handle, remove nut (15).
Go to sheet 3
12-133
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 3 of 10)
REMOVAL
9.
Using a rubber mallet, remove
cylinder assembly (16) from mounting
brackets.
10.
Using slip joint pliers, remove pin
(17).
11.
Using slip joint pliers, remove
cotter pin (18) and pin (19) from
cylinder assembly (21) and mounting
bracket. Discard cotter pin (18).
12.
Using a 1-1/8” socket and socket
wrench handle, remove nut (20).
13.
Using a rubber mallet, remove
cylinder assembly (21) from mounting
brackets.
14.
Using slip joint pliers, remove pin
(22).
Go to sheet 4
12-134
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 4 of 10)
DISASSEMBLY
NOTE
This procedure is for maintenance
of the lower fork position
cylinder. Procedure for the upper
fork position cylinder i S
identical.
15.
Using a strap wrench, remove cap (23)
from cylinder shell (24).
NOTE
Observe positioning of wipers,
packings, rings and riders when
removing them. Record positioning, as necessary, for proper
assembly.
16.
Remove items 25 thru 37 as an
assembly from cylinder shell (24).
Go to sheet 5
12-135
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 5 of 10)
DISASSEMBLY
17.
Using a 14" adjustable wrench, remove
nut (25) from rod (37).
18.
Using a plastic hammer, remove piston
half (26) with attached parts.
19.
Remove piston half (27) and preformed
Discard preformed
packing (28).
packing (28).
20.
Remove and discard nylon rider (29),
preformed packing (30) and nylon
rider (31) from piston half (26).
21.
Remove bushing (32) from rod (37).
22.
Remove and discard preformed packing
(33), ring (34) and preformed packing
(35 from bushing (32).
23.
Remove and discard wiper (36) from
rod (37).
Go to sheet 6
12-136
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 6 of 10)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek q edical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
air
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
24.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
25.
Inspect rod (37) and inside of
cylinder shell (24) for scratches,
grooves, or burrs. Small burrs and
shallow scratches can be polished out
with fine emery cloth and oil.
26.
Inspect piston half (26), piston half
(27), rod (37) and cylinder shell
(24). Replace items which cannot be
repaired and items with scoring,
scratches or burrs.
Go to sheet 7
12-137
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-15.
Fork Position Cylinders (S/N 2000 and below). (sheet 7 of 10)
CLEANING/INSPECTION
27.
Inspect all other parts.
paragraph 2-9.
Refer to
ASSEMBLY
28.
Coat bushing (32), rod (37) and
inside of cylinder shell (24) with
clean hydraulic fluid,
29.
Coat new wiper (36) with clean
hydraulic fluid and using seal
installer, install on rod (37).
30.
Coat new preformed packing (35), new
ring (34) and new preformed packing
(33) with clean hydraulic fluid and
install on bushing (32).
31•
Install bushing (32) on rod (37).
32.
Coat new preformed packing (28), new
nylon rider (31), new preformed
packing (30), and new nylon rider
(29) with clean hydraulic fluid and
install on piston half (26).
33.
Coat piston half (27) and piston half
(26) with clean hydraulic fluid.
34.
Install piston half (27) and piston
half (26) with attached parts on rod
(37).
35.
Using a 14” adjustable wrench,
install nut (25).
36.
Install items 37 thru 25 as an
assembly in cylinder shell (24).
37.
Using a strap wrench, install cap
(23) on cylinder shell (24).
Go to sheet 8
12-138
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 8 of 10)
INSTALLATION
38.
Install cylinder assembly (21) in
mounting bracket. Hydraulic fluid
ports are to be positioned as shown.
39•
Using a plastic mallet, install pin
(22).
40.
Using a 1-1/8" socket and torque
wrench, install nut (20) and tighten
to 90 lb-ft, then back off 1/4 turn.
This is necessary to allow cylinder
end movement between the bracket and
cylinder assembly.
41.
Using a plastic hammer and slip joint
pliers, install pin (19) and new
cotter pin (18).
42.
Install cylinder assembly (16) in
mounting bracket. Hydraulic fluid
ports are to be positioned as shown.
43.
Using a plastic hammer, install pin
(17)
●
Go to sheet 9
12-139
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 9 of 10)
INSTALLATION
44.
Using a 1-1/8" socket and torque
wrench, install nut (15) and tighten
to 90 lb-ft, then back off 1/4 turn.
This is necessary to allow cylinder
end movement between the bracket and
cylinder assembly,
45.
Using a plastic hammer and slip joint
pliers, install pin (14) and new
cotter pin (13).
46.
Using an 11/16" open end wrench,
install new preformed packing (12)
and elbow (11) .
47.
Install tube assembly (10) at elbow
(11) and flow divider. Tighten both
ends.
48.
Install new preformed packing (9) and
elbow (8).
49.
Install tube assembly (7) at elbow
(8) and flow divider. Tighten both
ends.
50•
Install new preformed packings (6 and
5) and elbows (4 and 3).
51
Connect tube assemblies (2 and 1) to
tee fitting and to elbows (4 and 3).
●
52.
Check hydraulic fluid level. Add
hydraulic fluid if necessary, refer
to LO 10-3910-643-12.
Go to sheet 11
12-140
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-15.
Fork Position Cylinders (S/N 2000 and below). (Sheet 10 of 10)
TESTING
Only a qualified operator may
perform the next procedure.
All
other personnel must clear the
immediate area. Failure to follow
this procedure could result in
SERIOUS INJURY or DEATH. If
injured, obtain medical aid
immediately.
53.
Start engine.
54.
Operate fork position cylinder
slowly.
55.
Move fork position cylinder through
at least five full movements of
travel to bleed air from system.
56.
Check for binding in operation of
hydraulic cylinders and vehicle.
57.
Stop engine.
58.
Inspect hydraulic fluid tubes,
fittings and cylinder assemblies for
leaks.
59.
Check hydraulic fluid level again.
Add hydraulic fluid, if necessary,
refer to LO 10-3930-643-12.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-141
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 1 of 10)
This task covers:
a. Removal
C.
Cleaning/Inspection
e. Installation
b. Disassembly
d. Assembly
f. Testing
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item5)
Clean cloth (App. C, Item 24)
Hydraulic fluid (App. C, Item 19)
Small tag (App. C, Item 28)
Fine emery cloth (App. C, Item 4)
Seal (4)
Preformed packing (5)
Cotter pin (2)
Strip
Wiper
Torques
Nuts (15 and 20) to 90 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Go to sheet 2
12-142
Condition Description
Hydraulic pressure vented.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 2 of 10)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using an 11/16” open end wrench,
disconnect tube assemblies (1 and 2)
from tee fitting and elbows (3 and 4)
on vehicle carriage assembly.
2.
Remove elbows (3 and 4) and preformed
packings (5 and 6). Discard
preformed packings (5 and 6).
3.
Disconnect tube assembly (7) from
elbow (8) and flow divider.
4.
Remove elbow (8).
5.
Remove and discard preformed packing
(9).
6.
Disconnect tube assembly (10) from
elbow (11) and flow divider.
7.
Remove elbow (11) and preformed
packing (12). Discard preformed
packing (12).
Go to sheet 3
12-143
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 3 of 10)
REMOVAL
8.
Using slip joint pliers, remove
cotter pin (13) and pin (14) from
cylinder assembly (16) and mounting
bracket. Discard cotter pin (13).
9.
Using a 1-1/8" socket and socket
wrench handle, remove nut (15).
10.
Remove cylinder assembly (16) from
mounting brackets.
11.
Using slip joint pliers, remove pin
(17).
12.
Using slip joint pliers, remove
cotter pin (18) and pin (19) from
cylinder assembly (21) and mounting
bracket. Discard cotter pin (18).
13.
Using a 1-1/8" socket and socket
wrench handle, remove nut (20).
14.
Remove cylinder assembly (21) from
mounting brackets.
15.
Using slip joint pliers, Remove pin
(22).
Go to sheet 4
12-144
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 4 of 10)
DISASSEMBLY
NOTE
This procedure is
of the lower fork
Procedure for the
position cylinder
16.
for maintenance
position cylinder.
upper fork
is identical.
Using a strap wrench, remove collar
(23) from barrel (24).
NOTE
Observe positioning of seals,
wipers, strip and packings when
removing them. Record positioning,
as necessary, for proper assembly.
17.
Remove items 25 thru 35 as an
assembly from barrel (24).
18.
Using a 14" adjustable wrench, remove
nut (25).
19.
Remove items 26 thru 30 as an
assembly.
20.
Remove and discard seal (27) and
preformed packing (28) from piston
(26).
21.
Remove and discard strip (29) and
seal (30).
22.
Remove items 31 thru 34 as an
assembly from shaft (35).
23.
Remove and discard wiper (32) and
seals (33 and 34) from retainer (31).
Go to sheet 5
12-145
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 5 of 10)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
24.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
Go to sheet 6
12-146
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 6 of 10)
CLEANING/INSPECTION (cont)
25.
Inspect shaft (35) and inside of
barrel (24) for scratches, grooves,
burrs or other damage which could
cause a malfunction. Use fine emery
cloth and oil to remove small burrs
and shallow scratches.
26.
Inspect piston (26), retainer (31),
barrel (24) and shaft (35) and
replace items which cannot be
repaired or have scoring, scratches
or burrs. Replace items with damage
which might cause a malfunction; this
may include indentations, flat sides
and such distortions as bent shafts.
Threads on barrel (24) and shaft (35)
Be sure
must not be damaged.
residues of abrasives and foreign
matter have been cleaned away prior
to assembly.
27.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 7
12-147
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 7 of 10)
ASSEMBLY
28.
Coat retainer (31), shaft (35) and
new seal (30) with clean hydraulic
fluid.
29.
Coat new seals (34 and 33) and new
wiper (32) with clean hydraulic
fluid.
Install seals (34 and 33) on retainer
(31). Use suitable seal installer,
if necessary. Lip on seal (33) is to
face inside cylinder.
30.
31.
Install new wiper seal (32) on
retainer (31).
32.
Install items (34 thru 31) on shaft
(35) .
33.
Coat new seal (30), new strip (29),
new preformed packing (28) and new
seal (27) with clean hydraulic fluid.
34,
Install new seal (30), new strip
(29), new preformed packing (28) and
new seal (27) on piston (26). Use
suitable seal expander, if necessary.
35.
Coat piston (26) with clean hydraulic
fluid.
36.
Install items (30 thru 26) on shaft
(35).
37.
Using a 14" adjustable wrench,
install nut (25).
38.
Coat inside of barrel (24) liberally
with clean hydraulic fluid.
Co to sheet 8
12-148
TM 10-3930-643-3-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 8 of 10)
ASSEMBLY (cont)
39•
Install items 35 thru 25 as an
assembly in barrel (24).
40.
Using a strap wrench, install collar
(23) on barrel (24). Tighten until
snug.
INSTALLATION
41.
Install cylinder assembly (21) in
mounting bracket. Hydraulic fluid
ports are to be positioned as shown.
42.
Using a plastic mallet, install pin
(22).
43.
Using a 1-1/8" socket and torque
wrench, install nut (20) and tighten
to 90 lb–ft, then back off 1/4 turn.
This is necessary to allow cylinder
end movement between the bracket and
cylinder assembly.
44.
Using a plastic hammer and slip joint
pliers, install pin (19) and new
cotter pin (18).
45.
Install cylinder assembly (16) in
mounting bracket. Hydraulic fluid
ports are to be positioned as shown.
Go to sheet 9
12-149
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 9 of 10)
INSTALLATION
46.
Using a plastic hammer, install pin
(17).
47.
Using a 1-1/8" socket and torque
wrench, install nut (15) and tighten
to 90 lb-ft, then back off 1/4 turn.
This is necessary to allow cylinder
end movement between the bracket and
cylinder assembly.
48.
Using a plastic hammer and slip joint
pliers, install pin (14) and new
cotter pin (13).
49.
Using an 11/16" open end wrench,
install new preformed packing (12)
and elbow (11).
50.
Install tube assembly (10) at elbow
(11) and flow divider. Tighten both
ends.
51.
Install new preformed packing (9) and
elbow (8).
52.
Install tube assembly (7) at elbow
(8) and flow divider. Tighten both
ends.
53.
Install new preformed packings (6 and
5) and elbows (4 and 3).
Go to sheet 10
12-150
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-16.
Fork Position Cylinders (S/N 2001 and above). (Sheet 10 of 10)
INSTALLATION (cont)
54.
Connect tube assemblies (2 and 1) to
tee fitting and to elbows (4 and 3).
55.
Check hydraulic fluid level. Add
hydraulic fluid if necessary, refer
to LO 10-3910-643-12.
TESTING
Only a qualified operator may
perform the next procedure.
All
other personnel must clear the
immediate area. Failure to follow
this procedure could result in
SERIOUS INJURY or DEATH. If
injured, obtain medical aid
immediately.
56.
Start engine.
57.
Operate fork position cylinder
slowly.
58.
Move fork position cylinder through
at least five full movements of
travel to bleed air from system.
59.
Check for binding in operation of
hydraulic cylinders and vehicle.
60.
Stop engine.
61.
Inspect hydraulic fluid tubes,
fittings and cylinder assemblies for
leaks.
62.
Check hydraulic fluid level again.
Add hydraulic fluid, if necessary,
refer to LO 10-3930-643-12.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-151
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 1 of 8)
This task covers:
a. Removal
c. Cleaning/Inspection
e. Installation
b.
d.
f.
Disassembly
Assembly
Testing
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Hydraulic fluid (App. C, Item 19)
Multi-purpose grease
(App. C, Item 12)
Seal (4)
Ring (4)
Preformed packing (4)
Wiper
Bearing
Retainer bearing
Hoist and sling
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
GO to sheet 2
12-152
Condition Description
Hydraulic pressure vented.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 2 of 8)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a 7/8" open end wrench,
disconnect hose assembly (1) and
union (2) from cylinder assembly (11)
from vehicle carriage assembly.
2.
Using a scribe, remove and discard
preformed packing (3).
3.
Using a 7/8" open end wrench,
disconnect hose assembly (4) and
elbow (5) from cylinder assembly
(11).
4.
Using a scribe, remove and discard
preformed packing (6).
5.
Using a 3/4” socket and socket wrench
handle, remove two screws (7),
washers (8) and anchors (9).
Go to sheet 3
12-153
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 3 of 8)
REMOVAL
6.
Attach hoist and sling to cylinder
assembly (11).
7.
Using a hammer and wooden dowel,
remove two pins (10). Drive pins
(10) out using care not to damage
pins (10).
8.
Using a hoist and sling, remove
cylinder assembly (11) from mounting
brackets and place on a suitable work
bench.
9.
Remove hoist and sling.
DISASSEMBLY
10.
Using a spanner wrench, loosen
retainer (13) from cylinder assembly
(11).
NOTE
Observe positioning of seals,
wipers and packings when removing
them. Record positioning, as
necessary, for proper assembly.
11.
Remove items 13 thru 27 as an
assembly from cylinder shell (12).
Go to sheet 4
12-154
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 4 of 8)
DISASSEMBLY (cont)
12.
Using a 14" adjustable wrench, remove
nut (14).
13.
Remove items 15 thru 19 as an
assembly from rod (21).
14.
Using a scribe, remove and discard
bearing (16), seal (17), two rings
(18) and preformed packing (19) from
piston (15).
15.
Pull rod (21) through parts remaining
on rod (21) to facilitate removal of
retainer bearing (20).
16.
Remove and discard retainer bearing
(20).
17.
Remove and discard preformed packing
(22), ring (23), two seals (24),
wiper ring (25), ring (26) and seal
(27) .
18.
Remove retainer (13).
19.
Using a 5/16" socket and socket
wrench handle, remove two fittings
(28) from pins (10).
Go to sheet 5
12-155
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 5 of 8)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable.
Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
solvent,
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
20.
Clean all parts with cleaning solvent
P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
21.
Inspect piston (15), rod (21) and
inner and outer surfaces of cylinder
shell (12). Replace items which
cannot be repaired and items which
have burrs, scoring, scratches, or
grooves.
22.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 6
12-156
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 6 of 8)
ASSEMBLY
23.
Using a 5/16" socket and socket
wrench handle, install two fittings
(28) on two pins (10).
24.
Coat retainer (13), rod (21) and
inside of cylinder shell (12) with
clean hydraulic fluid.
25.
Install retainer (13) on rod (21).
NOTE
Lubricate all preformed packings,
wipers , seals. sliding parts and
housing before installing.
26.
Install new retainer bearing (20) on
rod (21).
27.
Install new preformed packing (19),
two rings (18), new bearing (16) and
new seal (17) on piston (15). Lip on
seal (17) is to face inside cylinder.
28.
Install items 19 thru 15 as an
assembly on rod (21).
29.
Using a adjustable wrench, install
nut (14) on rod (21).
30.
Install items 27 thru 14 as an
assembly in cylinder shell (12).
31.
Using a spanner wrench, tighten
retainer (13) on cylinder assembly
(11).
Go to sheet 7
12-157
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 7 of 8)
INSTALLATION
32.
Attach hoist and sling on cylinder
assembly (11).
33.
Position cylinder assembly (11) on
vehicle carriage assembly.
34.
Using a rubber mallet, install two
pins (10).
35•
Remove hoist and sling.
36.
Using a 3/4" socket and socket wrench
handle, install two anchors (9),
washers (8) and screws (7).
37.
Using a 5/16" socket and socket
wrench handle, install two fittings
(28).
38.
Install new preformed packing (6).
39.
Using a 7/8" open end wrench, connect
elbow (5) and hose assembly (4) on
cylinder assembly (11).
40.
Install new preformed packing (3).
41.
Connect union (2) and hose assembly
(1) on cylinder assembly (11).
42.
Lubricate two fittings (28) until
clean grease appears.
Use multipurpose grease where temperature
allows. If necessary, refer to
LO 10-3930-643-12.
43.
Check hydraulic fluid level.
Add
hydraulic fluid, if necessary, refer
to LO 10-3930-643-12.
Go to sheet 8
12-158
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-17.
Oscillation Cylinder (S/N 2000 and below). (Sheet 8 of 8)
TESTING
Only a qualified operator may
perform the next procedure. All
other personnel must clear the
Failure to
immediate area.
follow this procedure could
result in SERIOUS INJURY or
If injured, obtain
DEATH .
medical aid immediately.
44.
Start engine.
45.
Operate oscillation cylinder slowly.
46.
Move oscillation cylinder through at
least five full movements of travel
to bleed air from system.
47.
Check for binding in hydraulic
cylinder operation.
48.
Stop engine.
49.
Inspect hydraulic fluid hoses,
fittings and cylinder assemblies for
leaks.
50.
Check hydraulic fluid level again.
Add fluid, if necessary, refer to LO
10-3930-643-12.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-159
TM 10-3930-643-34
HYDRAULIC TROUBLESHOOTING AND MAINTENANCE.
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 1 of 10)
This task covers:
a. Removal
b. Disassembly
c. Cleaning/Inspection d. Assembly
f. Testing
e. Installation
INITIAL SETUP
Tools
Shop Equipment, Automotive
Maintenance and Repair:
Organizational Maintenance,
Common No. 1, Less Power
NSN 4910-00-754-0654
Shop Equipment, Automotive
Maintenance and Repair:
Organizational Maintenance,
Common No. 2, Less Power
NSN 4910-00-754-0650
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Hoist and sling
1-7/8" socket and socket
wrench handle
NSN 5120-00-169-2990
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Hydraulic fluid (App. C, Item 19)
Fine emery cloth (App. C, Item 4)
Preformed packing (4)
Seal (3)
Wiper
Strip
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-10
Go to sheet 2
12-160
Condition Description
Hydraulic pressure vented.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 2 of 10)
REMOVAL
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation. Cap all hose ends
to prevent contamination.
1.
Using a 7/8" open end wrench,
disconnect hose assembly (1) and
union (2) from cylinder assembly (11)
from vehicle carriage assembly.
2.
Using a scribe, remove and discard
preformed packing (3).
3.
Using a 7/8" open end wrench,
disconnect hose assembly (4) and
elbow (5) from cylinder assembly
(11).
4.
Using a scribe, remove and discard
preformed packing (6).
5.
Using a hammer, 3/4" socket and
socket wrench handle, remove two
bolts (7), washers (8) and anchors
(9).
Go to sheet 3
12-161
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 3 of 10)
REMOVAL
6.
Attach hoist and sling to barrel (13)
on cylinder assembly (11).
Remove
slack from sling.
7.
Using a hammer and wooden dowel,
remove two pins (10).
Drive pins
(10) out, using care not to damage
pins (10) or fittings (25).
8.
Using a hoist and sling, remove
cylinder assembly (11) from mounting
brackets. For convenience, lower
cylinder assembly (11) onto suitable
repair stand or work bench with
padding.
9.
Remove hoist and sling.
DISASSEMBLY
10.
Using a strap wrench, remove collar
(12) from barrel (13) from cylinder
assembly (11).
NOTE
Observe positioning of seals,
wipers and packings when removing
them. Record positioning, as
necessary, for proper assembly.
11.
Using a rubber mallet, remove items
14 thru 24 as an assembly from barrel
(13).
Go to sheet 4
12-162
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 4 of 10)
DISASSEMBLY (cont)
12.
Using a 1-7/8" socket, socket wrench
handle and vise, remove nut (14).
13.
Remove items 15 thru 19 as an
assembly.
14.
Using a scribe, remove and discard
seal (16) and preformed packing (17).
15.
Remove and discard strip (18) and
preformed packing (19).
16.
Remove items 20 thru 23 as an
assembly.
17.
Remove gland (20) from rod (24).
18.
Remove and discard wiper (21) and
seals (22 and 23).
19.
Using a 5/16” box and open end
wrench, remove two fittings (25) from
pin (10).
GO to sheet 5
12-163
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 5 of 10)
CLEANING/INSPECTION
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
20.
GO
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
to sheet 6
12-164
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 6 of 10)
CLEANING/INSPECTION (cont)
21.
Inspect rod (24) and inside of barrel
(13) for scratches, grooves, burrs,
or other damage which might cause a
malfunction. Small burrs and shallow
scratches can be polished out with
fine emery cloth and oil.
22.
Inspect piston (15), gland (20), rod
(24) and barrel (13) and replace
items which cannot be repaired and
items which have scoring, scratches,
burrs, or other damage which might
Threads on
cause a malfunction.
barrel (13) and rod (24) must not be
Be sure residues of
damaged.
abrasives and foreign matter have
been cleaned away prior to assembly.
23.
Inspect all other parts. Refer to
paragraph 2-9.
Go to page 7
12-165
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 7 of 10)
ASSEMBLY
24.
Coat rod (24) and inside of barrel
(13) with clean hydraulic fluid.
25.
Coat new seals (23 and 22) and new
wiper (21) with clean hydraulic
fluid.
26.
Install new seals (23 and 22) on
gland (20) using suitable seal
installer, if necessary.
Lip on
properly installed seal (22) faces
inside cylinder assembly (11). Wiper
(21) will be placed, as shown.
27.
Dip gland (20) in clean hydraulic
fluid.
28.
Install gland (20) on rod (24).
29.
Coat new preformed packing (17), new
seal (16), new preformed packing (19)
and new strip (18) with clean
hydraulic fluid.
30.
Install new preformed packing (17),
new seal (16), new preformed packing
(19) and new strip (18) on piston
(15), using suitable seal expander,
if necessary.
31.
Dip items 15 thru 19 as an assembly
in clean hydraulic fluid and install
on rod (24).
Go to sheet 8
12-166
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 8 of 10)
ASSEMBLY (cont)
32.
Dip items 12 and 14 thru 24 as an
assembly in clean hydraulic fluid.
33.
Install items 14 thru 24 as an
assembly in barrel (13).
34.
Using a strap wrench, install collar
(12) on barrel (13). Tighten until
snug.
INSTALLATION
35.
Attach hoist and sling to cylinder
assembly (11). Remove slack from
sling.
36.
Position cylinder assembly (11) for
position hydraulic
installation.
fluid ports as observed during
REMOVAL.
37. Using a large rubber mallet, install
two pins (10).
38.
Using a 3/4" socket and socket wrench
handle, install two anchors (9),
washers (8) and bolts (7).
39.
Remove hoist and sling from cylinder
assembly (11).
12-167
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 9 of 10)
INSTALLATION
40.
Using a 7/16" box and open end
wrench, install two fittings (25).
41.
Install new preformed packing (6).
42.
Using a 7/8" open end wrench, install
elbow (5) and hose assembly (4) to
cylinder assembly (11).
43.
Install new preformed packing (3).
44.
Install union (2) and hose assembly
(1) to cylinder assembly (11).
45.
Lubricate two fittings (25) until
clean grease appears.
Use multipurpose grease where temperature
allows, if necessary, refer to
LO 10-3930-643-12.
46.
Check hydraulic fluid level.
Add
hydraulic fluid, if necessary, refer
to LO 10-3930-643-12.
Go to sheet 10
12-168
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-18.
Oscillation Cylinder (S/N 2001 and above). (Sheet 10 of 10)
TESTING
Only a qualified operator may
perform the next procedure.
All
other personnel must clear the
immediate area. Failure to follow
this procedure could result in
SERIOUS INJURY or DEATH. If
injured, obtain medical aid
immediately.
47.
Start engine.
48. Operate oscillation cylinder slowly.
49.
Move oscillation cylinder through at
least five full movements of travel
to bleed air from system.
50.
Check for binding in hydraulic
cylinder operation.
51.
Stop engine.
52.
Inspect hydraulic fluid hoses,
fittings and cylinder assemblies for
leaks.
53. Check hydraulic fluid level again.
Add fluid, if necessary, refer to
LO 10-3930-643-12.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-169
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-19.
Hydraulic Reservoir and Filter. (Sheet 1 of 11)
This task covers:
b. Disassembly
a. Removal
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling
3/4-10 Eyebolt
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Preformed packing (5)
Rivet (6)
Gasket
References
TB 43-0212
TM 9-237
Torques
Bolts (33) to 80 lb-ft.
Bolts (36) to 15 to 20 lb-ft.
Indicator (47) to 250 to 300 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Go to sheet 2
12-170
Condition Description
Hydraulic reservoir drained.
Battery removed.
Slave receptacle and mounting removed.
Hydraulic reservoir relief valve
removed.
Hydraulic filter removed.
Air cleaner and mounting removed.
Master disconnect switch removed.
Fenders removed.
Ether start valve and mounting removed.
Transmission sampling valve removed.
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-19.
Hydraulic Reservoir and Filter. (Sheet 2 of 11)
REMOVAL
NOTE
The following is a difference
between M10A Forklift models. The
removal/installation procedure is
identical.
1.
Using a 9/16” socket and socket
wrench handle, remove four bolts (1),
washers (2) and plate (3) from left
side of hydraulic reservoir (35) on
vehicles S/N 2001 and above.
NOTE
All wire must be tagged when
removed from connector. Indicate
whether wire is connected to pintype or socket-type connector.
2.
Using slip joint pliers, disconnect
harness assembly (4) at connector.
3.
Using a cross tip screwdriver, remove
four screws (5) and lock washers (6).
4.
Disconnect harness assembly (7) at
connector.
Go to sheet 3
12-171
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-19.
Hydraulic Reservoir and Filter. (Sheet 3 of 11)
REMOVAL
5.
Using a 1-1/4" open end wrench.
remove indicator (8) and adapter (9)
from rear of hydraulic reservoir
(35).
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
6.
Using a 9/16" open end wrench,
disconnect tube assembly (10).
7.
Remove adapter (11).
8.
Using a 3/4" socket and socket wrench
handle, remove four locknuts (12),
bolts (13), two flanges (14) and
disconnect tube assemblies (15 and
16) from front bottom of hydraulic
reservoir (35).
9.
Using a 9/16" socket. socket wrench
handle and open end wrench, remove
nut (17), clamps (18 and 19) and bolt
(20) from right side of hydraulic
reservoir (35). Move breather tubes
to one side.
Go to sheet 4
12-172
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-19.
Hydraulic Reservoir and Filter. (Sheet 4 of 11)
REMOVAL (cont)
10.
Using a 9/16" socket and socket
wrench handle or 1/2" open end
wrench, remove four bolts (21) and
two flange halves (22) from right
side of hydraulic reservoir (35)
11.
Disconnect hose assembly (23)
12.
Remove and discard preformed packing
(24).
13.
Using a 5/8" socket and socket wrench
handle, remove four bolts (25) and
two flange halves (26).
14.
Disconnect hose assembly (27) and
remove and discard preformed packing
(28).
15.
Using a 5/8" socket and socket wrench
handle, remove four bolts (29) from
hose assembly (30) on top of hydraulic
pump.
16.
Disconnect hose assembly (30).
17.
Disconnect hose assembly from
hydraulic control valve, refer to
TM 20-3930-643-20.
18.
Disconnect hose assembly (30a) from
shut off valve on rear of engine.
Go to sheet 5
12-173
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-19.
Hydraulic Reservoir and Filter. (Sheet 5 of 11)
REMOVAL
Weight of hydraulic reservoir
is approximately 300 pounds.
Use adequate hoist and sling for
lifting. Failure to follow this
procedure may cause damage to
equipment or INJURY. If you are
injured, seek medical aid
immediately.
19.
Using a 14" adjustable wrench,
install 3/4-10 NC eyebolt in boss on
top of hydraulic reservoir (35).
Attach hoist and sling.
20.
Using a 3/4" socket, socket wrench
handle and a 3/4" box and open end
wrench, remove four nuts (31),
washers (32), bolts (33), washers
(34) and hydraulic reservoir (35).
21.
Remove hoist and sling.
DISASSEMBLY
22.
Using a 9/16" socket and socket
wrench handle, remove six bolts (36),
washers (37), items 39 thru 43 as an
assembly and preformed packing (38)
from hydraulic reservoir (35).
Discard preformed packing (38).
23.
Using snap ring pliers, remove cap
(39), gasket (40), retaining ring
(41) and filter (42) from filler neck
(43). Discard gasket (40).
Go to sheet 6
12-174
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (cont)
12-19.
Hydraulic Reservoir and Filter. (Sheet 6 of 11)
DISASSEMBLY (cont)
24.
Using a 14" adjustable wrench, remove
indicator (44) and preformed packing
(45) from hydraulic reservoir (35).
Discard preformed packing (45).
25.
Remove plug (46), plug cock (47),
adapter (48) and preformed packing
(49). Discard preformed packing
(49).
26.
Remove 16 key washers (50) and plates
(51 thru 54).
27.
Using a drill, remove four rivets
(56), panel (57) and spring (58) from
panel (55). Discard four rivets
(56) . Panel (55) is removed during
battery removal procedure.
28.
Remove two rivets (59) and latch (60
from panel (57). Discard two rivets
(59).
29.
Using a 5/8" and 1/2" socket and
socket wrench, remove bolts (61 and
62), tube assembly (15) and preformed
packing (63) from filter head
assembly (71). Discard preformed
packing (63).
30•
Using an 11/16" socket, socket
handle and an open end wrench,
two locknuts (64), bolts (65),
(66) and couplings (67 and 68)
tube assembly (15).
31•
Using a 1/2" socket and socket wrench
handle, remove four bolts (69),
washers (70), filter head assembly
(71) and preformed packing (72) from
hydraulic reservoir (35). Discard
preformed packing (72).
32.
Using a 1/4" socket and socket wrench
handle, remove two screws (73) and
filter indicator (74) from filter
head assembly (71).
wrench
remove
link
from
Go to sheet 7
12-175
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-19.
Hydraulic Reservoir and Filter. (Sheet 7 of 11)
CLEANING/INSPECTION
33.
Purge and clean hydraulic reservoir
(35). If welding is required, use
steel. Purging and cleaning must be
performed according to purge section
of TB 43-0212.
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
34.
Clean all other parts except plates
(51 thru 54) with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Inspect hydraulic reservoir (35). If
leaks are evident and welding is
required, refer to TM 9-237, Welding
Theory and Application.
36. Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 8
35.
12-176
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE. (Cont)
12-19.
Hydraulic Reservoir and Filter. (Sheet 8 of 11)
ASSEMBLY (Cont)
37.
Using a 1/4” socket and socket wrench
handle, install filter indicator (74)
and two screws (73) on filter head
assembly (71).
38.
Using a 1/2” socket and socket wrench
handle, install new preformed packing
(72), filter head assembly (71), four
washers (70) and bolts (69) on
hydraulic reservoir.
39.
Using an 11/16” socket, socket wrench
handle and an open end wrench,
install couplings (68 and 67), link
(66), two bolts (65) and locknuts
(64) on tube assembly (15).
40.
Using a 5/8” and 1/2” socket and
socket wrench handle, install new
preformed packing (63), tube assembly
(15) bolts (62 and 61) on filter head
assembly (71).
41.
Using an air hammer and backing bar,
install latch (60) and two new rivets
(59 to panel.
42.
Install spring (58), panel (57) and
four new rivets (56) to panel (55).
43.
Install plates (54 thru 51) and 16
key washers (50 to hydraulic
reservoir (35).
44.
Using a 14” adjustable wrench,
install new preformed packing (49),
adapter (48), plug cock (47) and plug
(46).
45.
Using a 1-1/4” socket and torque
wrench, install new preformed packing
Tighten
(450) and indicator (44).
indicator (44) to 250 to 300 lb-ft.
Go to sheet 9
12-177
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
Hydraulic Reservoir and Filter. (Sheet 9 of 11)
12-19.
INSTALLATION
46.
Using snap ring pliers, install
filter (42), retaining ring (41), new
gasket (40) and cap (39) to filter
neck (43).
47.
Using a 9/16” socket and torque
wrench, install new preformed packing
(38), items 43 thru 39 as an
assembly, six washers (37) and bolts
(36) on hydraulic reservoir (35).
Tighten bolts (36) to 15 to 20 lb-ft.
48.
Using a 14” adjustable wrench,
install 3/4-10 NC eyebolt in boss on
top of hydraulic reservoir (35).
Attach hoist and sling.
49.
Position on vehicle.
50.
Using a 3/4” socket, socket wrench
handle and a 3/4” box and open end
wrench, install hydraulic reservoir
(35), four washers (34), bolts (33),
washers (32) and nuts (31). Do not
tighten bolts (33).
51.
Using a hoist and sling, position
engine top access cover on vehicle.
52.
Aline mounting bolt holes on
hydraulic reservoir (35) and engine
top access cover.
53.
Tighten bolts (33) to 80 lb-ft.
54.
Remove access cover and hoist and
sling.
Go to sheet 10
12-178
TM 10-3930-643-34
HYDRAULIC SYSTEM TROUBLESHOOTING AND MAINTENANCE.
12-19.
Hydraulic Reservoir and Filter. (Sheet 11 of 11)
INSTALLATION
63.
Using a 9/16” socket, socket wrench
handle and a 9/16” box and open end
wrench, install bolt (20), clamps (19
and 18) and nut (17) to right side of
hydraulic reservoir (35).
64.
Using a 3/4” socket and socket wrench
handle, connect tube assemblies (16
and 15), and install two flanges
(14), four bolts (13) and locknuts
(12) to front bottom of hydraulic
reservoir.
65.
Using a 9/16” open end wrench,
install adapter (11) to rear of
hydraulic reservoir (35).
66.
Connect tube assembly (10).
67.
Using a 1-1/4” open end wrench,
install adapter (9) and indicator
(8).
68.
Connect harness
connector.
69.
Using a cross tip screwdriver,
install four lock washers (6) and
screws (5) to left side of hydraulic
reservoir (35) .
70.
Using slip joint pliers, connect
harness assembly (4) at connector.
71.
Using a 9/16” socket and socket
wrench handle, install plate (3),
four washers (2) and bolts (1) in
vehicles S/N 2001 and above.
assembly (7) at
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
12-180
TM 10-3930-643-34
CHAPTER 13
GENERAL SUPPORT ENGINE, FUEL, EXHAUST
AND COOLING MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized general support level
maintenance procedures on the M10A Forklift engine.
INDEX
Title
Front Cover
Cylinder Head Assembly with Valves
Crankcase and Cylinder Sleeves
Crankshaft
Crankshaft Main Bearings
Rear Oil Seal
Flywheel and Housing
Pistons, Connecting Rods and
Connecting Rod Bearings
Camshaft and Timing Gears
Oil Pump Inlet Tube
Engine Oil Pump
Fuel Injectors
Fuel Solenoid
Turbocharger
Fuel Tank
Radiator
Paragraph
Page
13-1
13-2
13-3
13-4
13-5
13-6
13-7
13-2
13-8
13-14
13-25
13-34
13-38
13-44
13-8
13-9
13-10
13-11
13-12
13-13
13-14
13-15
13-16
13-49
13-61
13-69
13-72
13-77
13-81
13-86
13-96
13-97
13-1
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-1. Front Cover. (Sheet 1 of 6)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Gasket (4)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
5/16-18 bolt with heads
removed (2)
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Alternator and mounting removed.
Water pump removed.
Air compressor base and mounting
removed.
Paragraph 4-14
Fuel injection pump, cover plate,
adapter and drive gears removed.
Paragraph 13-11
Engine oil pump removed.
Go to sheet 2
13-2
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-1. Front Cover. (Sheet 2 of 6)
REMOVAL
1.
Remove crankshaft pulley. Refer to
paragraph 13-4.
2.
Using a flat tip screwdriver, loosen
two clamps (1) at front of engine.
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
3*
Remove hose (2).
4.
Using a flat tip screwdriver, loosen
clamp (3).
5.
Using 9/16” socket and socket wrench
handle, remove three bolts (4),
washers (5), elbow (6) and gasket
(7). Discard gasket (7). Remove all
gasket material from
mounting
surfaces.
6.
Using 1/2” socket and socket wrench
handle, remove six bolts (8), washers
(9), two bolts (10), washers (11),
bolts (12), washers (13), four bolts
(14) and washers (15).
7.
Using 3/4” socket and socket wrench
handle, remove two bolts (16) and
washers (17) from bottom, rear of
engine.
Go to sheet 3
13-3
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-1.
Front Cover. (Sheet 3 of 6)
REMOVAL (cont)
8.
Using 9/16” socket and socket wrench
handle, remove four bolts (18) and
washers (19).
9.
Using a gasket scraper, remove cover
(20) and gaskets (21,22 and 23) from
front of engine.
Discard gaskets
(21,22 and 23).
10.
Using a magnet, remove two balls (24)
from cover (20).
11.
Using slip joint pliers, remove
indicator (25).
12.
Using a 3/8” box and open end wrench,
remove two plugs (26).
13.
Using a flat brass punch and hammer,
remove three cups (27).
Go to sheet 4
13-4
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-1.
Front Cover. (Sheet 4 of 6)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
If
with eyes, skin or clothing.
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
14.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
15.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
13-5
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-1.
Front Cover. (Sheet 5 of 6)
INSTALLATION
16.
Using a flat brass punch and hammer,
install three cups (27) in cover
(20).
17.
Using a 3/8” box and open end wrench,
install two plugs (26).
18.
Using flat brass punch and hammer,
install indicator (25).
19.
Install two balls (24).
20.
Position new gasket (23) in rear of
engine.
21.
Using 1/2” socket and socket wrench
handle, install two 5/16-18” bolts
with heads removed on oil pick-up
tube and position new gasket (23) on
bolts . New gasket (23) must be cut
to fit section of oil pan.
22.
Position new gaskets (22 and 21) and
cover (20).
23.
Position guide bolts in oil pick-up
tube alining holes in cover (20).
24.
Using a 9/16” socket and socket
wrench handle, install four washers
(19) and bolts (18) in bottom, rear
of engine.
Go to sheet 6
13-6
TN 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-1.
Front Cover. (Sheet 6 of 6)
INSTALLATION
25.
Using a 1/2” socket and socket wrench
handle, remove guide bolts.
26.
Install two washers (17) and bolts
(16).
27. Install four washers (15). bolts
(14), two washers (13), bolts (12),
washers (11), bolts (10), six washers
(9) and bolts (8) in rear of engine.
28.
Using a 9/16” socket and socket
wrench handle, install new gasket
(7), elbow (6), three washers (5) and
bolts (4).
29.
Using a flat tip screwdriver, tighten
clamp (3).
30.
Install hose (2).
31. Using a flat tip screwdriver, tighten
two clamps (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-7
TN 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-2.
Cylinder Head Assembly with Valves. (Sheet 1 of 6)
This task covers:
a. Disassembly
b.
Cleaning/Inspection/Assembly
INITIAL SETUP
Tools
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, Less Power
NSN 3470-00-754-0708
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, MAP only
NSN 3470-00-919-0068
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Loctite 277 (App. C, Item 16)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 4-4
Go to sheet 2
13-8
Condition Description
Cylinder head and valve assemblies
removed.
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-2.
Cylinder Head Assembly with Valves. (Sheet 2 of 6)
DISASSEMBLY
1.
Inspect 12 guides (1) in cylinder
head (2). Replace if burned, cracked
Ream guides
or excessively worn.
with a .374 reamer to remove burrs or
correct mushrooming. I.D. of valve
guides must not be more than 0.3750
inches.
2.
Measure I.D. of 12 valve guides (1)
at top, middle and bottom with a ball
gage. Replace valve guides only if
worn beyond limits.
3.
Using valve guide remover tool,
remove any worn valve guides (1).
Go to sheet 3
13-9
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cent)
13-2.
Cylinder Head Assembly with Valves. (Sheet 3 of 6)
CLEANING/INSPECTION/ASSEMBLY
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
4.
Clean counterbore with cleaning
solvent P-D-680 and nylon brush. Dry
thoroughly with compressed air.
Refer to paragraph 2-8.
Go to sheet 4
13-10
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-2.
Cylinder Head Assembly with Valves. (Sheet 4 of 6)
CLEANING/INSPECTION/ASSEMBLY
5.
Lubricate outside diameter of new
valve guides (1) with lubricating
oil.
NOTE
The 30 degree chamfer at the top
of the valve guide is intended to
allow excess oil to drain away
from the top. Inverting the valve
guides can lead to excessive oil
consumption.
6.
Using valve guide installer tool,
install new valve guides (1) with
threaded portions down.
7.
Using a dial indicator, measure
height from top deck of cylinder head
(2) to top of valve guide (l).
Clearance for valve guides (1) must
be between 1.207 and 1.227 inches for
intake and valve guides (1) must be
between 1.287 and 1.307 inches for
exhaust.
8.
Inspect six seats (3) and inserts
(4), refer to paragraph 4-4. Replace
if valve guide (1) does not seat
properly after being resurfaced.
9.
Using a slide hammer and expanding
screw, with pre-cup puller (exhaust),
remove damaged seats (3) or inserts
(4).
Go to sheet 5
13-11
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-2. Cylinder Head Assembly with Valves. (Sheet 5 of 6)
CLEANING/INSPECTION/ASSEMBLY
(cont)
10.
Using a feeler gage, install six new
standard size seats (3) and inserts
(4) with insert driver tool and an
arbor press. Exert an even pressure
of 500 lb-ft for five seconds.
Proper depth of seat (3) and insert
(4) counterbore is between 0.509 and
0.511 inches for intake and 0.455 and
0.459 inches for exhaust.
11.
Inspect for proper valve seat (3)
mating. If surfaces do not mate
correctly, oversize inserts (4) and
seats (3) must be installed.
NOTE
The following procedure must be
followed before installing 0.15 in
oversize seats and inserts.
12.
Measure bore of valve seat and insert
counterbores to determine if cylinder
head (2) must be machined. If
machining is necessary, send cylinder
head (2) to depot maintenance. Bores
must be within 2.011 and 2.012 inches
for intake valves and 1.639 and 1.640
inches for exhaust valves.
Co to sheet 6
13-12
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-2.
Cylinder Head Assembly with Valves. (Sheet 6 of 6)
CLEANING/INSPECTION/ASSEMBLY
13.
Chill new 0.15 inch oversize inserts
(4) and seats (3) and insert driver
tool in dry ice for 30 minutes before
installing. Chilling will prevent
metal scraping of counter- bore.
This will ensure maximum mating of
surfaces.
14.
Coat six inserts (4) and seat
with Loctite 277.
15.
Aline six inserts (4) and seats
to avoid cocking.
16.
Using a insert driver tool and arbor
press, install new inserts (4) and
seats (3).
Exert an even pressure
of 500 lb-ft for five seconds.
17.
Inspect all six inserts (4) and seats
(3) to ensure that they are properly
seated.
18.
Inspect all other parts. Refer to
paragraph 2-9.
(3)
(3)
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-13
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-3.
Crankcase and Cylinder Sleeves. (Sheet 1 of 11)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, Less Power
NSN 3470-00-754-0708
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, MAP only
NSN 3470-00-919-0068
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Engine oil SAE 30 (App. C, Item 19)
Permatex #2 (App. C, Item 26)
Preformed packing (18)
Gasket
Shim (6)
Plug (9)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 4-7
Condition Description
Oil pan removed.
Paragraph 13-4
Crankshaft removed.
Paragraph 13-6
Rear oil seal removed.
Paragraph 13-8
Pistons, connecting rods and connecting
rod bearings removed.
Paragraph 13-9
Camshaft and timing gears removed.
Go to sheet 2
13-14
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-3.
Crankcase and Cylinder Sleeves. (Sheet 2 of 11)
DISASSEMBLY
1.
Using slip joint pliers, remove
restrictor (1).
2.
Remove four pins (2).
3.
Using a magnet, remove ball bearing
(3).
4.
Using a punch and hammer, punch hole
in three plugs (4) and remove.
5.
Remove and discard nine plugs (5).
6.
Using a 3/16” socket and socket
wrench handle, remove five plugs (6).
7.
Using a 9/16” socket and socket
wrench handle, remove plugs (7 and
8).
8.
Using a 1/2” socket and socket wrench
handle, remove two bolts (9), lock
washers (10), washers (11), cover
(12), gasket (13) and baffle (14).
Discard gasket (13).
9.
Using slip joint pliers, remove two.
dowels (15).
Go to sheet 3
13-15
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-3.
Crankcase and Cylinder Sleeves. (Sheet 3 of 11 )
DISASSEMBLY (cont)
NOTE
Make sure that each sleeve is
marked with the number of the
cylinder from which it was
removed.
Sleeves must be
installed into their original
cylinders.
10.
Using a universal wet sleeve puller,
remove six sleeves (16). If
necessary, thread a slide hammer into
the forcing screw to aid removal.
11.
Using a flat brass punch and hammer,
remove and discard six shims (17).
12.
Using a small flat tip screwdriver,
remove and discard 18 preformed
packings (18) from six sleeves (16).
Go to sheet 4
13-16
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-3.
Crankcase and Cylinder Sleeves. (Sheet 4 of 11)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
air
solvent,
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
13.
Clean six sleeves (16) with a clean
cloth moistened with mild detergent
and water solution and a non Make sure that
abrasive brush.
grooves are clean. Dry thoroughly
with compressed air.
Go to sheet 5
13-17
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-3 l
Crankcase and Cylinder Sleeves. (Sheet 5 of 11)
CLEANING/INSPECTION (cont)
14.
Clean crankcase and seven caps (3)
with cleaning solvent P-D-680.
Remove all carbon and mineral
deposits. Clean all passages, ports
and holes.
Dry thoroughly with
compressed air. If cleaning solvent
P-D-680 fails to remove scale, send
crankcase to Depot Maintenance.
15.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
Do not resurface the crankcase.
Damage and defects not correctable
indicates
by light filing
replacement is needed.
Damaged
crankcase must be sent to Depot
Maintenance to
determine
salvageability.
16.
Check deck of crankcase for “pulled”
thread holes. Lightly file area to
restore flatness.
17.
Inspect threaded holes. Threads may
be retapped or repaired with
heli-coils, if necessary.
Go to sheet 6
13-18
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-3.
Crankcase and Cylinder Sleeves. (Sheet 6 of 11)
CLEANING/INSPECTION
18.
Inspect lower cylinder sleeve pilot
bore for erosion. If water leakage
is evident, replace crankcase. Send
Depot
damaged crankcase to
Maintenance.
19.
Inspect for coolant or oil leaks in
crankcase. If leaks are found,
notify Depot Maintenance.
20.
Inspect sleeve counterbore for burrs
or fractures.
If repair is
indicated, notify Depot Maintenance.
21.
Inspect twelve oil jets for dirt and
Clean and open, if
blockage.
necessary.
22.
Inspect jets for cracks and chips.
Replace damaged jets.
23.
Remove only if jets are damaged using
pilot driver.
24.
Install new jets with pilot driver.
25.
Jets
Check surface recess of jets.
must be recessed 1/8 inch below
surface.
Go to sheet 7
13-19
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
Crankcase and Cylinder Sleeves. (Sheet 7 of 11)
13-3.
CLEANING/INSPECTION (cont)
NOTE
Do not hone cylinder sleeves. If
excessively damaged, they must be
replaced.
26.
Inspect six sleeves (16) for
scuffing, scoring, scratches and
gouges. Replace if necessary.
27.
Using an inside micrometer or a bore
gage, measure I.D. of sleeve from the
top to bottom of piston travel.
Measure the preformed packing area.
Take all measurements at right
angles. Replace sleeve if out of
not
meet
does
round or
specifications. Maximum permissible
diameter of sleeve wear at top of
ring travel is 0.004 inch.
NOTE
The following procedure is for
Use
deglazing cylinder sleeve.
the procedure if new piston rings
are being used with new cylinder
sleeves. Do not deglaze new
sleeves.
28.
Using a deglazing tool and drill,
deglaze sleeve to provide a good
seating surface for rings.
29.
Inspect all other parts. Refer to
paragraph 2-9.
Co to sheet 8
13-20
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-3.
Crankcase and Cylinder Sleeves. (Sheet 8 of 11)
ASSEMBLY
30.
Install six sleeves (16) in engine
crankcase without 18 new packings
(18).
310
Clamp down one sleeve (16) using
three holding adapters, bolts and
hardened washers. Space the bolts to
obtain uniform pressure on sleeve.
32.
Place a dial indicator with block
across cylinder sleeve.
33.
With dial indicator set on the flange
of the sleeve, adjust indicator to
zero.
34.
Move indicator block until pointer
Record
drops to crankcase deck.
reading.
35.
If sleeve is below deck, rest
indicator pointer on deck and set
indicator on zero.
36.
Move the indicator block until the
pointer drops to he sleeve flange.
Take a reading.
Go to sheet 9
13-21
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-3.
Crankcase and Cylinder Sleeves. (Sheet 9 of 11)
ASSEMBLY (cont)
NOTE
Shims are available in 0.002 inch,
0.004 inch, 0.010 inch, 0.020 inch
and 0.032 inch thickness.
37.
Take readings at three or four points
around the sleeve. Use an average to
determine which shims, if any, are
needed. Protrusion must be within
0.002 to 0.005 inch.
38.
Remove three bolts, hardened washers
and holding adapters.
39.
Remove one sleeve (16).
40.
Repeat previous steps for each of six
sleeves (16).
Go to sheet 10
13-22
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-3.
Crankcase and Cylinder Sleeves. (Sheet 10 of 11)
ASSEMBLY
NOTE
Preformed packings must be
installed in the following order:
bottom, center and top.
41.
Coat 18 new preformed packings (18)
in engine crankcase with clean engine
oil and install 18 new preformed
packings (18) on six sleeves (16).
42.
Install new shims (17) in cylinder
counterbores.
43.
Coat sealing surfaces with clean
engine oil. Using a hydraulic press,
install six sleeves (16) into bores.
Make sure that sleeves are installed
into same cylinders from which they
were removed.
44.
Check sleeve protrusion again. Make
additional adjustments, if necessary.
45.
Using a flat brass pump, install two
dowels (15).
46.
Coat threads of two bolts (9) with
permatex #2. Using a 1/2” socket and
socket wrench handle, install baffle
(14), new gasket (13), cover (12),
two washers (11), lock washers (10)
and bolts (9).
Go to sheet 11
13-23
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-3.
Crankcase and Cylinder Sleeves. (Sheet 11 of 11)
ASSEMBLY (cont)
47.
Coat threads of plugs (8, 7 and 6)
with Permatex #2. Using 7/16” and
3/16” sockets and socket wrench
handle, install plugs (8 and 7) and
five plugs (6).
48.
Using a flat brass punch and hammer,
install nine new plugs (5).
49.
Using a flat brass punch and hammer,
install three plugs (4).
50.
Install ball bearing (3).
51.
Using a flat brass punch and hammer,
install four pins (2).
52.
Using a flat brass punch and hammer,
install restrictor (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-24
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-4.
Crankshaft. (Sheet 1 of 9)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, Less Power
NSN 3470-00-754-0708
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, MAP only
NSN 3470-00-919-0068
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5 )
Clean cloth (App. C, Item 24)
Small tag (App. C, Item 28)
Engine oil (App. C, Item 19)
Fel-Pro C-670 (App. C, Item 7)
Wire (0.010 inch)
Sleeve
Wood block
Nylon brush
Gear (2)
Pin
Torques
Bolts (1, 3 and 6) to 115 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 4-10
Condition Description
Oil pump inlet tube removed.
Paragraph 13-1
Front cover removed.
Paragraph 13-7
Flywheel and housing removed.
Go to sheet 2
13-25
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-4.
Crankshaft. (Sheet 2 of 9)
REMOVAL
NOTE
Bearing caps are not interchangeable within the crankcase
or with other crankcases.
If a bearing has spun, the
entire engine must be
disassembled and cleaned.
Immediately tag all bearing caps
upon removal to aid in
installation.
1.
Using a 13/16” socket and socket
wrench handle, remove 12 bolts (1),
link (2) and six bearing caps (3)
from bottom of engine crankcase.
2.
Using a 5/8” socket and socket wrench
handle, remove 12 bolts (4) and six
connecting bearing caps (5), refer to
paragraph 13-8.
3.
Using a 13/16” socket and socket
wrench handle, remove two bolts
(6)
and thrust bearing cap (7).
Go to sheet 3
13-26
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-4. Crankshaft. (Sheet 3 of 9)
Weight of crankshaft is approximately 375 pounds. Use adequate
hoist and sling to lift
crankshaft. Failure to follow
this procedure could result in
SEVERE INJURY.
Two five foot nylon slings,
attached around two journals at
equal distances from the end of
the crankshaft is the preferred
method of lifting. If another
method is used, protect crankshaft
surface from lifting device with
plastic tubing or soft brass.
Failure to follow this procedure
could result in damage to
crankshaft.
4.
Attach hoist and slings around
journals of crankshaft (8) and
remove.
Go to sheet 4
13-27
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-4.
Crankshaft. (Sheet 4 of 9)
REMOVAL (cont)
5.
Place crankshaft (8) on wood blocks
to prevent damage to journals.
6.
Remove hoist and sling.
7.
Support nose of crankshaft (8) with
wood blocks.
8.
Using a chisel and hammer, separate
and remove gears (9 and 10). Discard
gears (9 and 10).
9.
Using a flat brass punch and hammer.
remove pin (11) from crankshaft (8).
Discard pin (11).
Exercise care when removing wear
sleeve. Do not damage crankshaft
surface.
10.
Using a muffler tool, remove wear
sleeve (12) from crankshaft (8).
Discard wear sleeve (12).
Go to sheet 5
13-28
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-4.
Crankshaft. (Sheet 5 of 9)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
air
solvent,
get
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
11.
Wash crankshaft (8) with cleaning
solvent P-D-680. Use nylon brush to
remove deposits and sludge from
internal oil passages.
12.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 6
13-29
TN 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-4.
Crankshaft. (Sheet 6 of 9)
CLEANING/INSPECTION (cont)
NOTE
If crankshaft or connecting rod
journals have been overheated or a
bearing has spun, crankshaft must
be magnafluxed.
13.
Inspect main journals of crankshaft
(8) for scoring.
14.
Using a micrometer, measure diameter
of each crankshaft (8) journal in two
or three places. Journal diameter
should be 3.3742 to 3.3755 inches.
15.
Using a micrometer, measure diameter
of each connecting rod journal in two
or three places with micrometer.
Journal diameter should be 2.9977 to
2.9990 inches.
16.
Using a sclerometer, measure hardness
in at least three locations on each
crankshaft (8) and connecting rod
journal. Minimum hardness is -45 Rc.
17.
Replace crankshaft (8) if journals
are scored or if test results are
outside acceptable limits.
18.
Inspect crankshaft (8) for sludge
deposits or other obstructions in oil
jet holes in each journal.
19.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 7
13-30
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-4.
Crankshaft. (Sheet 7 of 9)
INSTALLATION
NOTE
Pin must protrude not more than
0.070 inch (1.78 mm) from
crankshaft, as shown.
20.
Press a new pin (11) into crankshaft
(8).
21.
Heat new gears (10 and 9) in an oil
bath to 400 degrees F.
22.
Using heat resistant gloves to handle
the gear, remove drive spline gear
(10) from oil bath, aline notch on
rear of gear (10) with pin (11) in
crankshaft (8) and slide gear (10)
onto crankshaft (8) until it seats
against crankshaft (8) shoulder.
23.
Using heat resistant gloves to handle
gear (9), remove sector gear (9) from
oil bath and install onto crankshaft
(8) until it contacts gear (10).
24.
Allow gears (10 and 9) to cool until
they are securely fitted to
crankshaft (8).
25.
Attach hoist and sling around
journals of crankshaft (8).
Go to sheet 8
13-31
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-4.
Crankshaft. (Sheet 8 of 9)
INSTALLATION (cont)
NOTE
If bearings have been removed,
insure that new bearings have been
installed before
installing
crankshaft, refer to paragraphs
13-5 and 13-9. Lubricate bearing
with Fel-Pro C-670.
26.
Place crankshaft (8) into crankcase.
27.
Remove hoist and sling.
28.
Lubricate threads of two bolts (6),
twelve bolts (4 and 1) with clean
engine oil.
29.
Install thrust bearing cap (7), two
bolts (6), six bearing caps (3), link
(2) and twelve bolts (l).
30.
After all six bearing caps (3) are
installed, tighten 12 bolts (1) and
two bolts (6) to 115 lb-ft.
31.
Install six connecting rod bearings
caps (5) and 12 bolts (4) , refer to
paragraph 13-8.
Go to sheet 9
13-32
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-4.
Crankshaft. (Sheet 9 of 9)
INSTALLATION
32.
Position contact pin of dial
indicator against end of crankshaft
(8).
Do not use a metal hammer to move
Do not contact
crankshaft.
machined surfaces of crankshaft
with a metal prybar. Failure to
follow this procedure could
result in damage to crankshaft.
33.
Using a pry bar, move crankshaft (8)
forward, then backward.
34.
Measure end play of crankshaft (8).
Maximum end play is 0.020 inch.
35.
For installation of new wear sleeve
(12), refer to paragraph 13-7.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-33
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-5.
Crankshaft Main Bearings. (Sheet 1 of 4)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2" Open end wrench
NSN 5120-00-184-8489
Micrometer
Torque wrench
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubriplate C-670 (App. C, Item 7)
Plastigage
Wire (0.040 diameter)
Bearing half (12)
Thrust bearing half (2)
Torques
Bolts of Crankshaft (5) to
115 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 13-4
Go to sheet 2
13-34
Condition Description
Crankshaft removed.
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
Crankshaft Main Bearings. (Sheet 2 of 4)
13-5.
REMOVAL
1.
Remove and discard six bearing halves
(1) from crankcase.
2.
Remove and discard thrust bearing
half (2).
3.
Remove and discard six bearing halves
(3) from six saddle caps.
4.
Remove and discard thrust bearing
half (4) from thrust bearing saddle
cap.
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
air
fresh
get
solvent,
immediately.
5.
Clean crankshaft (5) with cleaning
solvent P-D-680.
6.
Inspect crankshaft (5), crankcase
saddles and saddle caps, refer to
paragraph 13-4.
Go to sheet 3
13-35
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-5.
Crankshaft Main Bearings. (Sheet 3 of 4)
INSTALLATION
7.
Coat six new bearing halves (1) with
lubriplate. Install six new bearing
halves (1) in crankcase.
8.
Coat new thrust bearing half (2) with
lubricate and install in crankcase.
9*
Using a hoist and sling, install
crankshaft (5), refer to paragraph
13-4.
in
10.
Install six new bearing halves (3
six saddle caps.
11.
Install thrust bearing half (4) in
thrust bearing saddle cap.
12.
Position 0.010 inch thick by 1-1/2
inch long virgin lead on top of
thrust bearing journal.
13.
Install thrust bearing saddle cap and
two bolts in crankshaft (5).
14.
Using a 13/16” socket and torque
wrench, tighten bolts in crankshaft
(5) to 115 lb-ft.
15.
Using a 13/16” socket and socket
wrench handle, remove bolts.
16.
Remove thrust bearing saddle cap.
17.
Using a micrometer, measure thickness
Lead
of lead (bearing clearance).
thickness should be 0.002 to .005
inch.
GO to sheet 4
13-36
TM l0-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-5.
Crankshaft Main Bearings. (Sheet 4 of 4)
INSTALLATION
18.
Using a micrometer, check six main
bearing clearance.
NOTE
If clearances are not within
specifications, check crankshaft, saddle caps or for
foreign matter behind bearings.
Refer to paragraph 13-4.
Return M10A Forklift to original
equipment condition.
END OF TASK
13-37
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-6.
Rear Oil Seal. (Sheet 1 of 6)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5 )
Clean cloth (App. C, Item 24)
Liquid Gasket (App. C, Item 14)
Hydraulic fluid (App. C, Item 19)
Grease (App. C, Item 8)
Torques
Except for special torques shown.
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 13-7
Go to sheet 2
13-38
Condition Description
Flywheel and housing removed.
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
Rear Oil Seal. (Sheet 2 of 6)
13-6.
REMOVAL
NOTE
Be careful not to damage the seal
bore in the flywheel housing.
1.
Using a brass and hammer, split oil
seal (1) and remove from flywheel
housing (2). Discard oil seal (1).
NOTE
Be careful not to damage the
crankshaft flange when removing
the wear sleeve.
2.
Using a muffler tool and hammer, cut
wear sleeve (3) and remove from
Discard
flange of crankshaft (4).
wear sleeve (3).
Go to sheet 3
13-39
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-6.
Rear Oil Seal. (Sheet 3 of 6)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
3.
Clean rear of crankshaft and
surrounding area with cloth moistened
with cleaning solvent P-D-680.
Dry
thoroughly with compressed air.
Refer to paragraph 2-8.
4.
Inspect for burrs or foreign material
in rear of crankshaft.
5.
Inspect all other parts. Refer to
paragraph 2-9.
Go to sheet 4
13-40
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-6.
Rear Oil Seal. (Sheet 4 of 6)
INSTALLATION
Before installing sleeve and seal,
check the seal bore for chamfer.
If no chamfer is found, use a file
to break the edge of the bore.
Failure to follow this procedure
could result in damage to casing
when sleeve and seal
are
installed. Be careful not to
damage the bore while filing the
chamfer edge.
6.
Lubricate lip of new oil seal (1)
with grease.
NOTE
Seal must be installed onto side
of sleeve with chamfer on O.D. to
avoid damage to seal lip, as
shown.
7.
Assemble new oil seal (1) onto new
wear sleeve (3) by pushing new oil
seal (1) in the direction of the
arrow.
8.
Install flywheel housing (2) to
crankcase, refer to paragraph 13-7.
Go to sheet 5
13-41
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-6.
Rear Oil Seal. (Sheet 5 of 6)
INSTALLATION (cont)
NOTE
Only four bolt holes in the crankshaft will line up with the holes
in the centering plate.
9.
Attach the centering plate to the
flange of crankshaft (4) using the
DO NOT
four allen head screws.
tighten the screws at this time.
NOTE
Never remove the oil seal from the
wear sleeve during assembly.
10.
Position new wear sleeve (3) with new
oil seal (1) on centering plate and
crankshaft (4), as shown.
Tighten
the four allen head screws.
NOTE
Do not allow liquid gasket
material to come into contact with
lip of seal or O.D. of wear
sleeve.
11.
Coat I.D. of new wear sleeve (3) and
O.D. of new oil seal (1) with a thin
film of liquid gasket material.
12*
Center new wear sleeve (3) and new
oil seal (1) on crankshaft (4).
Go to sheet 6
13-42
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-6. Rear Oil Seal. (Sheet 6 of 6)
INSTALLATION
13.
Position rear crankshaft wear sleeve
and seal installating tool onto the
centering plate, then tighten thrust
washer by turning hex nut, as shown.
Tighten hex nut until it reaches the
end of its travel, at which point new
oil seal (1) and new wear sleeve (3)
are correctly installed.
14.
Remove hex
crankshaft
installing
screws and
nut, thrust washer, rear
wear sleeve and seal
tool, four allen head
centering plate.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-43
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-7.
Flywheel and Housing. (Sheet 1 of 5)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Gasket (2)
Torques
Bolts (4) to 125 lb-ft.
Bolts (12) to 105 lb-ft.
Hoist and sling, capacity of
300 lbs.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Starter motor removed.
Paragraph 4-2
Engine assembly removed.
Paragraph 6-3
Torque converter removed.
Go to sheet 2
13-44
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
Flywheel and Housing. (Sheet 2 of 5)
13-7.
REMOVAL
1.
Using a 3/4” socket and socket wrench
handle, remove 16 bolts (1), washers
(2) and gear (3) in flywheel (6).
2.
Using a 3/4" socket and socket wrench
handle, remove eight bolts (4),
washers (5) and flywheel (6) in
flywheel housing (14).
3.
Using a 1" box and open end wrench,
remove elbows (7 and 8), plug (9) and
gasket (10). Discard gasket (10).
GO to sheet 3
13-45
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
Flywheel and Housing. (Sheet 3 of 5)
13-7.
REMOVAL (cont)
4.
Attach hoist and sling to flywheel
housing (14) in front of crankcase.
Weight of flywheel and housing is
approximately 300 lbs.
Use
adequate hoist and sling for
removal and installation.
Keep
unnecessary
area clear of
personnel. Failure to follow this
procedure could result in SEVERE
INJURY.
5.
Using a 9/16” open end wrench, remove
four bolts (11).
NOTE
Remove oil seal and wear
paragraph 13-6.
6.
sleeve,
Using a 3/4” socket and socket wrench
handle, remove eight bolts (12),
washers (13), flywheel housing (14)
and gasket (15).
Discard gasket
(15).
NOTE
Before removal, inspect gear.
Replace if gear is cracked,
warped, chipped or has broken
teeth.
7.
Using a flat punch and hammer, remove
gear (16) from flywheel (6).
Go to sheet 4
13-46
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-7.
Flywheel and Housing. (Sheet 4 of 5)
CLEANING/INSPECTION
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
air
solvent,
immediately.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
8.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
9.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
13-47
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-7.
Flywheel and Housing. (Sheet 5 of 5)
INSTALLATION
10.
Heat gear (16) to 500-550 degrees F
and place on flywheel (6) while hot.
NOTE
Install wear sleeve and oil seal,
paragraph 13-6.
11.
Position new gasket (15) and flywheel
housing (14) in front of crankcase
with hoist and sling.
12.
Using a 3/4” socket and torque
wrench, install new gasket (15),
flywheel housing (14), eight washers
(13) and bolts (12). Tighten eight
bolts (12) to 105 lb-ft.
13.
Install four bolts (11).
14.
Install new gasket (10), plug (9) and
elbows (8 and 7) in flywheel housing
(14).
15.
Install flywheel (6), eight washers
Tighten eight
(5) and bolts (4).
bolts (4) to 125 lb-ft. Eight bolts
(4) must be tightened evenly to draw
flywheel (6) onto crankshaft evenly.
Remove hoist and sling.
16.
Using a 3/4” socket and socket wrench
handle, install gear (3), 16 washers
(2) and bolts (1) on flywheel (6).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-48
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 1 of 12)
This task covers:
b. Disassembly
a. Removal
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Shop Equipment, Machine Shop :
Field Maintenance,
Basic, Less Power
NSN 3470-00-754-0708
Shop Equipment, Machine Shop :
Field Maintenance,
Basic, MAP only
NSN 3470-00-919-0068
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean-cloth (App. C, Item 24)
Fine crocus cloth
(App. C, Item 3)
Engine oil SAE 30
(App. C, Item 19)
Virgin lead wire
Rings (3)
Torques
Bolts (1) to 60 lb-ft., 130 lb-ft.
and 115 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 4-4
Condition Description
Cylinder head removed.
Paragraph 4-7
Oil pan removed.
Go to sheet 2
13-49
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 2 of 12)
REMOVAL
Before removing piston
and
connecting rod inspect the upper
edge of the cylinder sleeve for a
ridge. If a ridge is found it
must be removed with a fine crocus
cloth and a carbon scraper or
ridge reamer before the piston is
removed. Failure to follow this
procedure could result in damage
to piston ring lands during
removal and installation.
NOTE
Keep parts in order and observe
markings to prevent possible
mismatching during assembly and
installation. Keep rod caps and
bearings bolted to
their
original connecting rod.
The following procedure is for
one piston and connecting rod
assembly. The procedure for the
other five piston and connecting
rod assemblies is identical.
1.
Using a 5/8” socket and socket wrench
handle, remove two bolts (1), cap (2)
and two bearing halves (3) from
connecting rod (4) in
lower
crankcase.
Go to sheet 3
13-50
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 3 of 12)
DISASSEMBLY
Use extreme care when removing
rod
piston and connecting
assembly. Failure to follow this
procedure could result in damage
to cylinder sleeves or crankshaft
journals.
2.
Using a plastic mallet, remove items
4 thru 11 as an assembly through top
of crankcase by using a wood punch to
push connecting rod (4) and piston
(5) to top of cylinder from lower
crankcase.
3.
Wrap an oil soaked cloth around
crankshaft connecting rod journals in
lower crankcase to protect it until
installation.
4.
Using a ring expander tool, remove
rings (6, 7 and 8) in order and
discard.
Go to sheet 4
13-51
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 4 of 12)
DISASSEMBLY (cont)
NOTE
Do not force pin. If pin cannot
be removed when cold, heat the
piston in water 160-180 degrees F.
5.
Using retaining ring pliers, remove
two retainers (9) and pin (10) by
hand,
NOTE
Before removal, note the direction
of valve depressions in relation
to the connecting rod for proper
assembly.
6.
Separate connecting rod (4) and
piston (5).
7.
Using a dial indicator, measure pin
(10) in pin bushing. If reading is
not between .0006-.003 inches,
replace pin (10). If reading is not
accurate due to gumming on piston (5)
and pin (10), repeat measurement
after cleaning.
8.
Inspect bushing (11) for wear. Using
an arbor press, remove bushing (11)
and discard. only if worn.
Go to sheet 5
13-52
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 5 of 12)
CLEANING/INSPECTION
9.
Soak piston (5) in mild detergent
solution until carbon deposits are
soft.
10.
Using a carbon scraper, remove carbon
on piston (5).
11.
Using a non-metallic brush, clean
piston (5) ring grooves and oil
holes.
12.
Clean carbon deposits in connecting
rod (4) and cap (2) with mild
detergent solution and non-metallic
brush. Clean mating surfaces between
connecting rod (4) and cap (2).
Go to sheet 6
13-53
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 6 of 12)
CLEANING/INSPECTION (cont)
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
13.
Clean threads of two bolts (1) with
cleaning solvent P-D-680.
Dry
thoroughly with compressed air.
Refer to paragraph 2-8.
Go to sheet 7
13-54
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 7 of 12)
CLEANING/INSPECTION
14•
Inspect piston (5) for scuffed or
scored skirts, cracked or worn piston
lands. Check pin bore for wear and
cracks, replace if necessary.
15.
Using a feeler gage, measure running
clearance between piston (5) and
cylinder sleeve, replace piston (5)
if necessary. Measure piston (5) at
a 90 degree angle from the piston pin
(10). Clearance should be between
0.0045 and 0.0075 inches, refer to
paragraph 13-3.
NOTE
Full keystone grooves use the
0.1150 inch gage pins to determine
piston ring groove wear. Be sure
that the center of the gage pins
aline with the center of the
piston so that gage pins are
parallel. Rectangular grooves do
not use gage pins.
Use side
clearance and ring gap to
determine piston ring groove wear.
16.
Install tool 3020 in the top of
piston (5) ring groove.
17.
Using 4-5 inch micrometer, measure
piston (5) over gage pins, if
necessary.
18.
Repeat steps 16 and 17 for
intermediate ring (7) and ring (8).
For ring (7), upper limit is 4.3168
inches and replacement limit is
4.2844 inches. For ring (8), side
clearance must be between 0.002 and
0.004 inches.
19.
Remove tool 3020 from piston (5) ring
groove.
Go to sheet 8
13-55
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 8 of 12)
CLEANING/INSPECTION (cont)
20•
Push new rings (6 and 7) down into
cylinder sleeve with the top of a
piston positioning ring squarely in
the sleeve.
21.
Using a feeler gage, measure ring
gap. Replace ring if gap is too
wide. File ring to specification.
Ring (6) gap should be between 0.010
and 0.029 inches.
Ring (7) gap
should be between 0.020 and 0.033
inches for narrow gap and between
0.065 and 0.078 inches for wide gap.
22.
Inspect pin (10) and replace if worn,
etched or corroded.
23.
Inspect two bolts (1) for nicks or
thread damage, replace if necessary.
NOTE
Rods have a special rolled thread.
Do no retap rods.
24.
Lubricate thread of two bolts (1)
with SAE 30 engine oil. Screw two
bolts (1) into connecting rod (4)
face by hand. If two bolts (1) does
not screw into connecting rod (4)
freely, replace connecting rod (4).
25.
Using a micrometer, measure and
record the three inside diameters of
each rod at points “A”, “B” and “C”.
26.
Inspect two bearing halves (3) for
deep scratches, wear or burned areas.
27.
Insert two bearing halves (3) into
connecting rod (4) and cap (2).
28.
Check crank pin diameter of
crankshaft, refer to paragraph 13-4.
Go to sheet 9
13-56
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 9 of 12)
ASSEMBLY
29.
Using an arbor press, install new
bushing (11), if worn, in piston (5)
and connecting rod (4) with parting
line 60 degrees to left of oil hole
in top of rod.
30.
Bore bushing (11) to 1.6256 to 1.6258
inches.
31.
Coat piston (5) bore and pin (10)
with moly lube.
32.
Insert pin (10) end into piston of
connecting rod (4). Aline bore holes
of connecting rod (4) and piston (5).
Aline bushing (11) with pin (10)
hole.
33.
Install pin (10).
at 70 degrees F.
34•
Using internal snap ring pliers,
install two retainers (9).
Pin is loose fit
Go to sheet 10
13-57
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 10 of 12)
ASSEMBLY (cont)
A piston ring expander must be
used to install rings. Use of any
other tool may cause damage to
piston lands.
NOTE
During installation of rings, make
sure the proper order is followed.
first,
then
Bottom ring
consecutively upwards. Shiny face
of ring should be up.
35.
Using a ring expander tool, install
new rings (8, 7 and 6).
36.
Position ring (8) 90 degrees from
intermediate ring. Position ring (7)
180 degrees from top ring. Position
split of ring (6) 30 degrees from pin
bore.
37.
Coat cylinder sleeve in upper
crankcase with thick lubricating oil.
38.
Coat piston (5) and rings (8,7 and 6)
with clean lubricating oil, working
oil into ring grooves.
Go to sheet 11
13-58
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-8.
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 11 of 12)
ASSEMBLY
Avoid striking cylinder sleeve
rod
when
with connecting
installing pistons. Failure to
follow this procedure will result
in damage to the cylinder sleeve.
39.
Using piston ring compressor, insert
through the top of the cylinder head
to compress ring as you install
piston (5). The numbers on the rod
must face away from the camshaft.
The valve depression on the top of
piston (5) must face toward the
camshaft.
INSTALLATION
40.
Coat two bearing halves (3) with moly
lube. Install bearing half (3) on
connecting rod (4) in
lower
crankcase.
41.
Using a wood punch, tap down
connecting rod (4) and piston (5)
Make
onto crankshaft.
sure
connecting rod (4) does not nick,
scratch or damage crankshaft.
42. Position bearing half (3) and cap (2)
on connecting rod (4).
NOTE
If bolts (1) are being replaced,
it will be necessary to repeat
step 43, three times. New bolts
need to be loosened and retorqued three times. This only
applies to new bolts.
43.
Using a 5/8” socket and torque
wrench, install two bolts (1).
Tighten to 60 lb-ft, then 130 lb-ft.
Turn crankshaft and check tightening.
Go to sheet 12
13-59
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
Pistons, Connecting Rods and Connecting Rod Bearings. (Sheet 12 of 12)
13-8.
INSTALLATION (cont)
44.
Using a 5/8” socket and socket wrench
handle, remove two bolts (1), cap (2)
and bearing half (3) in lower
crankcase.
45.
Place suitable length of 0.010 inch
virgin lead wire across bearing in
cap.
46.
Using a 5/8” socket and torque
wrench, install bearing half (3), cap
(2) and two bolts (1). Tighten two
bolts (1) to 115 lb-ft.
47.
Remove lead wire and measure with a
micrometer to determine running
clearance.
48.
Using a feeler gage, measure
connecting rod (4) end clearance.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-60
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-9.
Camshaft and Timing Gears. (Sheet 1 of 8)
This task covers:
a. Removal
c. Installation
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, Less Power
NSN 3470-00-754-0708
Shop Equipment, Machine Shop:
Field Maintenance,
Basic, MAP only
NSN 3470-00-919-0068
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Gasket
Preformed packing
Bearing (4)
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
EQUIPMENT CONDITION
References
Paragraph 4-2
Condition Description
Engine assembly removed.
Pargraph 4-4
Cylinder head removed.
Paragraph 4-6
Rocker arm assembly and push rods
removed.
Paragraph 13-1
Front cover removed.
Go to sheet 2
13-61
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
Camshaft and Timing Gears. (Sheet 2 of 8)
13-9.
REMOVAL
NOTE
Before removal of camshaft,
check lobe lift with dial
indicator. Intake total lobe
lift is 0.2905 inch.
Exhaust
total lobe lift is 0.2907 inch.
Replace camshaft and tappets if
total wear of 0.020 inch is
indicated.
Before removal of camshaft,
End
check camshaft end play.
play must be 0.005 to 0.013
inches. Replace thrust plate if
greater end play is indicated.
Before removal of camshaft,
check backlash of timing gears
using dial indicator. Backlash
of cam and idler gear must not
exceed 0.016 inch. Backlash of
idler and crankshaft gear must
not exceed 0.016 inch. Backlash
of idler and injection pump gear
must not exceed 0.016 inch.
Replace any pair of gears with
excessive backlash.
1.
Mark location of 12 tappets (1) in
crankcase and remove.
Go to sheet 3
13-62
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
Camshaft and Timing Gears. (Sheet 3 of 8)
13-9.
REMOVAL
NOTE
Crank engine until timing marks
on camshaft gear, idler gear and
crankshaft gear are alined, as
shown before removing camshaft.
Camshaft must be supported along
its length during removal to
prevent cam lobes from damaging
bearings.
2.
Using a 1/2” socket and socket wrench
handle, remove two bolts (2) in front
of engine,
3. Remove items 3 thru 6 as an assembly.
Go to sheet 4
13-63
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-9.
Camshaft and Timing Gears. (Sheet 4 of 8)
Using an arbor press, remove gear
(3), key (4) and plate (5) from
camshaft (6). Press gear (3) off
camshaft (6).
4.
NOTE
Bearing consists of two bearings,
two cups and two spacers to be
replaced as an assembly.
5.
Using a 5/8” socket and socket wrench
handle, remove bolt (7), shaft (8),
bearing (9), gear (10) and spacer
(11).
6.
Using a 1/2” socket and socket wrench
handle, remove four bolts (12), plate
(13) and gasket (14). Discard gasket
(14). Remove all gasket material
from mounting surfaces.
NOTE
Inspect camshaft bearings for
wear. Inside diameter of bearings
must be 2.2845 to 2.2880 inches.
Replace if worn.
7.
Using puller, remove and discard
bearings (15 thru 18) and preformed
packing (19) from rear of engine.
Go to sheet 5
13-64
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-9.
Camshaft and Timing Gears. (Sheet 5 of 8)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
8.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 6
13-65
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
Camshaft and Timing Gears. (Sheet 6 of 8)
13-9.
CLEANING/INSPECTION (cont)
9.
Measure lobes in camshaft (6) across
points A-C and B-D, as shown.
Replace if excessively worn.
10.
Measure bearing journals in camshaft
(6). Replace if excessively worn.
11.
Inspect gears (3 and 10) in camshaft
(6) for worn or damaged teeth.
12.
Inspect bore of gear (3). Replace if
enlarged.
13.
Inspect all other parts. Refer to
paragraph 2-9.
INSTALLATION
NOTE
Oil holes in bearings must line
up with oil holes in crankcase.
To ease oil hole alinement, mark
back-up nut in line with oil
hole in bearing before installation.
14.
Using puller, expanding collet and
back-up nut, install new preformed
packing (19) and new bearings (18
thru 15) in rear of engine.
Go to sheet 7
13-66
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-9.
Camshaft and Timing Gears. (Sheet 7 of 8)
INSTALLATION
15.
Using a 1/2” socket and socket wrench
handle, install new gasket (14),
plate (13) and four bolts (12).
16.
Using a 5/8” socket and socket wrench
handle, install spacer (11), gear
(10), bearing (9), shaft (8) and bolt
(7).
Use asbestos gloves when handling
gear during installation to
prevent severe burn injury.
Temperature of gear is approximately 400 degrees F.
17. Using an arbor press, install plate
(5), key (4) and gear (3) in camshaft
(6).
18. Using a rubber mallet, install
camshaft (6) and items 6 thru 3 as an
assembly in front of engine.
19.
Using a 1/2” socket and torque
wrench, install two bolts (2).
Tighten bolts (2) to 20 lb-ft.
Go to sheet 8
13-67
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-9.
Camshaft and Timing Gears. (Sheet 8 of 8)
INSTALLATION (cont)
20.
Install 12 tappets (1) in top of
engine.
21.
Check timing of fuel pump, refer to
paragraph 4-15.
NOTE
Return H10A Forklift to original
equipment condition.
END OF TASK
13-68
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-10.
Oil Pump Inlet Tube. (Sheet 1 of 3)
This task covers:
b.
a. Removal
c. Installation
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Gasket
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 4-2
Condition Description
Engine assembly removed.
Paragraph 4-7
Oil pan removed.
REMOVAL
1.
Using a 9/16” socket, socket wrench
handle and a 9/16" box and open end
wrench, remove nut (1), lock washer
(2), bolt (3) and washer (4) from
under engine.
2.
Using a 1/2" socket and socket wrench
handle, remove two bolts (5), washers
(6), tube assembly (7) and gasket
(8). Discard gasket (8).
Go to sheet 2
13-69
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-10.
Oil Pump Inlet Tube. (Sheet 2 of 3)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
3.
Clean all parts
moistened with
P-D-680.
Dry
compressed air.
2-8.
40
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 3
13-70
with clean cloth
cleaning solvent
thoroughly with
Refer to paragraph
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-10.
Oil Pump Inlet Tube. (Sheet 3 of 3)
INSTALLATION
5.
Using 1/2” socket and socket wrench
handle, install new gasket (8), tube
assembly (7), two washers (6) and
bolts (5).
6.
Using a 9/16” socket, socket wrench
handle and a 9/16” box and open end
wrench, install washer (4), bolt (3),
lock washer (2) and nut (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-71
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-11.
Engine Oil Pump. (Sheet 1 of 5)
This task covers:
b. Disassembly
a. Removal
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Tool Kit. General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Grease (App. C, Item 11)
Plastigage (App. C, Item 22)
Preformed packing (2)
Seal
Lock screw (6)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
References
Paragraph 4-5
Go to sheet 2
13-72
Condition Description
Vibration damper removed.
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-11.
Engine Oil Pump. (Sheet 2 of 5)
REMOVAL
1.
Using a 1/2” socket and socket wrench
handle, remove six lock screws (1),
washers (2), housing (3) and
preformed packing (4) from front
cover. Retain six lock screws (1)
and preformed packing (4) to be used
for measurement of end clearance.
DISASSEMBLY
2.
Remove inner rotor (5), plate (6) and
Discard
preformed packing (7).
preformed packing (7).
3.
Remove outer rotor (8), seal (9) and
two pins (10) from housing (3).
Discard seal (9).
Go to sheet 3
13-73
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-11.
Engine Oil Pump. (Sheet 3 of 5)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
•
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
4.
Clean all parts
moistened with
Dry
P-D-680.
compressed air.
2-8.
Go to sheet 4
13-74
with clean cloth
cleaning solvent
thoroughly with
Refer to paragraph
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-11.
Engine oil Pump. (Sheet 1 of 5)
CLEANING/INSPECTION
5. Inspect housing (3), inner rotor (5),
outer rotor (8) and plate (6) for
nicks, burrs, scoring or unusual
wear.
6.
Install outer rotor (8) in housing
(3).
7.
Check clearance between outer rotor
(8) and housing (3) with feeler gage.
Clearance must be 0.0055 to 0.0095
inches.
ASSEMBLY
8.
Install new preformed packing (7),
plate (6), inner rotor (5) and outer
Place
rotor (8) on front cover.
plastigage strip across rotors (5 and
8).
9.
Using a 1/2” socket and socket wrench
handle, install preformed packing
(4), housing (3), six washers (2) and
lock screws (1) on rear cover.
10.
Using a 1/2” socket and socket wrench
handle, remove and discard six lock
screws (1), washers (2), housing (3)
Discard
and preformed packing (4).
preformed packing (4).
11.
Clearance
Measure plastigage.
between rotors (5 and 8) and housing
(3) must be 0.0015 to 0.0043 inches.
Go to sheet 5
13-75
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-11.
Engine Oil Pump. (Sheet 5 of 5)
ASSEMBLY (cont)
12.
Install two pins (10), new seal (9)
and outer rotor (8) in housing (3).
Pack grooves of outer rotor (8) with
grease.
13.
Install new preformed packing (7),
plate (6) and inner rotor (5).
INSTALLATION
14.
Using a 1/2” socket and socket wrench
handle, install new preformed packing
(4), housing (3), six washers (2) and
new lock screws (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-76
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-12.
Fuel Injectors. (Sheet 1 of 4)
This task covers:
a. Disassembly
c. Assembly
b.
d.
Cleaning/Inspection
Testing
INITIAL SETUP
Tools
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, Less Power
NSN 4910-00-754-0714
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, MAP only
NSN 4910-00-919-0083
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Torques
Nut (1) to 33 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 4-12
Condition Description
Fuel injectors removed.
Go to sheet 2
13-77
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-12.
Fuel Injectors. (Sheet 2 of 4)
DISASSEMBLY
NOTE
There are six fuel injector
nozzles. The following is a
disassembly procedure for one fuel
injector nozzle. The disassembly
procedure for the remaining five
is identical.
1.
Using a 15 mm box wrench and vice,
separate nut (1) and housing (7).
2.
Remove spacer (2) and nozzle (3) from
nut (1).
3.
Remove seat (4), spring (5) and
spacer (6) from housing (7).
Go to sheet 3
13-78
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-12.
Fuel Injectors. (Sheet 3 of 4)
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
get
air
solvent,
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
4.
Clean all parts with clean cloth
moistened with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
13-79
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-12.
Fuel Injectors. (Sheet 4 of 4)
CLEANING/INSPECTION (cont)
Be extremely careful when handling
nozzle. Tip is damaged easily.
5.
Inspect nozzle (3) for damage
blocked passages.
6.
Inspect all other parts.
paragraph 2-9.
and
Refer to
ASSEMBLY
7.
Install spacer (6), spring (5) and
seat (4) in housing (7).
8.
Install nozzle (3) and spacer (2) in
nut (l).
9.
Position nut (1) on housing (7). Be
certain opening and two pins on
spacer (2) aline with nozzle (3).
Using a torque wrench, tighten nut
(1) to 33 lb-ft.
TESTING
10.
Test items 1 thru 7 as an assembly,
refer to paragraph 4-12.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-80
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-13.
Fuel Solenoid. (Sheet 1 of 5)
This task covers:
b. Disassembly
a. Removal
c. Cleaning/Inspection d. Assembly
e. Installation
INITIAL SETUP
Tools
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, Less Power
NSN 4910-00-754-0714
Shop Equipment, Fuel & Electrical
System, Engine: Field Maintenance,
Basic, MAP only
NSN 4910-00-919-0083
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Gasket (2)
Lockwire
Torques
Screws (5) to 28 in-lb.
Solenoid body (10) to 125 in-lb.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Battery negative disconnect
Go to sheet 2
13-81
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-13. Fuel Solenoid. (Sheet 2 of 5)
REMOVAL
1.
Remove engine side access cover (1)
from right side of engine compartment, refer to TM 10-3930-643-20.
2.
Using a 7/16” open end wrench, remove
nut (2) and wire assembly (3) at
terminal from right side of engine.
3.
Using side cutters, cut, remove and
discard lockwire (4).
4.
Using a flat tip screwdriver, remove
two screws (5), lock washers (6),
screws (7), cover (8) and gasket (9).
Discard gasket. Remove all gasket
material from mounting surfaces.
DISASSEMBLY
5.
Using a 3/4” open end wrench, remove
solenoid body (10), gasket (11),
spring (12), plunger (13), washer
(14) and ring (15) from cover (8).
Discard gasket (11).
Remove all
gasket material from
mounting
surfaces.
Go to sheet 3
13-82
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-13.
6.
Fuel Solenoid. (Sheet 3 of 5)
Wipe solenoid body (10) with clean
cloth.
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
•
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
7.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
Go to sheet 4
13-83
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-13.
Fuel Solenoid. (Sheet 4 of 5)
CLEANING/INSPECTION (cont)
8.
Inspect two screws (5), lock washers
(6), screws (7), cover (8), spring
(12), plunger (13), washer (14) and
ring (15). Replace if cracked, bent,
distorted, broken or damaged or if
threads are damaged.
9.
Apply 24 volts DC between terminal
connection and outside diameter of
solenoid body (10), Resistance should
be 17.6 to 19.2 ohms (measured at 76
degrees F).
10.
Assemble solenoid body (10), new
gasket (11), plunger (13), washer
(14), ring (15) and cover (8). Do
not include spring (12).
11.
Apply 18 volts DC between terminal
connection and cover (8).
Observe
plunger (13) action. Plunger (13)
should be drawn freely into solenoid
body (10) with no evidence of binding
or sticking.
12.
Apply 18 volts DC between terminal
connection and cover (8) while
holding plunger (13) with fingers.
Compare with force required to
operate pump linkage. Force exerted
by plunger (13) should be sufficient
to operate pump linkage.
13.
Disassemble all parts. Inspect all
parts. Refer to paragraph 2-9.
Go to sheet 5
13-84
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-13.
Fuel Solenoid. (Sheet 5 of 5)
ASSEMBLY
14.
Using a 3/4” open end wrench, install
ring (15), washer (14), plunger (13),
spring (12), new gaskets (12 and 11)
and solenoid body (10) into cover
(8). Tighten solenoid body (10) to
125 in-lb.
15.
Using a flat tip screwdriver, install
new gasket (9), cover (8), two screws
(7), lock washers (6) and screws (5)
in right side of engine. Tighten two
screws (5) to 28 in-lb.
INSTALLATION
16.
Using long round nose pliers, install
new lockwire (4).
17. Using a 7/16” open end wrench,
install wire assembly (3) at terminal
and nut (2).
18. Install engine side access cover (1)
on right side of engine compartments
refer to TM 10-3930-643-20.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
13-85
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-14.
Turbocharger. (Sheet 1 of 10)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Anti-seize compound
(App. C, Item 1)
Locknut
Seal ring
Retaining ring (4)
Piston ring (2)
Torques
Bolts (5) to 100 to 130 in-lb.
Locknut (9) to 18 to 20 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 4-15
Go to sheet 2
13-86
Condition Description
Turbocharger removed.
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-14.
Turbocharger. (Sheet 2 of 10)
DISASSEMBLY
1.
Using a 1/2” socket and socket wrench
handle, remove six bolts (1), three
lockplates (2) and clamp plate (3)
from compressor housing (4).
2.
Remove six bolts (5),
lockplates (6) and clamps
turbine housing (8).
3.
Lift items 9 through 28 as an
assembly carefully from turbine
housing (8).
three
(7) in
Do not place center housing on
either impeller or turbine wheel
or damage to wheel will result.
4.
Using a 9/16” socket and socket
wrench handle, remove and discard
locknut (9) from center housing (28).
Be careful not to apply side thrust
when loosening locknut (9) to avoid
bending shaft of wheel assembly (10).
NOTE
Impeller on shaft of wheel
not
slip-fit
assembly is
press-fit; however due to carbon
build-up, a press may be required.
If necessary, grind a radius on
the end of a 1/4 inch bolt to fit
end of shaft of wheel assembly and
press out.
5.
Remove wheel assembly (10).
6.
Using a press, remove impeller
and shroud (12).
(11)
Go to sheet 3
13-87
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-14.
Turbocharger. (Sheet 3 of 10)
DISASSEMBLY (cont)
7.
Using a 1/2” socket and socket wrench
handle, loosen four bolts (13). Turn
center housing (28) over and remove.
8.
Remove two lockplates
backplate (15).
9.
Remove seal ring (16), thrust collar
(17) and thrust bearing (18).
Discard seal ring (16).
10.
Using a small flat tip screwdriver,
remove spring (19) from backplate
(15).
11.
Remove and discard piston ring (20)
from thrust collar (17).
12.
Remove and discard piston ring (21)
from center housing (28).
13.
Remove retaining ring (22), bearing
(23) and retaining ring (24).
Discard retaining rings (22 and 24).
14.
Using external snap ring pliers,
remove retaining ring (25), bearing
(26) and retaining rings (27).
Discard retaining rings (25 and 27).
15.
Cover intake and exhaust ports on
turbocharger assembly.
Go to sheet 4
13-88
(14) and
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-14 l
Turbocharger. (Sheet 4 of 10)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
air
fresh
get
solvent,
immediately.
16.
Clean exterior of turbocharger
thoroughly with cleaning solvent
P-D-680. Refer to paragraph 2-8.
17.
Place turbocharger on bench with
shaft horizontal and spin wheels by
hand. Wheels must spin freely. If
wheel drags, disassemble and clean
turbocharger.
18.
Place turbocharger in vise and
position dial indicator with foot on
turbine end of shaft.
Go to sheet 5
13-89
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-14.
Turbocharger. (Sheet 5 of 10)
CLEANING/INSPECTION (cont)
19.
Move shaft back and forth by hand.
Total indicator reading must be 0.001
to 0.004 inch. If reading is outside
of this range, disassemble and repair
turbocharger.
20•
Position dial indicator with foot in
contact with shaft through oil drain
port in center housing (28).
21.
Hold both ends of shaft and move
shaft up and down, parallel to dial
Total indicator
indicator shaft.
reading must be 0.003 to 0.006 inch.
If reading is outside of this range,
disassemble and repair turbocharger.
22.
Punch mark assembled position of
compressor housing (4) to backplate
(15), backplate (15) to center
housing (28) and center housing (28)
to turbine housing (8) to aid in
assembly.
NOTE
Place turbocharger assembly on
work surface with compressor
housing on bottom.
23.
Lift turbine housing (8), center
housing (28) and items 5 thru 28 as
an assembly carefully from compressor
housing (4).
24.
Position dial indicator with foot in
contact with shaft through oil drain
port in turbocharger assembly.
25.
Inspect shaft radial movement. Total
indicator reading must be 0.003 to
0.006 inches. If reading is outside
of this range, disassemble and repair
turbocharger.
Go to sheet 6
13-90
(cont)
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-14.
Turbocharger. (Sheet 6 of 10)
CLEANING/INSPECTION
26.
Inspect all parts for signs of
rubbing or other defects. Inspection
before cleaning is performed to
identify defects which might not be
evident after cleaning.
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
get
solvent,
air
immediately.
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
27.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
Go to sheet 7
13-91
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-14.
Turbocharger. (Sheet 7 of 10)
CLEANING/INSPECTION (cont)
28.
Inspect wheel assembly (10) and
impeller (11) for damaged or
distorted vanes for contact with
housings. Spacing between vanes and
Check
contour must be uniform.
cracked or bent blades. If any of
evident,
above conditions are
replace.
Do not attempt to
straighten blades.
29.
Inspect turbine housing (8) for
cracks or excessive scoring in outlet
contour.
30.
Inspect compressor housing (4) for
damage.
31.
Inspect bearing surfaces in wheel
assembly (10) for excessive scratches
and wear. If shaft is only slightly
scratched, it may be reused. Do not
grind or polish shaft as balance will
be affected.
32.
Inspect bearings (23 and 26) for
scratches or worn surfaces. Replace
if tin plate is worn off.
Inspect
bearing bores in center housing (28)
for worn or scored surfaces. Replace
if bores show signs of excessive
scoring or wear.
33.
Inspect flange halves which mate to
compressor housing (4) and turbine
Replace if flange
housing (8).
halves are damaged.
34.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 8
13-92
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-14.
Turbocharger. (Sheet 8 of 10)
ASSEMBLY
35.
Lubricate bearing (26) with engine
oil. Using external snap ring
pliers, install new retaining ring
(27), bearing (26) and new retaining
ring (25) in center housing (28).
36.
Lubricate bearing (23) with engine
oil. Using external snap ring
pliers, install new retaining ring
(24), bearing (23) and new retaining
ring (22).
37.
Using a flat brass punch, install new
piston ring (21).
38.
Position shroud (12) over turbine end
of center housing (28).
39.
Install wheel assembly (10) through
shroud (12) and center housing (28).
40.
Using a flat brass punch, install new
piston ring (20) into thrust collar
(17).
41.
Install thrust bearing (18).
42.
Install thrust collar (17) over shaft
of wheel assembly (10) in center
housing (28) with thrust bearing (18)
first.
Go to sheet 9
13-93
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-14.
Turbocharger. (Sheet 9 of 10)
ASSEMBLY (cont)
NOTE
Aline punch marks on backplate and
center housing. Use care not to
To ease
damage seal ring.
installation, engage
side of
- - open
seal ring in backplate bore first.
43.
Install new seal ring (16) on
compressor side of center housing
(28).
44.
Using a flat brass punch, install
spring (19) in backplate (15).
45.
Install backplate (15) over shaft of
wheel assembly (10) and thrust collar
(17) in center housing (28).
46.
Install lockplates (14) and four
bolts (13) in center housing (28).
47.
Bend tabs on lockplate (14) to secure
four bolts (13).
48.
Install impeller (11),
49.
Lubricate threads of wheel assembly
(10) shaft and contact face of
locknut (9) with clean engine oil.
50.
Install new locknut (9), finger
tight.
NOTE
Place center housing in softjawed vise. Clamp on hex-end of
turbine wheel.
51.
Using a 9/16” socket and torque
wrench, tighten locknut (9) to 18 to
20 lb-ft. Tighten an additional 1/4
turn after reaching specification.
Go to sheet 10
13-94
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-14.
Turbocharger. (Sheet 10 of 10)
ASSEMBLY
NOTE
Aline punch marks on turbine
housing and center housing and
well as on compressor housing and
during
housing
center
installation.
52.
Install turbine housing (8).
53.
Coat bolt threads with anti-seize
compound. Using a 1/2” socket and
torque wrench, install three clamps
(7), lockplates (6) and six bolts
(5). Tighten bolts (5) to 100 to 130
in-lb.
54.
Bend tabs on lockplate (6) to secure
bolts (5).
55.
Install compressor housing (4).
56.
Using a 1/2” socket and socket wrench
handle, install three clamp plates
(3), lockplates (2) and six bolts
(l).
57.
Push wheel assembly (10) shaft as far
as possible from turbine end.
58.
Rotate wheel assembly (10) shaft and
check for binding. Wheel assembly
(10) shaft must rotate freely without
Push as far as
interference.
possible from compressor end.
59.
Rotate wheel assembly (10) shaft and
check for binding.
NOTE
. If turbocharger is not to be
installed immediately, lubricate
internally and install protective covers on all openings.
. Return M10A Forklift to original
equipment condition.
END OF TASK
13-95
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE. (cont)
13-15.
Fuel Tank. (Sheet 1 of 1)
For repair of the Fuel Tank, refer to the following publications:
TB 43-0212, dated 1 April 1977.
TM 9-237, dated October 1976, Welding Theory and Application.
13-96
TM 10-3930-643-34
GENERAL SUPPORT ENGINE, FUEL, EXHAUST AND COOLING MAINTENANCE.
13-16. Radiator Assembly. (Sheet 1 of 1)
For repair of the Radiator, refer to the following publications:
TM 9-237, dated October, 1976, Welding Theory and Application.
TM 750-254, dated March, 1972, Cooling System:
Tactical Vehicles with Change 1, dated 31 October 1972, Change 2, dated 1973.
13-97/(13-98 blank)
TM 10-3930-643-34
CHAPTER 14
GENERAL SUPPORT ELECTRICAL SYSTEM
MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized general support level
maintenance procedures on the M10A Forklift electrical system.
INDEX
Title
Alternator
Solenoid
Paragraph
14-1
14-2
Page
14-2
14-3
14-1
TM 10-3930-643-34
GENERAL SUPPORT ELECTRICAL MAINTENANCE.
14-1. Alternator. (Sheet 1 of 1)
For repair of the Alternator refer to TM 9-2920-225-34.
14-2
TM 10-3930-643-34
GENERAL SUPPORT ELECTRICAL SYSTEM MAINTENANCE.
14-2.
Solenoid. (Sheet 1 of 4)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Solenoid removed.
Go to sheet 2
14-3
TM 10-3930-643-34
GENERAL SUPPORT ELECTRICAL SYSTEM MAINTENANCE. (cont)
14-2.
Solenoid. (Sheet 2 of 4)
DISASSEMBLY
1.
Using a flat tip screwdriver, remove
clamp (1) from solenoid (9).
2.
Using retaining ring pliers, remove
retaining ring (2), washer (3),
spring (4) and washer (5).
3.
Remove bellows (6), washer (7) and
plunger (8).
CLEANING/INSPECTION
4.
Clean bellows (6) with cloth
moistened with mild detergent and
water solution.
5.
Wipe solenoid (9) with clean cloth.
Go to sheet 3
14-4
TM 10-3930-643-34
GENERAL SUPPORT ELECTRICAL SYSTEM MAINTENANCE.
14-2.
Solenoid. (Sheet 3 of 4)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
6.
Wipe all other parts with clean cloth
moistened with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
7.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
14-5
TM 10-3930-643-34
GENERAL SUPPORT ELECTRICAL SYSTEM MAINTENANCE. (cont)
14-2.
Solenoid. (Sheet 4 of 4)
ASSEMBLY
8.
Install plunger (8), washer (7) and
bellows (6) in solenoid (9).
9.
Using snap ring pliers, install
washer (5), spring (4), washer (3)
and retaining ring (2).
10.
Using a flat tip screwdriver, install
clamp (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
14-6
TM 10-3930-643-34
CHAPTER 15
GENERAL SUPPORT TRANSMISSION
MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized general support level
maintenance procedures on the M10A Forklift.
INDEX
Title
Torque Converter
Torque Converter Charging Pump
Transmission Assembly
First Gear Assembly
Second and Third Gear Assembly
Forward and Reverse Steering Gear Assembly
Transmission Control Valve
Transmission Scheduling Valve
Paragraph
15-1
15-2
15-3
15-4
15-5
15-6
15-7
15-8
Page
15-2
15-17
15-23
15-49
15-56
15-73
15-86
15-95
15-1
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-1.
Torque Converter. (Sheet 1 of 15)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Torque wrench
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Permatex No. 2 (App. C, Item 26)
Grease (App. C, Item 11)
Lubricating oil (App. C, Item 19)
Crocus cloth (App. C, Item 3)
Output shaft oil seal installer
(App. D, Item D-8)
Preformed packing (4)
Gasket
Seal (2)
Washer (24)
Spring pin (8)
Torques
Bolt (1) to 77 to 85 lb-ft.
Bolts (8, 13, 44 and 51) to 37 lb-ft.
Bolts (11 and 16) to 38 lb-ft.
Bolts (20 and 31) to 21 lb-ft.
Bolts (23) to 26 lb-ft.
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Torque converter and high pressure
regulator valves removed.
Paragraph 6-3
Torque converter removed.
Paragraph 6-4
Torque converter charging pump removed.
Go to sheet 2
15-2
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-1.
Torque Converter. (Sheet 2 of 15)
DISASSEMBLY
1.
Using a 3/4" socket and socket wrench
handle, remove bolt (l), washer (2),
preformed packing (3) and yoke (4)
from torque converter assembly, output
side. Discard preformed packing.
2.
Remove four bolts (5), access cover
(6) and gasket (7). Discard gasket
(7).
3.
Remove four bolts (8), access cover
(9) and preformed packing (10).
Discard preformed packing.
4.
Using a 9/16" socket and socket wrench
handle, remove six bolts (11) and
washers (12) from torque converter
assembly, output side.
Weight of housing is approximately
80 pounds. Use adequate hoist and
sling for lifting. Failure to
follow this procedure may cause
damage to equipment or INJURY. If
you are injured, seek medical aid
immediately.
5.
Using hoist and sling, remove housing
(13) from torque converter assembly,
output side.
6.
Turn torque converter assembly over to
input side. Using a 9/16" socket and
socket wrench handle, remove six bolts
(14) and retainer (15).
7.
Using a 3/4" socket and socket wrench
handle , remove bolt (16), washer (17)
with spring pin (18). Pry up spring
pin (18) with washer (17) as an
assembly. Do not drill out spring pin
(18) from washer (17).
Go to sheet 3
15-3
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cent)
15-1.
Torque Converter. (Sheet 3 of 15)
DISASSEMBLY (Cent)
8.
Pry up evenly on both sides of bearing
(19) removing both outer and inner
races of bearing (19) from shaft (35).
9.
Using a 1/2" socket and socket wrench
handle, remove 24 bolts (20) and
washers (21) from housing (40).
10.
Install four bolts (20), removed in
step 9, into threaded holes in
impeller (22).
11.
Turn down four bolts (20) to separate
impeller (22) from housing (40). Four
bolts (20) must be turned down evenly
to avoid distortion or fracture of
impeller (22).
12.
Separate impeller (22) from housing
(40)
●
Go to sheet 4
15-4
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-1.
Torque Converter. (Sheet 4 of 15)
DISASSEMBLY
13.
Turn impeller (22) over. Using a
5/16"-12 point socket and socket
wrench handle, remove six bolts (23)
and two clamps (24) from impeller
(22).
14.
Remove guide wheel (25) from impeller
(22). Two wooden wedges may be used
on each side of guide wheel (25) to
pry it off evenly.
15.
Separate carrier (26) from impeller
(22).
16.
Remove piston ring (27) from carrier
(26).
17.
Using slip joint pliers, squeeze split
sleeve (28) and remove from carrier
(26).
NOTE
It is not necessary to remove
spring pins 29 and 30 unless the
carrier (26) is being replaced.
18.
Remove four spring pins (29 and 30)
from carrier (26) if necessary.
Go to sheet 5
15-5
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-1. Torque Converter. (Sheet 5 of 15)
DISASSEMBLY
Using a 1/2" socket and socket wrench
handle, remove eight bolts (31) and
two clamps (32) from impeller (22),
and separate gear (33) and bushing
(34) as an assembly.
19.
NOTE
Separate bushing (34) from gear
(33) only if inspection shows
replacement is necessary.
20,
Using a arbor press, remove bushing
(34) from gear (33), if necessary.
21.
Using a hammer and brass drift, drive
out items 35 thru 38 as an assembly
from housing (40).
22.
Remove and discard seal (36) from
shaft (35).
23.
Using snap ring pliers, remove
retaining ring (37) from shaft (35).
24.
Using hammer and brass drift, drive
out shaft (35) from turbine (38) in
direction of arrow shown, separating
inner bearing race (39a) from turbine
(38).
25.
Tap outer bearing assembly (39) from
housing (40) in one direction only
because of retaining ring (41) in
bearing assembly (39).
26.
Using snap ring pliers, remove
retaining ring (41) from bearing (39).
Go to sheet 6
15-6
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-1.
Torque Converter. (Sheet 6 of 15)
DISASSEMBLY
27.
Using a flat tip screwdriver, remove
retaining ring (42) and hub (43) from
housing (13).
28.
Using a 9/16" socket and socket wrench
handle, remove bolt (44) and items 45
thru 48 as an assembly.
29.
Using a flat tip screwdriver, remove
ring (45) from gear (48).
30.
Using hub (43) and an arbor press,
press out items 46 and 47 as an
assembly from gear (48).
31.
Press out retainer (47) from bearing
(46). Bearing (46) inner race must
be supported during pressing operation
to prevent damage to bearing (46).
32.
Using a flat tip screwdriver, remove
retaining ring (49) and hub (50 from
housing (13).
33.
Using a 9/16" socket and socket wrench
handle, remove bolt (51) and items 52
thru 55 as an assembly.
Go to sheet 7
15-7
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-1.
Torque Converter. (Sheet 7 of 15)
DISASSEMBLY (cont)
34.
Using a flat tip screwdriver, remove
ring (52) from gear (55).
35•
Using an arbor press and hub (50),
press out items 53 and 54 as an
assembly from gear (55).
36.
Using an arbor press, press out
retainer (54) from bearing (53).
Bearing (53) inner race must be
supported during pressing operation
to prevent damage to bearing (53).
37.
Using a chisel and hammer, drive out
seal (56). Discard seal (56).
38.
Using a flat tip screwdriver, remove
ring (57) from housing (13).
39.
Using a 1-1/2" socket and socket
wrench handle, remove plug (58) and
preformed packing (59). Discard
preformed packing (59).
40.
Remove connector (60) and preformed
packing (61). Discard preformed
packing (61).
41.
Using a 9/16" open end wrench, remove
plug (62) from connector (6).
Go to sheet 8
15-8
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-1.
Torque Converter. (Sheet 8 of 15)
CLEANING/INSPECTION
TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
42.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Co to sheet 9
15-9
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-1.
Torque Converter. (Sheet 9 of 15)
CLEANING/INSPECTION (cont)
43•
for
Inspect housings (13 and 40)
cracks, Check bearing bores and
mounting faces for wear, grooves or
scratches. Remove minor burrs and
scratches with crocus cloth.
44.
Inspect impeller (22), guide wheel
(25) and turbine (38) for cracks or
other damage.
45.
Inspect yoke (4), guide wheel (27),
gear (33), hub (43), gear (48), hub
(50) and gear (55) for worn, twisted,
Remove
chipped or burred teeth.
burrs with soft stone.
NOTE
All parts must be free of metal
shavings and foreign material.
46.
Inspect all other parts. Refer to
paragraph 2-9.
ASSEMBLY
47.
Using a 9/16" open end wrench,
install plug (62) to connector (60).
48.
Using a 1-1/2" socket and socket
wrench handle, install new preformed
packing (61) and connector (60) to
housing (13).
49.
Install new preformed packing (59)
and plug (58).
50.
Using snap ring pliers, install ring
(57).
51.
Apply Permatex No. 2 to O.D. of new
seal (56).
Go to sheet 10
15-10
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-1.
Torque Converter. (Sheet 10 of 15)
ASSEMBLY
NOTE
Seal is a double lip seal. Large
lip with spring tensioner must
face housing interior.
52.
Using an arbor press, press new seal
Use an
(56) into housing (13).
output shaft oil seal installation
for
tool , refer to App. D,
fabrication of an output shaft oil
seal installation tool.
53.
Lubricate I.D. of new seal (56) with
grease.
Bearing inner race must be
pressing
during
supported
operation.
54.
Using an arbor press, press retainer
(54) into bearing (53).
55.
Press items 53 and 54 as an assembly
into gear (55). Be sure pressure
from arbor press is exerted on
bearing (53) outer race.
56.
Using snap ring pliers, install ring
(52) onto gear (55).
Go to sheet 11
15-11
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-1.
Torque Converter. (Sheet 11 of 15)
ASSEMBLY (cont)
57.
Using a 9/16" socket and torque
wrench, install items 52 thru 55 as
an assembly and bolt (51) to housing
(18). Tighten bolt (51) to 37 lb-ft.
58.
Install hub (50) and retaining ring
(49).
Bearing inner race must be supported during pressing operation.
59.
Using an arbor press, press retainer
(47) into bearing (46).
Be sure pressure from arbor press
is exerted on bearing outer race.
60.
Using an arbor press, press items 47
and 46 as an assembly into gear (48).
61.
Using snap ring pliers, install ring
(45).
Go to sheet 12
15-12
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-1.
Torque Converter. (Sheet 12 of 15)
ASSEMBLY
62.
Using a 9/16" socket and torque
wrench, install items 48 thru 45 as
an assembly and bolt (44) into
housing (13). Tighten bolt (44) to
37 lb-ft.
63.
Using a flat tip screwdriver, install
hub (43) and retaining ring (42).
64.
Using snap ring pliers, install
retaining ring (37) and new seal
(36) to shaft (35).
65.
Using hammer and brass drift, drive
shaft (35) into turbine (38) in
direction of arrow shown.
NOTE
Be sure inner bearing race (39a)
is fully seated on shoulder of
shaft (35).
66.
Using a bearing installation tool
install inner bearing race (39a) on
shaft (35).
67.
Using snap ring pliers, Install
retaining ring (41) onto outer race
of bearing assembly (39).
NOTE
Be sure that retaining ring (41)
is fully seated on shoulder of
housing (40).
68.
Using a bearing installation tool
install outer bearing assembly (39)
and retaining ring (41) as an assembly
into housing (40).
69.
Install items 39a thru 35 as an
assembly into housing assembly (40).
Go to sheet 13
15-13
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-1.
Torque Converter. (Sheet 13 of 15)
ASSEMBLY (cont)
70.
If removed, using a plastic hammer,
install four spring pins (30 and 29)
into carrier (26).
71.
Using slip joint pliers, squeeze split
sleeve (28) and install into carrier
(26) .
72.
Install piston ring (27) onto carrier
(26) .
73.
If removed, using an arbor press,
install bushing (34) to gear (33).
74.
Install gear (33) to impeller (22).
75.
Using a 1/2" socket and torque wrench,
install two clamps (32) and eight
bolts (31). Tighten eight bolts (31)
to 21 lb-ft.
76.
Install impeller (22) and guide wheel
(25) to carrier (26). Mounting bolts
and spring pin bores must be aligned.
77*
Using a 5/16" socket and torque
wrench, install two clamps (24) and
six bolts (23). Tighten six bolts
(23) to 26 lb-ft.
78.
Install impeller (22) on housing (40)
q aking sure the bolt holes are in
alignment.
79.
Using an arbor press, press evenly on
both inner and outer races of bearing
(19) and install on torque converter,
output side.
Go to sheet 14
15-14
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-1.
Torque Converter. (Sheet 14 of 15)
ASSEMBLY
80.
Using a 1/2" socket and socket wrench
handle , install 24 new washers (21)
and bolts (2o). Tighten 24 bolts (20)
to 21 lb-ft.
81.
Turn torque converter assembly over
with the input side up.
82.
If removed, install new spring pin
(18) into washer (17).
83.
Using a 3/4" socket and socket wrench
handle , install washer (17) with
spring pin (18) and bolt (16) to
torque converter assembly, input side.
84.
Apply liquid gasket to retainer (15).
85.
Using a 9/16" socket and socket wrench
handle, retainer (15) and six bolts
(14). Tighten six bolts (14) to 37
lb-ft .
Go to sheet 15
15-15
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-1.
Torque Converter. (Sheet 15 of 15)
ASSEMBLY (cont)
86.
Turn torque converter assembly over
with the output side up.
Use care when installing housing
(13) to avoid damage to output
yoke seal in housing by shaft,
86.
Using hoist and sling, position
housing (13) on torque converter
assembly.
87.
Using a 9/16" socket and torque
wrench, install six washers (12) and
bolts (11). Tighten six bolts (11) to
38 lb-ft.
88.
Using a 3/4" socket and torque wrench,
install new preformed packing (10),
access cover (9) and four bolts (8).
Tighten four bolts (8) to 37 lb-ft.
89.
Install new gasket (7), access cover
(6) and four bolts (5).
90.
Install yoke (4) , new preformed
packing (3), washer (2) and bolt (l).
Tighten bolt (1) to 77 to 85 lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
15-16
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-2.
Torque Converter Charging Pump. (Sheet 1 of 6)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Seal (5)
Preformed packing (4)
Gasket
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 6-4
Condition Description
Torque converter charging pump removed.
Co to sheet 2
15-17
TM 10-3930-643-34
GENRAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-2.
Torque Converter Charging Pump. (Sheet 2 of 6)
DISASSEMBLY
1.
Using a 9/16" socket and socket
wrench handle, remove three bolts
(l), flange (2) , seal (3), gasket (4)
and ring (5) from drive side of
charging pump. Discard seal (3) and
gasket (4).
2.
Remove four screws (6), seals (7),
bolts (8), plate (9) and preformed
packing (10). Discard four seals (7)
and preformed packing (10).
3.
Using slip joint pliers, remove pins
(11 and 12) from plate (9).
4.
Using a rubber mallet, remove case
(13) and preformed packing (14) from
drive side of charging pump. Discard
preformed packing (14).
5.
Remove gear (15), pin (16) and items
17 thru 21 as an assembly.
6.
Using snap ring pliers, remove
retaining ring (17), gear (18), pin
(19) and retaining ring (20) from
shaft (21).
7.
Using a rubber mallet, remove spacer
(22) with preformed packing (23) and
items 24 thru 27 as an assembly.
Discard preformed packing (23).
8.
Using slip joint pliers, remove pins
(24, 25, 26 and 27) from spacer (22).
Go to sheet 3
15-18
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-2.
Torque Converter Charging Pump. (Sheet 3 of 6)
DISASSEMBLY
9*
Remove items 28 thru 32 as an
assembly.
10.
Using snap ring pliers, remove
retaining ring (28), gear (29),
retaining ring (30) and pin (31) from
shaft (32).
11.
Remove items 33 thru 37 as an
assembly from plate (42).
12.
Remove retaining ring (33), gear
(34), pin (35) and retaining ring
(36) from shaft (37).
13.
Using a rubber mallet, remove case
(38) and preformed packing (39) from
Discard preformed
plate (42).
packing (39).
14.
Using slip joint pliers, remove pins
(40 and 41) from case (38)".
Go to sheet 4
15-19
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Torque Converter Charging Pump. (Sheet 4 of 6)
15-2.
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
air
get
immediately.
● Compressed AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
15.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
16.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 5
15-20
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-2.
Torque Converter Charging Pump. (Sheet 5 of 6)
ASSEMBLY
NOTE
Lubricate all parts with lubricating oil before assembly.
17.
Using a plastic hammer, install pins
(41 and 40) in case (38).
18.
Install new preformed packing (39)
and case (38) in plate (42).
19.
Using snap ring pliers, install
retaining ring (36), pin (35), gear
(34) and retaining ring (33) in shaft
(37)0
20.
Install items 37 thru 33 as an
assembly.
21.
Using a plastic hammer, install pin
(31), retaining ring (30), gear (29)
and retaining ring (28) on shaft
(32).
Go to sheet 6
15-21
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-2.
Torque Converter Charging Pump. (Sheet 6 of 6)
ASSEMBLY (cont)
22.
Install items 32 thru 28 as an
assembly.
23.
Using a plastic hammer, install pins
(27, 26, 25 and 24).
24.
Install new preformed packing (23)
and spacer (22) with items 27 thru 24
as an assembly.
25.
Using snap ring pliers, install
retaining ring (20), pin (19), gear
(18) and retaining ring (17).
26.
Using a rubber mallet, install items
21 thru 17 as an assembly, pin (16)
and gear (15) on drive side of
charging pump.
27.
Install new preformed packing
and case (13).
28.
Using a plastic hammer, install pins
(11 and 12).
29.
Using an 9/16” socket and socket
wrench handle, install new preformed
packing (10), plate (9), four bolts
(8), new seals (7) and screws (6) on
drive side of charging pump.
30.
Install ring (5), new gasket (4), new
seal (3), flange (2) and three bolts
(1).
(14)
NOTE
Return M10A Forklift to
equipment condition.
15-22
original
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 1 of 26)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Hoist and sling, capacity of
780 lbs.
Two 3/8-16NC forcing screws
Lifting eyebolts
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Permatex sealant (App. C, Item 26)
Loctite 277 (App. C, Item 16)
Preformed packing (28)
Seal (3)
Gasket (7)
Seal ring
Wood block
Torques
Screw (12) to 50 lb-ft.
Bolt (24) to 100 to 150 lb-ft.
Nut (36) to 60 lb-ft.
Bolts (47) to 24 lb-ft.
Bolts (52 thru 54) to 24 lb-ft.
Nut (59) to 50 lb-ft.
Bolts (65) to 25 to 30 in-lb. and
50 in-lb.
Go to sheet 2
15-23
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cent)
15-3.
Transmission Assembly. (Sheet 2 of 26)
EQUIPMENT CONDITION
References
TM 10-3930-643-20
Condition Description
Sample valve removed.
Breather removed.
Paragraph 6-6
Transmission removed.
Paragraph 6-8
Scheduling and control valve removed.
Go to sheet 3
15-24
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 3 of 26)
DISASSEMBLY
NOTE
Tag all hose and tube assemblies
before disconnecting to aid in
installation.
1.
Using a 1-1/4" open end wrench,
disconnect hose assembly (98) at
top of transmission housing.
2.
Remove adapter (1) and preformed
packing (2). Discard preformed
packing (2).
3.
Disconnect hose assembly (15).
4.
Remove elbow (3) and preformed
packing (4). Discard preformed
packing (4).
5.
Using a 9/16" socket and socket
wrench handle, remove bolt (5),
washer (6), manifold (7) and
preformed packing (8). Discard
preformed packing (8).
6.
Using a 3/16" socket head screw
key, remove plug (9).
7.
Using a 1-1/4" socket and socket
wrench handle, remove plug )10)
and preformed packing (11) .
Discard preformed packing (11).
Go to sheet 4
15-25
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3.
Transmission Assembly. (Sheet 4 of 26)
DISASSEMBLY (cont)
8.
Using a 3/8" socket head screw key,
remove screw (12) preformed packing
(13) and washer (14) from side of
transmission housing. Discard
preformed packing (13).
9.
Using an 11/16" open end wrench,
remove hose assembly (15) at front of
transmission housing.
10.
Using a 1-1/8" and 9/16" open end
wrench, remove elbow (16), plug (17),
nine bolts (18) and lockwashers (19).
11.
Using a 9/16" open end wrench,
install two 3/8 in-16 NC forcing
screws and tighten until cover (20)
is loose.
12.
Remove two 3/8-16NC forcing screws.
13.
Using a rubber mallet, remove cover
(20) and gasket (21). Discard gasket
(21)0
14.
Remove bearing (22) from cover (20).
15.
Using a scribe, remove and discard
two preformed packings (23).
16.
Using a flat tip screwdriver, bend
washer (25) back from clutch pack
shaft (27).
17.
Using a 1-1/8" socket and socket
wrench handle, remove bolt (24),
washer (25) and two seal rings (26).
18.
Remove clutch pack (27). Fro
disassembly of first gear, refer to
paragraph 15-4.
Go to sheet 5
15-26
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 5 of 26)
DISASSEMBLY
19.
Using a 9/16" socket and socket
wrench handle, remove six bolts (28),
lock washers (29) and housing (30).
20.
Remove two bearings (31), spacer
(32), washer (33), thrust bearing
(34) and thrust washer (35) from
upper countershaft.
21.
Using a 1-7/16" socket and socket
wrench handle, remove nut (36),
washer (37) and preformed packing
(38). Discard preformed packing
(38).
22.
Remove yoke (39), deflector (40) and
seal (41). Discard seal (41).
23.
Using a 3/4" socket and socket wrench
handle, remove six bolts (42) and
retainer (43).
24.
Using a scribe, remove preformed
packing (44) and bearings (45 and
46). Discard preformed packing (44).
Go to sheet 6
15-27
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE, (cont)
15-3. Transmission Assembly. (Sheet 6 of 26)
DISASSEMBLY (cont)
25.
Using a 9/16" socket ,socket wrench
handle and a 5/16" socket head screw
key, remove five bolts (47), adapter
plate (48) and gasket (49). Discard
gasket (49). Remove all gasket
material from mounting surfaces.
26.
Using a 3/8" open end wrench, remove
three plugs (50) and two plugs (51).
27.
Using a 9/16" socket and socket
wrench handle, remove six bolts (52),
bolt (53) and bolt (54).
28.
Using a rubber mallet, remove cap
(55) and two preformed packings (56).
Discard preformed packings (56).
29.
Using 1-1/8" open end wrench, remove
plug (57) and preformed packing (58).
Discard preformed packing (58).
Weight of transmission assembly
Use
is approximately 730 lbs.
adequate hoist and sling. Failure
to follow this procedure could
result in SERIOUS INJURY. If
injured, seek medical attention
immediately.
30.
Attach hoist and sling to lifting
eye.
31.
Using a hoist and sling, turn housing
over so that cover end is up.
32.
Remove hoist and sling.
Go to sheet 7
15-28
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 7 of 26)
DISASSEMBLY
33.
Using a 1-7/16" socket and socket
wrench handle, remove nut (59),
washer (60) and preformed packing
(61) from rear of transmission
housing. Discard preformed packing
(61).
34.
Using a rubber mallet, remove yoke
(62), deflector (63) and seal ring
(64).
35.
Using a 9/16" socket and socket wrench
handle , remove six bolts (65) , lock
washers (66), retainer (67), preformed
packing (68) and shim (69). Discard
preformed packing (68).
36.
Remove bearing (70) and bearing (71).
37.
Using a 9/16" socket and socket
wrench handle, remove six bolts (72),
lock washers (73), cover (74) and
gasket (75). Discard gasket (75).
Remove all gasket material from
mounting surfaces.
38.
Using a 1-7/16" socket and socket
wrench handle, remove nut (76) , washer
(77), yoke (77a), retaining ring (78)
and seal (79). Discard seal (79).
39.
Using a 9/16” socket and socket
wrench handle, remove six bolts (80),
lock washers (81), retainer (82) ,
gasket (83) and retaining ring (84).
Remove all
Discard gasket (83).
mounting
gasket material from
surfaces.
40.
Using a 3/4" and 11/16" open end
wrench, remove items 85 thru 87 as an
assembly.
Go to sheet 8
15-29
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Transmission Assembly. (Sheet 8 of 26)
15-3.
DISASSEMBLY (cont)
41.
Using a 3/4" open end wrench, remove
gasket (88), nut (89) and preformed
packing (90). Discard preformed
packings (88 and 90).
42.
Remove seal (91) and elbow (92).
Discard seal (91).
43.
Remove items 93 and 94 as an
assembly.
44.
Remove gasket (95), nut (96) and
preformed packing (97). Discard
preformed packing (97).
45.
Using a 1-1/4" open end wrench, remove
hose assembly (98).
46.
Remove elbow (99).
47.
Using a 3/16" socket head screw key,
remove two plugs.
48.
Using a 9/16" socket and socket
wrench handle, remove six bolts
(101), lock washers (102), retainer
Discard
(103) and gasket (104).
gasket (104).
49.
Remove bearing (105) and three seal
rings (106) from cover (111).
50.
Remove 19 bolts (107) and lock washers
(108) .
51.
Using a
handle,
washers
(112) 0
Go to sheet 9
15-30
3/8" socket and socket wrench
remove two bolts (109, lock
(110), cover (111) and gasket
Discard gasket (112).
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 9 of 26)
DISASSEMBLY
52.
Using long round nose pliers, remove
snap ring (113) from internal
transmission housing.
53.
Using a bearing puller, remove
bearing (114).
54.
Using a bearing puller, remove gear
(115) and spacer (116).
Use care when performing the next
procedure. Do not let idler
shaft fall to ground. Failure to
use care could result in damage
to idler shaft.
55.
Using a drift punch, drive items 117
thru 119 out through rear of transmission housing.
56.
Remove washer (121) and gear (122).
57.
Using a 3/4" socket and socket wrench
handle, remove bolt (118) and
preformed packing (119). Discard
preformed packing (119).
58.
Remove clutch pack (120). For
disassembly of forward and reverse
clutch , refer to paragraph 15–6.
Go to sheet 10
15-31
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Transmission Assembly. (Sheet 10 of 26)
15-3.
DISASSEMBLY (cont)
59.
Using a scribe, remove two sleeves
(123), bearings (124) and retaining
rings (125) from gear (122) using a
soft metal drift punch for bearing on
tooth side of gear and a shop press
for opposite bearing.
60.
Place a jack under clutch pack (128).
61.
Raise jack until one leg of transmission stand is about 1-1/2 inches
off the floor.
62.
Insert drift punch through hole in
first speed driven gear and against
bearing (126) race.
63.
Using a hammer, tap drift punch to
drive out and remove bearing (126).
64.
Lower jack until transmission stand
is flat on floor.
65.
Remove jack.
66.
Tilt clutch pack (128) toward bottom
of transmission.
67.
Remove gear (127).
Go to sheet 11
15-32
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 11 of 26)
DISASSEMBLY
68.
Remove clutch pack (128). For
disassembly of second and third gear
clutch, refer to paragraph 15–5.
69.
Place a jack under shaft (129).
70.
Raise jack until one leg of
transmission stand is off floor.
71.
tap
Using a wooden q allet,
transmission case to free bearing
(130).
72.
Remove items 129 thru 131 as an
assembly.
73.
Using snap ring pliers, separate
shaft (129), bearing (130) and
retaining ring (131).
74.
Repeat steps 69 thru 71 for removal of
shaft (132).
75.
Remove items 132 thru 135 as an
assembly.
76.
Remove shaft (132), gear (133), spacer
(134) and bearing (135).
Go to sheet 12
15-33
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Transmission Assembly. (Sheet 12 of 26)
15-3.
DISASSEMBLY (cont)
NOTE
Do not remove items 135 thru 145
unless inspection shows replacement is necessary.
77.
Using a scribe, remove ten bushings
(135) and washers (136) from
transmission housing.
78.
Remove tubes (137 thru 141), ten
preformed packings (142), washers
Discard
(136) and bushings (135).
ten preformed packings (142).
79.
Remove pin (143).
80.
Using a 3/4" open end wrench, remove
plug (144) and gasket (145). Discard
gasket (145).
Go to sheet 13
15-34
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3. Transmission Assembly. (Sheet 13 of 26)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
If you
flush with cold water.
become dizzy while using cleaning
fresh
air
get
solvent,
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
NOTE
All parts should be oiled after
cleaning to keep them clean until
assembly.
81.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
82.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 14
15-35
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3. Transmission Assembly. (Sheet 14 of 26)
ASSEMBLY
83.
Install new gasket (145) and plug
(144) in transmission housing.
84.
Using a plastic hammer, install pin
(143).
85.
Using a 3/4" open end wrench, install
tubes (141 thru 137).
86•
Coat with lubricating oil and install
ten new preformed packings (142),
washers (136) and bushings (135).
87.
Using a center punch to prevent
pressure from pushing tube out,
expand tube ends (141 thru 137).
88.
Install clutch pack (120).
89.
Using a 3/4" socket and socket wrench
handle, install new preformed packing
(119) and bolt (118) on idler shaft
(117).
90.
Install items 117 thru 114 as an
assembly with flat end of idler shaft
(117) facing clutch pack (120).
Go to sheet 15
15-36
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 15 of 26)
ASSEMBLY
91.
Using snap ring pliers, install two
retaining rings (125) in grooves in
gear (122).
92.
Using a wooden dowel, press two
bearings (124) into gear (122) until
they bottom against two retaining
rings (125).
93.
Install two sleeves (123) in two
bearings (124).
94.
Position washer (121) on tooth side
of gear (122)*
95.
Position items 125 thru 121 with
gear teeth up on idler shaft (117).
96.
Using a hammer and wooden dowel,
drive idler shaft (117) down until
flush with face of web.
97.
Using a wooden dowel, drive idler
shaft (117) back into original
position.
98.
Using an arbor press, press bearing
(130) on shaft (129) until it
bottoms against shoulder on shaft
(132).
99.
Using snap ring pliers, install
retaining ring (131) on shaft (129).
100.
Using a rubber mallet, drive shaft
(129) down until bearing is flush
with bearing bore.
101.
Install gear (127) on shaft (129),
counterbore in gear hub will index
with retaining ring on shaft (132).
102.
Install clutch pack (128).
Go to sheet 16
15-37
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3.
Transmission Assembly. (Sheet 16 of 26)
ASSEMBLY (cont)
1030
Install gear (133) by sliding it
between case wall and clutch pack
(120) to position it, long side of
hub up, on it’s bore in transmission
housing.
104.
Engage splines of shaft (132) into
gear (133) and seat clutch pack
(128) in gear (133).
105. Using a wooden dowel, install spacer
(116).
106.
Using a bearing installation tool,
install gear (115) with the long hub
side of gear toward spacer (116).
107. Block bottom end of shaft (129) with
wood blocks.
with
108.
Position bearing (114)
retaining ring groove up.
109 l
Using a bearing installation tool,
drive bearing onto shaft (129).
110.
Using snap ring pliers, install snap
ring (113).
111.
Heat bearing (135) to 250 degrees F in
oil or oven.
112.
Using insulated gloves and bearing
installation tool, seat bearing (135)
on shaft (132).
Go to sheet 17
15-38
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 17 of 26)
ASSEMBLY
113.
Position new gasket (112) and cover
(111) and using a plastic hammer tap
into place.
114.
Using a 3/8” socket and socket wrench
handle, install two lock washers (110)
and bolts (109).
115.
Install 19 lock washers (108) and
bolts (107).
116.
Install bearing (105) into cover
(111) bore.
Allow bearing to
protrude 1/8 inch above cover (111)
Bearing will seat properly when
retainer (l03) is installed.
117.
Install three seal rings (106) on
shaft of clutch pack (128). Be sure
that rings do not bind and that
groove is deeper than seal thickness
at all points.
118.
Position new gasket (104) and
retainer (103).
119.
Install six lock washers (102) and
bolts (101).
120.
Using a 3/16" socket head screw key,
install two plugs (100).
121.
Using a 1-1/4" open end wrench,
install elbow (99).
122.
Connect hose assembly (98).
123.
Using a 3/4" open end wrench,
install new preformed packing (97),
two nuts (96) and new gasket (95).
Go to sheet 18
15-39
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3.
Transmission Assembly. (Sheet 18 of 26)
ASSEMBLY (cont)
124.
Using a 3/4" open end wrench,
install two adapters (93) on tube
(94).
125.
If new tube (94) is used, expand
tube ends with a large center punch
to prevent pressure from pushing
tube out.
126.
Install items 94 and 93 as an
assembly on cover (111).
127.
Install elbow (92) and seal (91) in
retainer (103).
128.
Install new preformed packing (90),
nut (89) and new gasket (88) in
cover (111).
129.
Install nut (86) and adapter (85) on
tube (87).
130.
If new tube (87) is being used,
expand ends with a large center
punch to prevent pressure from
pushing tube out.
Go to sheet 19
15-40
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3. Transmission Assembly. (Sheet 19 of 26)
ASSEMBLY
131.
Install retaining ring (75a). new
gasket (75) and cover (74).
132.
Using a 9/16" socket and socket
wrench handle, install six lock
washers (73) and bolts (72).
133.
Press new seal (79) into retainer
(82).
134.
Using retaining ring pliers, install
retaining ring (84).
135.
Position new gasket
retainer (82).
136.
Install six lock washers (81) and
bolts (80).
137.
Using a 1-7/16" socket and socket
wrench handle, install retaining ring
(78), yoke (77a), washer (77) and nut
(76) on clutch pack (128).
(83) and
Go to sheet 20
15-41
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3.
Transmission Assembly. (Sheet 20 of 26)
ASSEMBLY (cont)
138.
Install new preformed packing (68)
on retainer (67).
139. Press new seal rings (64) and
bearing (70) into retainer (67).
140.
Using a 9/16" socket and socket wrench
handle , install retainer (67) and six
bolts (65). Place at 180 degrees.
141.
Attach hoist and sling to lifting
eye.
142.
Using a hoist and sling, turn
housing over so that cover end is
down.
143.
Remove hoist and sling.
144.
Heat bearing (126) to 250 degrees F
in oil or oven.
145.
Using insulated gloves and rubber
mallet , install bearing (126) in
transmission housing. Allow bearing
(126) to protrude 18 inches above
housing surface.
146.
Heat bearing (46) to 250 degrees F
in oil or oven.
147.
Using a plastic hammer, install
spacer (134) and bearing (46) on
shaft (132).
Using a bearing
installation tool, seat bearing (46)
on shoulder of shaft (132).
Go to sheet 21
15-42
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 21 of 26)
ASSEMBLY
148.
Using a 5/16” socket head screw key,
install new gasket (49) and adapter
(48).
149.
Apply Loctite 277 to five bolts (47)
and using a 9/16” socket and torque
wrench. install five bolts (47).
Tighten five bolts (47) to 24 lb-ft.
150.
Install two new preformed packings
(56).
151.
Apply Permatex sealant No. 2 to cap
(55) mounting surface, refer to
Chapter 2.
152.
Using a 9/16" open end wrench,
install two plugs (51) and three
plugs (50) in cap (55).
153.
Position cap (55) on transmission
housing.
Apply Loctite 277 to bolts (54 and
53) and six bolts (52) and using a
9/16” socket and torque wrench,
install bolts (54 and 53) and six
bolts (52). Tighten bolts (54 and
53) and six bolts (52) to 24 lb-ft.
Go to sheet 23
15-43
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3.
Transmission Assembly. (Sheet 22 of 26)
ASSEMBLY (cont)
155.
Install thrust washer (35), thrust
bearing (34), washer (33), spacer
(32) and two bearings (31).
156.
Install two new preformed packings
(23).
157.
Apply Permatex sealant No. 2 to
housing (30) mounting surface.
158.
Position housing (30), being careful
not to dislodge two new preformed
packings (23).
159.
Using a 9/16” socket and socket
wrench handle, install six lock
washers (29) and bolts (28).
160.
Install clutch pack (27) and two seal
rings (26).
161.
Using a 1-1/8” socket and torque
wrench, install washer (25) and bolt
(24). Tighten bolt (24) to 100-150
lb-ft.
162.
Bend washer (25) back on shaft (27).
163.
Using a wooden block, press bearing
(22) into cover (20).
164.
Position new gasket (21) and cover
(20).
165.
Using a 1-1/8 and 9/16” open end
wrench, install nine lock washers (19)
and bolts (18).
166.
Install plug (17) in cover (20).
167.
Install elbow (16) in cover (20).
168.
Using an 11/16” open end wrench,
connect hose assembly (15).
Go to sheet 22
15-44
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3.
Transmission Assembly. (Sheet 23 of 26)
ASSEMBLY
169.
Using an arbor press, press bearing
(45) and new seal (41) into retainer
(43).
170.
Install new preformed packing (44)
in retainer (43).
171.
Apply plastic gasket to retainer
(43) mounting surface and position
retainer (43) on transmission
housing.
172.
Using a 3/4” socket and socket
wrench handle, install six bolts
(42).
173.
Install deflector (40) and yoke (39)
while rotating shaft to prevent seal
damage.
174.
Using a 1-7/16” socket and torque
wrench, install new preformed packing
(38), washer (37) and nut (36).
Tighten nut (36) to 60 lb-ft.
175.
Attach hoist and sling to lifting
eye.
176.
Using a hoist and sling, turn
transmission housing over.
177.
Remove hoist and sling.
178.
Remove lifting eye.
Go to sheet 24
15-45
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3. Transmission Assembly. (Sheet 24 of 26)
ASSEMBLY (cont)
179.
Using a 9/16” socket and torque
wrench, install six bolts (65).
Tighten six bolts (65) to 25-30 in-lb.
180.
Rotate shaft (132) several times.
181.
Tighten six bolts (65) to 50 in-lb.
182.
Rotate shaft (132) several times.
183.
Using a feeler gage measure gap
between using and retainer (67) at
If readings are
each screw.
different, take the two numbers and
divide by two. Add .020 inch.
184.
Make shim (69) or shims
that thickness.
185.
Using a 9/16 socket and socket wrench
handle, remove six bolts (65).
186.
Position shim (69) and retainer
(67).
187.
Install six lock washers (66) and
bolts (65).
Go to sheet 25
15-46
equal to
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-3. Transmission Assembly. (Sheet 25 of 26)
ASSEMBLY
188.
Install a dial indicator to measure
shaft (132) end play.
189.
Place a jack under opposite end of
shaft (132). Use a block, do not
contact the shaft (132).
190.
Using a pry bar to exert pressure on
end of shaft (132), note reading on
dial indicator. Correct shim pack
if not within specifications.
Allowable end play is 0.005-0.009
inches.
191.
Using a rubber mallet, install
deflector (63) and yoke (62) on
shaft (132). Rotate shaft (132) to
prevent seal damage.
192.
Install new preformed packing (61),
washer (60), and nut (59). Using a
1-7/16” socket and torque wrench,
tighten nut (59) to 50 lb-ft.
Go to sheet 26
15-47
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-3.
Transmission Assembly. (Sheet 26 of 26)
ASSEMBLY (cont)
193.
Install new preformed packing (8) in
manifold (7).
194. Position manifold (7) on housing.
195.
Using a 9/16” socket and socket
wrench handle, install washer (6)
and bolt (5).
196.
Using a 3/16” open end wrench, install
plug (9).
197.
Using a 1-1/4 socket and socket wrench
handle, install new preformed packing
(11) and elbow (10).
198.
Install new preformed packing (4) and
elbow (3).
199.
Connect hose assembly (15).
200.
Install new preformed packing (2) and
adapter (1).
201.
Connect hose assembly (98).
202.
Using a 3/8” socket head screw key and
torque wrench, install washer (14),
preformed packing (13) and screw (12)
on idler shaft (117). Tighten screw
(12) to 50 lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
15-48
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-4.
First Gear Assembly. (Sheet 1 of 7)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Preformed packing
Seal ring
Spring (28)
Retaining ring (3)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 15-3
Condition Description
Transmission disassembled.
DISASSEMBLY
NOTE
Use care when removing retaining
rings.
1.
Using a flat tip screwdriver, remove
and discard retaining ring (1).
2.
Remove gear (2).
Go to sheet 2
15-49
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
First Gear Assembly. (Sheet 2 of 7)
15-4.
DISASSEMBLY (cont)
3.
Using two “C” clamps, depress plate
(4).
4.
Using retaining ring pliers, remove
and discard retaining ring (3).
5.
Remove “C” clamps from plate (4).
6.
Remove plate (4).
Wave springs are thin and have
sharp edges.
Use care when
handling them to avoid cutting
hands and fingers.
Use care when removing and
handling clutch plates to avoid
nicking and scratching friction
surfaces.
7.
Remove 15 plates (5), 14 plates (6)
and 28 wave springs (7) from housing
(9). Discard 28 wave springs (7).
Go to sheet 3
15-50
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-4.
First Gear Assembly. (Sheet 3 of 7)
DISASSEMBLY
● COMPRESSED AIR HAZARD
Compressed air will not exceed 30
psi. Use only with effective chip
guarding and personal protective
equipment
(goggles/shield,
gloves, etc.).
Do not blast piston out of
housing. Use air pressure with
Failure to follow
restraint.
this procedure could result in
damage to piston or housing.
8.
Apply air pressure at bore on housing
(9).
9.
Remove piston (12).
10.
Remove and discard preformed packing
(13) and seal ring (14).
11.
Remove thrust bearing (10) and two
races (11).
12.
Using a flat tip screwdriver, remove
and discard retaining ring (8).
13.
Using a rubber mallet, remove housing
(9) from housing (15).
Go to sheet 4
15-51
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
First Gear Assembly. (Sheet 4 of 7)
15-4.
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
14.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 5
15-52
TN 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-4.
First Gear Assembly. (Sheet 5 of 7)
CLEANING/INSPECTION
15.
Inspect teeth on gear (2), housings
(9 and 15) and plates (4 thru 6) for
missing
wear, chips, cracks or
teeth. Replace, if necessary.
16.
Inspect all other parts. Refer to
paragraph 2-9.
ASSEMBLY
17.
Install new retaining ring (8) in
housing (15). Be sure that open
space between retaining ring (8) ends
does not aline with oil holes.
18.
Install housing (9) in housing (15).
19.
Install two races (11) and thrust
bearing (10).
20.
Install new preformed packing (13)
and new seal ring (14) on piston
(12).
21.
Install piston (12) in housing (15).
22.
Place housing (15) in an arbor press.
Go to sheet 6
15-53
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-4.
First Gear Assembly. (Sheet 6 of 7)
ASSEMBLY (cont)
Before installing friction plates
(5 and 6), friction plates must be
soaked in transmission oil for one
hour. Failure to follow this
procedure will result in damage
to the transmission.
23.
Install 15 plates (5), 14 plates (6)
and 28 new springs (7) in housing (9)
in the following order: One plate
(5), two springs (7) and one plate
(6). Be sure that open ends of
springs (7) have bend facing up.
Each pair of springs (7) must have
open ends alined with each other.
24.
Continue stacking until stack is 1
inch from top of housing.
25.
Insert guide pins in each oil hole
slot, refer to illustration.
26.
Continue stacking plates (6 and 5)
and springs (7) using guide pins to
aline teeth of plates. When properly
alined, plate will drop freely into
place.
27.
Install plate (4).
28.
Using an adapter, gradually press
springs (7) and plates (6 and 5). Do
not press plates (6 and 5) all at
once. This procedure will allow
springs (7) to seat properly.
29.
Repeat several times, each time
pressing plates a little further into
housing.
Go to sheet 7
15-54
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-4.
First Gear Assembly. (Sheet 7 of 7)
ASSEMBLY
30.
Press plates far enough to expose
retaining ring (3) groove.
31.
Lock arbor press and remove guide
pins with removal tools.
32.
Install new retaining ring (3) in
housing (9). Be sure that open space
between retaining ring (3) ends does
not aline with oil holes.
33.
Install gear (2).
34.
Using a flat tip screwdriver,
install new retaining ring (1).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
15-55
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5.
Second and Third Gear Assembly. (Sheet 1 of 17)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item S)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Wave spring (40)
Preformed packing (2)
Retaining ring (6)
Seal ring (2)
Wood block
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 15-3
Go to sheet 2
15-56
Condition Description
Transmission disassembled.
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5.
Second and Third Gear Assembly. (Sheet 2 of 17)
DISASSEMBLY
Using snap ring pliers, remove and
discard retaining ring (1) from
second gear side. Second gear side
has three oil holes in housing (40).
Third gear side has only one oil hole
in housing.
2.
Using a gear puller, remove race (2)
and gear (3).
3.
Remove gear (4).
4.
Remove two races (5) and thrust
bearing (6). Note thickness of races
for assembly references.
5.
Remove gear (7).
6.
Remove two bearings (8) from gear
(7).
7.
Remove two races (9) and thrust
bearing (10). Note that inner races
are thinner than outer races.
GO to sheet 3
15-57
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5.
Second and Third Gear Assembly. (Sheet 3 of 17)
DISASSEMBLY (cont)
Using two C clamps, depress plate
(12) into third gear side of housing
(40).
8.
Use care when removing retaining
ring. Take care not to let
fingers inside housing in case “C”
clamps fail and plate tension is
released.
Using a machinist’s scribe, remove
and discard retaining ring (11).
9.
10.
Remove C clamps from plate (12).
11.
Remove plate (12).
Wave springs are thin and have
sharp edges.
Use care when
handling them to avoid cutting
hands and fingers.
Use care when removing and
handling clutch plates.
Avoid
nicking or scratching friction
surfaces.
12.
Using snap ring pliers, remove and
discard retaining ring (16).
13.
Remove plates (13), plates (14) and
springs (15) to allow a gear puller
to be installed on gear (20).
Discard springs (15).
Go to sheet 4
15-58
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5.
Second and Third Gear Assembly. (Sheet 4 of 17)
DISASSEMBLY
14.
Using a gear puller, remove race
(17), two races (18), thrust bearing
(19) and gear (20).
15.
Remove two bearings (21) from gear
(20).
16.
Remove remaining plates (13), plates
Discard
(14) and springs (15).
springs (15).
17.
Remove two races (22) and thrust
bearing (23). Note that inner races
are thinner than outer races.
Go to sheet 5
15-59
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5.
Second and Third Gear Assembly. (Sheet 5 of 17)
DISASSEMBLY (cont)
18.
Using two C clamps, depress plate
(25) in second gear side.
Use care when removing retaining
ring. Take care not to let
fingers inside housing in case C
clamps fail and plate tension is
released.
19.
Using a machinist’s scribe, remove
and discard retaining ring (24).
20. Remove “C” clamps from plate (25).
Wave springs are thin and have
sharp edges.
Use care when
handling them to avoid cutting
hands and fingers. If cut, seek
medical attention.
Use care when removing and
handling clutch plates.
Avoid
nicking or scratching friction
surfaces.
21. Using long round nose pliers,
remove 15 plates (26), 14 plates
(27) and 28 wave springs (28).
Discard 28 springs (28).
Go to sheet 6
15-60
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5.
Second and Third Gear Assembly. (Sheet 6 of 17)
DISASSEMBLY
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
(goggles/shield,
equipment
gloves, etc.).
Do not blast piston out of
cylinder. Use air pressure with
restraint. Failure to follow
this procedure could result in
damage to piston or cylinder.
NOTE
Third gear port is closest to the
rear of the shaft.
22.
Apply air pressure to shaft bore at
third gear side.
23.
Remove piston (29).
24.
Using a machinist’s scribe, remove
and discard preformed packing (30)
and seal ring (31).
25.
Using a machinist’s scribe, remove
and discard retaining ring (32).
Go to sheet 7
15-61
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5.
Second and Third Gear Assembly. (Sheet 7 of 17)
DISASSEMBLY (cont)
NOTE
Second gear port is closest to
the front of-the shaft.
26.
Apply air pressure to shaft bore at
second gear port.
27.
Remove piston (33).
28.
Using a machinist’s scribe, remove
and discard preformed packing (34)
and seal ring (35).
29.
Using a punch and hammer, drive three
pins (36) down past retaining ring
(37).
30.
Using a machinist’s scribe, remove
and discard retaining ring (37).
31.
Remove cylinder (38) and shaft (39)
as an assembly from housing (40).
32.
Using an arbor press, press shaft
(39) from cylinder (38).
33.
Using a 3/16” socket head screw key,
remove setscrew (41) from shaft (39).
34.
Using slip joint pliers, remove two
pins (42) from shaft (39),
35.
Remove two balls (43).
Go to sheet 8
15-62
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5. Second and Third Gear Assembly. (Sheet 8 of 17)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If y o u
become dizzy while using cleaning
get
fresh
solvent,
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
36.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
37.
Inspect shaft (39) splines for wear
or damage. Replace, if necessary.
38.
Inspect gears (3, 4, 7 and 20),
cylinder (38) and plates (12 thru 14
and 25 thru 27) for wear, cracks or
Replace, if
missing teeth.
necessary.
Go to sheet 9
15-63
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Second and Third Gear Assembly. (Sheet 9 of 17)
15-5.
CLEANING/INSPECTION (cont)
39.
Inspect clutch plates for wear,
burning or warping.
Replace, if
necessary.
40.
Inspect pistons (29 and 33) and
relief orifices to make certain they
are open.
41.
Inspect all bearings and races for
pits or spalled areas. Replace, if
necessary.
42.
Inspect all other parts.
ASSEMBLY
43.
Install two balls (43).
44.
Using a plastic hammer, install two
pins (42) on shaft (39).
45.
Using a 3/16” socket head screw key,
install setscrew (41) on shaft (39).
46.
Heat cylinder (38) to 275 degrees F.
47.
With chamfer bore of cylinder (38),
facing splined end of shaft (39),
aline oil holes of shaft (39) with
oil holes in cylinder (38).
48.
Using insulated gloves, lower hot
Hot
cylinder (38) onto shaft (39).
cylinder (38) will position itself
correctly on shaft (39).
Go to sheet 10
15-64
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5.
Second and Third Gear Assembly. (Sheet 10 of 17)
ASSEMBLY
NOTE
Wait until shaft and cylinder
assembly is cool before continuing.
49.
Install pistons (33 and 29) in
cylinder (38).
50.
Rotate pistons (33 and 29) to check
clearance.
51.
Remove pistons (33 and 29).
52.
Install new preformed packing (34)
and new seal ring (35) in piston (33)
on second gear side of shaft (39).
53.
Coat piston (33) with
lubricating oil.
54.
Insert piston (33) with new preformed
packing (34) and new seal ring (35)
end entering cylinder (38) first.
55.
Using a plastic hammer, tap piston
(33) into place.
56.
Turn over shaft (39) so that third
gear side is facing up.
clean
Go to sheet 11
15-65
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5. Second and Third Gear Assembly. (Sheet 11 of 17)
ASSEMBLY (cont)
57.
Install new preformed packing (30)
and new seal ring (31) in piston
(29).
58.
Coat piston (29) with
lubricating oil.
59.
Insert piston (29) with new preformed
packing (30) end entering cylinder
first.
60.
Using plastic hammer, tap piston (29)
into place into housing.
clean
NOTE
The clutch housing has three oil
holes in the second gear side and
one hole in the third gear side.
61.
Install new retaining ring (37) in
second gear side of housing (40). Be
sure that open space between new
retaining ring (37) end does not
aline with oil holes.
62.
Using a rubber mallet, install shaft
(39) and cylinder (38) as an assembly
in housing (40) with splined end of
shaft facing toward second gear side
of housing (40).
63.
Install new retaining ring (32) in
housing (40) of third gear side. Be
sure that open space between new
retaining ring (32) end does not
aline with oil holes.
Go to sheet 12
15-66
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5.
Second and Third Gear Assembly. (Sheet 12 of 17)
ASSEMBLY
64.
Using a plastic hammer, install three
pins (36) on second gear side,
driving pin down until head of pin
just clears upper surface of
retaining ring (37).
65.
Place housing (40) in an arbor press
third gear side up.
Before installing friction plates
(13 and 14), friction plates must
be soaked in transmission oil for
one hour. Failure to follow this
procedure will result in damage
to the transmission.
66.
Install 12 new wave springs (15) and
six plates (14) and seven plates (13)
in the following order: One plate
(13), two wave springs (15) and one
plate (14). Be sure that open ends of
new wave springs (15) have bend facing
up. Each pair of new wave springs
(15) must have opens ends alined with
each other.
67.
Continue stacking in order until
stack is 1 inch from top of housing
(40).
68.
Insert guide pins at each oil hole
slot, refer to illustration.
69.
Continue stacking plates and springs,
using guide pins to properly aline
teeth until all have been installed.
Final plate to be installed must be
seventh plate (13). When properly
alined, plate will drop freely into
place.
Go to sheet 13
15-67
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5.
Second and Third Gear Assembly. (Sheet 13 of 17)
ASSEMBLY (cont)
70.
Install plate (12). Do not
guide pins.
71.
Using an adapter, gradually press
plates and springs into housing (40).
Do not press all at once. Press and
release gradually in 1/4 inch
increments to allow springs to seat.
72.
When retaining ring groove of housing
is exposed, lock arbor press.
73.
Using slip joint pliers, remove guide
pins.
74.
Install new retaining ring (11). Be
sure that open space between new
retaining ring (11) end does not
aline with oil holes.
75.
Turn housing (40) over and place in
an arbor press with second gear side
up.
remove
Before installing friction plates
(26 and 27), friction plates must
be soaked in transmission oil for
one hour. Failure to follow this
procedure will result in damage
to the transmission.
76.
Install 28 new wave springs (28) and
14 plates (27) and 15 plates (26) in
the following order: One plate (26),
two wave springs (28) and one plate
(27). Be sure that open ends of new
wave springs (28) have bend facing up.
Each pair of new wave springs (28)
must have opens ends alined with each
other.
77.
Continue stacking in order until
stack is 1 inch from top of housing
(40).
Go to sheet 14
15-68
TN 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5.
Second and Third Gear Assembly. (Sheet 14 of 17)
ASSEMBLY
78. Insert guide pins at each oil hole
slot.
79.
Continue stacking plates (27 and 26)
and springs (28) using guide Pins to
properly aline teeth until all have
When properly
been installed.
alined, plate (29) will drop freely.
80. Install plate (25). Do not remove
guide pins.
81.
Using an adapter, gradually press
plates and springs into housing (40).
Do not press all at once. Press and
release gradually in 1/4 inch
increments to allow springs to seat
properly.
82. When retaining ring groove of housing
(40) is exposed, lock arbor press.
83. Using slip joint pliers, remove guide
pins.
84.
Install new retaining ring (24). Be
sure that open space between new
retaining ring (24) end does not
aline with oil holes.
Go to sheet 15
15-69
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5.
Second and Third Gear Assembly. (Sheet 15 of 17)
ASSEMBLY (cont)
Inner races of second gear are
thinner than those used on outer
face of gear. Do not mix or
interchange races. Failure to
follow this procedure could
result in damage to transmission.
85.
Install thrust bearing (10) and two
races (9).
86.
Position gear (7) on shaft (39).
87.
Install bearing (8) in bore of gear
(7).
88.
Rotate gear (7) back and forth to
engage teeth of gear with teeth of
clutch plates. If gear does not
bottom out fully, remove it and
visually aline clutch plate keeping
gear from bottoming out.
Repeat
installation procedure.
89.
Install thrust bearing (6) and two
races (5).
Go to sheet 16
15-70
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-5.
Second and Third Gear Assembly. (Sheet 16 of 17)
ASSEMBLY
90.
Install gear (4).
91.
Install gear (3).
92.
Heat races (2) to 250 degrees F.
93.
Using insulated gloves and plastic
hammer, drive races (2) onto shaft
(39).
94.
Using retaining ring pliers, install
new retainer ring (1).
NOTE
Inner and outer races are the
same thickness in third gear.
95.
Install thrust bearing (23) and race
(22) onto shaft (39).
Go to sheet 17
15-71
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-5.
Second and Third Gear Assembly. (Sheet 17 of 17)
ASSEMBLY (cont)
96.
Position gear (20) on shaft (39).
97.
Install two bearings (21) in bore of
gear (20).
98.
Rotate gear (20) back and forth to
engage teeth of gear with teeth of
clutch plate. If gear does not
bottom out fully, remove it and
visually aline clutch plate keeping
gear from bottoming out.
Repeat
installation procedure.
99.
Install one race (19), thrust
bearing (18) and remaining race (17)
onto shaft (39).
100.
Heat race (17) to 250 degrees F,
refer to Chapter 2.
101.
Using insulated gloves and plastic
hammer, drive race (17) onto shaft
(39).
102.
Using snap ring pliers, install new
retaining ring (16).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
15-72
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE,
15-6.
Forward and Reverse Steering Gear Assembly. (Sheet 1 of 13)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lubricating oil (App. C, Item 19)
Preformed packing (2)
Seal ring (5)
Wave spring (36)
Retaining ring (5)
Wood block
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 15-3
Condition Description
Transmission disassembled.
Go to sheet 2
15-73
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Forward and Reverse Steering Gear Assembly. (Sheet 2 of 13)
15-6.
DISASSEMBLY
1. Using a flat tip screwdriver, remove
and discard three seal rings (1) from
shaft (40) at forward gear side.
2.
Using snap ring pliers, remove and
discard retaining ring (2).
3.
Remove bearing (3) and spacer (4).
4.
Remove two washers (5) and thrust
washer (6).
5.
Using a gear puller, remove gear (7)
from shaft (40).
6.
Remove two bearings (8).
7. Using snap ring pliers, remove and
discard retaining ring (9) from
reverse gear side.
8.
Remove bearing (10) and spacer (11).
9.
Remove two washers (12) and thrust
bearing (13).
10.
Remove gear (14) from shaft (40).
11.
Remove two bearings (15) from gear
(14).
Go to sheet 3
15-74
5
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-6.
Forward and Reverse Steering Gear Assembly. (Sheet 3 of 13)
DISASSEMBLY
12.
Depress plate (17) using two “C”
clamps at forward side gear.
Be extremely careful
removing ring.
when
13.
Remove and discard retaining ring
(16).
14.
Remove two C clamps from plate (17).
15.
Remove plate (17) from housing (42).
16.
Remove nine plates (18 and 19) and 18
wave springs (20). Discard 18 wave
springs (20).
17.
Remove two washers (21) and thrust
bearing (22).
18.
Remove plate (23).
19.
Depress plate (25) using two
clamps at reverse gear side.
"C"
GO to sheet 4
15-75
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Forward and Reverse Steering Gear Assembly. (Sheet 4 of 13)
15-6.
DISASSEMBLY (cont)
20.
Remove and discard retaining ring
(24).
21.
Remove two C clamps from plate (25).
22.
Remove plate (25).
23.
Remove nine plates (26 and 27) and 18
wave springs (28). Discard 18 wave
springs (28).
24.
Remove two washers (29) and thrust
washer (30).
25.
Remove plate (31).
26.
Remove retainer ring (32).
COMPRESSED AIR HAZARD
Compressed air will not exceed 30
psi. Use only with effective
chip guarding and personal
equipment
protective
(goggles/shield, gloves, etc.).
Do not blast piston out of
housing. Use air pressure with
restraint. Failure to follow
this procedure could result in
damage to piston or housing.
27.
Apply air pressure to reverse oil
supply port at end of shaft (40).
28.
Remove piston (33) from cylinder (41).
Go to sheet 5
15-76
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-6.
Forward and Reverse Steering Gear Assembly. (Sheet 5 of 13)
DISASSEMBLY
29.
Remove and discard preformed packing
(34) from piston (33) and seal ring
(35) from shaft (41).
30.
Apply air pressure to forward oil
supply port at end of shaft (40). DO
not blast piston from cylinder.
31.
Remove piston (37).
32.
Remove and discard preformed packing
(38) and seal ring (39).
33.
Using a punch and hammer, drive three
pins (44) down past retaining ring
(36).
34.
Remove and discard
(36).
35.
Remove items 40 and 41 as an assembly
from housing (42).
36.
Using an arbor press, press shaft
(40) from cylinder (41).
37.
Separate shaft (40) and cylinder
(41).
38.
Using a punch, remove pin (43) from
shaft (40).
39.
Using slip joint pliers, remove three
pins (44) from cylinder (41).
retaining
ring
Go to sheet 6
15-77
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-6.
Forward and Reverse Steering Gear Assembly. (Sheet 6 of 13)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
40.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 7
15-78
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-6.
Forward and Reverse Steering Gear Assembly. (Sheet 7 of 13)
CLEANING/INSPECTION
41.
Inspect shaft (40) splines for wear
and damage. Replace, if necessary.
42.
Inspect all plates, gears, housings
and cylinders for chips, cracks, wear
Replace, if
or missing teeth.
necessary.
43.
Inspect all other parts. Refer to
paragraph 2-9.
ASSEMBLY
44.
Install pistons (33 and 37) in
cylinder (41).
45.
Rotate pistons to check clearance.
46.
Remove pistons (33 and 37).
47.
Heat cylinder (41) to 275 degrees F.
48.
With chamfered bore of cylinder
facing splined end of shaft, aline
oil holes of shaft (40) with oil
holes in cylinder (41).
49.
Using insulated gloves, lower hot
cylinder (41) onto shaft (40). Hot
cylinder (41) will position itself
correctly on shaft.
Go to sheet 8
15-79
TN 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Forward and Reverse Steering Gear Assembly. (Sheet 8 of 13)
15-6.
ASSEMBLY (cont)
NOTE
Wait until shaft and cylinder
cool
before
assembly is
continuing.
50.
Using a plastic hammer, install pin
(43) in shaft (40). Must be flush in
shaft (40).
51.
Install new preformed packing (38)
and new seal ring (39) on piston
(37).
52.
Coat piston (37) with clean lubricating oil.
53.
Insert piston (37) in cylinder (41)
with new preformed packing (38)
entering cylinder first.
54.
Using a plastic hammer, tap piston
(37) into place.
55.
Turn shaft {40) over.
56.
Install new preformed packing (34)
and new seal ring (35) on piston
(33).
57.
Coat piston (33) with clean lubricating oil.
Go to sheet 9
15-80
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION
MAINTENANCE.
15-6. (Forward and Reverse) Steering Gear Assembly. (Sheet 9 of 13)
ASSEMBLY
58.
Insert piston (33) with new
preformed packing (34) end entering
cylinder first.
59.
Using a plastic hammer, tap piston
(33) into place.
60.
Install new retaining ring (36) in
housing (42). Be sure that open
space between new retaining ring
(36) end does not aline with oil
holes.
61.
Install shaft (40) and cylinder (41)
into housing (42).
62.
Install new retaining ring (32) into
housing (42). Be sure that open
space between new retaining ring
(32) does not aline with oil holes.
63.
Using a plastic hammer, install
three pins (44), driving three Pins
(44) down until heads of three pins
(44) just clear upper surface of
retaining ring (36).
64.
Position housing (42) in arbor press
at reverse gear side.
65.
Install plate (31).
Go to sheet 10
15-81
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-6. Forward and Reverse Steering Gear Assembly. (Sheet 10 of 13)
ASSEMBLY (cont)
66.
Install two washers (29) and thrust
washer (30).
Before installing friction plates
(26 and 27), friction plates must
be soaked in transmission oil for
one hour. Failure to follow this
procedure will result in damage
to the transmission.
67.
Install 18 new wave springs (28) and
nine plates (27 and 26) in the
following order: One plate (27), two
wave springs (28) and one plate (26).
Be sure that open ends of new wave
springs (28) have bend facing up.
Each pair of new wave springs (28)
must have opens ends alined with each
other.
68.
Continuing stacking in order until
stack is 1 inch from top of housing
(42).
69.
Insert guide pins at each oil hole
slot, refer to illustration.
70.
Continue stacking plates and springs
using guide pins to properly aline
teeth, until all have been installed.
When properly alined, plates will
drop freely into place.
71.
Install plate (25). Do not remove
guide pins.
72.
Using an adapter, gradually press
plates (27 and 26) and 18 new springs
(28) into housing (42). Do not press
Press and release
all at once.
gradually in 1/4 inch increments to
allow springs to seat properly.
Go to sheet 11
15-82
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-6. Forward and Reverse Steering Gear Assembly. (Sheet 11 of 13)
ASSEMBLY
73.
When retaining ring groove in housing
is exposed, lock arbor press.
74.
Using slip joint pliers, remove guide
pins.
75.
Install new retaining ring (24). Be
sure that open space between new
retaining ring (24) end does not
aline with oil holes.
76.
Turn housing (42) over and position
in arbor press at forward gear side.
77.
Install plate (23).
78.
Install two washers (21) and thrust
washer (22).
Before installing friction plates
(19 and 18), friction plates must
be soaked in transmission oil for
one hour. Failure to follow this
procedure will result in damage
to the transmission.
79.
Install 18 new wave springs (20) and
nine plates (19 and 18) in the
following order: One plate (19), two
wave springs (20) and one plate (18).
Be sure that open ends of new wave
springs (20) have bend facing up.
Each pair of new wave springs (20)
must have opens ends alined with each
other.
80. Continue stacking in order until
stack is 1 inch from top of housing
(42).
Go to sheet 12
15-83
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-6. Forward and Reverse Steering Gear Assembly. (Sheet 12 of 13)
ASSEMBLY (cont)
81.
Insert guide pins at each oil slot
hole.
82.
Continue stacking plates and springs,
using guide pins to properly aline
teeth until all have been installed.
When properly alined, plate will drop
freely into place.
83.
Install plate (17). Do not remove
guide pins.
84.
Using an adapter, gradually press
plates and springs into housing (42).
Do not press all at once. Press and
release gradually in 1/4 inch
increments to allow springs to seat
properly.
85.
When retaining ring groove in housing
is exposed, lock arbor press.
86.
Using slip joint pliers, remove guide
pins.
87.
Install new retaining ring (16). Be
sure that open space between new
retaining ring (16) ends does not
aline with oil holes.
Go to sheet 13
15-84
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-6.
Forward and Reverse Steering Gear Assembly. (Sheet 13 of 13)
ASSEMBLY
88.
Install gear (7) on shaft (40). Turn
gear back and forth to aline teeth.
89.
Install two bearings (8) in gear (7).
90.
Install two washers (5) and thrust
washer (6).
91.
Install spacer (4) and bearing (3).
92.
Using snap ring pliers, install new
retaining ring (2).
93.
Install three new seal rings (1).
94.
Install gear (14) on shaft (40) at
reverse gear side. Turn gear back and
forth to aline teeth.
95.
Install two bearings (15) in gear
(14).
96.
Install two washers (12) and thrust
washer (13).
97.
Install spacer (11) and bearing (10).
98.
Using snap ring pliers, install new
retaining ring (9).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
15-85
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-7.
Transmission Control Valve. (Sheet 1 of 9)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean-cloth (App. C, Item 24)
Grease (App. C, Item 11)
Transmission oil (App. C, Item 19)
Preformed packing (6)
Seal (3)
Wiper (3)
Torques
Except for special torques shown,
all fasteners are tightened to a
standard torque. Refer to
Appendix E.
EQUIPMENT CONDITION
References
Paragraph 6-8
Go to sheet 2
15-86
Condition Description
Transmission control valve removed.
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-7.
Transmission Control Valve. (Sheet 2 of 9)
DISASSEMBLY
NOTE
Prepare a clean work area for
Maintain clean
disassembly.
conditions at all times while
working on valve.
1.
Using an 1-7/16” open end wrench,
remove plug (1) and preformed packing
(2). Discard preformed packing (2).
2.
Using a wooden dowel, remove pin (3).
Note location of pin (3) for
reference during assembly.
3.
Remove and discard preformed packing
(4).
4.
Push items 7 thru 12 as an assembly
out of housing (32) through plug
assembly (5).
5.
Using an 1-7/16” open end wrench,
remove plug assembly (5) and
preformed packing (6).
Discard
preformed packing (6).
Bolt is under pressure from
spring. Use care when removing
bolt. Point bolt away from
personnel and unscrew slowly.
Failure to follow this procedure
could result in INJURY. If
injured, seek medical attention
immediately.
6.
Using a 1/2” socket and socket
wrench handle, remove bolt (7),
washer (8), spring (9), spacer
(10) and washer (11) from plunger
(12).
Go to sheet 3
15-87
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-7.
Transmission Control Valve. (Sheet 3 of 9)
DISASSEMBLY (cont)
7.
Using a 1-7/16” open end wrench,
unscrew plug (13) from housing (32).
Do not remove plug (13).
8.
Push items 13 thru 19 as an assembly
out of housing (32). Plug (13) and
plunger (19) must remain attached.
9.
Wrap clean cloth entirely around
plunger (19) and carefully separate
plug (13), four balls (14), cam (15)
and spring (16) from plunger (19).
Balls (14), cam (15) and spring (16)
will drop into cloth.
10.
Remove and discard preformed packing
(17).
11.
Using snap ring pliers, remove
retaining ring (18) from plunger
(19).
12.
Using an 1-7/16” open end wrench,
unscrew plug (20) from housing (32).
13.
Push items 20 thru 27 as an assembly
out of housing (32). Plug (20) and
plunger (27) must remain attached.
14.
Wrap clean cloth entirely around
plunger (27) and carefully separate
plug (20), four balls (21), cam (22)
and spring (23) from plunger (27).
Balls (21), cam (22) and spring (23)
will drop into cloth.
15.
Using flat tip screwdriver, remove
plug (24).
16.
Remove and discard preformed packing
(25) from plug (20).
17.
Using snap ring pliers, remove
retaining ring (26) from plunger
(27).
Go to sheet 4
15-88
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-7.
Transmission Control Valve. (Sheet 4 of 9)
DISASSEMBLY
18.
Using an 7/8” socket and socket
wrench handle, remove plug (28) and
preformed packing (29) from housing
(32). Discard preformed packing
(29).
19.
Using long round nose pliers, remove
and discard three seals (30) and
wipers (31).
Go to sheet 5
15-89
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-7.
Transmission Control Valve. (Sheet 5 of 9)
CLEANING/INSPECTION
● TOXIC/FLAMMABLE
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
20.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 6
15-90
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-7.
Transmission Control Valve. (Sheet 6 of 9)
CLEANING/INSPECTION
21.
Inspect plungers (12, 19 and 27) for
scoring, damage or excessive wear.
If any of these conditions are
indicated, replace entire control
valve assembly.
22.
Inspect housing (32) valve bores for
scoring, damage or excessive wear.
If any of these conditions are
indicated, replace entire control
valve assembly.
23.
Inspect all other parts. Refer to
paragraph 2-9.
ASSEMBLY
24.
Apply light coating of grease to
three new wipers (31) and new seals
(30) and install in housing (32) in
seal groove. Recessed face of new
seal (30) faces inside of housing
(32).
25.
Using an 7/8” socket and socket
wrench handle, install new preformed
packing (29) and plug (28).
Go to sheet 7
15-91
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-7.
Transmission Control Valve. (Sheet 7 of 9)
ASSEMBLY (cont)
26.
Using snap ring pliers,
retaining ring (26).
27.
Install new preformed packing (25) in
plug (20).
install
NOTE
● Install correct plug on each
plunger. Range plunger with
holes bored in lands uses longer
plug.
● Secure eye end of plunger in
soft jawed vise with plunger in
vertical position.
28.
Using a flat tip screwdriver, install
plug (24) in plunger (27).
29.
Install spring (23) and cam (22).
30.
Hold four balls (21) in position in
plunger (27) with one hand.
31.
Position plug (20) on end of plunger
(27).
32.
Push down over balls (21) with quick
downward movement.
33.
Lubricate items 27 thru 20 as an
assembly in housing (32) with clean
transmission oil and install into
valve bore.
34.
Using an 1-7/16” open end wrench,
tighten plug (20).
Go to sheet 8
15-92
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-7.
Transmission Control Valve. (Sheet 8 of 9)
ASSEMBLY
35.
Using snap ring pliers, install
retaining ring (18) to plunger (19).
36.
Install new preformed packing (17) in
plug (13).
NOTE
Secure eye end of plunger in soft
jawed vise with plunger in
vertical position.
37.
Install spring (16) and cam (15) in
plunger (19).
38.
Hold four balls (14) in position in
plunger (19) with one hand.
39.
position plug (13) on end of plunger
(19).
40.
Push down over balls (14) with quick
downward movement.
41.
Lubricate items 19 thru 13 as an
assembly in housing (32) with clean
transmission oil and install into
valve bore.
42.
Using a 1-7/16” open end wrench,
tighten plug (13).
Go to sheet 9
15-93
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Transmission Control Valve. (Sheet 9 of 9)
15-7.
ASSEMBLY (cent)
43.
Install washer (11), spacer (10),
spring (9) and washer (8) in plunger
(12).
44.
Using a 1/2” socket and socket wrench
Hold
handle, install bolt (7).
plunger (12) in groove with locking
pliers and tighten bolt (7). Do not
hold plunger (12) on polished land
surfaces.
45.
Using a 1-7/16” open end wrench,
install new preformed packing (6) and
plug assembly (5) in housing (32).
46.
Lubricate items 12 thru 7 as an
assembly with transmission oil and
install.
47.
Install new preformed packing (4) in
pin (3).
48.
Install pin (3) in plug (l).
Preformed packing (4) must be away
from housing (32) end of plug.
49.
Using an 1-7/16” open end wrench,
install new preformed packing (2) and
plug (1) in housing (32).
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
15-94
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-8.
Transmission Scheduling Valve. (Sheet 1 of 7)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Preformed packing (18)
Torques
Check valve (1, 7, 13, 22, 26 and
30) to 30 to 35 lb-ft.
Retainer (34) to 50 to 60 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 6-8
Condition Description
Transmission scheduling valve removed.
Go to sheet 2
15-95
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-8.
Transmission Scheduling Valve. (Sheet 2 of 7)
DISASSEMBLY
NOTE
Prepare a clean work area for
disassembly.
Maintain clean
conditions at all times while
working on valve. Note proper
sequence during disassembly.
Identify and segregate all
components. Do not mix parts.
1.
Using a drive socket and socket
wrench handle, remove check valve
(1), preformed packing (2), retainer
(3), preformed packing (4), retainer
(5) and preformed packing (6) from
body (51).
Discard preformed
packings (2,4 and 6).
2.
Remove check valve (7), preformed
packing (8), retainer (9), preformed
packing (10), retainer (11) and
preformed packing (12).
Discard
preformed packings (8,10 and 12).
3. Remove check valve (13), preformed
packing (14), retainer
(15),
preformed packing (16), retainer (17)
and preformed packing (18). Discard
preformed packings (14, 16 and 18).
4.
Using a wooden dowel, remove spools
(19 thru 21).
Go to sheet 3
15-96
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-8.
Transmission Scheduling Valve. (Sheet 3 of 7)
DISASSEMBLY
5.
Using a 1"- socket and socket wrench
handle, remove check valve (22),
preformed packing (23), retainer (24)
and preformed packing (25). Discard
preformed packings (23 and 25).
6.
Remove check valve (26), retainer
(27), preformed packing (28) and ring
(29). Discard preformed packing
(28).
7.
Remove check valve (30), retainer
(31), preformed packing (32) and ring
(33). Discard preformed packing
(32).
8.
Using a 1-1/2” open end wrench,
remove retainer (34), spring (35),
piston (36) and preformed packing
(37) . Discard preformed packing
(37).
NOTE
Sleeve should not be removed
unless it is known to be damaged
or not operating properly.
9.
Using a wire hook, remove sleeve
(38). Wire must be bent into U shape
and ends bent outward to form hooks.
Hooks can be engaged in cross drilled
oil holes in sleeve (38).
10.
Remove spring (39), spool (40) and
preformed packings (41 thru 43).
Discard preformed packings (41 thru
43).
Go to sheet 4
15-97
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
15-8. Transmission Scheduling Valve. (Sheet 4 of 7)
DISASSEMBLY (cont)
NOTE
Inspect sleeves before removal.
Replace only if scored or
damaged.
11.
Using a wooden dowel, press sleeves
(44 thru 46) out with rod. Rod must
have diameter smaller than bore in
body (51) but larger than inner bore
of sleeves (44 thru 46).
12.
Remove sleeve (47) and preformed
Discard preformed
packing (48).
packing (48).
13. Using a 3/16” socket head screw key,
remove plugs (49 and 50).
Go to sheet 5
15-98
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-8. Transmission Scheduling Valve. (Sheet 5 of 7)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
If
with eyes, skin or clothing.
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
get
fresh
air
solvent,
immediately.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
14.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
15.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 6
15-99
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE. (cont)
Transmission Scheduling Valve. (Sheet 6 of 7)
15-8.
ASSEMBLY
16.
Using a 3/16” socket head screw key,
install plugs (50 and 49) to body
(51).
17.
Install new preformed packing (48)
and sleeve (47).
18.
Install sleeves (46 thru 44), only if
inspection proved necessary to
remove.
19.
Install new preformed packings (43
thru 41), spool (40) and spring (39).
20.
Install sleeve (38).
21.
Using a 1-1/2” socket and torque
wrench, install new preformed packing
(37), piston (36), spring (35) and
retainer (34). Tighten retainer (34)
to 50 to 60 lb-ft.
22.
Using a 1“ socket and torque wrench,
install ring (33), new preformed
packing (32), retainer (31) and check
valve (30). Tighten check valve (30)
to 30 to 35 lb-ft.
Go to sheet 7
15-100
TM 10-3930-643-34
GENERAL SUPPORT TRANSMISSION MAINTENANCE.
15-8.
Transmission Scheduling Valve. (Sheet 7 of 7)
ASSEMBLY
23.
Using a 1“ socket and torque wrench,
install ring (29), new preformed
packing (28), retainer (27) and check
valve (26). Tighten check valve (26)
to 30 to 35 lb-ft.
24.
Install new preformed packing (25),
retainer (24), new preformed packing
Tighten
(23) and check valve (22).
check valve (22) to 30 to 35 lb-ft.
25.
Install spools (21 thru 19).
26.
Install new preformed packing (18),
retainer (17), new preformed packing
(16), retainer (15), new preformed
packing (14) and check valve (13).
Tighten check valve (13) to 30 to 35
lb-ft.
27.
Install new preformed packing (12),
retainer (11), new preformed packing
(10), retainer (9), new preformed
packing (8) and check valve (7).
Tighten check valve (7) to 30 to 35
lb-ft.
28.
Install new preformed packing (6),
retainer (5), new preformed packing
(4), retainer (3), new preformed
packing (2) and check valve (1).
Tighten check valve (1) to 30 to 35
lb-ft.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
15-101 (15-102 blank)
TM 10-3930-643-34
CHAPTER 16
GENERAL SUPPORT PROPELLER AND
PROPELLER SHAFTS MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized general support level
maintenance procedures on the M10A Forklift.
INDEX
Title
Front Differential Carrier Assembly
Front and Rear Planetary
Rear Differential Carrier Assembly
Paragraph
16-1
16-2
16-3
Page
16-2
16-15
16-19
16-1
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cent)
16-1.
Front Differential Carrier Assembly. (Sheet 1 of 13)
This task covers:
a.
c.
Disassembly
Assembly
b.
d.
Cleaning/Inspection
Adjustment
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Fine emery cloth (App. C, Item 4 )
Permatex No. 2 (App. C, Item 26)
Gear oil (App. C, Item 18)
Soft iron wire
Cotter pin (3)
Lockwire (2)
Gasket
Seal (2)
Torques
Bolts (4) to 160 to 190 lb-ft.
Bolts (10, 12 and 29) to 105 to
135 lb-ft.
Nuts (34 and 56) to 300 to 400 lb-ft.
Bolts (38, 40, 60 and 62) to 50 to
65 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 7-4
Go to sheet 2
16-2
Condition Description
Front differential carrier assembly
removed.
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-1.
Front Differential Carrier Assembly. (Sheet 2 of 13)
DISASSEMBLY
NOTE
Prior to disassembly of differential carrier assembly, backlash
of gears must be measured and
recorded. Steps 1 thru 3 are
necessary only if gears are to be
reused.
1.
Position dial scale indicator on
differential carrier assembly as
shown.
2.
Using a padded vise, secure yoke (38
or 58) and rotate gear (32) back and
forth.
3.
Record backlash as indicated on dial
scale indicator.
NOTE
Except where noted, The following disassembly procedure for
the differential assembly is
identical for both vehicles S/N
2001 to 2903 and S/N 2000 and
below and 2904 and above.
4.
Using long round nose pliers, remove
two cotter pins (1) and adjustment
rings (2) from carrier (54). Discard
two cotter pins.
NOTE
The following is a difference
between M10A Forklift models.
5.
Using diagonal cutters, cut and
discard two lock wires (3) on vehicles
S/N 2000 and below and 2904 and above.
6.
Using a 15/16” socket and socket
wrench handle, remove nut (4) and
screw (5) from carrier (54) on
vehicles S/N 2001 to 2903 only.
Go to sheet 3
16-3
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-1.
Front Differential Carrier Assembly. (Sheet 3 of 13)
DISASSEMBLY (cent)
7.
Using a 15/16” socket and socket
wrench handle, remove four bolts (6),
washers (7), two bearing caps (8), and
pins (9). Mark location of bearing
caps (8).
8.
Using hoist and sling, remove items
10 thru 35 as an assembly and place
on suitable work bench.
9.
Mark location of cups (10 and 11) on
differential assembly and remove.
10.
Using a hammer, punch mark cases (15
and 32).
NOTE
The following is a difference
between M10A Forklift models.
11.
Using a 1/2” socket and socket wrench
handle , remove 16 bolts (12) and
washers (13) or 12 bolts (14). 16
bolts (12) and washers (13) on
vehicles S/N 2000 and below and 2904
and above or 12 bolts (14) on vehicles
S/N 2001 to 2903.
12.
Remove case (15), gear (16) and
washer (17).
13.
Remove items 18 thru 26 as an
assembly.
Go to sheet 4
16-4
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-1.
Front Differential Carrier Assembly. (Sheet 4 of 13)
DISASSEMBLY
14.
Remove washers (18, 19, 20 and 21)
from spider (26).
15.
Remove gears (22, 23, 24 and 25).
16.
Remove gear (27) and washer (28)
from case (34).
17.
Using a 3/4 open end wrench and 3/8”
socket head screw key, remove 12
nuts (29), washers (30), bolts (31)
and gear (32).
18.
Use puller and heat, if required to
remove bearing (33) from case (34).
NOTE
Be certain force is exerted on the
inner race, not the bearing cage.
19.
Use puller and heat, if required to
remove bearing (35) from case (15).
Go to sheet 5
16-5
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-1. Front Differential Carrier Assembly.
DISASSEMBLY (cont)
NOTE
The following steps (20 thru 28) is
the disassembly procedure of the
differential carrier assembly for
vehicles S/N 2000 and below and
2904 and above. The disassembly
procedure of the differential
carrier assembly for vehicles S/N
2001 to 2903, proceed to steps (29
thru 38).
20.
Using 1-1/2 socket and socket wrench
handle. remove nut (36) , and washer
(37) from carrier (54).
21.
Using suitable puller, remove yoke
(38) from deflector (39).
22.
Using a flat tip screwdriver, remove
deflector (39).
23.
Using a 5/8 socket and socket wrench
handle , remove eight bolts (40),
washers (41), two bolts (42), shim
(43) and items 44 thru 53 as an
assembly.
24.
Using an arbor press, remove items 45
thru 49 as an assembly from cage (44).
NOTE
Identify and mark location of
all cups and cones on gear or in
bearing cage. Relationship
between cups and cones must be
maintained during reassembly.
25.
Remove ring (46) from gear (45).
26.
Remove bearing (47) and cone (49) from
gear (45).
27.
Using a flat tip screwdriver, remove
and discard seal (50) and cone (48)
from cage (44).
28.
Using a brass punch and hammer, remove
cup (51), shim (52) and cup (53).
Go to sheet 6
16-6
(Sheet 5 of 13)
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-1.
Front Differential Carrier Assembly. (Sheet 6 of 13)
DISASSEMBLY
NOTE
The following steps (29 thru 38)
are for vehicles S/N 2001 to 2903.
29.
Using a long round nose pliers, 1-1/2
socket and socket wrench handle,
remove cotter pin (55), nut (56) and
washer (57). Discard cotter pin (55).
30.
Using a suitable puller, remove yoke
(58) .
31.
Using a flat tip screwdriver, remove
deflector (59).
32.
Using a 9/16” socket and socket wrench
handle , remove six bolts (60), washer
(61), two bolts (62), cover (63) and
gasket (64). Discard gasket (64).
33.
Using a rubber mallet, remove items
66 thru 75 as an assembly and shim
(65) from carrier (54).
34.
Using an arbor press, press items 66
thru 74 as an assembly from cage
(75).
NOTE
Identify and mark location of
all cups and cones on gear or in
bearing cage. Relationship
between cups and cones must be
maintained during reassembly,
35.
Using snap ring pliers, remove ring
(67) from gear (662).
36.
Using a arbor press. remove bearing
(68) and cones (69 and 70).
37.
Remove and discard seal (71) from
cage (75).
38.
Using a brass punch and hammer,
remove cup (72) and spacer (73) and
cup (74) from cage (75).
Go to sheet 7
16-7
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-1.
Front Differential Carrier Assembly. (Sheet 7 of 13)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
get
air
immediately.
COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc,).
39.
Wipe all parts
moistened with
P-D-680.
Dry
compressed air.
2-8.
40.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 8
16-8
with clean cloth
cleaning solvent
thoroughly with
Refer to paragraph
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-1.
Front Differential Carrier Assembly. (Sheet 8 of 13)
ASSEMBLY
NOTE
The following steps (41 thru 55)
is the assembly procedure for
differential carrier assembly for
vehicles S/N 2001 to 2903. The
assembly procedure for differential
carrier assembly for vehicles S/N
2000 and below and 2904 and above,
proceed to steps (56 thru 68).
When replacing parts, gears must
be replaced as a matched set.
Side gear thrust washers must be
replaced as a matched set.
41.
Install cup (74), spacer (73) and cup
(72) to cage (75).’
42.
Install cone (70) and bearing (68) to
gear (66).
43.
Install ring (67).
44.
Using arbor press, install gear (66)
in cage (75).
45.
Install cone (69).
46.
Rotate cage (75) to verify normal
bearing contact.
47.
Apply load of 6 tons with press as
shown.
48.
Using soft iron wire and scale
indicator, measure bearing preload
torque as shown. Bearing preload
torque should be 5 to 15 in-lb. Be
sure to measure rotating torque and
not starting torque. Install thinner
spacer (73) to increase or thicker
spacer (73) to decrease preload as
required.
Go to sheet 9
16-9
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-1.
Front Differential Carrier Assembly. (Sheet 9 of 13)
ASSEMBLY (Cent)
49.
Lubricate O.D. of new seal (71) with
Permatex No. 2.
50.
Install new seal (71) in cover (63).
51.
Install shim (65) and items 75 thru
72 and 70 thru 66 as an assembly to
carrier (54).
52.
Using a 9/16” socket and torque
wrench, install new gasket (64),
cover (63), two bolts (62), six
washers (61) and bolts (60). Tighten
bolts (60 and 62) to 50 to 65 lb-ft
torque.
53.
Install deflector (59).
54.
Using rubber mallet, install yoke
(58).
55.
Using a
wrench,
and new
(56) to
1-1/2” socket and torque
install washer (57), nut (56)
cotter pin (55). Tighten nut
300 to 400 lb-ft torque.
Go to sheet 10
16-10
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-1. Front Differential Carrier Assembly. (Sheet 10 of 13)
ASSEMBLY
NOTE
The following steps (56 thru 68)
are for vehicles S/N 2000 and
below and 2904 and above
56.
Install cup (53), shim (52) and cup
(51) to cage (44).
57.
Install cone (49) and bearing (47) to
gear (45).
58.
Install ring (46).
59.
Using arbor press, install gear (45)
in cage (44).
60.
Install cone (48).
61.
Apply load of 6 tons with press as
shown.
62.
Using soft iron wire and scale
indicator, measure bearing preload
torque as shown. Bearing preload
torque should be 5 to 15 in-lb. Be
sure to measure rotating torque and
not starting torque. Install thinner
shim (52) to increase or thicker shim
(52) to decrease preload as required.
63.
Lubricate O.D. of new seal (50) with
Permatex No. 2.
64.
Install new seal (48).
65.
Install shim (43) and items 53 thru 44
as an assembly to carrier (54).
66.
Using a 5/8” socket and socket wrench
handle, install two bolts (42), eight
washers (41) and bolts (40). Tighten
bolts (42 and 40) to 50 to 65 lb-ft.
67.
Install deflector (39).
68.
Using a 1-1/2” socket and torque
wrench, install yoke (38), washer (37)
and nut (36). Tighten nut (36) to 300
to 400 lb-ft torque.
Go to sheet 11
16-11
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-1.
Front Differential Carrier Assembly. (Sheet 11 of 13)
ASSEMBLY (Cont)
NOTE
Except where noted, The following assembly procedure for the
differential assembly is
identical for both vehicles S/N
2001 to 2903 and S/N 2000 and
below and 2904 and above.
69.
Using a 3/4 open end wrench, 3/8”
socket head screw key and torque
wrench, install gear (32), 12 bolts
(31), washers (30) and nuts (29) to
case (32). Tighten 12 bolts (31) to
105 to 135 lb-ft torque.
70.
Lubricate washer (28) and gear (27)
with gear oil and install.
71.
Lubricate gears (25, 24, 23 and 22)
with gear oil and install on spider
(26).
72.
Lubricate washers (21, 20, 19 and
18) with gear oil and install.
73.
Install items 26 thru 18 as an
assembly to case (34).
74.
Lubricate washer (17) and gear (16)
with gear oil and install.
Go to sheet 12
16-12
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-1.
Front Differential Carrier Assembly. (Sheet 12 of 13)
ASSEMBLY (Cont)
NOTE
The following is a difference
between M10A Forklift models.
75.
Be sure to aline identification marks
on cases (15 and 34). Using a 1/2”
socket and socket wrench handle,
install case (15) with four equally
spaced bolts (14) on vehicles S/N 2001
to 2903 or case (15), 16 washers (13)
and bolts (12) on vehicles S/N 2000
and below and 2904 and above.
76.
Check assembly for free rotation of
differential gears.
77.
Install remaining bolts (14) and
washers (13) or bolts (12). Tighten
bolts (13 or 12) to 105 to 135 lb-ft.
78.
Install bearings (33 and 35) on
differential carrier and lubricate
with gear oil.
79.
Using a 15/16” socket and torque
wrench, install blue cups, two pins
(9), bearing caps (8), four washers
(7) and bolts (6) to carrier (54).
Tighten bolts (6) to 160 to 190 lb-ft.
Identification marks on bearing caps
and carrier must be alined during
installation.
80.
Check fit of cups in bearing cap
bores. Cups must be a hand push fit.
If cups are too tight, bores must be
reworked with emery cloth until push
fit is obtained. A blued cup should
be used as a gage to check fit.
81.
Remove four bolts (6), washers (7),
two bearing caps (8), pins (9) and
blued cups.
GO to sheet 13
16-13
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-1.
Front Differential Carrier Assembly.
(Sheet 13 of 13)
ASSEMBLY (cont)
82.
Install cups (11 and 10) on
differential assembly.
83.
Using hoist and sling, position
items 10 thru 35 as an assembly to
carrier (51).
84.
Install two adjustment rings (2).
Hand turn against cups (11 and 10).
85.
Install two pins (9), bearing caps
(8), four washers (7) and bolts (6).
Tighten bolts (6) to 160 to 190 lb-ft
torque. Identification marks on
bearing caps and carrier must be
alined during installation. If
bearing caps do not seat properly,
check adjustment rings (2) for cross
threading.
86.
Using a 15/16” socket and socket
wrench handle, install screw (5) and
nut (4).
NOTE
The following is a difference
between M10A Forklift models.
87.
Using long round nose pliers, install
cotter pin (1) and on vehicles S/N
2000 and below and 2904 and above,
install two new lockwires (3).
ADJUSTMENT
Refer to paragraph 16-3 for
differential assembly adjustment
procedures.
88.
NOTE
Return M10A Forklift to original
equipment condition.
GO to sheet 14
16-14
END OF TASK
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-2.
Front and Rear Planetary. (Sheet 1 of 4)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Lockwire (2)
Torques
Bolts (3) to 110-120 lb-ft.
Bolts (16) to 24-26 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 7-5
Equipment Condition
Front and rear planetary removed.
Go to sheet 2
16--15
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
Front and Rear Planetary. (Sheet 2 of 4)
16-2.
DISASSEMBLY
NOTE
The following is a difference
between M10A Forklift models,
1.
Using side cutting pliers, cut and
discard lockwire (1) from planetary
carrier (17).
2.
Cut and discard lockwire (2) on
vehicles S/N 2001 and above only.
3.
Using a 1-1/2” socket and socket
wrench handle, remove three lock
bolts (3).
4.
Using a brass punch and hammer,
drive three pins (4), dowels (5) and
spacers (6) out, through the
planetary carrier (17).
5.
Remove three spacers (7) items 8
thru 15 as an assembly. Move two
gears assemblies to O.D. of case to
remove third gear assembly through
center hole.
NOTE
The following steps are for the
disassembly of one gear assembly.
Disassembly of the remaining two
gear assemblies is identical.
6.
Remove cone (9), spacer (10) and cone
(11).
7.
Using a brass punch and hammer,
remove cups (12 and 13), spacer (14)
and retaining ring (15).
8.
Using a 9/16” socket and socket
wrench handle, remove two bolts (16)
from planetary carrier (17).
Go to sheet 3
16-16
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-2.
Front and Rear Planetary. (sheet 3 of 4)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
9.
10.
Clean all parts with cleaning solvent
Dry thoroughly with
P-D-680.
compressed air. Refer to paragraph
2-8.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 4
16-17
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
Front and Rear Planetary. (Sheet 4 of 4)
16-2.
ASSEMBLY
11.
Using a 1-1/2” socket and torque
wrench, install two bolts (16) to
planetary carrier (17).
Tighten
bolts (16) to 24 to 26 lb-ft torque.
NOTE
The following steps are for the
assembly of one gear assembly.
Assembly of the remaining two
gear assemblies is identical.
12.
Using snap ring pliers, install
retaining ring (15), spacer (14) and
cups (13 and 12) to gears (6).
cup
(13 and 12) must be chilled until
cups can drop into gears (6) without
a press.
13.
Install cone (11), spacer (10) and
cone (9).
Install items 15 thru 8 as an
assembly and three spacers (7) in
planetary carrier.
14.
15.
Install three spacers (6) on pins
(4) making sure tapered side of
spacer (7) is flush with tapered
portion of pin (4)
15.
Using a hammer, install three pins
(4) with spacers (6) and dowels (5)
into planetary carrier. Flat of
pins (4) must be toward outside of
planetary carrier.
16.
Install three lock bolts (3). Tighten
bolts (3) to 110 to 120 lb-ft torque.
17.
Using long round nose pliers, install
new lockwire (2) on vehicles S/N 2001
and above only.
18.
Install new lockwire (1).
19.
Peen the planetary housing at dowel
hole to secure dowel (5) in housing.
END OF TASK
16-18
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-3.
Rear Differential Carrier Assembly. (Sheet 1 of 12)
This task covers:
a. Disassembly
c. Assembly
b.
d.
Cleaning/Inspection
Adjustment
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Permatex No. 2 (App. C, Item 26)
Gear oil (App. C, Item 18)
Fine emery cloth (App. C, Item 19)
Soft iron wire
Cotter pin (2)
Lockwire
Gasket
Seals (1 for S/N 2000 and below)
(1 for S/N 2001 and above)
Torques
Bolts (4) to 160 to 190 lb-ft.
Bolts (10, 12, 29 and 30) to 105
to 135 lb-ft.
Nut (34) to 140 to 170 lb-ft.
Bolt (36) to 50 to 65 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 7-8
Condition Description
Rear differential carrier assembly
removed.
Go to sheet 2
16-19
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-3.
Rear Differential Carrier Assembly. (Sheet 2 of 12)
DISASSEMBLY
NOTE
Prior to disassembly of differential assembly, backlash of gears
must be measured and recorded.
Steps 1 thru 3 are necessary only
if gears are to be reused.
Except where noted, The following disassembly procedure for
the differential assembly is
identical for both vehicles S/N
2001 to 2903 and S/N 2000 and
below and 2904 and above.
indicator as
1.
Position dial scale
shown.
2.
Secure flange yoke and rotate gear
(30) back and forth.
3.
Record backlash as indicated on dial
scale indicator.
4.
Using a 1-1/2” socket and socket
wrench handle, remove flange yoke.
5.
Using side cutting pliers, remove two
cotter pins (1) and adjustment rings
Discard
(2) from carrier (51).
cotter pins (l).
Go to sheet 3
16-20
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-3.
Rear Differential Carrier Assembly. (Sheet 3 of 12)
DISASSEMBLY (Cont)
NOTE
The following is a difference
between M10A Forklift models.
6.
Using diagonal cutters, cut and
discard two lock wires (3) on vehicles
S/N 2000 and below and 2904 and above.
7.
Using a 15/16” socket and socket
wrench handle, remove nut (4) and
screw (5) from carrier (51) on
vehicles S/N 2001 to 2903 only.
8.
Using a hammer, punch mark bearing
caps (8) and carrier (51).
9.
Using a 15/16” socket and socket
wrench handle, remove four bolts (6),
washers (7), two bearing caps (8), and
pins (9).
10.
Using hoist and sling, remove items
10 thru 35 as an assembly and place
on suitable work bench.
11.
Mark location of cups (10 and 11) on
differential assembly and remove.
12.
Using a hammer, punch mark cases (15
and 32).
NOTE
The following is a difference
between M10A Forklift models.
13.
Using a 1/2” socket and socket wrench
handle, remove 16 bolts (12) and
washers (13) or 12 bolts (14). 16
bolts (12) and washers (13) on
vehicles S/N 2000 and below and 2904
and above or 12 bolts (14) on vehicles
S/N 2001 to 2903.
14.
Remove case (15), gear (16) and
washer (17) .
Go to sheet 4
16-21
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-3.
Rear Differential Carrier Assembly. (Sheet 4 of 12)
DISASSEMBLY
15.
Remove items 18 thru 26 as an
assembly.
16.
Remove washers (18, 19, 20 and 21)
from spider (26).
17.
Remove gears (22, 23, 24 and 25).
18.
Remove gear (27) and washer (28)
from case (34).
19.
Using a 3/4 open end wrench and 3/8”
socket head screw key, remove 12
nuts (29), washers (30), bolts (31)
and gear (32).
20.
Use puller and heat, if required to
remove bearing (33) from case (34).
21.
Use puller and heat, if required to
remove bearing (35) from case (15) .
Go to sheet 5
16-22
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-3.
Rear Differential Carrier Assembly. (Sheet 5 of 12)
DISASSEMBLY
22.
Using a 5/8” socket and socket wrench
handle, remove two bolts (36), cover
(37) and gasket (38). Discard gasket
(38) .
NOTE
The following is a difference
between M10A Forklift models.
23.
Remove and discard seals (39 and 40)
from cover (37). Seal (40) for
vehicles S/N 2001 to 2903 only.
24.
Using a rubber mallet, remove items 42
thru 50 as an assembly and shim (41)
from carrier (51).
25.
Using an arbor press, press items 42
thru 46 as an assembly from cage
(50).
NOTE
Identify and mark location of
all cups and cones on gear or in
bearing cage. Relationship
between cups and cones must be
maintained during reassembly.
26.
Using snap ring pliers, remove ring
(43) from gear (42).
27,
Using a arbor press. remove bearing
(44) and cones (45 and 46).
28.
Using a brass punch and hammer,
remove cups (47 and 48) and spacer
(49) from cage (50).
Go to sheet 5
16-23
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
Rear Differential Carrier Assembly. (Sheet 6 of 12)
16-3.
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is q ade,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
fresh
air
get
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
29.
Clean all parts
moistened with
P-D-680.
Dry
compressed air.
2-8.
30.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 7
16-24
with clean cloth
cleaning solvent
thoroughly with
Refer to paragraph
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-3.
Rear Differential Carrier Assembly. (Sheet 7 of 12)
ASSEMBLY
NOTE
When replacing parts, gears must
be replaced as a matching set.
Washers must be replaced as a
q atched set.
31.
Using an arbor press, install spacer
(49) and cups (48 and 47) to cage
(50).
32.
Install cone (46) and bearing (44) to
gear (42).
33.
Using retaining ring pliers, install
ring (43).
34.
Using an arbor press, install gear
(42) to cage (50).
35.
Install cone (45).
36.
Rotate cage to verify normal bearing
contact.
37.
Apply load of 6 tons with press as
shown.
38.
Using soft iron wire and scale
indicator, measure bearing preload
Bearing preload
torque as shown.
torque should be 5 to 15 in-lb. Be
sure to measure rotating torque and
not starting torque. Install thinner
spacer (49) to increase or thicker
spacer to decrease preload, as
required.
Go to sheet 8
16-25
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
16-3.
Rear Differential Carrier Assembly. (Sheet 8 of 12)
ASSEMBLY
39.
Lubricate outside diameter of new
seals (40 and 39) with Permatex No.
2. Seal (40) for vehicles S/N 2001
to 2903, install to cover (37).
40.
Install shim (41) and items 42 thru
50 as an assembly to carrier (51).
41.
Using a 5/8” socket and torque
wrench, install new gasket (38) ,
cover (37) and two bolts (36).
Tighten bolts (36) to 50 to 65 lb-ft
torque.
42.
Using a 3/4 open end wrench, 3/8”
socket head screw key and torque
wrench, install gear (30), 12 bolts
(29), washers (28) and nuts (27) to
case (32). Tighten 12 bolts (29) to
105 to 135 lb-ft torque.
43.
Lubricate washer (28) and gear (27)
with gear oil and install.
44.
Lubricate gears (25, 24, 23 and 22)
with gear oil and install on spider
(26).
45.
Lubricate washers (21, 20, 19 and
18) with gear oil and install.
46.
Install items 26 thru 18 as an
assembly to case (34).
47.
Lubricate washer (17) and gear (16)
with gear oil and install.
Go to sheet 9
16-26
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-3.
Rear Differential Carrier Assembly. (Sheet 9 of 12)
ASSEMBLY (Cont)
NOTE
The following is a difference
between M10A Forklift models.
48.
Be sure to aline identification marks
on cases (15 and 34). Using a 1/2”
socket and socket wrench handle,
install case (15) with four equally
spaced bolts (14) on vehicles S/N 2001
to 2903 or case (15), 16 washers (13)
and bolts (12) on vehilces S/N 2000
and below and 2904 and above.
49.
Check assembly for free rotation of
differential gears.
50.
Install remaining bolts (14) and
washers (13) or bolts (12). Tighten
bolts (13 or 12) to 105 to 135 lb-ft.
51.
Install bearings (33 and 35) on
differential carrier and lubricate
with gear oil.
52.
Using a 15/16” socket and torque
wrench, install blue cups, two pins
(9), bearing caps (8), four washers
(7) and bolts (6) to carrier (51).
Tighten bolts (6) to 160 to 190 lb-ft.
Identification marks on bearing caps
and carrier must be alined during
installation.
53.
Check fit of cups in bearing cap
bores. Cups must be a hand push fit.
If cups are too tight, bores must be
reworked with emery cloth until push
fit is obtained. A blued cup should
be used as a gage to check fit,
54.
Remove four bolts (6), washers (7),
two bearing caps (8), pins (9) and
blued cups.
Go to sheet 10
16-27
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
Rear Differential Carrier Assembly.
16-3.
ASSEMBLY
55.
Install cups (11 and 10) on
differential assembly.
56.
Using hoist and sling, position
items 10 thru 35 as an assembly to
carrier (51).
57.
Install two adjustment rings (2).
Hand turn against cups (11 and 10).
58.
Install two pins (9), bearing caps
(8), four washers (7) and bolts (6).
Tighten bolts (6) to 160 to 190 lb-ft
torque. Identification marks on
bearing caps and carrier must be
alined during installation. If
bearing caps do not seat properly,
check adjustment rings (2) for cross
threading.
59.
Using a 15/16” socket and socket
wrench handle, install screw (5) and
nut (4).
NOTE
The following is a difference
between M10A Forklift models.
60.
Using long round nose pliers, install
cotter pin (1) and on vehicles S/N
2000 and below and 2904 and above,
install two new lockwires (3).
Go to sheet 11
16-28
(Sheet 10 of 12)
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE. (cont)
16-3.
Rear Differential Carrier Assembly. (Sheet 11 of 12)
ADJUSTMENT
61.
Adjust cone center: Measure diameter
of differential case, Dimension C.
62.
Record one half of C, Dimension B.
63.
Record Dimension D etched on end
pinion gear (42).
64.
Subtract Dimension B from Dimension D
to find Dimension A. (D - B = A).
65.
Measure distance between end on
pinion gear (42) and differential
case with feeler gage.
66.
Add or remove shims (41) between case
(50) and carrier (51) as required to
obtain Dimension A.
67.
Adjust backlash: Rotate gears until
match marked teeth of ring and pinion
gear are meshing.
68.
Install dial scale indicator as
shown.
69.
Loosen adjustment ring
onside
opposite gear teeth just enough to
show end play on indicator.
70.
Tighten same adjustment ring enough
to obtain 0.00 end play.
71.
From 0.00 end play setting, tighten
both adjustment rings one notch each
to preload bearings.
Go to sheet 12
16-29
TM 10-3930-643-34
GENERAL SUPPORT PROPELLER AND PROPELLER SHAFTS MAINTENANCE.
Rear Differential Carrier Assembly. (Sheet 12 of 12)
16-3.
ADJUSTMENT
NOTE
If gears were not replaced, use
backlash dimension recorded in
Step 1. If gears were replaced,
use backlash dimension etched on
gear.
72.
Adjust differential assembly to
obtain correct backlash dimension by
backing off one adjustment ring and
advancing the opposite adjustment
ring by an equal amount.
73.
Measure clearance between gear (30)
and screw (35).
Screw (35) on
vehicles S/N 2001 and above only.
Clearance should be 0.010 to 0.015
inches.
74.
Tighten nut (34) to 140 to 170 lb-ft.
75.
Check gear tooth contact: Coat
pinion gear teeth with gear mark.
76.
Rotate pinion gear.
77.
Check contact pattern on gear teeth.
if too much toe or heel bearing,
adjust cone center, refer to Step 61.
78.
If bearing too too high or low,
adjust backlash, refer to Step 67.
79.
If cross bearing, reject differential
assembly.
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
16-30
TM 10-3930-643-34
CHAPTER 17
GENERAL SUPPORT BRAKE MAINTENANCE
CHAPTER OVERVIEW
The purpose of this chapter is to help the technician efficiently repair
malfunctioning equipment and to perform authorized general support level
maintenance procedures on the M10A Forklift brakes.
INDEX
Title
Power Cluster (S/N 2000 and below)
Pressure Converter (S/N 2001 and above)
Paragraph
17-1
17-2
Page
17-2
17-9
17-1
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE. (cont)
17-1.
Power Cluster (S/N 2000 and below and 2904 and above). (Sheet 1 of 7)
This task covers:
a. Disassembly
c, Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Hydraulic fluid (App. C, Item 19)
Retainer
cup
Sealing band
Gasket
Torques
Locknut (7) to 20 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 8-5
Go to sheet 2
17-2
Condition Description
Power cluster removed.
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE.
17-1.
Power Cluster (S/N 2000 and below and 2904 and above). (Sheet 2 of 7)
DISASSEMBLY
1.
Using a 3/4” open end wrench, remove
four studs (1).
2.
Separate master cylinder (2) and
support (11).
3.
Using a 1/2” open end wrench, remove
fitting (3) and gasket (4). Discard
gasket (4).
4.
Using a small flat tip screwdriver,
remove and discard sealing band (5).
5.
Using a 3/8” open end wrench, remove ,
bleeder valve (6).
6.
Using a 9/16” socket and socket
wrench handle, remove
stroke
indicator (7), lock washer (8), three
bolts (9), lock washers (10) and
support (11).
7.
Using a 5/8” open end wrench, remove
breather (12).
8.
Using a 9/16” open end wrench, remove
switch (13).
Go to sheet 3
17-3
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE. (cont)
17-1.
Power Cluster (S/N 2000 and below and 2904 and above). (Sheet 3 of 7)
DISASSEMBLY (cont)
Spring is under pressure. Remove
screws carefully to keep spring
from becoming a projectile.
9.
Secure head (15) and shell (18) in
press.
10.
Using a 9/16” socket and socket
wrench handle, remove eight screws
(14).
11.
Release head (15) and remove from
press.
12.
Remove spring (16) and boot (17).
13.
Remove piston assembly (21) from
shell (18).
14.
Remove and discard retainer (19) and
cup (20) from piston assembly (21).
Go to sheet 4
17-4
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE.
17-1.
Power Cluster (S/N 2000 and below and 2904 and above). (Sheet 4 of 7)
CLEANING/INSPECTION
15.
Clean boot (17) with detergent and
water. Wipe dry with clean cloth.
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
used or stored.
Avoid contact
with eyes, skin or clothing. If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
solvent,
get
fresh
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
16.
Clean exterior of master cylinder (2)
with cleaning solvent P-D-680. Wipe
dry with clean cloth.
17.
Clean all other parts with cleaning
solvent P-D-680. Dry thoroughly with
compressed air. Refer to paragraph
2-8.
Go to sheet 5
17-5
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE. (cont)
17-1.
Power Cluster (S/N 2000 and below and 2904 and above). (Sheet 5 of 7)
CLEANING/INSPECTION (cont)
18.
Inspect master cylinder (2) for
cracks, blocked bores, leakage or
damaged threads.
NOTE
Replace master cylinder if
hydraulic fluid was present in
boot at disassembly.
19.
Inspect all parts. Refer to paragraph 2-9.
ASSEMBLY
20.
Soak new retainer (19) in clean
hydraulic fluid.
21.
Install new cup (20) and new retainer
(19) on piston assembly (21).
22.
Coat inside of shell (18) with clean
hydraulic fluid and install piston
assembly (21) in shell (18).
23.
Install boot (17) in head (15).
24.
Install spring (16) on shaft of
piston assembly (21).
Go to sheet 6
17-6
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE.
17-1.
Power Cluster (S/N 2000 and below and
2904 and above). (Sheet 6 of 7)
ASSEMBLY
25.
Position head (15) on shell (18).
26.
Secure head (15) and shell (18) in
press.
27.
Using a 9/16” socket and socket
wrench handle, install eight screws
(14).
28.
Using a 9/16” open end wrench,
install switch (13) and breather
(12).
29.
Using a 9/16” socket and socket
wrench handle, install support (11),
three lock washers (10) and bolts
(9).
30.
Install lock washer (8) and stroke
indicator (7) until contact with
piston assembly (21) is made. Piston
assembly (21) must be in a relaxed
position.
31.
Measure length of stroke indicator
(7) rod extending past nut when
piston assembly (21) iS relaxed in
shell (18).
Go to sheet 7
17-7
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE. (cont)
17-1.
Power Cluster (SIN 2000 and below and 2904 and above). (Sheet 7 of 7)
ASSEMBLY (cont)
NOTE
Activate piston assembly until
stroke indicator extends past the
nut to the length of the above
measurement plus 2.31 inch.
32.
Adjust screw of stroke indicator (7)
until contact with piston is made.
Tighten locknut of stroke indicator
(7) to 20 lb-ft.
33.
Using a 3/8” open end wrench, install
bleeder valve (6) in master cylinder
(2).
34.
Install new sealing band (5).
35.
Using a 1/2” open end wrench, install
new gasket (4) and fitting (3).
36.
Install master
support (11).
37.
Using a 3/4” open end wrench, install
four studs (1).
cylinder (2) to
NOTE
Return M10A Forklift to original
equipment condition.
END OF TASK
17-8
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE.
17-2.
Pressure Converter (S/N 2001 to 2903). (Sheet 1 of 7)
This task covers:
a. Disassembly
c. Assembly
b.
Cleaning/Inspection
INITIAL SETUP
Tools
Tool Kit, General Mechanic’s
Automotive
NSN 5180-00-177-7033
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance, Basic,
Less Power
NSN 4910-00-754-0705
Shop Equipment, Automotive
Maintenance and Repair:
Field Maintenance
NSN 4910-00-919-0076
1-1/2” Open end wrench
NSN 5120-00-184-8489
Materials/Parts
Cleaning solvent P-D-680
(App. C, Item 5)
Clean cloth (App. C, Item 24)
Brake fluid (App. C, Item 2)
Torques
Cap (1) to 70 lb-ft.
Bleeder valve (4) to 15 lb-ft.
Nuts (5) to 9 lb-ft.
Switch (8) to 6 lb-ft.
Nut (23) to 30 lb-ft.
EQUIPMENT CONDITION
References
Paragraph 8-7
Condition Description
Pressure converter removed.
Go to sheet 2
17-9
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE. (cont)
17-2.
Pressure Converter (S/N 2001 to 2903). (Sheet 2 of 7)
DISASSEMBLY
1.
Using a 1-1/2” open end wrench, remove
cap (1) and ring (2) from body (12).
Discard ring (2).
2.
Using a 3/8” open end wrench, remove
cap (3) and bleeder valve (4).
3.
Using a 9/16” open end wrench, remove
six nuts (5).
4.
Remove shell (6) and gasket (7) from
items 12 thru 31. Discard gasket (7).
5.
Using a 11/16” open end wrench, remove
switch (8) and preformed packing (9).
Discard preformed packing (9).
6.
Remove indicator rod (10) and
preformed packing (11). Discard
preformed packing (11).
7.
Position items 12 thru 31 as an
assembly in soft-jaw vice, securing
body (12).
8.
Using a 1 1/8” open end wrench on
bushing (16), remove items 13 thru 31
from body (12).
17-10
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE.
17-2.
Pressure Converter (S/N 2001 to 2903). (Sheet 3 of 7)
DISASSEMBLY
9.
Using an 11/16” open end wrench,
remove nut (13), washer (14) and items
26 thru 31 as as assembly from rod
(25).
10.
Remove spring (15).
11.
Remove items 16 thru 19 as an assembly
from rod (25).
13.
Remove and discard preformed packing
(17) and two seals (18) from bushing
(16).
14.
Using snap ring pliers, remove ring
(19) in piston assembly (20) on end of
rod (25). Discard ring (19).
16.
Remove valve (21) from rod (25).
17.
Remove regulating valve (22) from
valve (21).
16.
Remove piston assembly (20) from rod
(25).
17.
Remove seal (23) and retainer (24)
from piston (20).
Go to sheet 4
17-11
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE. (cont)
17-2.
Pressure Converter (S/N 2001 to 2903). (Sheet 4 of 7)
DISASSEMBLY
18.
Separate items 26 and 28 as an
assembly from items 27 and 29 thru 31
as an assembly.
19.
Remove and discard preformed packing
(28) from plate (26).
20.
Remove felt (29), cup (30) and spring
(31) from piston (27). Discard felt
(29) and cup (30).
Go to sheet 5
17-12
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE.
17-2.
Pressure Converter (S/N 2001 to 2903). (Sheet 5 of 7)
CLEANING/INSPECTION
Dry cleaning solvent P-D-680, used
for cleaning parts, is toxic and
flammable. Use only in well
ventilated areas. Wear protective
goggles and gloves. Do not smoke
or allow open flames or sparks in
areas where cleaning solvent is
Avoid contact
used or stored.
with eyes, skin or clothing.
If
contact with eyes is made, flush
with cold water and seek medical
attention immediately. If contact
with skin or clothing is made,
flush with cold water.
If you
become dizzy while using cleaning
fresh
solvent,
get
air
immediately.
● COMPRESSED AIR HAZARD
Compressed air used for cleaning
purposes will not exceed 30 psi.
Use only with effective chip
guarding and personal protective
equipment (goggles/shield, gloves,
etc.).
21.
Clean all parts with cleaning solvent
P-D-680.
Dry thoroughly with
compressed air. Refer to paragraph
2-8.
22.
Inspect all parts. Refer to paragraph 2-9.
Go to sheet 6
17-13
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE. (cont)
17-2.
Pressure Converter (S/N 2001 to 2903). (Sheet 6 of 7)
ASSEMBLY
23.
Install spring (31) in groove of
piston (27).
24.
Install new cup (30) over spring (31)
and new felt (29) on piston.
25.
Install new preformed packing (28) in
center hole of plate (26).
27.
Install items 31 thru 27 as an
assembly and items 28 and 26 as an
assembly together.
28.
Install retainer (24) and seal (23) on
piston (20).
29.
Lubricate rod (25) with clean brake
fluid and install piston assembly
(20).
30.
Lubricate regulating valve (22) and
install in valve (21)
31.
Install valve (21) on rod (25).
32.
Using snap ring pliers, install new
ring (19) in piston assembly (20).
33.
Lubricate and install two new seals
(18) and new preformed packing (17) on
bushing (16).
34.
Install items 19 thru 16 as an
assemblyon rod (25).
35.
Install spring (15).
36.
Install items 31 thru 26 as an
assembly, washer (14) and nut (1 3) on
rod (25). Tighten nut 13 to 30 lb-ft.
Go to sheet 7
17-14
TM 10-3930-643-34
GENERAL SUPPORT BRAKE MAINTENANCE.
17-2.
Pressure Converter (S/N 2001 to 2903). (Sheet 7 of 7)
ASSEMBLY
37.
Position body (12) in a soft-jaw vice.
38.
Using a 1 1/8” open end wrench on
bushing (16), install items 31 thru 13
on body (12).
39•
Remove items 31 thru 12 from vice.
40.
Lubricate and install new preformed
packing (11) and indicator rod (10) to
body (12).
41.
Using a 11/16” open end wrench,
install new preformed packing (9) and
switch (8). Tighten switch (8) to 6
lb-ft. Switch must engage with groove
in indicator rod (10).
42.
Install new gasket (7), shell (6) and
six nuts (5) on items 31 thru 13 as an
assembly. Tighten nuts (5) 9 lb-ft.
43.
Using 3/8” socket and socket wrench
handle, install bleeder valve (4) and
new cap (3) in body (12). Tighten
bleeder valve (4) to 15 lb-ft.
44.
Using a 1-1/2” open end wrench,
install new ring (2) and cap (1) in
body (12). Tighten cap (1) to 70
lb–ft.
NOTE
Return M10A Forklift to original
equipment condition.
Go to sheet 8
17-15
TM 10-3930-643-34
APPENDIX A
REFERENCES
A-1.
PUBLICATION INDEXES AND GENERAL REFERENCES.
Indexes should be consulted frequently for latest changes or revisions of
references given in this appendix and for new publications relating to material
covered in this publication.
a. MILITARY PUBLICATION INDEXES.
Consolidated Index of Publications and Blank Forms . . . . . . . . .DA PAM 310-1
b.
A-2.
GENERAL REFERENCES.
Dictionary of United States Army Terms . . . . . . . . . . . . . . . . . . . . . . . .AR 310-25
Authorized Abbreviations and Brevity Codes . . . . . . . . . . . . . . . . . . . .AR 310-50
Military Training Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TC 21-5-7
Military Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 21-30
OTHER PUBLICATIONS.
The following publications contain information pertinent to the major item
materiel and associated equipment.
a. VEHICLE.
Truck, Forklift, DED Pneumatic Tire, 10,000 LB.
Capacity Rough Terrain, Articulated Frame Steer
(Dresser Industries Model M10A, MHE 23) . . . . . . . . . . .L0 10-3930-643-12-1
b.
CAMOUFLAGE.
Camouflage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FM 5-20
c.
DECONTAMINATION .
Chemical, Biological, and Radiological
Decontamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 3-220
Chemical, Biological, Radiological, and Nuclear Defense . . . . . . . .TM 21-40
d.
GENERAL.
Accident Reporting and Records . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AR 385-40
Basic Cold Weather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-70
Cooling Systems: Tactical Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 750-254
Manual for Wheeled Vehicle Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 21-305
Driver Selection and Training (Wheeled Vehicles ) . . . . . . . . . . . . . . .FM 55-30
Mountain Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 90-6
Northern Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 31-71
Operation and Maintenance of Ordnance Materiel in
Cold Weather (0°F. to -65°F.) . . . . . . . . . . . . . . . . . . . . FM 9-207
Principles of Automotive Vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-8000
Prevention of Motor Vehicle Accidents . . . . . . . . . . . . . . . . . . . . . . . . .AR 385-55
Procedures for Destruction of Tank Automotive Equipment
to Prevent Enemy Use.... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TM-750-244-6
A-1
TM 10-3930-643-34
REFERENCES (cont)
A-2.
OTHER PUBLICATIONS. (cont)
e.
FIRST AID.
First Aid for Soldiers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .FM 21-11
f.
MAINTENANCE AND REPAIR.
Organizational, Direct Support and General Support
Care Maintenance and Repair:
Pneumatic Tires and Inner Tubes . . . . . . . . . . . . . . . . . . . . . .TM 9-2610-200-20
Description, Use, Bonding Techniques and
Properties of Adhesives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TB ORD 1032
Inspection, Care, and Maintenance of Antifriction
Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-214
Materials Used for Cleaning, Preserving, Abrading,
and Cementing Ordnance Materiel and Related
Materiels Including Chemicals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-247
Metal Body Repair and Related Operations . . . . . . . . . . . . . . . . . . . . . . . .FM 43-2
Operation and Organizational Maintenance Manual for
Lead-Acid Storage Batteries . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-6140-200-14
Organizational, Policies, and Responsibilities for
Army Materiel Maintenance Concepts and Policies . . . . . . . . . . . . . .AR 750-1
Use of Antifreeze Solutions and Cleaning Compounds
in Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TB 750-651
Welding Theory and Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 9-237
Color, Marking, and Camouflage Painting of Military
Vehicles Construction Equipment, and Materials
Handling Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TB 43-0209
g.
SHIPMENT AND LIMITED STORAGE.
Color Marking, and Preparation of Equipment for
Shipment of Army Materiel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .AR 746-1
Preservation and Packing of Military
Supplies and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TM 38-230-1 & 2
Preservation of USAMECOM Mechanical Equipment
for Shipment and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TB 740-97-2
Preservation, Packaging, Packing and Marking
Materials, Supplies, and Equipment Used by
the Army . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SB 38-1OO
Shipment and Limited Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .MIL-V-62038
Storage and Serviceability Standard: Tracked
Vehicles, Wheeled Vehicles and Component Parts . . . . . . . . . . . . .SB 40-98-1
Storage and Supply Activities: Covered and Open
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .SB 740-1
The Army Maintenance Management Systems (TAMMS) . . . . . . . . . . . . . . .TM 38-750
A-2
TM 10-3930-643-34
APPENDIX B
MAINTENANCE ALLOCATION CHART
NOT APPLICABLE TO THIS MANUAL
B-1 (B-2 blank)
TM 10-3930-643-34
APPENDIX C
EXPENDABLE SUPPLIES AND MATERIALS
Section I.
INTRODUCTION.
C-1. SCOPE . This appendix lists expendable supplies and materials you will
need to maintain the M10A Forklift. These items are authorized to you by CTA
50-970, Expendable Items (except Medical, Class V, Repair Parts, and Heraldic
Items) .
C-2.
EXPLANATION OF COLUMNS.
a. Column 1 - Item Number. This number is assigned to the entry in the
listing and is referenced in the narrative instructions to identify the
material (e.g., “Use anti-seize graphite, App. C, Item 14”).
b. Column 2 - Level. This column identifies the lowest level of maintenance that requires the listed item:
C
O
F
H
-
Operator/Crew
Organizational Maintenance
Direct Support Maintenance
General Support Maintenance
This is the National Stock Number
c. Column 3 - National Stock Number.
assigned to the item; use it to request or requisition the item.
Indicates the Federal item name and. if
d. Column 4 - Description.
The last line for each item
required, a description to identify the item.
indicates the part number followed by the Federal Supply Code for Manufacturer
(FSCM) in parentheses, if applicable.
Indicates the measure used in
e. Column 5 - Unit of Measure (U/M).
This measure is expressed by a
performing the actual maintenance function.
This measure is expressed by a twotwo-character alphabetical function.
character alphabetical abbreviation (e.g., ea, in, pr). If the unit of measure
differs from the unit of issue, requisition the lowest unit of issue that will
satisfy your requirements.
C-1
TM 10-3930-643-34
Section II.
ITEM
NUMBER
C-2
LEVEL
EXPENDABLE SUPPLIES AND MATERIALS LIST.
NATIONAL
STOCK
NUMBER
DESCRIPTION
U/M
1
0
8030-00-243-3285
ANTI-SEIZE COMPOUND
MIL-T-5544B
TU
2
0
9150-01-072-8379
BRAKE FLUID,
MIL-B-46176 (81349)
CN
3
0
5350-00-221-0872
CLOTH, ABRASIVE CROCUS .50
SHEETS P-C-458 (81348)
PC
4
0
5350-00-584-4654
CLOTH, ABRASIVE EMERY
PC
5
0
6850-00-281-3061
DRY CLEANING SOLVENT 4 OZ.
CAN P-D-680 (81348)
CN
6
0
8010-00-297-2105
GL
7
0
9150-00-868-0134
ENAMEL, SEMIGLOSS, OLIVE
DRAB TT-E-485 (81348)
LUBRIPLATE 105-lLB
8
0
9150-00-935-1017
GL
9
0
9150-00-190-0904
CREASE, AUTOMOTIVE, ART.
14 OZ. CAN MIL-C-10924D
(81349)
CREASE, AUTOMOTIVE, ART.
1 LB. CAN MIL-G-1092
(81349)
10
0
9150-00-985-7248
GREASE, GEAR, MJLTI-PURPOSE,
35 LB. CAN MIL-L-2105B
LB
11
0
9150-00-985-7316
CREASE, GENERAL PURPOSE
1-3/4 LB. CAN MIL-G-23549
(81349)
LB
12
0
9150-01-095-5512
GREASE, #2 LITHIUM,
MULTI-PURPOSE MIL-C-10924O
CN
13
0
9150-00-935-9808
14
0
8030-01-137-6964
HYDRAULIC OIL, GRADE 3,
MIL-H-Y6001C
LIQUID GASKET, TYPE 1
MIL-A-46016A
15
0
8030-01-159-4374
LOCTITE 262, GRADE N
MIL-S-46163
CN
16
0
8030-00-111-2762
LOCTITE 277, GRADE I
MIL-S-46163
CN
17
0
8030-01-054-0740
LOCTITE 592 MIL-S-22473D
CN
18
0
9150-00-231-6689
LUBRICANT, GEAR MIL-10924D
TU
19
0
9150-00-189-6727
LUBRICATING OIL, 1 QT. CAN
HIL-L-2104C (81349)
QT
CN
CN
TM 10-3930-643-34
Section II.
ITEM
NUMBER
LEVEL
19 (Cont)
EXPENDABLE SUPPLIES AND MATERIALS LIST.
NATIONAL
STOCK
NUMBER
DESCRIPTION
U/M
9150-00-186-6668
LUBRICATING OIL ENG, 5 GAL.
DRUM MIL-L-2104C
5 CAL.
9150-00-191-2772
OE/HDO 10
55 GAL
9150-00-186-6681
OE/HDO 30
QT
9150-00-188-9858
OE/HDO 30
5 GL
9150-00-188-9859
OE/HDO 30
55 GL
9150-00-402-4478
MIL -L-46167
(subzero)
9150-00-402-2372
OEA
5 GAL
9150-00-491-7197
OEA
55 GAL
9150-01-152-4117
15 W40
QT CN
9150-01-178-4725
15 W40
9150-01-152-4118
15W40
QT
PLASTIC
5 GAL
15 W40
LUBRICATING OIL ENG, SUBZERO
1 QT. CAN MIL-L-461467
20
0
9150-01-152-4119
9150-00-402-4478
21
0
9150-00-657-4959
LUBRICATING OIL, GEAR
MULTI-PURPOSE
22
5210-00-640-6177
PLASTIGAGE
23
8010-00-652-3626
PRUSSIAN BLUE
QT
5 GAL.
QT
GL
24
0
7920-00-205-3570
CLEAN RAG, WIPING
DDD-R-30 (81348)
A-A-531 (58536)
25
0
8030-00-159-8176
SEALING COMPOUND, 303 TUBE
MIL-S-45180 (81349)
26
0
8030-00-052-2599
SEALANT, PERMATEX, NO. 2,
TYPE 2 MIL-S-45180C
27
0
6850-01-080-2387
SEALANT, SILICONE
MIL-A-46146A
BE
28
0
9905-00-034-3097
TAGS, PAPER
TU
TU
C-3
TM 10-3930-643-34
Section II.
EXPENDABLE SUPPLIES AND MATERIALS LIST.
ITEM
NUMBER
LEVEL
NATIONAL
STOCK
NUMBER
29
0
7510-01-026-4661
DESCRIPTION
U/M
RO
TAPE, INSULATING
THERMOMELT 1 RAYON
PLT-118-1
30
8010-00-180-6343
VARNISH, ANTI-CORROSIVE
MIL-V-173
31
8030-00-009-5023
SEALANT, TEFLON THREAD
32
9150-00-141-6770
CREASE, HMS B27-008
33
7930-OO-249-8036
DETERGENT
9150-01-102-9455
1 GAL
9150-01-123-3152
BRAKE FLUID BFS
(MIL-B-46176)
BFS
9150-01-035-5390
LUBRICATING OIL, GEAR
QT
9150-01-035-5391
GO 75W (MIL-L-2105)
5 GAL
9150-01-035-5392
9150-01-035-5393
9150-01-035-5394
GO 80W-90
QT
5 GAL
55 GAL
34
35
0
0
9150-01-048-4591
9150-01-035-5395
9150-01-035-5396
36
0
QT
GO 85W-140
5 GAL
55 GAL
9150-00-065-0029
9150-00-935-1017
9150-00-190-0904
9150-00-190-0905
9150-00-190-0907
9150-00-530-7369
GAA (MIL-G-10924)
(Extreme Temperature)
-65° F. to 300° F
2.25 OZ
14.0 OZ
1.75 LB.
6.5 LB.
35.0 LB.
120.0 LB.
9150-00-935-1017
9150-00-190-0904
GAA (MIL-G-10924)
(MULTIPURPOSE AUTO MPG)
-12° C to 52° C
CART - 14 OZ
CAN 1.75 LB.
CAN 6.5 LB.
CAN 35 LB.
DR 120 LB.
9150-00-190-0905
9150-00-190-0907
9150-00-530-7369
C-4
5 GAL
TM 10-3930-643-34
APPENDIX D
ILLUSTRATED LIST OF MANUFACTURED ITEMS
D-1. INTRODUCTION. This appendix includes complete instructions for making
items authorized to be manufactured or fabricated at direct and general support
An index is provided for cross-referencing the item to be
maintenance.
All bulk
manufactured to the figure which covers fabrication criteria.
materials needed for manufacture of an item are listed with the illustration.
D-2.
MANUFACTURED ITEMS INDEX.
ITEM
FIGURE
Thermostat Housing Pressure Plate
Thermostat Housing Gasket
Bottom Pressure Plate
Bottom Gasket
Oil Cooler Pressure Plates
Cylinder Sleeve Holding Adapter
Output Shaft Oil Seal Installation Tool
Lifting Eye
Transmission Stand
Clutch Plate Alinement Pin and
Extractor Tool
Bearing Removal Tool
Sandwich Test Block
D-1
D-2
D-3
D-4
D-5
D-6
D-7
D-8
D-9
D-10
D-11
D-12
D-1
TM 10-3930-643-34
D-2
TM 10-3930-643-34
D-3
TM 10-3930-643-34
Part D-5.
D-4
Oil Cooler Pressure Plates
TM 10-3930-643-34
Part D-6.
Cylinder Sleeve Holding Adapter
D-5
TM 10-3930-643–34
D-7.
D-6
Output Shaft Oil Seal Installation Tool.
TM 10-3930-643-34
D-8.
Lifting Eye
D-7
TM 10-3930-643-34
D-9.
D-8
Transmission Stand
TM 10-3930-643-34
D-10.
Clutch Plate Alinement Pin and Extractor Tool
D-9
TM 10-3930-643-34
D-11.
D-10
Bushing Removal Tool
TM 10-3930-643-34
D-12.
Sandwich Test Block
D-11 (D-12 blank)
TM 10-3930-643-34
APPENDIX E
TORQUE LIMITS
E-1. General Information. This appendix provides general torque limits for
fasteners. Special torque values are indicated in the maintenance procedures
for applicable components. The general torque values given in this appendix
shall be used when specific torque values are not indicated in the maintenance
procedures. When applying torque in tightening direction, check torque when
the fastener just begins to turn. Conformance is best determined by checking
immediately after assembly.
E-2.
Torque Limits.
a. Table E-1. Torque Limits for Standard Fasteners. This table provides
tightening torque for general purpose applications using Grade 8, coarse thread
bolts and nuts, through hardened flat washers (Rockwell “C” 38-45), all
phosphate coated, and assembled without supplemental lubrication. The torques
shown also apply to the following:
1.
Phosphate coated bolts used in tapped holes in steel or gray iron.
2.
Phosphate coated bolts used with phoshate coated prevailing torque
nuts (nuts with distorted threads or plastic inserts).
3.
Phosphate coated bolts used with copper plated weld nuts.
NOMINAL
THREAD
DIAMETER
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1-1/8
1-1/4
1-3/8
1-1/2
1-3/4
2
STANDARD TORQUE
PLUS OR MINUS 10%
FOOT
POUNDS
7
14
24
38
60
80
115
200
320
480
590
830
1100
1400
2300
3400
NEWTON
METERS
10
19
32
51
80
110
155
270
440
650
800
1100
1500
1900
3100
4600
E-1
TM 10-3930-643-34
APPENDIX E. (cont)
b. Table E-2. Torque Limits for Hose Clamps.
This table provides
tightening torques for hose clamps used in all rubber applications (radiator,
air cleaner, operating level boots, hydraulic system, etc.).
TORQUE PLUS OR MINUS 0.6 N.m(5 in-lb)
RADIATOR, AIR
CLEANER, BOOTS, ETC.
CLAMP
TYPE & SIZE
INCH
POUNDS
NEWTON
METER
HYDRAULIC
SYSTEM
INCH
POUNDS
NEWTON
METERS
“T” Bolt (Any Diameter)
55-60
6-7
40-50
5-6
Worm Drive--25-50 mm(1-2
in.) Open Diameter &
Under
25
3
25
3
Worm Drive--50-102 mm
(2-4 in.) Open Diameter
100
11
— --
----
This table
c. Table E-3. Torque Limits for Split Flange Connections.
provides tightening torques for split flange connections used in hydraulic
systems.
Split flanges and fitting shoulders should fit squarely. Install all
bolts finger tight and then torque evenly. Do not overtorque bolts or damage
to flanges and/or bolts may occur and leakage may result.
FLANGE
SIZE (*)
mm
in.
13
19
25
32
38
64
76
89
1/2
3/4
1
1-1/4
1-1/2
2
2-1/2
3
3-1/2
BOLT
SIZE
5/16
3/8
3/8
7/16
1/2
1/2
1/2
5/8
5/8
BOLT TORQUE
IN FOOT
POUNDS
MIN.
MAX.
BOLT TORQUE
IN NEWTON
METERS
MIN.
MAX.
MAX.
WORKING
PRESSURE
kPa
psi
15
22
27
35
46
55
79
138
117
20
30
37
48
62
75
107
187
159
34474
34474
34474
27579
20684
20684
17237
13790
3447
18
27
35
45
58
65
91
150
133
24
37
48
61
79
88
123
203
180
(*)Inside diameter of hydraulic tube or hose fitting.
E-2
5000
5000
5000
4000
3000
3000
2500
2000
500
TM 10-3930-643-34
APPENDIX E (cont)
d. Table E-4. Torque Limits for Tube Nuts. This table provides tightening
torques for tube nuts when tubes are flared to use 37 degree fittings. Torque
limits given are for plain, cadmium, or zinc plated fittings for wet or dry
installations.
TORQUE
IN NEWTON
METERS
TORQUE
IN FOOT
POUNDS
FITTING NO.
4
5
6
8
10
12
14
16
20
24
32
THREAD SIZE
7/16-20
1/2 -20
9/16-18
3/4 -16
7/8 -14
1-1/16-12
1-3/16-12
1-5/16-12
1-5/8 -12
1-7/8 -12
2-1/2 -12
12
15
24
40
58
82
100
120
150
175
240
9
12
21
35
53
77
90
110
140
162
225
MIN.
MAX.
12
16
29
47
72
104
122
149
190
217
305
16
20
33
54
79
111
136
163
204
237
325
e. Table E-5. Torque Limits for Hydraulic Fittings. This table provides
tightening torques for preformed packing, boss connectors and plugs, 37 degree
seat swivel nuts (fittings and hose), and locknuts on adjustable fittings.
TORQUE
IN FOOT
FITTING NO.
4
5
6
8
10
12
14
16
20
24
32
THREAD SIZE
MIN.
7/16-20
1/2 -20
9/16-18
3/4 -16
7/8 -14
1-1/16-12
1-3/16-12
1-5/16-12
1-5/8 -12
1-7/8 -12
2-1/2 -12
6
10
15
25
35
60
70
80
95
120
250
TORQUE
IN NEWTON
METERS
MAX.
MIN.
MAX.
10
15
20
30
40
70
80
90
115
140
300
8
14
20
34
48
81
95
109
129
163
339
14
20
27
41
54
95
109
122
156
190
407
E-3/(E-4 blank)
TM 10-3930-643-34
GLOSSARY
Terms listed in this manual are adequately defined in the Army, Navy, Air
Force, DOS or standard dictionary. The following is a list of abbreviations
used in this manual.
A
AAL
B
BII
B.O.
CCE
COEI
D
DA
D.C.
DED
EIR
F
°F
FSCM
Gal
H
ICOEI
In.
Kg
L
LB
LH
M
MHE
Mph
N
No.
NSN
PMCS
PSI
Qty
R
RH
Rec‘d
SER.
S/N
TAMMS
U/M
After
Additional Authorization List
Before
Basic Issue Items
Blackout
Commercial Construction Equipment
Components of End Item
During
Department of Army
District of Columbia
Diesel Engine Driven
Equipment Improvement Recommendations
Full
Degrees Fahrenheit
Federal Supply Code for Manufacturer
Gallons
High
Integral Components of End Item
Inch
Kilogram
Low
Pounds
Left Hand
Medium
Material Handling Equipment
Miles per hour
Neutral
Number
National Stock Number
Preventive Maintenance Checks and Services
Pounds per square inch
Quantity
Reverse
Right Hand
Received
Service
Serial Number
The Army Maintenance Management System
Unit of measure
Glossary 1/(Glossary 2 blank)
TM 10-3930-643-34
INDEX
Page
Subject
B
A
Adhesives, Application of
Air Compressor
Alphabetical Index
Alternator
Appendix A (References)
Appendix B (MAC Chart)
Appendix C (Expendable
Supplies and Materials List)
Appendix D (Illustrated
List of Manufactured Items)
Application of Adhesives
Assembly:
Boom
Boom Valve
Carriage, Lifting Forks and
Cylinder Head with Valves
Engine
First Gear
Fork Valve
Forward and Reverse
Steering Gear
Cylinder Head, with valves
Inlet Valve
Lifting Forks and Carriage
Parking Brake
Radiator
Rocker Arm and Valve Cover
Second and Third Gear
Service Brake
Steering Gear
Tilt Valve
Transmission
Water Pump
Axle:
Front (S/N 2000 and below)
Front (S/N 2001 and above)
Rear (S/N 2000 and below)
Rear Drive (S/N 2001
and above)
Troubleshooting
Page
Subject
2-7
8-62
INDEX 1
14-2
A-1
B-1
C-1
D-1
2-7
12-75
12-50
12-86
4-29
4-15
15-52
12-33
15-74
13-8
12-27
12-86
8-80
4-110
4-51
15-59
8-11
9-6
12-42
15-22
4-112
7-11
7-5
7-38
Base, Oil Filter
Bearing Procedures
(General Maintenance)
Bolster
Boom Assembly
Boom Assembly Valve
Brake System:
Air Compressor
Check Valves-Treadle
(S/N 2001 and above)
Governor Assembly
Parking Brake Air
Cylinder
Parking Brake Assembly
Power Cluster (S/N 2000
and below)
Power Cluster Reservoir
(S/N 2000 and below)
Pressure Converter
(S/N 2001 and above)
Pressure Converter
Reservoir (S/N 2001
and above)
Service Brake Assembly
Treadle Two Way Valves
(S/N 2000 and below)
Treadle Check Valves
(S/N 2001 and above)
Troubleshooting, Parking
Brake
Troubleshooting Service
Brake
Treadle Valve
(S/N 2000 and below)
Treadle Valve
(S/N 2001 and above)
4-64
2-26
10-2
12-75
12-50
8-62
8-40
8-75
8-6
8-80
8-17,
17-2
8-21
8-26,
17-9
8-31
8-11
8-37
8-40
8-5
8-2
8-47
8-54
7-32
7-2
Index 1
TM 10-3930-643-34
INDEX(cont.)
Page
Subject
C
Camshaft and Timing Gears
Carriage Assembly, Lifting
Forks and
Cautions and Warnings
Check Valve, Control Valve and
Check Valve-Treadle
(S/N 2001 and above)
Cleaning (General Maintenance)
Condition of the Vehicle
(General Maintenance)
Connecting Rods and Connecting
Rod Bearings, Pistons
Control Valve, Transmission
Control Valve and Check Valve
Counterweights
Crankcase, Cylinder Sleeves
Crankshaft,
Crankshaft Main Bearings
Cylinder:
Fork Position (S/N 2000
and below)
Fork Position (S/N 2001
and above)
Head Assembly with Valves
Lift
Oscillation (S/N 2000
and below)
Oscillation (S/N 2001
and above)
Parking Brake Air
Sideshift (S/N 2000 and
below)
Sideshift (S/N 2001 and
above)
Steering
Tilt
Index 2
Page
Subject
D
13-61
12-86
a
9-36
8-40
2-6
2-5
13-49
6-54,
15-87
9-36
10-19
13-14
13-25
13-34
12-132
12-142
4-29,
13-8
12-101
12-152
12-160
8-6
12-111
12-121
9-31
12-65
Damper, Vibration
Destruction to Prevent
Enemy Use
Differences Between Models
Differential:
Front Differential
Carrier Assembly
Rear Differential
Carrier Assembly
Disassembly and Assembly
Procedures
4-47
1-3
1-5
7-18,
16-2
7-46,
16-19
2-5
E
Electrical Repair (General
Maintenance)
Engine:
Assembly
Camshaft and Timing Gears
Crankcase Cylinder Sleeves
Crankshaft
Crankshaft Main Bearings
Cylinder Head Assembly
with Valves
Front Cover
Intake and Exhaust Manifolds
Mounts
Oil Cooler
Oil Filter Base
Oil Pan
Oil Pressure Regulator Valve
Oil Pump
Pistons, Connecting Rods
and Connecting Rod
Bearings
Rear Oil Seal
Rocker Arm Assembly and
Valve Cover
Engine, Fuel, Exhaust and
Cooling Troubleshooting
Exhaust Manifolds, Intake and
Expendable Supplies and
Materials List (Appendix C)
2-10
4-15
13-61
13-14
13-25
13-34
4-29
13-2
4-11
4-25
4-68
4-8
4-60
4-73
13-72
13-49
13-38
4-51
4-2
4-76
C-1
TM 10-3930-643-34
INDEX
Subject
Page
Front Cover
Front Differential
Carrier Assembly
4-117
15-52
13-44
12-56
5-49
12-132
12-142
12-33
1-3
15-74
10-6
7-24
16-15
13-2
7-18,
16-2
Front Axle Assembly
(S/N 2000 and below)
Front Axle Assembly
(S/N 2001 and above)
Front Lights Wiring Harness
Fuel System:
Injectors
Injector Lines
Injection Pump, Cover Plate,
Adapter and Drive Gears
Solenoid
Tank
Page
G (cont)
F
Fan and Clutch
First Gear Assembly
Flywheel and Housing
Fork Control Valve
Fork Control Wiring Harness
Fork Position Cylinders
(S/N 2000 and below)
Fork Position Cylinders
(S/N 2001 and above)
Fork Valve Assembly
Forms and Records,
Maintenance
Forward and Reverse Steering
Gear Assembly
Frame Assembly and Hinge Pin
Front and Rear Planetary
Subject
7-11
7-5
5-53
4-83,
13-77
4-88
4-93
13-81
4-107,
13-96
General Repair Practices
(General Maintenance)
Governor Assembly
Ground Driven Steering Pump
(S/N 2000 and below)
Ground Driven Steering Pump
(S/N 2001 and above)
2-6
8-75
9-14
9-24
H
Heater (S/N 2001 and above)
Hinge Pin, Frame Assembly
Hoses, Lines and Fittings:
Transmission and Torque
Converter
Housing, Flywheel and
Hydraulic System:
Fork Position Cylinders
(S/N 2000 and below)
Fork Position Cylinders
(S/N 2001 and above)
Lift Cylinder
Oscillation Cylinder
(S/N 2000 and below)
Oscillation Cylinder
(S/N 2001 and above)
Pump
Reservoir and Filter
Sideshift Cylinder
(S/N 2000 and below)
Sideshift Cylinder
(S/N 2001 and above)
Tilt Cylinder
Troubleshooting
11-2
10-6
6-26
13-44
12-132
12-142
12-101
12-153
12-160
12-9
12-170
12-111
12-121
12-65
12-2
G
Gear:
4-93
Drive
15-52
First
Forward and Reverse Steering 15-74
15-59
Second and Third
9-6
Steering
13-61
Timing
General Maintenance
2-1
Procedures
Index 3
TM 10-3930-643-34
INDEX(cont.)
Page
Subject
Page
Subject
O
Illustrated List of
Manufactured Items
(Appendix D)
Index, Alphabetical
Index, Troubleshooting
Inlet Valve Assembly
Inspection Criteria
(General Maintenance)
Instrument Panel Wiring
Harness
Intake and Exhaust Manifolds
Intermediate Wiring Harness
(S/N 2000 and Below)
Intermediate Wiring Harness
(S/N 2001 and Above)
Introduction
Lift Cylinder
Lifting Forks and Carriage
Assembly
Lines, Fuel Injector
Loader Control Valve
Lubrication (General
Maintenance)
D-1
INDEX 1
3-1
12-27
2-6
5-17
4-76
12-101
12-86
4-88
12-13
2-7
2-1
1-3
4-76
5-26
1-5
4-25
1-4
Parking Brake:
Air Cylinder
Assembly
Troubleshooting
Personnel Precautions
Pistons, Connecting Rods and
Connecting Rod Bearings
Planetary Front and Rear
Power Cluster (S/N 2000
and below)
Power Cluster Reservoir
(S/N 2000 and below)
Pressure Converter
(S/N 2001 and above)
Pressure Converter Reservoir
(S/N 2001 and Above)
Pump:
Fuel Injection
Ground Driven Steering
(S/N 2000 and below)
Ground Driven Steering
(S/N 2001 and above)
Hydraulic
Oil, Engine
Torque Converter Charging
Water
Index 4
12-152
12-160
P
5-45
1-3
N
Nomenclature Cross Reference
4-68
6-58
4-64
4-60
4-73
13-72
13-69
13-38
5-41
M
Maintenance, General
Maintenance Forms and Records
Manifolds, Intake and Exhaust
Main Wiring Harness
Models, Differences Between
Mounts, Engine
Oil Cooler
Oil Cooler, Transmission
Oil Filter Base
Oil Pan
Oil Pressure Regulator Valve
Oil Pump, Engine
Oil Pump Inlet Tube
Oil Seal, Rear
Oscillation Cylinder
(S/N 2000 and below)
Oscillation Cylinder
(S/N 2001 and above)
7-44,
8-6
8-80
8-5
2-2
13-49
7-24
8-17,
17-2
8-21
8-26,
17-9
8-31
4-93
9-14
9-24
12-9
13-72
6-20,
15-15
4-112
TM 10-3930-643-34
INDEX
Subject
Page
1-3
R
4-110,
13-97
Radiator Assembly
Rear Differential Carrier
Assembly
Rear Axle Assembly
(S/N 2000 and below)
Rear Drive Axle Assembly
(S/N 2001 and above)
Rear Oil Seal
Rear Planetary, Front and
References (Appendix A)
Remedies for Injuries
(General Maintenance)
Replacement of Parts
(General Maintenance)
Reporting Equipment
Improvement Recommendations
(EIR)
Reservoir:
Hydraulic, and Filter
Power Cluster (S/N 2000
and below)
Pressure Converter
(S/N 2001 and above)
Rocker Arm Assembly and
Valve Cover
Roll Over Protection Structure
(S/N 2000 and below)
7-46,
16-19
7-38
7-32
13-38
7-24,
16-15
A-1
2-2
2-6
1-4
12-170
8-21
8-31
4-51
10-23
S
Scheduling Valve, Transmission
Second and Third Gear Assembly
Service Brake Assembly
Service Brakes Troubleshooting
Sideshift Cylinder
(S/N 2000 and below)
Sideshift Cylinder
(S/N 2001 and above)
Solenoid
Starter Motor
Page
S (cent)
Q
Quality Assurance/Quality
Control
Subject
6-54
15-59
8-11
8-2
12-111
12-121
14-3
5-2
Steering Cylinder
Steering System:
Gear Assembly
Ground Driven Pump
(S/N 2000 and below)
Ground Driven Pump
(S/N 2001 and above)
Cylinder
Control Valve and Check
Valve
Circuit Relief Valve
Troubleshooting
9-31
9-6
9-14
9-24
9-31
9-36
9-51
9-2
T
Table of Contents
Tank, Fuel
Tilt Cylinder
Tilt Valve Assembly
Timing Gears, Camshaft and
Tool Kits (General
Maintenance)
Torque Converter:
Assembly
Charging Pump
Hoses, Lines and Fittings
Troubleshooting
Transmission:
Assembly
Control Valve
Control Valve and
Scheduling Valves
First Gear Assembly
Forward and Reverse Steering
Gear Assembly
Hoses, Lines and Fittings
Oil Cooler
Scheduling Valve
Second and Third Gear
Assembly
Troubleshooting
Treadle Valve (S/N 2000
and below)
i
4-107,
13-96
12-65
12-42
13-61
2-4
6-11,
15-2
6-20,
6-26
6-2
6-36,
15-22
6-54,
15-87
6-54
15-52
15-74
6-26
6-58
15-95
15-59
6-6
8-47
Index 5
TM 10-3930-643-34
INDEX(cont.)
Subject
Page
T (cont)
Treadle Valve (S/N 2001
and above)
Troubleshooting Index
Troubleshooting:
Axle, Front and Rear
Engine, Fuel, Exhaust
and Cooling
Hydraulic
Index
Parking Brake
Service Brake
Steering
Torque Converter
Transmission
Turbocharger
Turbocharger and Piping
Two-way Valves, Treadle
(S/N 2000 and below)
W
8-54
7-2
4-2
12-2
3-2
8-5
8-2
9-2
6-2
6-6
3-81
4-101
8-37
V
Valve Assembly:
Boom Assembly Valve
Check Valves-Treadle
(S/N 2001 and Above)
Fork Control Valve
Fork Valve
Inlet Valve
Loader Control Valve
Oil Pressure Regulator Valve
Steering Control Valve
and Check Valve
Steering Circuit Relief
Valve
Tilt Valve
Transmission Control Valve
Transmission Scheduling
Valve
Treadle Two-way Valves
(S/N 2000 and below)
Treadle Valve (S/N 2000
and below)
Treadle Valve (S/N 2001
and above)
Valve Cover, Rocker Arm
Assembly and
Vehicle Precautions
(General Maintenance)
Vibration Damper
Index 6
12-50
8-40
12-56
12-33
12-27
12-13
4-61
9-36
9-51
12-42
15-87
15-95
8-37
8-47
8-54
4-51
2-3
4-47
Warnings
Warranty Information
Water Pump Assembly
Wiring Harness:
Fork Control
Front Lights
Instrument Panel
Intermediate (S/N 2000
and below)
Intermediate (S/N 2001
and above)
Main
a
1-4
4-112
5-49
5-53
5-17
5-45
5-41
5-26
By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:
WILLIAM J. MEEHAN II
Brigadier General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12–25F (Block No. 2241) Direct Support/General Support maintenance
requirements for Fork Lift, 10,000 LB Capacity, Rough Terrain, Pneumatic Tire, Diesel (Model-MHE-236).
U.S.
GOVERNMENT
PRINTING
OFFICE:
1990
743-015/20021
PIN:
067295-000
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