TM-10-3930-615-15
TM 10-3930-615-15
TECHNICAL MANUAL
OPERATOR, ORGANIZATIONAL DIRECT SUPPORT, GENERAL SUPPORT
AND DEPOT MAINTENANCE MANUAL
TRUCK, FORK LIFT, ELECTRIC, SOLID RUBBER TIRES,
4,000 LB CAPACITY
BAKER MODEL FTD-040-EE, ARMY MODEL MHE 208)
FSN 3930-494-8151
(100 IN. LIFT) FSN 3930-236-6253 (180 IN. LIFT)
This copy is a reprint which includes current
pages from Changes 1 and 2.
HEADQUARTERS, DEPARTMENT 0F THE ARMY
FEBRUARY 1970
SAFETY PRECAUTIONS
BEFORE OPERATION
When servicing battery, do not smoke or use flame in vicinity. Batteries generate hydrogen, a highly explosive gas.
Avoid contact with the battery electrolyte. If the solution comes in con- tact with the skin, rinse the area immediately
with clean water to avoid skin burns.
Check equipment logbook for record of proper servicing and maintenance.
Check the operating area to be sure it is clear of personnel and obstructions.
DURING OPERATION
Be alert for other workers to be sure they are not in the way of the load or the moving truck.
Be sure there Is sufficient clearance overhead and on each side of the truck.
Always travel with the mast tilted back and with forks raised just high enough to clear any uneven floor conditions.
Avoid sudden starting and stopping of the truck. Reduce speed when making a turn.
Face in the direction of travel.
Know the rated capacity of the truck and do not overload it.
safely.
Never pick up a load until certain it can be carried
Make sure the load Is steady before lifting it and keep the load against the carriage backrest.
When transporting bulky loads, travel in reverse. Always descend ramps In reverse when carrying a load.
When unloading a heavy elevated load, position the load directly over the unloading spot, as low as possible, before
tilting the mast forward.
Be very careful when high-tiering.
Do not butt loads with the forks or with the rear of the truck.
Report any evidence of faulty truck performance.
AFTER OPERATIONS
Make sure forks are lowered to the ground and handbrake is engaged firmly.
If truck is parked on an Incline, block at least two wheels in the event of handbrake failure.
TM 10-3930-615-15
C2
Change In force: C 1, and C 2
CHANGE
No. 2
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, DC, 7 February 1980
}
Operator Organizational, Direct Support, General
Support, and Depot Maintenance Manual
TRUCK, FORK, LIFT, ELECTRIC; SOLID RUBBER TIRES; 4000 LB. CAPACITY, (BAKER
MODEL FTD-040-EE, ARMY MODEL MHE-208) (NSN 3930-00-494-8151), 100-IN LIFT; (NSN
3930-0-236-6253, 180-IN LIFT).
TM 10-3930-615-15, 3 February 1970, is changed as follow:
Page 5-1. after paragraph 5-4. Add the following:
WARNING
Insure that static electricity discharge straps are installed on the forklift truck and are in good condition.
Failure to use the straps could result in the generation of a spark which could ignite explosives or
flammables.
By Order of the Secretary of the Army:
Official:
E. C. MEYER
General, United States Army
Chief of Staff
J. C. PENNINGTON
Major General, United States Army
The Adjutant General
Distribution:
To be distributed in accordance with DA Form 12-25A, Organizational maintenance requirements for Warehouse
Equipment.
TM 10-3930-615-15
C1
CHANGE
No. 1
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 16 May 1972
}
Operator, Organizational, Direct and General
Support, and Depot Maintenance Manual
TRUCK, LIFT, FORK; ELECTRIC; SOLID RUBBER TIRES; 4,000 LB. CAPACITY (BAKER
MODEL FTD-040-EE, ARMY MODEL MHE-208) FSN 3930-494-8151, 100-IN LIFT;
FSN 3930-236-6253, 180-IN LIFT
TM 10-3930-615-15, 3 February 1970, is changed as follows:
Page B-1. Appendix B is superseded as follows:
APPENDIX B
BASIC ISSUE ITEMS LIST AND ITEMS
TROOP INSTALLED OR AUTHORIZED
B-1.
(2) Maintenance code, indicates the lowest
level of maintenance authorized to install the listed item.
The maintenance level code is:
Code
Explanation
C
Crew/Operator
Scope
This appendix lists items required by the operator for
operation of the truck.
B-2.
General
(3) Recoverability code, indicates whether
unserviceable items should be returned for recovery or
salvage.
Items not coded are nonrecoverable.
Recoverability codes are:
code
explanation
R
Applied to repair parts (assemblies and
components), special tools and test
equipment
which
are
considered
economically reparable at direct and
general support maintenance levels.
S
Repair parts, special tools, test
equipment and assemblies which are
economically reparable at DSU and GSU
activities and which normally are
'furnished by supply on an exchange
basis.
b. Federal Stock Number. This column indicates
the Federal stock number assigned to the item and will
be used for requisitioning purposes.
c. Description. This column indicates the Federal
item name and any additional description of the item
required.
d. Unit of Measure
(U/M).
A 2 character
alphabetic abbreviation indicating the amount or
quantity of the item upon which the allowances are
based, e.g., ft, ea, pr, etc.
e. Quantity Furnished with Equipment (BIIL). (Not
applicable).
f.
Quantity Authorized (Items Troop lnstalled or
Authorized). This column indicates the quantity of the
item authorized to be used with the equipment.
This list is divided into the following sections:
a. Basic Issue Items List-Section II.
Not
applicable.
b. Items Troop lnstalled or Authorized ListSection III. A list of items in alphabetical sequence,
which at the discretion of the unit commander may
accompany the truck. These items arc NOT SUBJECT
TO TURN-IN with the truck when evacuated.
B-3.
Explanation of Columns
The following provides an explanation of columns in the
tabular list of Basic Issue Items List, Section II and
Items Troop Installed or Authorized, Section III.
a. Source, Maintenance and Recoverability
Code(s) (SMR):
(1) Source code, indicates the source for the
listed item. Source codes are:
Code
Explanation
P
Repair parts, special tools and test
equipment supplied from GSA/DSA
or Army supply system and
authorized for use at indicated
maintenance levels.
P2
Repair parts, special tools and test
equipment which are procured and
stocked for insurance purposes
because the combat or military
essentiality of the end item dictates
that a minimum quantity be
available in the supply system.
TAGO 3459A
1
Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST
(3)
(1)
(2)
SMR
Federal stock
Code
number
7510-889-3494
7520-559-9618
4210-889-2222
Description
(4)
(5)
Qty Auth
Ref No. and Mfr.
Usable
Unit of
code
on code
meas
BINDER, Looseleaf
CASE, Maintenance and Operation Manuals
EXTINGUISHER, Fire
EA
EA
EA
1
1
1
By Order of the Secretary of the Army:
W. C. WESTMORELAND,
General, United States Army,
Chief of Staff.
Official:
VERNE L. BOWERS,
Major General, United States Army,
The Adjutant General.
Distribution:
To be distributed in accordance with DA Form 126A, (qty rqr block No. .B4) Organizational Maintenance Requirements
for Warehouse Equipment
2
TM 10-3930-615-15
TECHNICAL MANUAL
HEADQUARTERS
DEPARTMENT OF THE ARMY
WASHINGTON, D.C., 3 February 1970
NO. 10-3930-615-15
OPERATOR, ORGANIZATIONAL, DIRECT SUPPORT, GENERAL SUPPORT AND DEPOT MAINTENANCE
MANUAL
TRUCK, FORK LIFT, ELECTRIC, SOLID RUBBER TIRES, 4,000 LB CAPACITY
(BAKER MODEL FTD-040-EE, ARMY MODEL MHE 208)
FSN 3930-494-8151
(100 IN. LIFT) FSN 3930-236-6253 (180 IN. LIFT)
Page
SECTION
APPENDIX
1.
GENERAL DESCRIPTION ...............................................................................................1-1
2.
PREPARATION FOR USE ...............................................................................................2-1
3.
OPERATING INSTRUCTIONS.........................................................................................3-1
4.
PRINCIPLES OF OPERATION ........................................................................................4-1
5.
PREVENTIVE MAINTENANCE ........................................................................................5-1
6.
CORRECTIVE MAINTENANCE .......................................................................................6-1
7.
ILLUSTRATIONS .............................................................................................................7-1
A.
MAINTENANCE ALLOCATION CHART .......................................................................... A-1
B.
BASIC ISSUE ITEMS...................................................................................................... B-1
SECTION 1
GENERAL DESCRIPTION
1-1.
1-3.
INTRODUCTION.
DESCRIPTION.
1-4. The electric fork lift truck has a safe load capacity
of 4,000-pounds, and is primarily designed for
warehouse operation to load, transport, unload and
stack loads at a load center of 24-inches. Tile truck is
equipped with either a load lift of 100-inches of 180inches. The fork lift truck is illustrated in figures 1-1 and
1-2.
1-2. This manual contains general service, operating
and maintenance instructions for Truck, Fork Lift,
Electric, Solid Rubber Tires, 4,00Pound Capacity, Baker
Model FTD-040-EE.
Figure 1-1. Truck, Three Quarter Front View
1-1
bevel ring gear and pinion in the axle, through the axle
drive shafts and wheels.
1-5. TRUCK. Power for travel and lifting is provided
by a 3(-volt battery. The travel system includes the
motor, all operating controls, and power axle assembly
to provide stepless speeds forward and reverse. The
lifting system includes an electric motor, pump, controls,
reservoir, lift and tilt cylinders, mast assembly and
forks. Hydraulic service brakes and both hand and
automatic parking brakes are used.
1-7. CONTROL SYSTEM. Travel motor power and
vehicle speed and direction are regulated by a system
which includes relays, an electronic silicon controlled
rectifier (SCR) control system, an accelerating master
switch and directional switch providing stepless forward
or reverse speeds. A foot accelerator operates the
accelerating master switch to control the speed of the
truck. Steering System. The steering system includes
power steering gear of the rotary valve type in which a
recirculating ball nut functions
1-6. POWER AXLE AND MOTOR ASSEMBLY. The
power train consists of the travel motor, coupling, power
axle with differential, axle shafts, and drive wheels.
Power Is transmitted direct from the travel motor
through an adapter incorporating reduction gearing to a
Figure 1-2. Truck, Three Quarter Rear View
1-2
inner and outer upright assemblies, and provides
additional mast rigidity and an overall truck profile
height of 83 inches while permitting a lift height of 180
inches. As the plunger of the hydraulic cylinder raises
the inner upright assembly, tension is applied to chains
attached between a cross member attached at the top
and reeved around rollers oil the intermediate upright
assembly to anchors at tile top of tile outer upright
assembly to separate the inner and intermediate
assemblies from the outer upright assembly.
4
Lift Carriage Assembly. The lift carriage rides
on rollers within the inner upright assembly. Two forks
are mounted on the front of the lift carriage assembly for
handling of loads.
1-11.
HYDRAULIC SYSTEM. Tile hydraulic system
consists of a reservoir, pump control valve, hoist and tilt
cylinder, arid hydraulic hoses. The hoist cylinder raises
the lift carriage and forks by hydraulic pressure supplied
by the pump. Gravity lowers the lift carriage.
1-12.
LIFT CYLINDER. A compound lift , used on
this vehicle. The lift carriage rises to top of the outer
upright before the inner and/or intermediate uprights
together with the lift carriage move upward. This is
achieved by a dual hydraulic hoist cylinder assembly
with two pistons working in sequence.
1-13.
TILT CYLINDERS.
The tilt cylinders are
double-acting. Tile uprights are tilted in and out by
hydraulic pressure to the tilt cylinders.
1-14.
ELECTRICAL SYSTEM. The electrical system
is a two-wire, undergrounded type. Tile battery Is
connected into the circuit by means of a removable
connector. This charging connection is also made
through this connector. The weight of the operator in tile
drivers seat closes tile circuit to the accelerating switch
by an interlock.
Travel control is through the
accelerating switch, with circuit made and broken by
relays. A panic switch mounted on tile dash panel
opens and closes the travel circuit. The direction of
travel is selected by the directional switch lever on the
steering gear post. The stop and taillight is enclosed in
a guard on the rear of the truck. The headlight,
mounted on the left side of the hoist upright, is
controlled by a toggle switch on the instrument housing.
1-15.
BATTERY. The 36-volt battery used will weigh
approximately 1600 pounds. The inside of the truck
battery compartment is 26-13/16,inches long, 32-7/8
inches wide, and 23-3/8 inches high.
1-16.
ACCELERATOR MASTER ASSEMBLY. The
accelerator master assembly contains three sensitive
switches, operated in sequence by cams. The cams are
actuated by the accelerator pedal.
The switches
energize relays which through the SCR control system
govern the speed of the travel motor. A potentiometer
governs signal strength and thereby power output of the
SCR travel motor control circuit. The accelerating
switch is located under the floor plate.
as a nut within the gear housing. A double acting valve
responds to turns of the steering wheel to apply turning
power to the steering bellcrank, tie rods and steering
knuckles on the trailing axle as in conventional manual
steering.
1-8.
BRAKE SYSTEM. The brake system consists
of a mechanical parking brake and a hydraulic foot
brake. The mechanical brake operates on a drum on
the travel motor armature shaft. This brake is applied
either by a handle on the floor to the right of the driver
or automatically through spring action as the driver rises
from the seat.
The hydraulic brake system is a
conventional automotive type, effective only on the front
wheels.
1-9.
DUAL LIST MAST ASSEMBLY. The dual lift
mast assembly consists of the following assemblies:
1. Outer Upright Assembly. The outer upright
assembly serves as a guide for the inner upright
assembly, a base for the hoist cylinder, and provides
brackets for connecting the uprights to the power axle
and for connecting the upright to the tilt cylinders.
2. Inner Upright Assembly. The inner upright
assembly is nested in and guided by the outer upright
assembly. The hoist cylinder, mounted in the base of
the outer upright assembly, is secured to the inner
upright assembly. The inner upright assembly is raised
or lowered by action of the hoist cylinder.
3. Crosshead Assembly.
The crosshead
assembly is mounted over tile hoist cylinder. Chains are
reeved over rollers attached to the crosshead assembly.
The lower ends of the chains are connected to the lift
carriage. The upper ends of the chains are anchored to
the lift cylinder. As the plunger of the hydraulic cylinder
raises the crosshead, tension is applied to the chains,
raising the carriage.
4. Lift Carriage Assembly.
The lift carriage
assembly rides on rollers within the inner upright
assembly, which in turn slides up and down inside the
outer upright assembly to a lift height of 100 inches.
1-10.
TRIPLE LIFT MAST ASSEMBLY. The optional
triple lift mast assembly consists of the following
assemblies:
1. Outer Upright Assembly. The outer upright
assembly is a welded one-piece assembly that is
mounted on the truck frame assembly and encloses the
hoist cylinder, intermediate upright assembly and inner
upright assembly.
2. Inner Upright Assembly. The inner upright
assembly is a welded one-piece assembly that is
mounted within the intermediate upright assembly. The
hoist cylinder, mounted at the base of the assembly, is
secured to the top of the assembly. The inner upright
assembly is raised or lowered by action of the hoist
cylinder.
3. Intermediate Upright Assembly.
The
intermediate upright assembly is positioned between the
1-3
Left hand (2.061 turns of
steering wheel) ................................... 42 deg 20 min
Right hand (2.061 turns of
steering wheel) ................................. 42 deg 20. min
1-17.
LEADING PARTICULARS.
1-18.
The leading characteristics of the electric fork
lift truck are as follows:
Aisle width (minimum) (carrying 48 in. cube):
Battery
Intersecting..................................................69-5/8 in.
Voltage ...............................................................36 v
Right angle stacking ..................................137-5/8 in.
Type ......................................................... Lead acid
.................................................... or nickel-iron
Gradeability (maximum load) .................................. 15%
Weight
Hoist speed (empty)
Lead Acid .................................................... 2200 Ibs
(FSN 6140-900-6285)
Nickle Iron ................................................... 1645 lbs
(FSN 6140-901-1054)
Tires
Dual Mast Assembly Truck ......................61 ft/minute
Triple Mast Assembly Truck ....................56 ft/minute
Hoist speed (maximum load)
Dual Mast Assembly Truck .....................40 ft/minute
Type ...................................................... Solid rubber
Triple Mast Assembly Truck ....................33 ft/minute
Number:
Drive ............................................................. 2
Lift height
Steer ............................................................. 2
Dual Mast Assembly Truck .............................100 in.
Size
Triple Mast Assembly Truck ...........................180 in.
Load capacity (maximum) ................................. 4,000 lb.
Drive ................................... 18 x 8 x 12-1/8 in.
Maximum speed (empty):
Steer ................................... 16 x 5 x 10-1/2 in.
Over-all dimensions and weight
Forward ........................................................5.8 mph
Ground clearance (at mast center) .....................3 in.
Reverse ........................................................5.7 mph
Height (Over-all):
Maximum speed (loaded):
Forward ........................................................5.6 mph
With dual mast assembly retracted ...................83 in.
Reverse ........................................................5.5 mph
With dual mast assembly extended ..........119-1/2 in.
With triple mast assembly retracted ..................83 in.
Tilt limitation:
With triple mast assembly extended .........199-1/2 in.
Backward ...................................................... 10 Deg
Length:
Forward ........................................................... 3 Deg
Over-all .....................................................125-1/2 in.
Turning radius (no load):
Inside ...........................................................6-7/8 in.
Forks ................................................................40 in.
Outside .......................................................69-5/8 in.
Weight w/battery (dual mast assembly truck) . . 9,170 lbs
Steering gear ratio ................................................17.5:1
Weight; w/battery (triple mast assembly truck) . 9,080 lbs
Steering wheel travel
Weight w/o battery (dual mast assembly truck) .6,885 lbs
1-4
Steer .......................................................... 5,740 lbs
Weight w/o battery (triple mast assembly truck) .7,453 lbs
Width
Wheel load (triple mast assembly type)
42 in.
Drive .......................................................... 4,080 lbs
Wheel load (dual mast assembly truck)
Steer .......................................................... 5,000 lbs
Drive .......................................................... 3,430 lbs
1-5
SECTION 2
PREPARATION FOR USE
2-1.
GENERAL.
2-8.
2-2.
This section describes the procedures required
to place the electric fork lift truck into operating
condition upon receipt. The sparking units such as
motor, controller, contactors, switches and other
sparking devices are insulated or enclosed in metal
boxes. Whenever any sealed parts are opened for
inspection, repair or lubrication, make sure that they are
properly enclosed and sealed before the truck is put
back into operation.
SEPARATELY
2-9.
FIRE EXTINGUISHER. Remove separately
packed fire extinguisher and install in bracket at front of
truck. Be certain bracket clamp locks properly to secure
fire extinguisher in position.
2-10.
DIRECTIONAL CONTROL SWITCH KNOB.
Screw directional control switch knob onto lever of
directional control switch secured to steering gear
column.
2-3.
The truck is shipped as a completed unit
except for the separately packed components (para. 28).
After the separately packed components are
installed, the preservatives removed (para. 2-6) and the
inspection performed (para. 2-5) the truck may be
entered into service. No other installation or setting up
procedures are required other than operator orientation
and training.
2-4.
INSTALLATION
OF
PACKAGED COMPONENTS.
2-11.
HEADLIGHT. Install headlight as follows:
1. Secure headlight to left side of outer upright
with two screws, nuts and lock washers.
2. Remove headlight guard, bezel and sealed
beam light.
3. Insert conduit through rear of headlight shell
and connect conduit leads securely to headlight
terminals.
4. Install sealed beam light, bezel and headlight
guard using the same hardware that was removed.
5. Inspect the controls and instruments for breaks,
cracks, bends, or other defects.
UNPACKING AND INSPECTION.
2-5.
Unpack and inspect the equipment received as
follows:
1. Remove tape, paper, or other packing. Use
care when unpacking separately packaged components
to account for all hardware.
2. Inspect for missing components by checking
equipment received against packing list.
3. Inspect exterior surfaces for broken or dented
parts, and for damaged painted surfaces.
4. Inspect visible wiring and hydraulic lines for
cuts, breaks, or other damage.
5. Inspect the lift chain and carriage assembly for
damage.
2-12.
FORKS. Pull up ring catch on fork, position
fork in desired location on carriage and release ring
catch to lock fork on carriage. Repeat to install other
fork.
2-6.
CLEANING AND LUBRICATION.
2-13.
BATTERY. The battery is a 36-volt storage
type, shipped dry and separately from the equipment.
The electrolyte is also packed in a separate container.
Fill the battery with electrolyte to the level 3/8 inch
above the plates and connect the battery to a charger
until it is fully charged.
2-7.
Clean and lubricate the truck as follows:
To install battery, proceed as follows:
1. Open battery compartment top and side doors.
Latch top door to overhead guard.
2. Using a hoist rated at more than 2,000 pound
capacity, lift battery by hooks inserted through lifting
eyes at each side of battery. Use a spreader bar as
wide as the battery between the lifting hooks to avoid an
inward pull on the battery case.
1. Remove with a drycleaning solvent all
preservative compound from exposed metal surfaces.
Because this compound is not a lubricant, take special
care to see that it is completely removed from all
wearing surfaces. Lubricate truck (para 5-10).
2. Fill drive axle, hydraulic tank and master
cylinder with proper lubricant.
2-1
WARNING
2-15.
LOCAL WORKSITE. When the new worksite
is near, the fork lift truck may be operated under its own
power f the area is relatively level. If the ground is
rough, sandy, or muddy, tile fork lift may be loaded into
a truck, trailer, or other carrier to be moved. No
dismantling of the truck is required for movement to a
local worksite.
Avoid contact with the battery electrolyte. If the
solution comes in contact with the skin, rinse the
area immediately with clean water to avoid skin
burns. Do not smoke or use an open flame in
the vicinity when servicing batteries as they
generate hydrogen, an explosive gas.
2-16.
DISTANT WORKSITE. When the fork lift
truck must be moved to a distant worksite, it may be
loaded onto a truck, trailer, or other carrier and secured
with block, strapping, cables and the like. Disconnect
the battery cable connector before transporting tile fork
lift truck.
The only reinstallation after movement
required is the connection of the battery cable connector
with its mating receptacle.
3.
Position battery between battery clamps in
battery compartment and remove hoist. Tighten battery
clamp screws to prevent battery movement.
4.
Connect battery leads securely at battery
receptacles and close battery compartment doors.
2-14.
MOVEMENT TO WORKSITE.
2-2
SECTION 3
OPERATING INSTRUCTIONS
3-1.
position of the switch turns off the headlight and taillight.
GENERAL.
3-11.
PANIC BUTTON. The panic button is located
to the left of the light switch. Normal condition of the
switch is the up position. The depressed position of the
switch disables the power circuit to the truck.
3-2.
This section describes, illustrates, locates, and
furnishes the operator with sufficient information about
the various controls and instruments to insure proper
operation of the electric fork lift truck, Baker Model FTD040-EE.
3-3.
3-12.
LIFT CONTROL LEVER. The lift control lever
is located on the cowl to the right of the operator's seat.
The rear position of the lever lifts the forks. The forward
position of the lever lowers the forks. The mid position
of the lever maintains the forks at any desired height.
CONTROLS. (Refer to figure 3-1)
3-4.
BATTERY SWITCH.
When the battery
connector is mated and the battery connector lever is
operated to the locked (down) position, the lever
operates the battery switch. The switch is in series with
the panic switch and seat switch to the master switch
relay. This switch must be closed before the truck can
be operated.
3-13.
TILT CONTROL LEVER. The tilt control lever
is located directly to the right of the lift control lever.
The forward position of the tilt control lever tilts the forks
forward. The rear position of the lever tilts the forks
backward. The mid-position of the lever maintains the
fork at any desired tilt angle.
3-5.
OPERATOR'S SEAT. As the operator places
his weight on the operator's seat, a seat switch is closed
to enable operation of the truck. Simultaneously, the
mechanical travel motor brake is released. As the
driver removes his weight from the seat, the motor
brake is engaged and the electrical circuit of the truck Is
disabled.
3-6.
HORN BUTTON. The horn button is located in
the center of the steering handwheel. Depressing the
button energizes the horn to sound an audible alarm.
3-7.
PARKING BRAKE LEVER. The parking brake
lever is located to the right of the operator's seat in front
of the cowl. The up position of the lever applies and
sets the mechanical brake which holds the truck in a
stationary position. Twisting the lever clockwise and
returning it to the down position releases the mechanical
brake.
3-8.
STEERING WHEEL.
The steering wheel
controls the direction of travel of the truck. Turning the
steering wheel clockwise moves the truck to the right;
turning the steering wheel counterclockwise moves the
truck to the left.
3-9.
ACCELERATOR PEDAL.
The accelerator
pedal is adjacent to the brake pedal, convenient to the
operator's right foot. The distance the accelerator pedal
is depressed determines the speed and acceleration
desired by the operator. Released pressure on the
pedal slows the speed of the truck.
3-10.
LIGHT SWITCH. The light switch is located on
the left side of the instrument panel. The ON position of
the switch turns on the headlight and taillight. The OFF
Figure 3-1. Controls and Instruments.
3-1
seat.
2. Check that battery connector lever is in down
position and battery switch is closed.
3. Check that panic button is pulled up.
4. Depress brake pedal with right foot, and
simultaneously release parking brake lever with right
hand.
5. Move the lift control lever gradually to the rear
to raise the forks to normal traveling position (8 to 10
inches above working surface). Release control lever
when traveling position of forks is reached.
6. Move the tilt control lever backward and tilt tile
forks backward.
Release lever when forks are
sufficiently tilted.
7. Move the direction control level from the
center-off- position to forward or reverse position
depending on travel direction desired.
8. Remove foot from brake pedal and place on
accelerator pedal. Gradually depress accelerator pedal
until truck begins to travel. Continue to depress the
accelerator pedal until safe operating speed is attained.
3-14.
DIRECTION CONTROL LEVER. The direction
control lever is located on the right side of the steering
column. This lever provides three position control of
truck direction; forward, off, and reverse. The forward
position of the lever provides forward travel, the midposition off, and the backward position for reverse
travel. The lever is left in the mid-position when the
truck is parked. Mechanical linkages attached to the
operator's seat automatically return the lever to the midposition when the operator rises from the seat. The
directional control lever may be used for either forward
or reverse torque braking by moving the direction
control lever to the opposite direction of travel. The
truck will come to almost a complete stop before going
in the opposite direction.
3-15.
BRAKE PEDAL. The brake pedal is located on
the floor immediately to the right of the steering
column. When depressed, the brake pedal operates the
hydraulic brake system to stop the truck. Operation of
the brake pedal also lights the rear stoplight.
3-21.
STOPPING.
The recommended stopping
procedure for the electric fork lift truck is as follows:
1. Remove foot from, accelerator pedal.
2. Apply gradual pressure on brake pedal to bring
the truck to a safe smooth stop. Avoid sudden stops.
3. Apply parking brake.
4. Move direction control lever to the center-off
position.
5. Move tilt control lever forward to bring mast to
vertical position and release lever.
6. Move the lift control lever forward to lower
forks to ground and release lever.
7. As operator leaves tile , the travel motor brake
is applied and the seat switch is opened to disable the
electrical system The direction control lever is also
automatically returned to the center-off position.
3-16.
SEAT ADJUSTER.
The seat adjuster is
located on the lower left side of the operator's seat. The
outward position of the lever (away from the operator)
releases the seat and enables it to be moved forward or
backward, as desired. Returning the adjuster lever to
the inward position locks the seat in position.
3-17.
HOURMETER. The hourmeter is the only
instrument used on this truck. It is located on the
instrument panel to the right of the panic switch. This
meter operates only when the truck is in motion. The
figure (extreme right center) records 10th of an hour.
The small indicator (upper right) visibly turns when the
meter is recording.
3-18.
OPERATION UNDER USUAL CONDITIONS.
3-22.
EMERGENCY STOPPING. Tile mechanical
brake is automatically applied when the operator's
weight is removed from the seat. The power circuit is
automatically opened whenever the operator depresses
the panic switch mounted on the instrument panel.
Either above procedure will permit emergency of the
truck.
3-19.
GENERAL. The instructions in this section are
published for the information and guidance of personnel
responsible for operation of the fork lift truck. The
operator must know how to perform every operation of
which the fork lift truck is capable. Instructions include
starting and stopping the fork lift truck, operating the lift
and tilt system, and on coordinating the basic motions to
perform the specific tasks for which the equipment is
designed. Since nearly every job presents a different
problem, the operator may have to vary given
procedures to fit tile individual job.
3-23.
PICKING UP LOAD. The procedure for picking
up the load is as follows:
1. Approach load squarely with forks spaced to
divide load evenly, halting truck when load Is directly in
front of forks.
3-20.
STARTING.
The recommended starting
procedure for the electric fork lift is as follows:
1. Mount truck and take position in operator's
3-2
8.
Release parking brake lever.
9.
Slowly back the truck away from tiered stack
until the forks are clear.
10. Operate lift control lever forward to lower
forks into normal traveling position (8 to 10 inches
above surface).
2.
Operate tilt control lever forward to bring mast
assembly to vertical position.
3.
Operate lift control lever to raise or lower
forks to proper height to pick up load.
4.
Slowly move truck forward until forks are
positioned directly under load. Make certain forks are
fully inserted in pallet or under load.
5.
Apply parking brake to prevent truck from
shifting position during lifting operation.
6.
Operate direction control lever to center-off
position.
7.
Operate lift control lever to rear and raise load
approximately 12 inches above ground level and
release lever.
8.
Operate tilt control lever backward to tilt forks
backward and release lever.
3-26.
DEPOSITING LOAD IN STORAGE AREA.
The load is placed in a level storage area as follows:
1.
Carefully drive up to position where load is to
be deposited.
2.
Depress brake pedal to halt truck.
3.
Apply parking brake.
4.
Operate direction control lever to center-off
position.
5.
Operate tilt control lever forward to bring the
mast assembly to the vertical position, and release
lever.
6.
Operate lift control lever forward and carefully
lower load to ground. Continue to lower forks until free
from under load.
7.
Operate direction control lever to reverse
position.
8.
Release parking brake lever.
9.
Slowly back truck away from deposited load.
3-24.
MOVING LOAD. The load is transported in
the following manner:
1.
Operate direction control lever from center-off
position to proper forward or backward position for
desired direction of travel.
2.
Release the parking brake lever.
3.
Slowly depress accelerator pedal, and move
the load to the desired location.
3-27.
WARNING
BATTERY CARE.
3-28.
Every 8 hours of after a day's work with the
truck, the operator must have the battery charged
overnight for efficient operation of the fork lift truck the
following day. Refer to TM 10-1690A for battery
maintenance.
The operator must be alert at all times while
operating the fork lift truck. Failure to observe
this warning can result in serious injury or death
to the operator or other personnel.
3-25.
DEPOSITING LOAD ON TIERED STACK.
The load is deposited on a tiered stack as follows:
3-29.
OPERATION
CONDITIONS.
1.
Operate lift control lever to rear until load
height is above tier.
2.
Slowly drive truck forward until load is
positioned directly over tier.
3.
Apply parking brake.
4.
Operate direction control lever to center-off
position.
5.
Operate tilt control lever forward to tilt load
squarely over tier.
6.
Operate lift control lever forward and carefully
lower load into position on tier. Continue to lower forks
until free of pallet.
7.
Operate direction control lever to reverse
position.
UNDER
UNUSUAL
3-30.
OPERATION IN EXTREME COLD.
temperatures below 0 deg F:
In
1.
See that hydraulic reservoir is filled to proper
level. (Refer to figure 2-1.) Inspect for leaks at all
accessible lines, hoses and fittings.
2.
Inspect brakes for proper operation.
3.
Keep battery fully charged.
Maintain
electrolyte level.
4.
Be extremely careful when handling hoses,
lines, or wiring to avoid breakage.
5.
Wipe exposed areas dry with a clean cloth.
3-3
3-31.
OPERATION IN EXTREME
temperatures of extreme heat:
HEAT.
1. Wash the unit frequently with clean, fresh
water. Do not contaminate hydraulic system or damage
electrical components.
In
1. Make certain that hydraulic reservoir is filled to
proper level.
2. Inspect lines and fittings for breaks or leaks.
3. Inspect and maintain battery electrolyte level.
2. Coat exposed metal surfaces with dustproofing
material. Remove rust immediately and apply paint or
oil as applicable.
3-32.
OPERATION IN DUSTY OR SANDY AREAS.
To protect tile electric fork lift truck as much as possible
in these areas:
3-35.
OPERATION OF AUXILIARY EQUlPMENT.
3-36.
FIRE EXTINGUISHER. (Dry Chemical Type)
The dry chemical type fire extinguisher is effective in
areas where ambient temperature is -25 deg F. and
above. If winterized (pressurized with nitrogen), the tire
extinguisher may be used in temperatures below -25
deg F. Tile fire extinguisher is a 2-1/2 pound, stored
pressure, lever-operated extinguisher. To operate the
fire extinguisher, proceed as; follows:
1. Shield the fork lift truck from dust and sand as
much as possible when not in use. Take advantage of
natural barriers which offer protection from dust and
sand.
2. Check air filter frequently for clogged condition.
Wipe dust and dirt from filter area before removing from
reservoir. Wipe dust and dirt from cylinders frequently
as sand arid dust acts as an abrasive and can damage
the lift cylinders.
3. Clean all lubrication points thoroughly before
applying lubricants.
4. Wipe dust and dirt from all external areas
regularly.
1. Disconnect clamp that secures extinguisher on
mounting bracket, swing clamp open. and remove
extinguisher.
2. Hold extinguisher upright, aim nozzle at base
of fire and raise operating lever.
3.33.
OPERATION UNDER RAINY OR HUMID
CONDITIONS. If unit is outside and not operating,
protect it with a canvas or other waterproof covering.
Remove cover during dry periods. Keep hydraulic
reservoir full to avoid condensation. Wipe excess
moisture from external surfaces.
3. Direct discharge at base of fire with a side-toside sweeping motion.
CAUTION
Weigh the fire extinguisher every 6 months.
Replace the extinguisher if the weight is less
than 4-1/2 pounds, or tile pressure is below 125
pounds.
3-34.
OPERATION IN SALT-WATER AREAS. In
areas where salt water is a problem to the equipment:
3-4
SECTION 4
PRINCIPLES OF OPERATION
4-1.
F contacts close. This establishes a voltage path
through fuse 12FU, the travel motor, normally-open F
contacts of the forward relay, the series field of the
travel motor, the normally-closed R contacts of the
reverse relay, transformer IT primary and across
capacitor IC and conducting rectifier 2SCR.
This
permits capacitor IC to charge to battery voltage. As the
capacitor charges, current through rectifier 2SCR
reduces to zero, and when the capacitor voltage reaches
battery voltage rectifier 2SCR cuts off. The polarity of
terminal 2 of IC is positive with respect to terminal 1.
During pre-charge, the travel motor does not receive
enough power to produce torque.
GENERAL.
4-2.
This section presents the principles of lift truck
control panel operation, and includes the distribution of
electrical power for
the operation of its various
accessories. The control panel circuit controls the
operation and speed of the travel motor, the hydraulic
pump motor and the power steering motor through
relays whose contacts are designed with high power
handling capabilities. Secondary circuits, such as the
lights and horn are switch operated. The following
material is presented using figures 4-1 and 4-2 as
reference. Figure 4-1 is a schematic diagram of the
control circuitry, and figure 4-2, a wiring diagram.
4-3.
4-8.
TURN-ON. Turn-on occurs when the delayed
gate pulse from control pack 2CP reaches and opens
the gate of rectifier ISCR, allowing it to conduct.
Conduction of rectifier ISCR permits travel motor
current to increase through the primary winding of
transformer IT to induce a voltage in the secondary.
This voltage source is in series with the battery. This
induced voltage in the secondary produces a current in
the direction of the dot. Capacitor IC thus reverses
polarity; its charging path completed through coil IL,
rectifier ISCR, transformer IT SEC and diode 3RC.
During turn-on time, the travel motor receives power to
produce drive torque, the speed of the motor governed
by the width of the pulse. Pulse width, in turn, is
controlled by the speed potentiometer. For slow and
moderate speeds, pulse width is short; for higher
speeds, pulse width is longer.
POWER CIRCUIT CONTROL.
4-4.
Power for the operation of the electric truck is
received from the 36-volt battery, whose application to
the various circuits is controlled by master switch relay
IMS. Two conditions are required to operate this relay;
(1) the battery switch mounted on the
battery
compartment wall on tile lift side of the seat must be
closed, and (2) the seat switch must be operated. This,
then completes the battery circuit through fuse 8FU, (lie
battery switch, the panic switch, the seat switch, master
switch relay IMS and the diode across terminals 4 and 5
of suppresser 4SP to the positive side of the battery.
When relay IMS is energized, normally-open contacts
IMS close (pick up) to enable available power for
electric truck operation.
4-5.
4-9.
TURN-OFF. Turn-off occurs when the gate
pulse is applied to rectifier 2SCR.
This permits
capacitor IC to discharge through it and rectifier ISCR in
a direction opposite to the load current. When the
capacitor discharges, current through rectifier ISCR
reduces to zero, and the rectifier cuts-off. This permits
capacitor IC to charge again to battery voltage, and,
when charged, causes rectifier 2SCR to cut-off.
TRAVEL MOTOR CONTROL.
4-6.
The travel motor is a series field traction motor
under the control of silicon controlled rectifiers (SCR) for
creep and low speeds, and essentially directly across
the battery for high speed travel. Operation of the travel
motor for creep and slow speeds is described under
three modes of operation; pre-charge, turn-on and turnoff. Higher speed control follows in the latter part of the
text.
4-10.
HIGH SPEED CONTROL. For full speed
cruising, the solid state control circuit is bypassed by the
application of a voltage developed in control pack 2CP
and applied across shorting contactor relay SC. This
voltage is delivered across the relay when the 'final'
contacts in the accelerator switch close. When tile relay
energizes, its SC contacts close to permit travel motor
current to flow through field weakening pack FWP. This
effectively applies full battery power across the travel
motor. Additionally, a second set of SC contacts close
to permit battery voltage to energize field weakening
relay FW. The circuit established is through fuse 6FU,
the closed SC contacts, field weakening pack FWP and
the FW relay. When the relay energizes, its contacts in
series
4-7.
PRECHARGE. Pre-charge occurs when the
directional controller is set in either the forward or
reverse position and the accelerator switch is depressed
to the position where the INITIAL contacts close. This
condition generates a short duration from control pack
ICP which is delayed to rectifier ISCR but applied
directly to rectifier 2SCR, allowing it to conduct. With
the directional switch in the forward position, a voltage
path is thus completed from control pack 2CP, line
2PL6, the travel motor thermocouple, the brake switch,
the closed INITIAL contacts of the accelerator switch
and closed 1 CIRC FWD contacts of the directional
switch to the forward relay. When the relay energizes,
its normally-closed F contacts open and normally-open
4-1
Figure 4-1. Control Panel Circuit, Schematic Diagram.
4-2
Figure 4-2. Control Panel Circuit, Wiring Diagram.
4-3
with FW RES (a resistance) close, to connect the
resistance in parallel with the travel motor field. This
weakens the field, causing the motor to operate at a
higher speed. Thus, cruising travel motor speed is
established.
4-15.
4-16.
The hydraulic pump motor circuit is completed
when either the hoist or tilt control is operated from the
neutral position.
This closes the pump switch to
energize the pump motor relay. The completed circuit is
through fuse 7FU, the closed pump switch, the pump
motor and hydraulic oil thermocouples to pump motor
relay IMP. When the relay energizes, its IMP contacts
close to apply battery voltage across the pump motor
through fuse 11IFU.
4-11.
PLUGGING CONTROL Plugging is a term
used to define the situation where the direction of
motion of the truck is suddenly reversed. When this
occurs, the travel motor series field is reversed during
travel and the armature counter emf reverses polarity
and tends to increase the effective system voltage by
acting as an additional voltage source in series with the
battery. This would create high braking currents to
circulate around the armature field. Diode I REC,
across the travel motor, clamps the armature voltage to
a very low value when travel direction is suddenly
changed to prevent this armature voltage buildup.
4-17.
HORN CIRCUIT.
4-18.
The horn circuit is energized by the operation
of the horn switch. When the switch is closed, battery
voltage is applied across the horn through fuse 8FU to
sound an audible alarm.
4-12.
TURN-OFF PROTECTION.
When silicon
controlled rectifier ISCR is cut-off, a large amount of
energy remains stored in the inductances of the travel
motor armature and field. This energy, if left to
dissipate itself, would produce high voltage transients
which would appear across the cut-off SCR and lead to
the possibility of shorting out the device. Flyback diode
2REC prevents this by establishing a series path to
dissipate this energy through itself, the armature and the
field.
4-13.
PUMP MOTOR CIRCUIT.
4-19.
LIGHT CIRCUIT.
4-20.
The light circuit consists of the spotlight and tile
tail and stoplight. The spot and taillights arc energized
simultaneously by the operation of the light switch.
When the switch is closed, battery voltage is applied
through fuse 5FU directly across the spotlight and also
across series resistor 3RES and the tail and spotlight.
Thus the tail and spotlight illuminates at a reduced
brilliance. When the brake switch is closed, resistance
3RES is bypassed and full battery voltage is applied
directly across the tail and stoplight for full brilliance.
POWER STEERING CIRCUIT.
4-14.
The power steering circuit is completed when
the master switch relay is energized and the directional
switch is placed either in the forward or reverse position.
The completed circuit of the power steering relay IS is
through fuse 6FU, the steering motor thermocouple, the
FWD or REV 2 CIRC section of the directional switch,
the ARP pack to the IS relay coil. When the relay is
energized, its IS contacts close to apply battery voltage
across the power steering motor through fuse 10FU.
4-21.
HOURMETER CIRCUIT.
4-22.
The hourmeter circuit consists of elapsed time
indicator ETI, the two EHP diodes, capacitor IMF and
fuse 9FU. The hourmeter is placed in the circuit so that
whenever the travel motor or pump motor circuit is
energized, elapsed time is recorded.
4-4
SECTION 5
PREVENTIVE MAINTENANCE
5-1.
Any or all checks pertinent to any item (including
supporting, attaching or connecting members) are
performed automatically as general procedures, in
addition to any specific procedures given. General
inspection instructions are as follows:
GENERAL.
5-2.
The fork lift truck must be inspected
periodically and systematically to insure that it is ready
for operation at all times. Correct all defects discovered
before they result in serious damage or failure. The
necessary preventive maintenance checks and services
are listed and described below. The item numbers
indicate the sequence of minimum inspection
requirements.
Note all defects discovered during
operation of the unit for future correction, and make
these corrections as soon as operation has ceased.
Stop operation immediately if deficiency noted during
operation would damage the equipment if operation
were continued.
5-3.
1.
Visually inspect unit
for
safety
or
serviceability. Good condition is explained further as
meaning: not bent or twisted, not chafed or burned, not
broken or cracked, not bare or frayed, not dented or
collapsed, not torn or cut, not deteriorated.
2.
Inspect for correct assembly. Observe unit for
normal position in the truck and that all parts are present
and in their correct relative positions.
3.
Inspect for security. Perform visual, handfeel, pry-bar, wrench, or screwdriver inspection for
looseness in the unit.
Include any brackets,
lockwashers, locknuts, locking wires, and cotter pins as
well as any connecting tubes, hoses, or -wires.
CHECKS AND SERVICES.
5-4.
SCOPE. This paragraph contains tabulated
listing of preventive maintenance checks and services.
Refer to Table 5-1 for the preventive maintenance
checks and services. The items are listed consecutively
and indicate the sequence of minimum preventive
maintenance requirements on the truck.
4.
Inspect for wear. Note items worn beyond
serviceable limits, or likely to fail if not replaced before
the next scheduled inspection. Excessive wear of
mating parts or linkage connections is usually evidenced
by too much play (lash or lost motion). It includes
illegibility as applied to markings and data plates, and
printed matter.
5-5.
INTERVALS. Inspect truck each time it is
operated. This service is divided into three parts:
a.
Before-Operation Service. This is a brief
service to ascertain that the truck is ready for operation;
it is mainly a check for conditions affecting truck
readiness since the last after-operation service.
5-8.
GENERAL CLEANING. Any special cleaning
instructions required for specific mechanism or parts are
contained in the pertinent section. General cleaning
instructions are as follows:
b.
During-Operation Service.
This service
consists of detecting unsatisfactory performances.
While driving or operating the truck, be alert for any
unusual noises or odors, steering irregularities, or any
other indication of malfunction of any part of the truck.
Every time a load is picked up or deposited, the brakes
applied, the truck accelerated or turned, consider it a
test and note any unusual or unsatisfactory
performance.
1.
Use dry-cleaning solvent (SD) or volatile
mineral spirits to clean or wash grease or oil from all
parts of the truck.
2.
A solution of one part grease-cleaning
compound to four parts of dry-cleaning solvent or
volatile mineral spirits may be used for dissolving
grease and oil from chassis, mast and other parts. Use
cold water to rinse off any solution which remains after
cleaning.
3.
After parts are cleaned, rinse and dry
thoroughly. Apply a light grade of oil to all polished
metal surfaces to
prevent rusting.
4.
Before installing new parts, remove any
preservative materials, such as rust-preventive
compound, protective grease, etc. Prepare parts as
required (oil seals, etc.). For parts requiring lubrication,
apply the lubricant prescribed.
c.
After-Operation Service. This is the basic
daily service for all trucks. It consists of correcting, so
far as possible, any operating deficiencies noted to
prepare the truck for immediate use.
5-6.
GENERAL PROCEDURES FOR SERVICES
AND INSPECTIONS.
5-7.
GENERAL
INSPECTIONS.
General
inspections are performed to check that items are in
good condition, correctly assembled, secure, not
excessively worn, not leaking, and adequately
lubricated. These inspections apply to most items in the
preventive-maintenance and inspection procedures.
5-9.
PRECAUTIONS IN CLEANING. The general
precautions used in cleaning are as follows:
5-1
Figure 5-1. Lubrication Chart (Sheet 1 of 2)
5-2
Figure 5-1. Lubrication Chart (Sheet 2 of 2)
5-3
fuels or lubricants on rubber parts as they will
deteriorate the rubber.
1.
Dry-cleaning solvent and volatile mineral
spirits are inflammable and not to be used near an open
flame. Provide fire extinguishers when these materials
are used. Use only in well-ventilated places.
4.
The use of diesel fuel oil, gasoline or bensene
(benzol) for cleaning is prohibited.
2.
These cleaners evaporate quickly and have a
drying effect on the skin. If used without gloves, they
may cause cracks in the skin, and in the case of some
individuals, a mild irritation or inflammation.
5-10.
LUBRICATION.
5-11.
Lubricate all points requiring lubrication shown
ill lubrication diagram (figure 5-1) at the recommended
intervals.
3.
Avoid getting petroleum products, such as
dry-cleaning solvent, volatile mineral spirits, engine
TABLE 5-1. PREVENTIVE MAINTENANCE CHECKS AND SERVICES
5-4
SECTION 6
CORRECTIVE MAINTENANCE
6-1.
............................................................ 500 amps
GENERAL.
6-2. This section provides information useful in
diagnosing and correcting unsatisfactory operation or
failure of the fork lift truck. Included are troubleshooting
information, removal and replacement procedures, and,
finally, general overhaul procedures. The procedures
include adjustments where required.
Power steering motor
field coil
resistance at 70 deg F .... series 0.0190 ohms ± 10%
..........................................shunt 16 ohms ± 10%
6-3.
Travel motor horsepower
rating at 36 volts ..............................5.2 hp (approx)
Travel motor voltage (nominal) ......................... 36 volts
CHARACTERISTICS AND RATINGS.
6-4. ELECTRICAL COMPONENTS.
Electrical
characteristics of fork lift truck useful to maintenance is
as follows:
Travel motor speed
at 36 volts with
20 foot pound load ..............................890 rpm ±5%
Travel motor current
at 36 volts with
20 foot pound load ............................. 75 amps ±5%
Travel motor stalled
rotor torque at 36 volts .......................... 230 ft lbs at
............................................................ 550 amps
Travel motor field
coil resistance at 70 deg F .......... 0.021 ohms ±10%
Hydraulic pump motor
voltage (nominal) ........................................ 36 volts
Hydraulic pump motor
horsepower rating at 36 volts ............................3 hp
Hydraulic pump motor
speed at 36 volts with
33 foot pound load ............................1600 rpm ±5%
Accelerator switch
potentiometer resistance ................ 0 to 6,000 ohms
Hydraulic pump motor
current at 36 volts
with 33 foot pound load .................... 250 amps ±5%
Accelerator controller
potentiometer resistance
with starting contactor
energized (shaft rotated
approximately 7 deg) ............................... 300 ohms
Hydraulic pump motor
stalled rotor torque
at 36 volts ...............................60 ft lbs at 400 amps
Hydraulic pump
motor field coil
resistance at 70 deg F ................. 0.006 ohms ±10%
Accelerator controller
potentiometer resistance
with final switch actuated
(shaft rotated approximately 27 deg .. 30 ohms max.
Power steering motor
voltage (nominal) ........................................ 36 volts
Directional switch type ..........................................DPDT
Power steering motor
horsepower rating at 36 volts ............................1 hp
Pump motor relay type ......................................... SPST
Pump motor relay coil
resistance at 70 deg F ................... 30.2 ohms ±10%
Power steering motor
speed at 36 volts with
2 foot pound load ..............................2700 rpm ±5%
Master switch relay type ....................................... SPST
Power steering motor
current at 36 volts with
2 foot pound load ............................... 30 amps ±5%
Master switch relay
coil resistance at 70 deg F ............ 30.2 ohms ±10%
Forward relay type ............................................... SPDT
Power steering motor
stalled rotor torque
at 36 volts ............................................... 67 ft lbs at
Forward relay coil
resistance at 70 deg F ................... 25.3 ohms ±10%
6-1
valve type .................................................... 2 spool
Reverse relay type ............................................... SPDT
Reverse relay coil
resistance at 70 deg F ................... 25.3 ohms ±10%
Tilt cylinder bore .....................................................4 in.
Tilt cylinder stroke ............................................ 3.125 in.
Shorting contactor
relay type ....................................................... SPST
Shorting contactor relay
coil resistance at 70 deg F ............ 25.3 ohms ±10%
Tilt cylinder closed
length ....................................................... 13.000 in.
Lift cylinder ........................................... extended length
- dual ..................................................... 113.594 in.
- triple .................................................... 129.375 in.
Field weakening relay type ................................... SPST
Field weakening relay type
coil resistance at 70 deg F ............ 25.3 ohms ±10%
Lift cylinder
closed length
- dual ....................................................... 65.469 in.
- triple ...................................................... 78.625 in.
Steering relay type ............................................... SPST
Steering relay coil
resistance at 70 deg F ................... 46.9 ohms ±10%
6-6. MECHANICAL COMPONENTS. .....The pertinent
mechanical data is as follows:
Steering gear ratio ................................................17.5:1
Steering wheel rotation
(lock to lock) .......................................... 4.122 turns
Field weakening pack
(FWP) resistance at 70 deg F
(across terminals 1 and 2) ...... 50,000 ohms dropout
.......................................... 100,000 ohms pickup
Transformer IT primary
resistance ....................................... 0.000835 ohms
.................................................................. ±10%
Transformer IT secondary
resistance ........................................... 0.0755 ohms
.................................................................. ±10%
Field weakening
resistance (FW RES) .................. 0.019 ohms ±10%
Drive axle type ....................................double reduction,
.................................................... ring and pinion
........................................................ plus internal
........................................................ to sun gears
Drive axle
over-all reduction
(including adapter) .......................................12.75:1
Resistor 1 RES
resistance ........................................ 75 ohms ±10%
Resistor 2 RES
resistance ........................................ 4 ohms ±10%0
Resistor 3 RES
resistance ........................................ 40 ohms ±10%
Drive axle
pinion gear backlash ...................................0.005 to
.............................................................. 0.015 in.
Drive axle
bevel gear reduction ......................................41/9:1
Drive axle
brake type ................................................. hydraulic
............................................................drum type
6-7. WEAR LIMITS AND CLEARANCES.
6-5. HYDRAULIC COMPONENTS. ....... The hydraulic
characteristics are as follows:
Hydraulic fluid type ..................................... MIL-L2104B
Hydraulic fluid viscosity ..................................... SAE-10
6-8. Table 6-1 lists wear limits and clearances
applicable during overhaul of components.
Hydraulic fluid capacity ....................................... 8 gals.
6-9.
Hydraulic system
pressure relief setting ............................... 1800 psig
Hydraulic pump capacity
at 1200 rpm and
1000 psig ..................................................8.76 gpm
Hydraulic pump rotation
(facing shaft) ...................................................CCW
Direction control
6-10. PROCEDURES.
TROUBLESHOOTING.
6-11. The first step in any trouble-shooting procedure
is to determine the exact symptom. If the symptom
involves true motion, start by jacking up the truck so that
the drive wheels are off the floor. From the actual
symptom
6-2
TABLE 6-1. WEAR LIMITS AND CLEARANCES
Drive axle - axle shaft
run out
Drive axle - differential
bearings
Adapter - input gear backlash
Motor brake shoes
Service brake shoes
Steering gear - lash adjuster
Travel motor - brushes
Travel motor - armature
commutator
Hydraulic pump motor
brushes
Hydraulic pump motor armature
Power steering motor brushes
Power steering motor armature
Tires
0.003 inch maximum, total
indicator reading
0.000 to 0.003 inch loose
preload
0.006 to 0.008 inch
1/16 inch minimum thickness
1/16 inch minimum thickness
0.002 inch end play maximum
3/4 inch minimum length
4.375 inches minimum diameter,
16 microinch rms surface
roughness, 3/64 inch deep by
0.030 inch wide undercutting
-1/2 inch minimum length
2.375 inches minimum diameter,
16 microinch rms surface
roughness, 3/64 inch deep by
0.025 inch wide undercutting
1/2 inch minimum length
1.500 inches minimum diameter,
16 microinch rms surface
roughness, 3/64 inch deep by
0.020 inch wide undercutting
3/4 inch minimum thickness
(approximately)
observed, consult the corresponding or most closely
associated symptom listed in the left hand column of
table 6-2. Adjacent to the symptom column in the table,
note the listing of the probable causes, and conduct the
corrective actions given.
6-12.
6-14.
TESTING SCR'S AND DIODES. It is not
necessary to remove these components from the
chassis for testing. Proceed as follows:
1.
For power diodes (1REC, 2REC and 3REC),
remove anode cable connection and connect continuity
test light in diode circuit as shown in figure 6-1a. A good
diode will light test light when connection is made in one
direction and not light when connection is reversed. If
test light lights in both connections, diode is defective
and must be replaced.
TECHNIQUES.
6-13.
These techniques are primarily used for
locating defects in the electric power control circuit, and
stress the approach of using continuity checks
(ohmmeter or test light) to determine the condition of a
component part. When checking electrical or electronic
components, and unless otherwise stated, always
disconnect the battery connector. Table 6-3 provides a
list of the test equipment required in servicing. Consult
figures 4-1 and 4-2 for component locations and
connections.
2.
For SCR'S (1SCR and 2SCR), remove
cathode cable and white gate lead. Connect test light as
shown in figure 6-lb.
Next, reverse test light
connections. In each test, test light should not light. If
light comes on, SCR is shorted and must be replaced.
6-3
proceed as follows:
3. To check gate of SCR, connect test light as
shown in figure 6-lb. Touch gate lead to mounting block
of SCR. Reverse test light connections and repeat test.
In one of these tests, test light should light. If test light
does not light in either test, replace SCR.
Stud Size
9 to 10
12 to 15
65 to 75
125 to 150
6-15.
REPLACING SCR'S AND DIODE. To replace
defective SCR or diode, proceed as follows:
1. Use deep socket wrench to remove component
from panel. When inserting replacement, apply heat
transfer compound to flange and threads.
2.
Torque (poundinches)
No. 10-32
1/428
1/2-20
3/4-16
1. Visually observe connecting terminals and
condition of case. If terminals are broken, or oil is
present on case, replace capacitor.
Screw component in, applying torque specified:
2. Discharge
capacitor
by
connecting resistor across terminals.
6-16.
TESTING
COMMUTATING
CAPACITOR
(1C). When the commutating capacitor is suspected,
Figure 6-1. Test Circuits
6-4
momentarily
TABLE 6-2. TROUBLESHOOTING
STEP
PROCEDURE
CORRECTIVE ACTION
Electrical
1. Dead truck - Truck a. IMS relay fails to
completely inpick-up.
operable.
a. With drive wheels off
truck off floor, make
following checks:
(1) Check fuse 8FU
and replace if
defective.
(2) Remove fuse 8FU
and, with ohmmeter, check
continuity between battery
switch, panic
switch, seat
switch, and
relay IMS coil.
Also check
suppressor 4SP
especially
diode between
terminals 4 and
5. Replace
defective
component.
b. IMS relay contacts
dirty.
b. Clean contacts with
crocus cloth or fine
flat file.
c. Check suppressor 4SP
using ohmmeter. Replace if defective.
c. Defective suppressor
4SP.
2. Neither forward or a. Fuses 1FU, 2FU, 3FU
reverse operation.
or 12FU.
b. Directional switch
circuit.
a. Replace defective
fuse.
b. With drive wheels of
truck off floor, make
following checks:
(1) Check fuse 6FU.
Replace if
defective.
(2) Check continuity
through No. 2
Circ. FWD & REV
contacts of
switch with ohmmeter. Replace
directional
switch if defective.
6-5
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
PROCEDURE
CORRECTIVE ACTION
Electrical (Cont'd)
2. Neither forward or
c. Defective suppressor
reverse operation.(Cont'd) 3SP.
c.
Check diode across terminals 4 and 5 of suppressor 3SP using ohmmeter. Replace sup
pressor 3SP If defective.
d. Check continuity through
switch, using ohmmeter,
with accelerator pedal
depressed. Replace if
defective.
e. Check continuity through
switch using ohmmeter.
Replace switch if
defective.
f. Check in accordance
with manufacturers'
recommendations. Replace defective control packs.
d. Defective acceleration switch
e. Open brake switch.
f. Defective control
pack ICP or 2CP
g. Turn on silicon
control rectifiers
1SCR or 2SCR.
h. Accelerator speed
potentiometer.
g. Check using ohmmeter or
test light. Replace
defective SCR.
h. Check resistance of
potentiometer. Replace
if defective.
i. Check motor. Remove or
repair as required.
i. Defective travel
motor.
3.No forward motion.
a. F relay fails to
pick-up.
a. With truck drive wheels
off floor, make following checks:
(1) Check F relay coil
for continuity.
Replace if relay
is defective.
(2) Directional switch.
Check for closed FWD
contacts. Adjust or
replace as required.
(3) Check for shorted
suppressor circuit
between terminals 6
and 4 of 3SP. Replace 3SP if defective.
6-6
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
Electrical (Cont'd)
4. No reverse motion.
PROCEDURE
a.
R relay fails to
pick-up.
a.
Shorting contactor ISC
relay.
b.
Turn on 2SCR.
c.
Turn off ISCR.
d.
Shorted speed
potentiometer.
SC relay fails to
pick up.
CORRECTIVE ACTION
a. With truck wheels off
floor, make following
checks:
(1) Check R relay coil
for continuity. Replace if relay is
defective.
(2) Directional switch.
Check for closed
REV contacts. Adjust or replace as
required.
(3) Check for shorted
suppressor circuit
between terminals
7 and 4 of 3SP.
Replace 3SP if
defective.
With battery cable disconnected, make following checks:
a. Check for welded SC relay contacts. Replace
relay if contacts are
damaged.
b. Check diode. Replace
if defective.
c. Check diode. Replace
if defective.
d. Check with ohmmeter.
replace if defective.
a. With drive wheels of
truck off floor, check
following:
(1) Shorted speed
potentiometer.
Check with ohmmeter. Replace if
defective.
(2) Defective ICP or 2CP
module. Check in accordance with manufacturers' recommendations. Replace defective CP module.
5. Truck operates at full
speeds at low speed
settings.
6. Truck wheels turn
at 75% of maximum
a.
6-7
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
PROCEDURE
CORRECTIVE ACTION
Electrical (Cont'd)
6. Truck wheels turn
b.
at 75% of maximum(Cont'd)
7. No power steering.
SC relay.
c.
3SP suppressor.
d.
FW pack .
e.
Field weakening
contactor fails to
pick up.
a.
Power steering pump
motor circuit.
b. Check resistance of SC
relay coil. Replace relay if defective.
c. Check diodes between
terminals 1 and 2 of 3SP
module. Replace if defective.
d. Check resistance between
terminals 1 and 2 of FWP
in series with SC contacts. Replace if defective.
e. Check fuse 6FU. Replace
if defective. Check FW
relay coil. Replace if
defective. Check FW
resistor. Replace if
defective.
a. - Check the following:
(1) Fuses 6FU and 10FU.
Replace defective
fuse.
(2) ARP module. Replace
if defective.
(3) No. 2 Circ. of directional switch. Repair or replace as
required.
(4) IS relay coil open
or shorted. Check
using ohmmeter. Replace if defective.
(5) IS contact of relay
coil IS. Clean contact with crocus
cloth or fine file.
(6) Diodes between terminals 1 and 4 of
4SP suppressor module.
Check with ohmmeter.
Replace 4SP module if
defective.
(7) Power steering motor.
Check and replace if
defective.
6-8
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
PROCEDURE
CORRECTIVE ACTION
Electrical (Cont'd)
8. No hoist or tilt power.
a.
Pump motor circuit.
9. Horn does not blow.
a.
Horn circuit.
10.Neither spotlight or
taillights light.
a.
Light circuit.
11.Spotlight does not
light .
a.
Spotlight circuit.
a. Check the following:
(1) Fuses 7FU and I FU.
Replace defective
fuse.
(2) Continuity through
pump switch. Replace
if defective.
(3) Pump motor relay coil
IMP for open or short.
Check using ohmmeter.
Replace if defective.
(4) Diodes between terminals 3 and 4 of
suppressor module
3SP. Replace 3SP
if defective.
(5) IMP contacts of relay coil IMP. Clean
contact using crocus
cloth or fine file.
(6) Pump motor. Check
and replace if
defective.
a. Check following:
(1) Fuse 4FU. Replace
if defective.
(2) Shorted capacitor
across horn. Replace
if defective.
(3) Defective horn switch.
Replace if defective.
(4) Defective horn. Replace if placing 36
volts across horn
does not energize it.
a. Fuse 5FU. Replace if
defective.
a. Check following:
(1) Check spotlight using
39volt across terminals if light. Replace if defective.
6-9
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
PROCEDURE
CORRECTIVE ACTION
Electrical (Cont'd)
11.Spotlight does not
light. (Cont'd)
12. Tail and stoplight out.
a.
Taillight circuit.
1. Brakes dragging.
a.
2. Brake pedal goes to
floor, no resistance.
a.
Master cylinder
compensating port
plugged.
High rate of fluid
leakage at wheel
cylinder.
High rate of fluid
leakage from master
cylinder.
Scored master cylinder
barrel or defective
cup in master cylinder.
Leakage of fluid from
wheel cylinder.
Leakage of fluid from
master cylinder.
Brake backing plate
loose on axle housing.
(2) Check continuity
across light switch.
Replace if defective.
a. Check following:
(1) Check lights. Replace
if defective.
(2) Continuity through
brake switch with
brakes depressed.
Replace if defective.
(3) Continuity through
light switch. Replace
if defective.
(4) Resistor circuit 3RES.
Replace if defective.
Brakes
b.
3. Brake pedal under
force gradually goes
to floor.
a.
b.
c.
4. Heavy braking action.
a.
5. Truck pulls to one
side.
a.
a. Overhaul brake master
cylinder (para 6-139).
a. Repair wheel cylinder
(para 6-138).
b. Repair brake master
cylinder (para 6-139).
a. Repair brake master
cylinder (para 6-139).
b. Repair wheel cylinder
(para 6-138).
c. Repair brake master
cylinder (para 6-139).
a. Tighten or replace
brake backing plate
(paras. 6-133 through
6-137).
a. Tighten or replace
brake backing plate
(paras. 6-133 through
6-137).
Brake backing plate
loose on axle housing.
6-10
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
PROCEDURE
CORRECTIVE ACTION
Brakes (Cont'd)
5. Truck pulls to one
side. (Cont'd)
b.
Fluid on brake lining.
b. Replace brake lining
(paras. 6-133 through
6-137).
a.
Bent steering column.
b.
Broken spindle pin on
steering axle.
c.
Jammed ball nut in
steering gear.
a. Overhaul steering gear
(para 6-144 through
6-170).
b. Overhaul steering axle
(paras. 6-119 through
6-126).
c. Overhaul steering gear
(paras. 6-144 through
6-170).
a.
Steering gears worn.
b.
Tie rod ends worn.
a.
Hydraulic pump
defective.
b.
Defective seals in
hoist cylinder.
c.
Hydraulic pump motor
defective.
d.
Hydraulic control
valve defective.
Steering
1. Steering difficult.
2. Excessive looseness
in steering.
a. Overhaul steering gear
(paras. 6-144 through
6-170).
b. Overhaul steering axle
(paras. 6-1 19 through
6-126).
Hydraulic
1. Lift carriage will
not lift load.
2. Load creeps down from a.
raised position.
3. Hoisting speed
erratic.
a. Overhaul hydraulic
pump (paras. 6-171
through 6-176).
b. Repair hoist cylinder
(paras. 6-194 through
6-199).
c. Overhaul pump motor
(paras. 6-106 through
6-210).
d. Overhaul hydraulic
direction control
valve (paras. 6-181
through 6-188).
a. Repair hoist cylinder
(paras. 6-194 through
6-199).
b. Overhaul hydraulic
direction control valve
(paras. 6-181 through
6-188).
a. Overhaul mast assembly.
Leakage past rings in
hoist cylinder.
b.
Hydraulic direction
control valve defective.
a.
Bent or distorted
mast assembly.
6-11
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
PROCEDURE
CORRECTIVE ACTION
Hydraulic (Cont'd)
4. Control valve
plungers will not
return to neutral.
5. No operation of
hydraulic system
when first started
up.
6. Slow operation of
hydraulic system.
a.
Sticking plungers
in control valve.
b.
Broken springs or
dirt lodged in seats.
a.
Defective hydraulic
pump.
b.
Defective relief valve
in control valve or
control valve plunger
stuck.
Defective hydraulic
pump.
a.
b.
Pump rpm too low.
c.
Improper operation of
direction control
valve due to defective
parts or foreign matter.
Worn or scored hoist
cylinder packings.
d.
7. Jerky operation of
hydraulic system.
a.
8. Noisy operation of
hydraulic system.
a.
b.
9. Speed of operation
slows down after
usage.
a.
a. Overhaul control valve
(paras. 6-181 through
6-188).
b. Overhaul control valve
(paras. (6-181 through
6-188 ).
a. Overhaul hydraulic
pump (paras. 6-171
through (6-177).
b. Overhaul direction control valve (paras. (6-181
through (6-188).
a. Overhaul hydraulic
pump (paras. (6-171
through (6-177).
b. Check pump motor operation. Overhaul pump
motor if required
(paras. (6-208 through
6-211).
c. Overhaul direction control valve (paras. 6-181
through 6-188).
d. Overhaul hoist cylinder
(paras. 6-196 through
6-200).
a. Overhaul mast assembly.
Hoist cylinder misaligned due to distortion or deformation of
mast assembly,
Defective hydraulic
pump.
a. Overhaul hydraulic
pump (paras. 6-171
through 6-177).
b. Overhaul direction control valve (paras. 6181 through 6-188).
a. Overhaul hydraulic
pump (paras 6-171
through 6-177).
Chattering relief
valve in direction
control valve.
Defective hydraulic
pump.
6-12
TABLE 6-2. TROUBLESHOOTING (Cont'd)
STEP
PROCEDURE
CORRECTIVE ACTION
Hydraulic (Cont'd)
9. Speed of operation
slows down after
usage. (Cont'd)
b.
Defective direction
control valve.
b. Overhaul direction control valve (paras. 6-181
through 6-188).
10. Oil heats up rapidly.
a.
Defective direction
control valve.
b.
Defective hydraulic
pump.
a.
Worn packings.
b.
Piston scored.
a.
Worn packing in hoist
cylinder or tilt
cylinder.
b.
Defective hydraulic
direction control
valve.
a.
Defective hydraulic
pump.
b.
Defective direction
control valve.
c.
Defective tilt
cylinder.
a. Overhaul direction control valve (paras. 6-182
through 6-188).
b. Overhaul hydraulic pump
(paras 6-171 through
6-177).
a. Overhaul hoist cylinder
(paras. 6-195 through
6-200).
b. Overhaul hoist cylinder
(paras 6-195 through
6-200).
a. Overhaul hoist cylinder
(paras. 6-195 through
6-200), or tilt cylinder (paras. 6 189
through 6-194).
b. Overhaul hydraulic
direction control
valve (paras. 6-182
through 6-188).
a. Overhaul hydraulic
pump (paras. 6-171
through 6-177).
b. Overhaul direction
control valve (paras.
6-182 through 6-188).
c. Overhaul tilt cylinder
(paras. 6-189 through
6-194).
11. Hoist cylinder
packing leaks.
12. Hoist or tilt
cylinder lowers or
tilts while truck
is idle.
13. Mast will not tilt.
Forward and Reverse Travel Noise
1. Axle noise while
under power or
while coasting.
a.
b.
Defective gears or
bearings in drive
axle.
Brake shoe retainer
defective.
a. Overhaul drive axle
(paras 6-107 through
6-118).
b. Overhaul brake system
(paras. 6-132 through
6-137).
6-13
TABLE 6-2. TROUBLESHOOTING (Cont'd)
Symptom
Probable Cause
Corrective Action
Forward and Reverse Travel Noise Cont'd)
2. Adapter noise while
under power or
coasting.
a.
Defective gear or
pinion in adapter.
a.
Overhaul adapter (paras.
6-107 through 6-118).
b.
Defective bearing in
adapter.
b.
Overhaul adapter (paras.
6-107 through 6-118).
defective and must be replaced.
3.
Disconnect one terminal, and momentarily
connect ohmmeter, set to 10K resistance range, across
terminals. Meter Needle will rapidly increase towards
zero, then gradually increase towards infinity reading if
capacitor is good. If meter indicates zero resistance, or
fails to swing towards zero, capacitor is defective and
must be replaced.
6-20.
TESTING
SPEED
CONTROL
POTENTIOMETER.
Disconnect connector from
accelerator control, and proceed as follows:
1.
Connect ohmmeter to plug wires 27 and 28.
With accelerator pedal up reading will be 15 ohms or
less.
6-17.
TESTING
RESISTOR-CAPACITOR
SUPPRESSOR (1SP and 2SP). Use ohmmeter set to
RX100K ohm scale, and connect across suppressor
section. Meter will swing (kick) up-scale towards zero
then slowly swing towards infinity. If meter does not
respond, or indicates zero resistance, suppressor is
defective and must be replaced.
2.
Depress accelerator slowly. Resistance will
increase smoothly to a final value between 1350 and
1650 ohms.
3.
Connect ohmmeter to plug wires 28 and 29.
With accelerator pedal up, reading will be between 1350
and 1650 ohms.
6-18.
TESTING RESISTOR-DIODE SUPPRESSOR
(3SP). Use ohmmeter set to RXIK range, and connect
meter across suppressor section. Meter will indicate
less than 2,000 ohms in one direction, and near infinity
in the other direction on good suppressor. If not,
suppressor is defective and must be replaced.
4.
Depress accelerator pedal slowly. Resistance
will decrease smoothly to approximately 15 ohms.
5.
If proper resistance measurements are not
obtained, loosen set screw and adjust to obtain above
measurements.
6-19.
TESTING
ZENER
DIODE-DIODE
SUPPRESSOR (3SP and 4SP). Ohmmeter connected
across suppressor will indicate near infinity resistance in
both directions on good suppressor. If not, suppressor is
6.
If ohmmeter measurements are erratic or
jerky, potentiometer is defective and must be replaced.
TABLE 6-3. RECOMMENDED EQUIPMENT
Name
Manufacturer or Type
VOM (volt-ohm-millimeter)
Simpson or trippett 20,000 ohm/
volt portable meter.
Similar to those used with
transistor radios.
Sizes to 3/4 inch.
150-pound inches.
3-volt test light.
Dow Corning no. 340 or equivalent.
500 ohm 1/4 or 1/2-watt.
Earphone
Socket Wrench Set
Torque Wrench
Continuity Test Light
Heat Transfer Compound
Resistor
6-14
overhead guard (6, figure 7-38) to each side at front of
truck.
(2) Remove four nuts, two flat washers and
four lock washers securing overhead guard to each side
of cowl at rear of truck.
(3) Using suitable hoisting equipment,
remove overhead guard from truck.
b.
Installation. Reverse procedure in a. above.
6-21.
TESTING CONTROL PACK (ICP). To test for
gate pulses, proceed as follows:
1.
Disconnect battery connector.
2.
Connect earphone across terminals I and 2.
3.
Connect battery connector.
4.Operate directional switch and listen for audible
gate pulses in earphone.
5.
If gate pulses are not heard, replace control
pack.
6-26.
a.
BATTERY COMPARTMENT COVERS.
Removal.
(1) Tilt seat assembly full forward and fully
raise battery compartment top cover (7, figure 7-38)
releasing battery compartment side covers.
(2) Open side covers (8) and lower top cover
(7).
(3) Remove six screws and washers securing
each cover to truck and remove covers.
b.
Installation. Reverse procedure in a. above.
6-22.
REMOVAL AND INSTALLATION OF MAJOR
COMPONENTS AND AUXILIARIES.
6-23.
GENERAL. This section contains detailed
instructions for removal and installation of assemblies
and auxiliaries of the fork lift truck. Each assembly is
covered individually with its component subassemblies
as a related series of instructions. Always tag or in
some other manner, identify such parts as hoses and
wiring leads to facilitate reassembly. When possible,
replace attaching parts such as nuts, bolts, flat washers,
lockwashers and clamps on the part they attach. This
should prevent loss or misplacement.
WARNING
Disconnect battery charging connector by
pulling connector lever up and pulling receptacle
off before performing any maintenance
operations, except when battery power is
required to support maintenance functions
performed on installed equipment.
6-27.
a.
FLOOR PLATE.
Removal.
(1) Disengage
accelerator
pedal
from
accelerator rod by pulling pedal upward.
(2) Remove four screws and eight washers
securing floor plate (16, figure 7-38) to frame and
remove floor plate from truck.
b.
Installation. Reverse procedure in a. above.
6-28.
CONTROL PANEL COVER.
a.
Removal.
Remove eight screws and
lockwashers securing control panel cover (10, figure 738) to truck and remove from truck.
b.
Installation. Reverse procedure in a. above.
Replace cover mounting gasket if it is damaged to
prevent dust, dirt and other contaminants from entering
control panel compartment.
6-24.
SEAT ASSEMBLY.
a.
Removal. Tilt seat forward, remove hinge pin
(31, figure 7-28) from rail and remove seat assembly
from truck.
b.
Disassembly. Remove two nuts (3), screws
(2) and washers (4) securing seat backrest (1, figure 727) to frame and remove backrest.
c.
Repair.
Repair
slightly damaged (torn)
upholstery material in accordance with good commercial
practice, by sewing or the application of an adhesive
patch. If wear or damage is extensive, replace backrest
or seat cushion.
d.
Assembly. Reverse disassembly procedure of
b. above.
e.
Installation. Reverse procedure in a. above.
Adjust seat position as desired for operator
convenience.
6-25.
OVERHEAD GUARD.
a.
Removal.
(1) Loosen two set screws and nuts securing
6-29.
FUSE ACCESS COVER.
a.
Removal.
Remove six screws and
lockwashers securing fuse access cover (9, figure 7-38)
to control panel cover and remove fuse access cover
from truck.
b.
Installation. Reverse procedure in a. above.
6-30.
VALVE COVER.
a.
Removal. Remove six screws, flatwashers
and lockwashers securing valve cover to frame (15,
figure 7-38) and remove valve cover from truck.
b.
Installation. Reverse procedure in a. above.
6-15
(1) Insert link in end of chain and into brackets
on carriage assembly. Secure link with cotter pins in
ends.
6-31.
LOAD BACKREST.
a. Removal. Hoist load backrest (6, figures 7-23
and 7-25) to disengage from carriage and remove from
truck.
(2) Reeve chains over rollers.
b.
Installation. Reverse procedure in a. above.
(3) Secure other end of chain to chain anchor
with cotter pin through link ends (29, figure 7-23).
6-32.
FORKS.
a. Removal. Fully lower carriage, pull handle(2,
figures 7-23 and 7-25) fork (1) and disengage fork from
carriage. Repeat with other fork.
(4) Secure chain anchors to outer cylinder with
adjustment nuts and adjust chain tension (para. a.
above).
b. Installation. Reverse procedure in a. above
positioning forks in desired locations on carriage.
e. Triple Mast Assembly Adjustment. Lift chain
adjustments are provided at base of inner channel (48,
figure 7-25). Lower carriage until hoist cylinder bottoms.
Adjust chain adjusting nuts until slack is removed and
chains are taut.
6-33.
CHAIN ASSEMBLIES.
a. Dual Mast Assembly Adjustment. Lift chain
adjustment is provided at top of outer hoist cylinder.
Lower carriage until hoist cylinder bottoms. Adjust chain
adjusting nuts (30, 31, figure 7-23) until slack is
removed and chains are taut.
CAUTION
Be certain load is shared equally by both sets of
chains, otherwise first chain to begin lifting will
cock mast and cause rapid wear and damage to
hoist cylinder.
CAUTION
Be certain load is shared equally by both chains,
otherwise first chain to begin lifting will cock
mast and cause rapid wear and damage to hoist
cylinder.
f.
Triple Mast Assembly Removal.
(1) Lower carriage until hoist cylinder bottoms.
b.
Dual Mast Assembly Removal.
(1) Lower carriage until hoist cylinder bottoms.
(2) Loosen nuts (16, figure 7-25) and remove
bolt (15) securing chains to anchor of inner upright.
(2) Remove adjusting nuts (30, 31, figure 723) securing chain to outer cylinder.
(3) Remove pins and bottom chain link from
rear of carriage.
(3) Remove pin and bottom chain link from
rear of carriage (60).
(4) Remove chain assemblies from truck by
reeving over rollers.
(4) Remove chain assembly from truck by
reeving over rollers.
(5) Repeat steps (I) through (4) for opposite
chain assemblies.
(5) Repeat steps (1) through (4) for opposite
chain assembly.
(6) Remove nut (9) from chain end on outer
channel.
c. Dual Mast Assembly Repair. Chain repair is
limited to replacing damaged links.
(7) Remove nut (9) from chain end on inner
channel anchor.
(1) With chain removed from truck, use a
chain breaking tool and remove damaged link or links
from chain. Failure of one link may damage adjacent
links. Remove all damaged links.
(8) Reeve chain over roller and remove chain.
(9) Repeat for opposite chain.
(2) Install replacement link and rivet pin end to
secure side plates of chain.
g. Triple Mast Assembly Repair. Repair is limited
to replacing damaged links.
NOTE
Plates of end links are secured by cotter pins.
Do not rivet or peen these pins.
(1) Remove damaged links from chain using
chain breaking tool.
d.
(2) Install replacement links and rivet pin end
to secure side plates of chain.
Dual Mast Assembly Installation.
6-16
(3) If required, tighten brake shoe adjusting
nut to set clearance between these valves. Don't
overtighten, so as
brake won't drag.
(4) With loaded truck held on 15 degree
incline by foot brake application, raise from operator's
seat and release foot brake. If truck rolls, stop with foot
brake and continue to (5) below.
(5) Tighten spring adjusting nut (33) not over
two turns, and repeat (4) above to test results. Repeat
until spring application of motor brake holds loaded
truck on 15 degree incline.
NOTE
Plates of end links are secured by cotter pins.
Do not rivet these pins.
h.
Triple Mast Assembly Installation.
(1) Insert link in end of shorter chain into
brackets on carriage assembly. Secure link with cotter
pins in ends.
(2) Reeve chains over rollers on outer hoist
cylinder.
(3) Secure other end of chains to anchor on
bottom of inner mast, and adjust nut to remove chain
tension (para. e.).
(4) Insert link in end of longer chain into
brackets on top of inner upright. Secure link with cotter
pins.
(5) Reeve chain under rollers on bottom end
of hoist cylinder. Secure link with cotter pins.
(6) Secure chain anchors to anchor on inner
upright with adjustment nuts and adjust chain tension
(para. e.).
6-36.
SERVICE BRAKE.
a. Brake Adjustment. The service brakes are
self-adjusting to take up play due to lining wear. The
brake pedal must be adjusted for proper free pedal (para
6-37b-4).
b. Bleeding Service Brake System. The hydraulic
brake system must at times be bled to expel air in the
system. The need is generally indicated by springy or
spongy brake pedal action.
Unless special brake
bleeding equipment is available, two men are required
to bleed the system, one to maintain a constant supply
of fluid in the master cylinder and to pump the brake
pedal, the other to perform the bleeding operation.
(1) Remove filler plug from master cylinder
through hole in floor plate, and fill with hydraulic brake
fluid.
(2) Clean bleeder screws (22, figure 7-35) at
each wheel cylinder. Remove small screws from bore
of bleeder screws. Attach one end of bleeder hose to
bleeder screw and place other end of hose in clean
container partially filled with hydraulic brake fluid. Be
sure end of hose is submerged in the hydraulic fluid.
(3) Turn bleeder screw counterclockwise
three-quarters of a turn. Apply steady pressure to brake
pedal. Hydraulic fluid containing air bubbles should be
forced through bleeder hose into container.
(4) Maintain fluid level in master cylinder and
continue to operate brake pedal until fluid flows in a
steady solid stream without air bubbles. Close bleeder
screw by turning it clockwise. Remove bleeder hose
and replace small screw in bleeder screw.
(5) Repeat bleeding procedure at other
wheel, replenishing brake fluid in master cylinder before
each wheel cylinder is bled. Replace filler plug in
master cylinder.
CAUTION
Hydraulic brake fluid from the brake system
must not be reused.
6-34.
a.
HANDBRAKE LEVER.
Removal.
(1) Fully release handbrake lever (18) (figure
7-28) and remove screws, nuts and washers securing
handbrake lever to brake lever bracket (22).
(2) Remove pin(41) from clevis (40) securing
handbrake to seat and handbrake actuating lever (39)
and pull handbrake lever (18) out of truck.
b. Installation. Reverse procedure in a. above,
adjusting handbrake (para. 6-34) after installation.
6-35.
SEAT BRAKE AND HANDBRAKE LINKAGE.
a. General. The parts shown in figure 7-28
comprise the handbrake and seat brake linkage. These
parts and linkages are not subject to repair other than
replacement of individual damaged parts. The parts are
illustrated for general orientation, and to facilitate
removal and installation that may be performed in
conjunction with maintenance services.
b.
Seat Brake Adjustment.
(1) Two adjustments are provided to maintain
the motor brake at required efficiency. The brake shoe
adjusting nuts provides the basic adjustment on which
the seat actuation adjustment depends. The other is on
the handbrake handle.
(2) Remove valve cover (para. 6-30) and
floor plate (para. 6-27). With truck seat occupied and
handbrake released, check with leaf or round feeler
gauge for brake shoe lining-to-drum clearance of 0.010
inch to 0.020 inch.
c.
6-17
Brakeshoe Removal.
(1)
Remove front wheel (para. 6-76).
6-38.
a.
(2) With brake spring pliers, remove
brakeshoe return spring (27, figure 7-35) and retainer
spring (28). Carefully remove brakeshoes and install
brake clamps on wheel cylinder to prevent pistons being
pushed out of cylinder by residual pressure in brake
lines.
d.
(2) Remove cotter pin (17, figure 7-29) and
clevis pin (16) from push rod (34). Disconnect spring(5)
from brake pedal.
Brakeshoe Installation
(1)
Reverse procedure in c.(2) above.
(2)
Install front wheels (para. 6-76).
(3) Remove screw (19), nut (20) and
lockwasher (21) attaching brake pedal and remove
pedal from truck.
b. Installation and Adjustment.
Reverse
procedures in a. above and check for proper pedal
adjustment (para. 6-37b.(4).
6-39.
a.
HOURMETER.
Removal.
(1) Disconnect two leads at hourmeter from
under instrument panel, tape ends and tag leads for
identification.
MASTER CYLINDER.
Removal.
(1) Remove floor plate (para. 6-27).
(2) Remove two nuts holding hourmeter to
instrument panel and lift hourmeter off panel.
(2) Remove bolt connector (28, figure 7-29)
and brake line fitting (30) from front of master cylinder
along with gaskets (29, 31). Take precautions to keep
dirt from entering brake line.
6-40.
a.
(3) Remove nuts, lockwashers and screws
(25, 26, 27, figure 7-29) attaching master cylinder to
truck, and remove master cylinder. Push rod will remain
connected to brake shaft and need not be removed.
switch.
b.
627) from
truck.
e. Service Brake Adjustment. Brake lining-todrum clearance on the wheel brakes is self-adjusting.
Each application of the brake pedal sets the automatic
adjustment to compensate for brake lining wear. No
further adjustment is required during the life of the brake
linings. The only adjustment in the hydraulic brake
system is for brake pedal free play (para. 6-37b-4).
6-37.
a.
BRAKE PEDAL.
Removal.
(1) Remove floor plate (para.
b.
LIGHT SWITCH.
Removal.
(1) Remove nut at top of light switch and
lower switch out bottom of instrument panel.
(2)
Installation.
(1)
Reverse procedures in a. above.
(2)
Fill cylinder with hydraulic brake fluid.
(3)
Bleed brake hydraulic system (para.
Installation. Reverse procedures in a. above.
b.
Disconnect, tape and tag leads from
Installation. Reverse procedures in a. above.
6-41.
a.
PANIC SWITCH.
Removal.
(1) Pull button off panic switch, unscrew
knurled retaining nut at top of switch and lower switch
out bottom of instrument panel.
6-
36b.).
(2)
(4) Loosen jamnut (15, figure 7-29) on push
rod and adjust length of push rod by turning adjustment
to give 1/4-inch to 5/8-inch free travel of pedal before
brake application begins. Tighten jamnut to secure
adjustment.
Disconnect, tape and tag leads from
switch.
b.
6-18
Installation. Reverse procedures in a. above.
6-42.
a.
(1) Raise battery connector handle.
(2) Unscrew switch extension (figure 7-2)
from switch.
(3) Remove nut and lockwasher securing
switch to bracket and pull switch free.
(4) Disconnect, tape and tag leads from
switch.
BATTERY CONNECTOR RECEPTACLE.
Removal.
(1) Release battery connector and pull
connector free from receptacle.
(2) Remove four screws and lockwashers
securing receptacle to vehicle.
(3) Remove control panel cover (para. 6-28).
(4) Remove nuts, lockwashers and insulators
securing positive (+) and negative ( ) leads at bottom of
control panel.
(5) Remove clamps securing leads to bottom
of vehicle and withdraw battery connector receptacle
with leads attached.
b.
Installation. Reverse procedures in a. above.
b. Installation. Reverse procedure in a. above,
being certain to properly secure leads with removed
cable clamps to bottom of truck.
6-45.HEADLIGHT.
a. Removal.
(1) Remove clamps (figure 7-2) holding
conduit to outer upright.
(2) Disconnect two wires at terminals at
bottom end of conduit.
(3) Remove two screws (46), nuts (47) and
washers (48) attaching light to upright and remove light
and conduit as an assembly.
6-43.
a.
b. Repair. Repair of headlight is confined to
replacing the scaled beam plate.
STOPLIGHT SWITCH.
Inspection and Test.
(1) Remove floor plate (para. 627).
(2) Connect a voltmeter between wires
labeled 86-1 and 35 across switch (9, figure 7-29) (+
probe of meter to wire 35) and operate switch button by
hand. If meter reads system voltage with button free
and zero voltage with button pressed, switch is
operative.
(3) With voltmeter still connected as in
above, operate pedal manually. If operation of pedal
does not give same results, switch position must be
adjusted so brake application closes switch and brake
pedal release opens switch.
c.
6-46. STOP AND TAILLIGHT.
a. Removal.
(1) Remove four screws (51) ,and washers
(52) (figure 7-2) attaching guard to truck. Lift guard.
(2) Remove control panel cover (para.
6028).
(3) Disconnect stop and taillight connector
(49)..
(4) Remove nut and washer holding light to
truck and remove light.
b. Adjustment.
Disconnect leads and loosen
switch attaching nuts. Adjust switch position orientation
so switch lights stoplight before braking action begins
and light goes out before pedal reaches top of travel.
Tighten nuts.
c.
b. Repair. Remove lens attaching screws and
lens and install new bolt. Replace lens attaching screws
and lens.
c.
above.
Removal.
6-47.
a.
6-44.
a.
BATTERY CONNECTOR
SWITCH.
Removal.
installation. Reverse procedures shown in a.
TAILLIGHT RESISTOR.
Removal.
(1) Remove control panel cover (para. 6-28).
(2) Disconnect and tag wires from resistor 3
RES located at lower left adjacent to contactor IMS
(figure 7-3). Remove two mounting screws and remove
resistors.
b. Test. Test resistor with ohmmeter across
terminals for 40 ohms resistance, plus or minus 20%.
c. Installation. Reverse procedures in a. above.
(1) Remove floor plate (para. 6-27).
(2) Remove switch attaching screws, nut and
lockwashers and leads, and remove switch from
bracket.
d. Installation. Reverse procedures (c.
and adjust switch (b. above).
Installation. Reverse procedures in a. above.
above)
RECEPTACLE
6-19
6-48.
a.
the finishing rate after gravity has been adjusted.
(5) If the corrected specific gravity of any cell
is higher than normal (1.285) proceed as follows:
(6) As the battery charges, withdraw from the
cell a small amount of electrolyte and replace with
water. Repeat at 20 minute intervals if necessary until a
1.285 specific gravity reading is obtained.
HORN.
Removal.
(1) Remove floor plate (para. 6-27).
(2) Disconnect wires from horn (70. figure 7-
2).
(3) Remove screws (71) and washers (72)
holding horn to adapter and remove horn.
b.
c. Adding Water to Battery. Add only distilled
water or chemically analyzed and approved water from
public drinking source. The proper level of electrolyte is
1/4-inch from bottom of filler neck.
Installation. Reverse procedures in a. above.
6-49.
HORN BUTTON.
a. Removal. Remove four screws (11, figure 733) and lift off cover (1 3), button (12), separator (18),
contact (17). insulator (16), spring (15) and contact
(14).
b.
CAUTION
Do not use water which has passed through a
water softener.
This water is chemically
destructive to a lead-acid battery. It is not
equivalent to distilled water.
Installation. Reverse procedures in a. above.
6-50.
BATTERY MAINTENANCE.
a. Checking Specific Gravity.
The specific
gravity of the electrolyte at 77 deg F. with electrolyte at
normal level and cells fully charged should be 1.265 to
1.285.
(1) Add water slowly. Water should be added
before charging to insure prompt mixing with the
electrolyte.
(2) In sub-freezing temperatures battery must
be put on finish charge for one hour after water has
been added.
d. Cleaning the Battery. The entire battery and
battery compartment should be kept clean and dry. If
the electrolyte has been spilled or corrosion has formed
on the battery, proceed as follows:
b. Adjusting Specific Gravity. Acid or electrolyte
should never be added to a cell without first being sure
that charging will not restore the gravity. Charge should
be continued until Specific gravity when tested every
hour for three hours shows no further rise at any cell. If,
after charge, gravity is still below normal, proceed as
follows:
(1) Put battery oil charge again at the finish
rate so cells gas for thorough mixing of electrolyte.
(1) Add one pound of bicarbonate of soda to
one gallon of warm water. Pour solution over corrosion
or spilled electrolyte.
(2) When foaming action stops, rinse off the
entire battery with clear water.
NOTE.
Never take a gravity adjustment on a cell which
does not gas freely on charge.
CAUTION
Vent plugs must be installed in cells to prevent
soda solution from getting into the cells. Do not
use steam or very hot water to clean battery.
(2) Draw off electrolyte down to splash cover
front low reading cells. Slowly pour electrolyte of 1.3000
to 1.350 specific gravity in cell to high level (1/4-inch
below filler neck).
c. Charging the Battery.
Batteries normally
discharged more than one-third of their capacity daily
should be recharged daily. Other batteries in use should
be charged at least once a week. Do not charge
batteries more often than necessary to reduce gassing
and water loss. Plan on recharge time for a completely
discharged battery of about eight hours, less for partially
discharged batteries. Charge as follows:
CAUTION
Never use acid for higher specific gravity than
1.350.
(3) Wait twenty minutes for added electrolyte
to become thoroughly mixed by gassing charge and
then read specific gravities. If the gravity of any cell is
still below normal repeat steps (1) through (3). Repeat
as many times as necessary.
(4) Continue charging battery for one hour at
(1) Disconnect battery leads at battery
connector receptacle and connect charger to battery half
of connector.
6-20
lockwasher.
6-55.
RELAY CONTACT REPLACEMENT.
(2) Using procedure appropriate to the
charger being used, adjust initial charging rate for a fully
discharged battery to 130 to 160 amperes.
6-56.
Relay contact maintenance is restricted to
those relays having contacts visible for inspection and
replaceable without removing the relays. Contacts
require replacement when the silver has worn down to
the steel support.
a. Removal.
(1) Remove control panel cover (para. 6-28).
(2) Remove nuts holding contacts to be
removed. Remove contacts from relay.
(3) At end of charging time disconnect
charger and observe cell vent caps for signs of
excessive gassing.
This is usually indicated by
electrolyte around the fill hole of the cell.
6-51.
WIRING HARNESS.
6-52.
Repair of the wiring harness is limited to
isolating shorted and open circuits and using good
commercial practice in their repair. Refer to the wiring
diagram (figure 42) and conduct a systematic inspection
using an ohmmeter to isolate the trouble. Remedy the
trouble by splicing leads where required and applying
electrical tape to prevent short circuits from occurring.
6-53.
b. Installation. Put new contacts in position and
install nuts. No special check or adjustment is needed
after installation.
6-57.
a.
MOTOR BRUSH REPLACEMENT.
FUSE AND FUSETRON REPLACEMENT.
Removal.
(1) Remove fuse access cover (para. (629).
6-54.
Motor brush replacement for the travel motor
(figure 7-36), power steering motor (figure 7-32) or
hydraulic pump motor (figure 7-15) is the same.
a. Removal.
(1) Remove screw, nut and lockwasher
securing brush covers to motor housing and remove
brush covers.
(2) Loosen screws securing fusetron to fuse
panel and slide fusetron off fuse panel.
(2) Remove screw and lockwasher securing
brush leads.
6-58.
(3)
Pull fuses straight off fuse panel.
b. Installation. Reverse applicable procedures in
a. above to replace fusetrons and fuses.
DIRECTIONAL CONTROL SWITCH.
6-59.
Maintenance of the directional control switch
(figure 7-12) consists of replacing terminal switches.
The switch need not be removed.
a. Removal.
(1) Remove cover attaching screws (12) and
washers (13) and remove cover (11).
(3) Pull back on brush spring sufficiently to
release brush and pull brush out of brush holder.
(4) Repeat steps (1) through (3) for removal
of remaining brushes.
(2) Disconnect and tag leads from switch
terminals (18).
b. Inspection. Compare length of used brush with
length of a new brush from stock. Replace any brush
worn to half (or less) the length of new brush, as given
below.
(3) Remove switch attaching screws and nuts
and remove switch.
c.
Installation.
(1) Install new brushes in brush holders with
short side of brush toward spring side of holder so brush
friction surface contour mates with surface of armature
commutator. If brush edge meets commutator, reverse
brush in holder. Fasten brush leads to holder with
removed screws and lockwashers.
b.
6-60.
a.
Installation. Reverse procedure in a. above.
PUMP MOTOR SWITCH.
Removal.
(1) Remove valve cover (para. 6-30).
(2) Disconnect and tag leads at switch (60,
figure 7-2) loosen jamnut and screw switch out of switch
bracket.
(2) Hook brush springs over brushes and
check pressure exerted on brush with a pull scale. Pull
should be 26 ounces to 32 ounces at time scale lifts
spring from brush on either motor.
b. Installation. Reverse procedures in a. above,
turning switch in switch bracket to point where switch is
actuated when either the tilt or hoist lever is operated.
Lock with jamnut.
(3) Install brush covers and secure in position
on motor housing with removed screw, nut and
6-21
holding mounting bracket (3) to truck and remove
assembly.
(5) Remove cover screws (13), cover (12)
and gasket (14).
6-61.
a.
SEAT SWITCH.
Removal.
(1) Remove valve cover (para. 6-30).
(2) Disconnect and tag leads at switch (60,
figure 7-2).
(3) Remove switch attaching screws, nuts
and lockwashers securing switch to bracket and remove
switch.
b.
6-65.
a.
CONTROL VALVE LEVERS AND LINKAGE.
Removal.
(1) Remove valve cover plate (para. 6-30).
(2) Remove retaining rings (4, figure 7-20)
securing connecting rods (6) to hoist (2) and tilt levers
(1).
(3) Pull out cotter pin (3) securing pin (5) in
bracket (13) and pull out pin to release hoist and tilt
levers.
(4) Remove two screws (14), nuts (15) and
lockwashers (16) securing bracket (13) to truck and
remove bracket.
(5) Remove cotter pins (l I) and clevis pins
(12) securing clevis (10) and connecting rods to control
valve. If valve actuation is proper, note position of
sleeves
and
connecting
rod
devises
before
disassembling them from the connecting rods.
(6) Compress spring (22) turn disc (21) to
release pin (23) and remove disc, spring and pin from
bracket.
(7) Remove screws (25) securing spacer clips
(24); remove spacer clips.
b. Installation. Reverse procedures in a. above,
adjusting switch position up or down as required so that
it is just actuated as the operator's seat is fully lowered.
Loosen bracket screws to position bracket with attached
switch for proper actuation and then tighten bracket
screws.
6-62.
TERMINAL RELAY.
6-63.
Each motor is protected by a thermal relay
which will open the motor circuit if overheating occurs.
When temperature sensed by the relay drops to a safe
operating value, the relay will automatically close.
a. Removal.
(1) Remove
nut, lockwasher and clamp
(figure 7-2) which fastens relay to motor and lift relay
from motor.
(2) Scrap sealing compound from relay
terminals. Unsolder leads at terminals.
b. Installation. Reverse procedures in a. above,
soldering leads to terminals with rosin flux and solder.
Avoid unnecessary heating of the relay while soldering.
Coat terminals after soldering with silicone rubber
sealing compound.
(8) Remove screws (18), nuts (19) and
lockwashers (20) securing bracket (27) and switch
actuator hinge (26); remove bracket and switch actuator
hinge.
b. Installation. Reverse procedure in a. above,
adjusting position of sleeves (7) on connecting rods until
control valve actuation is proper, then secure with
setscrews (8).
c.
Test.
(1) Test electrical continuity of relay between
terminals with an ohmmeter or test light. Test at room
temperature.
(2) If controlled temperature is available, test
opening temperature of relay. It should open on rising
temperature at 224 degrees F. plus or minus 4 degrees.
6-64.
a.
6-66.
a.
TILT CYLINDERS.
Removal.
(1) Remove truck floor plate (para. 6-27).
(2) Tag and disconnect hoses (2, 3, 4, 5,
figure 7-13) from tilt cylinders. Cap hoses and plug
ports in cylinders (18, 19) to exclude dirt.
(3) Support mast so it will not suddenly tilt on
removal of tilt cylinders.
WARNING
If not supported the mast will fall forward when
the tilt cylinders are disconnected.
(4)
Remove screws (22) attaching pins to
brackets on truck frame and on uprights.
ACCELERATOR CONTROL CONTACT
ASSEMBLY.
Removal.
(1) Remove floor plate from truck (para. 6-
27).
(2) Disconnect Iinkage ball joint (I, figure 711) and spring from operating lever (9).
(3) Disconnect wiring harness at connector
(6).
(4)
Installation. Reverse procedures in a. above.
Remove screws (4) and lockwashers (5)
6-22
b. Installation. Reverse procedures in a. above
using new O-ring packing. Operate hoist control valve
several times to purge air and check for hydraulic fluid
leakage at fittings. Tighten as required.
(5) Pull or drive pins (20, 21) from cylinder
ends. Be careful not to let cylinder fall as pins are
removed.
b.
Installation.
(1) Position tilt cylinder (back end) In Ushaped bracket on truck frame.
(2) Align bracket holes and cylinder end hole.
Secure pin with screw.
(3) Remove plugs from ports and caps from
hoses and connect hydraulic hoses to cylinders.
(4) Check hydraulic fluid level in reservoir
(para 5-10).
(5) After installation, operate tilt control lever
several times to purge air from cylinders.
check
cylinders and hose fittings for leakage while operating.
(6) Secure front end of tilt cylinders to upright
brackets with pins and attaching screws.
6-67.
6-70. STEERING WHEEL
a. Removal.
(1) Remove horn button (para. 6-49).
(2) Remove steering wheel nut (20, figure 733) and using a suitable puller, remove steering wheel
(19) from steering gear column.
b. Installation. Reverse procedures in a. above
orienting steering wheel on steering gear column so that
keyway properly mates with key before securing steering
wheel with nut.
6-71.
STEERING GEAR.
a. Lash adjustment.
(1) Remove nut holding drag link tie rod end (5,
figure 7-30) to pitman arm and disconnect drag link.
HYDRAULIC FILTER CARTRIDGES.
6-68.
Two filters are used in the hydraulic system;
one in suction line adjacent to pump, the other in return
line from control valve at left rear of hydraulic tank.
a. Return Filter Cartridge Replacement.
(1) Unscrew cartridge filter element (7, figure
7-21) from filter head (8).
NOTE
If necessary use puller but do not damage
threads or place strain on pitman arm.
(2) Install new cartridge by reversing
procedure in (1) above. Wet sealing ring with clean
hydraulic oil and tighten hand-tight.
(2)
Remove horn button (para 6-49).
(3)
Adjust steering gear lash (para 6-168).
b.
Steering Linkage Adjustment.
(1) With steering wheel halfway between
extreme tight and extreme left turn, assemble pitman
arm (22, figure 7-33) to steering gear in vertical position.
b.
Suction Filter Element Replacement.
(1) Unscrew filter housing (1, figure 7-19)
from head (5) and discard housing seal (2).
(2) With trailing axle wheels in straight ahead
position, adjust drag link (7, figure 7-30) to proper length
by loosening clamps (6) and turning drag link tubing until
the rod end at front of drag link will enter hole in pitman
arm freely, with pitman arm vertical.
(2) Remove and discard filter element (3) and
element seat (4).
(3) Install new filter element and seals by
reversing procedures (1) and (2) above.
(3)
6-69.
HOIST REGULATING VALVE (Dual Mast
Truck).
Removal.
(1) Fully lower lift carriage.
Tighten drag link clamps(6).
(2) While working from front of truck, unscrew
hose from hoist regulating valve elbow (7, figure 7-23)
and cap to exclude dirt.
6-72.
WHEEL
ALIGNMENT
MEASUREMENT.
Determine if wheel alignment adjustment is needed as
follows:
a. With rear axle level front to rear, and wheels in
straight ahead position, measure inside span between
tires at hub height at front of axle. Mark point of
measurement.
(3) Unscrew hoist regulating valve (8) with
attached fittings from hoist cylinder and remove fittings.
Discard O-ring packings.
b. Roll truck until rear wheel rotates one-half
revolution. Measure between same points except this
time at rear of axle.
a.
6-23
grease, using a bearing packing device, if available.
c. If measurements obtained in a. and b. above
differ by over 1/16-inch, adjust as below until wheels are
parallel to within 1/16-inch as measured in a. and b.
above.
NOTE
Replace cups and cones as sets do not use old
cone in new cup or new cone in old cup.
6-73.
WHEEL ALIGNMENT ADJUSTMENT.
a. Loosen (but do not remove) screws and nuts
from all tie rod end clamps (figure 7034).
c. Installation. Reverse procedures in a. above
except press bearing cups into wheel fully before
installing wheel.
b. Turn each tie rod an equal number of turns in
the direction necessary to change toe-in as required.
6-76.
a.
NOTE
Each tie rod has right hand threads at one end,
left hand threads at the other so adjustment can
be made to change effective length without
dismounting tie rods.
DRIVE AXLE WHEELS.
Removal.
(1) Jack up front wheels as follows:
(a)
Tilt mast to extreme back position
(b)
Place block directly under mast at lift
(c)
Tilt mast forward until wheels are clear.
cylinder.
c. When adjustment has been completed, tighten
tie rod clamp screws and nuts and recheck wheel
alignment measurement(para 6-72).
(2) Remove 12 nuts (12, figure 7-35), washers
(13) and bushings (14) holding wheel and brake drum
(11) to truck.
6-74.
a.
REAR WHEELS
Removal.
(1) Lower forks fully and tilt mast back. Raise
rear of truck until wheels clear floor.
(3)
NOTE
If brake lining drags on wheel, interfering with
removal, slack off adjustment of brake adjusters
by vigorously wiggling wheel to force
brakeshoes inward. If wheel still will not come
off, release brake adjusters by reversing brake
adjustment procedure (para 6-36) until brake
shoes are fully retracted.
(2) Remove cap (5, figure 7-34) and remove
cotter pin (7), nut (8), and washer (9) from bore of
wheel.
(3) Draw wheel from steering axle spindle.
Because of manufacturing tolerances the cone and
rollers of the inboard bearing may remain with spindle.
If so, it can easily be removed. Avoid damaging oil
seal, if possible, when removing wheel.
b. Installation. Reverse procedures in a. above,
tightening wheel nut snug, then backing it off not more
than 1/6 turn, and install cotter pin.
b.
Installation. Reverse procedures in a. above.
c.
Adjust service brakes (para 6-36).
6-77.
6-75.
REAR WHEEL BEARINGS.
a. Removal.
(1) Remove rear wheels (para 6-74).
a.
HOIST CYLINDER.
(Dual Mast Assembly
Truck)
Removal
(1) Fully lower upright assembly.
(2)
(para 6-31).
(2) Pull bearing cups (10, figure 7-34) from
bore of wheel. A suitable bearing puller may be used to
pull bearings from wheel if they stick in bore.
(3)
b.
Service.
(1) Clean bearing with SD and dry thoroughly.
Remove load backrest from carriage
Remove chain assembly (para 6-33b).
(4) Disconnect hose at hoist cylinder elbow
(7, figure 7-23) and plug to prevent entrance of dirt.
NOTE
Do not use compressed air and spin dry.
(5) Remove four screws (15) lockwashers
(16) retainers (13, 14) securing hoist cylinder to
crosshead.
(2) Inspect cups and rollers for wear or
failure.
Inspect cone and roller assemblies for
roughness when rotated.
(3)
Remove wheel.
(6) Slide hoist cylinder from uprights, being
careful not to lose pivot ball (47).
If bearings are serviceable, repack with
6-24
(4) Disconnect hose at cylinder adapter (24,
figure 7-25).
b. Installation. Reverse procedure of a. above,
and purge air from hydraulic system.
6-78.
HOIST ASSEMBLY (Triple Mast Assembly
Truck)
a. Removal.
(1) Fully lower upright assembly.
(5)
Disconnect headlight at uprights (para 6-
(6)
Disconnect tilt cylinders at uprights (para
45).
6-66).
(2)
(para 63 1).
(3)
Remove load backrest from carriage
(7) Remove bearing caps holding mast to
axle, each attached with two screws and lockwashers.
Hoist mast from truck and lay on floor for disassembly.
Remove chain assembly (para 63-3f.)
b.
(4) Disconnect hose at adapter (24, figure 725) from base of cylinder.
6-81.
a.
CONTROL VALVE.
Removal.
(1) Disconnect control
control valve (para 6-65).
(5) Remove screw (46) and spacer (47) from
top to cylinder.
(6)
linkage
at
(2) Tag hoses for identification and
disconnect from control valve (40, figure 7-20). Cap or
plug hose ends and valve ports to prevent entrance of
dirt.
6-79.
DUAL MAST ASSEMBLY.
a. Removal. Removal of the complete mast is
Required when removing the drive axle. In most cases
the mast can be maintained by removal arid
replacement of Its individual components. Remove
complete mast as follows:
(1) Slide backrest from carriage and lift from
truck (para 6-31).
(2) Remove forks from truck (para 6-32).
(3) Attach a hoist to assembly and relieve the
weight of the assembly on its supporting parts. Arrange
to brace the mast against tipping as disconnections are
made.
(4) Disconnect hose at hoist cylinder fitting (7,
figure 7-23) and plug hose to prevent entrance or dirt.
(5) Disconnect headlight at uprights (para 645).
(6) Disconnect both tilt cylinders at uprights
by removing pivot pins and attaching screws (para 666).
(7) Remove bearing caps holding mast to
axle each attached with two screws and lockwashers.
Hoist mast from truck and lay it on floor for disassembly.
(3) Remove three screws (41), nuts (42), and
lockwashers (43) securing control ;valve (40) to truck
body and remove control valve. Screws are removed
from battery compartment side.
b.
Installation.
(1) Install three control valve mounting
screws through truck body from battery compartment
side and mount control valve on screws. Secure with
removed nuts and lockwashers.
(2) Reinstall removed hoses according to
tags attached at removal. Be certain hoses are tight.
(3) Attach control valve linkage to control
valve (para 6-65).
(4) Operate system while gradually increasing
loads to check for proper operation and hydraulic fluid
leakage.
6-82.
a.
HYDRAULIC OIL TANK.
Removal.
(1) Drain hydraulic oil tank through plug (6,
figure 7-18).
Installation. Reverse procedure in paragraph
6-80.
a.
TRIPLE MAST ASSEMBLY.
Removal.
(1) Slide backrest from carriage and lift from
truck (para 6-30).
(2) Remove forks from truck (para 6-32).
(3)
valve
Slide hoist cylinder from uprights.
b. Installation. Reverse procedure of a. above,
and purge air from hydraulic system.
b.
above.
Replacement. Reverse procedure in a. above.
(2)
Remove valve cover (para 6-30).
(3)
Remove seat (para 6-24).
(4)
Remove floor plate (para 6-27).
(5) Loosen hose clamp (14, figure 7-13) and
disconnect hoses (13) at hydraulic tank.
Attach a hoist to assembly to relieve
weight.
6-25
(6) Remove four screws (12, figure 7-18) and
washers (14, 15) and nuts (13) securing hydraulic tank
(I1) to truck body and lift hydraulic tank from truck.
(1)
Remove floor plate (para 6-27).
(2)
Remove directional control switch (para 6-
83).
b.
Installation.
(1) Position hydraulic tank on truck body and
secure with four screws, nuts and washers.
(2)
(3) Remove cover (6, figure 7-33) mounted
on steering gear column secured with two screws
housing horn leads and disconnect and tag horn leads at
connector.
Screw filters on hydraulic tank.
(3) Install return hose to filter fitting and
tighten hose clamp securely.
(4) Disconnect drag link at steering gear arm
(7, figure 7-30).
(4) Install suction hose to bottom of hydraulic
tank and tighten hose clamp securely.
(5) Disconnect
power
steering
hose
connection (8, 11, figure 7-30) from steering gear
housing (97, figure 7-33) cover hose connections to
prevent entrance of dirt.
(5) Position seat on hydraulic tank and secure
with hinge pin.
(6) Remove four screws (3, 4, figure 7-33)
and lockwashers (5) securing steering gear housing (97)
to truck body.
(6) Fill hydraulic tank with oil and operate
system to check for hydraulic fluid leakage.
(7) Support steering gear and remove clamp
securing steering gear to instrument panel by removing
attaching nuts and lockwashers. Pull steering gear out
of truck.
(7) At completion of operational test, install
cowl and floor plate.
6-83.
a.
DIRECTIONAL CONTROL SWITCH.
Removal.
(1) Remove directional control switch cover
(11, figure 7-12) and tag and disconnect internal
electrical lead.
(2) Remove return to neutral cable
loosening attaching connector (9, figure 7-28).
b.
procedure
in
paragraph
a.
above.
by
6-85.HYDRAULIC STEERING PUMP.
a. Removal.
(1) Remove floor plate (para 6-27).
(3) Remove four screws (5, figure 7-12)
securing directional control switch and clamp (4) to
steering gear column and remove clamp.
(2) Disconnect hoses (9, 11) from hydraulic
pump (18,' figure 7-30). Cap ends to prevent entrance
of dirt.
(4) Unscrew directional control switch off
conduit coupling (3) and remove from truck.
(3) Remove two screws and lockwashers
securing hydraulic steering pump to hydraulic steering
pump motor and remove hydraulic pump.
b.
Installation.
(1) Install directional control switch on conduit
coupling with lever oriented to right of steering gear
column.
(2) Secure switch
with clamp and four screws.
Installation.
(1) Reverse
b.
Installation.
(1) Position hydraulic steering pump on pump
motor, and secure in place with two screws and
lockwashers.
to steering gear column
(2) Securely connect outlet hose and inlet
hose to hydraulic pump. Operate hydraulic steering
system and check for fluid leakage.
(3) Secure return to neutral cable to switch
with attaching connector, adjusted so that with no
pressure on operator's seat, switch returns to neutral
from either the forward or reverse positions.
(3) Install floor plate.
HYDRAULIC STEERING PUMP MOTOR.
Removal.
(1) Raise truck off floor.
(2) Remove seven screws mounting travel
motor cover (13, figure 7-38) on truck frame.
6-86.
a.
(4) Reinstall electrical leads to switch
according to tags attached at removal and attach switch
cover.
6-84.
STEERING GEAR.
a. Removal.
6-26
terminals.
(3) Remove hydraulic steering pump from
motor (para 6-85).
(6) Remove screw and lockwasher securing
thermal relay (38, figure 7-2) to motor housing.
(4) Slide protective rubber elbows up
electrical leads and disconnect and tag leads from motor
terminals.
b. Installation. Reverse procedure in paragraph
a. above.
6-89.
STEERING AXLE.
a. Removal.
(1) Tilt mast back. Lift rear of truck high
enough to provide enough space in which to work.
Block truck so it cannot fall after being raised.
(2) Disconnect tie rod end (15, figure 7-34)
from bellcrank lever (38).
(3) If rear axle is raised from ground, support
it against falling when attaching parts are removed.
Remove four screws (2, figure 7-34) and lockwashers
(3) from retainer plate (1) and remove retainer plate.
(4) Lower axle, or hoist truck to get clearance
and roll axle from beneath truck.
(5) Remove screw and lockwasher securing
thermal relay (38, figure 7-2) to motor housing.
(6) While supporting motor (22, figure 7-30)
remove four screws, nuts and lockwashers securing
motor mounting bracket to truck body and remove motor
from under truck.
b.
Installation.
(1) Working from under truck, position
hydraulic steering pump motor on body and secure
motor mounting bracket to body with four screws, nuts
and lockwashers.
(2) Connect thermal relay to motor housing
with screw and lockwasher.
b.
Installation.
(1) Roll axle under jacked up truck and jack
up axle until axle blocks enter recesses in truck body.
(3) Secure electrical leads to terminals
tagged at removal and push protective rubber elbows
over terminals.
(2) Install retainer plate on truck body to
secure steering axle in position and secure retainer bar
with four screws and lockwashers.
(4) Connect hydraulic pump to hydraulic
pump motor with two screws and lockwashers.
6-87.
a.
(5) Install truck travel motor cover.
HYDRAULIC PUMP.
Removal.
(1) Remove floor plate (para 6-27).
(3) Remove two nuts (9) and lockwashers
(10) securing pump to motor and remove pump with
attached coupling half (11).
b. Installation. Reverse procedure in a. above,
making sure coupling halves engage.
6-88.
HYDRAULIC PUMP MOTOR.
a. Removal.
(1) Raise truck off floor.
Remove travel motor cover from under
(3)
Remove hydraulic pump (para 6-87).
Connect drag link lever to tie rod end.
(4)
Remove support and lower truck to floor.
(5) Adjust tie rods and steering linkage as
required (para 6-73).
6-90.
DRIVE AXLE, ADAPTER AND TRAVEL
MOTOR.
a. Removal.
(1) Remove entire mast assembly including
carriage, forks and lift cylinder as a unit (para 6-79 or 680).
(2) Disconnect hoses inlet elbow (3, figure 714) and outlet (I) from pump (8) and cap ends to prevent
entrance of dirt.
(2)
(3)
(2) Disconnect and remove brake line from
master cylinder at tee fitting (29, figure 7-13) on drive
axle. Protect line against kinking or entry of dirt while
disconnected.
(3) Remove floor plate (para 6-27) and
remove thermal relay from travel motor. Remove horn
(70, figure 7-2) attached to adapter. Disconnect rod (8,
figure 7-36) brake on rear of motor. Drain lubricant from
axle and adapter.
truck.
(4) Remove bottom plate from under truck.
Support travel motor from below with wheeled dolly or
floor jack. Disconnect and tag four leads from terminals
of travel motor.
(4) Remove tee bolt, nut and washers
securing hydraulic pump motor to strap, and lower
motor.
(5) Slide protective rubber elbows up
electrical leads and disconnect and tag leads from motor
6-27
holes in fuse panel and secure fuse holder with screws.
(5) Remove six screws (5, figure 7-35) nuts
(6) and washers (7) securing motor to mounting bracket.
Remove four bolts, lockwashers and two bearing
brackets securing axle to frame. Lift front end of truck
from axle and draw axle, adapter and travel motor from
under truck.
(2) Reconnect leads (disconnected during
disassembly) to screw-type fuse terminals.
(3) Reinstall cover.
PUMP MOTOR AND MASTER SWITCH
RELAYS.
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
6-92.
(6) Remove nine screws (9, 10, figure 7-37),
lockwashers (11) and two nuts (8) attaching adapter to
axle and take motor and adapter, as a unit, from axle.
(7) Remove six screws (3, figure 7-35) and
lockwashers (4) attaching adapter to motor and draw
motor (2) from adapter (8).
(2) Remove four cap screws and lockwashers
which secure base of each relay (1 and 2, figure 7-3) to
mounting panel; then, withdraw relay for access to
terminals.
b.
Installation.
(1) Place gasket between travel motor and
adapter, align holes and secure motor to adapter with
screws and lockwashers.
(3)
from relay.
(2) Place gasket (12, figure 7-37) between
drive axle and adapter, align holes and gears and
secure with screws, nut and lockwashers.
b.
(3) Position drive unit on a wheeled dolly and
roll unit under raised front end of truck. Lower front end
of truck until axle aligns with bearing bracket halves on
frame and travel motor mounting flange holes align with
holes in mounting brackets. Secure axle with bearing
brackets, screws and lockwashers and travel motor with
screws, nuts and washers.
(4)
(4) Withdraw relay from compartment.
Installation.
(1) Connect all leads to relay terminals.
(2) Align mounting holes in relay base with
hones in mounting panel and secure relay in place with
screws, lockwashers and flat washers.
6-93.
STEERING RELAY (IS).
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
Secure hydraulic tee fitting to adapter.
(2) Remove three screws which secure base
of steering relay (15, figure 7-3) to mounting panel.
Withdraw relay slightly from panel for accesses to
terminals.
(5) Attach tagged electrical leads to travel
motor terminals. Secure protective cover to underside
of truck.
(3)
(6) Lubricate drive axle and adapter.
Connect rod and cable at brake on rear of travel motor.
Install thermal relay on travel motor. Attach horn to
adapter. Replace floor plate.
(7)
Disconnect and tag all leads removed
Disconnect and tag all Ieads from steering
relay.
(4) Withdraw
steering
relay
compartment.
b. Installation.
(1) Connect all leads to relay.
Install mast assembly on truck.
from
(8) Bleed hydraulic brake system through
each wheel cylinder (para 6-36b.).
6-91.
FUSE HOLDER.
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
(2) Align holes in base of relay with tapped
holes in mounting panel and secure relay to panel with
screws.
(2) Disconnect and tag all electrical lead
wires from fuse holders (7, 8, figure 7-3).
6-94.
SHORTING
CONTACTOR,
FORWARD,
REVERSE, AND FIELD WEAKENING RELAYS
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
(3) Reinstall
compartment.
(3) Remove two screws which secure each;
fuseholder to fuse panel and withdraw fuse holder.
b. Installation.
(1) Align mounting holes in fuse holder with
6-28
cover
on
control
panel
compartment (para 6-28).
(2) Disconnect and tag all leads on pack (10,
figure 7-3).
(2) Remove three machine screws which
secure each relay (17, 18, or 19. figure 7-3) to mounting
panel. Withdraw relay from mounting panel slightly for
access to terminals.
(3) Remove
remove pack.
(3) Disconnect and tag all leads to relay.
(4) Withdraw relay from control
compartment.
b. Installation.
(1) Connect all leads to relay.
control
screws
and
(2) Disconnect and tag all electrical leads on
suppressor condenser 3SP (14, figure 7-3) or
suppressor condenser 4SP (11).
panel
(3) Remove
remove suppressor.
control
mounting
b. Installation. Reverse procedure in paragraph
a. above.
6-98.
SUPPRESSOR 3SP AND 4SP.
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
panel
(2) Align mounting holes of relay with tapped
holes in mounting panel and secure relay to panel with
screws, lockwashers and flat washers.
(3) Reinstall cover on
compartment.
6-95.
CONTROL PACK (2CP).
a. Removal.
(1) Remove cover from
compartment (para 6-28).
two
two
mounting
screws
and
panel
b. Installation. Reverse procedure in paragraph
a. above.
6-99.
FIELD WEAKENING PACK (FWP).
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
(2) Disconnect connector 4PL.
(3) Remove four machine screws and
washers which secure control pack (22, figure 7-3) to
mounting panel.
(2) Disconnect and tag all electrical leads on
pack (20, figure 7-3).
(4) Withdraw control pack from control panel
compartment.
b. Installation.
(1) Align mounting holes of pack with tapped
holes in mounting panel and secure pack with washers
and screws.
(3) Remove
remove pack.
two
mounting
screws
and
b. Installation. Reverse procedure in paragraph
a. above.
(2) Connect pendant cable connector 4PL.
c.
(3) Reinstall cover on control panel
compartment.
6-96.
FIELD WEAKENING RESISTOR (FW).
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
6-100.
a.
ANTI ROLLBACK PACK (ARP).
Removal.
(1) Remove cover from control
compartment (para 6-28).
(3) Remove
remove ARP.
(3) Remove two mounting nuts, flat washers
and lockwashers and remove resistor.
two
mounting
screws
and
b. Installation. Reverse procedure in paragraph
a. above
6-101. RESISTOR 3RES.
a. Removal.
(1) Remove cover from control panel
compartment (para 6-28).
b. Installation. Reverse procedure in paragraph
a. above.
ENGINE HOUR PACK (EHP).
Removal.
(1) Remove cover from control
panel
(2) Disconnect and tag all lead wires to ARP
(12, figure 7-3).
(2) Disconnect and tag all lead wires to FW
RESISTOR (21, figure 7-3).
6-97.
a.
Adjustment. See paragraph 6-240.
panel
6-29
below battery compartment and withdraw cover.
(2) Disconnect and tag all lead wires to 3RES
(9, figure 7-3).
(5) Disengage terminals on harness leads 99
and 13A-2 from terminals on wires extending from
headlight flexible conduit.
(3) Remove two mounting screws and
remove 3RES.
b. Installation. Reverse procedure in paragraph
a. above.
6-102. CONTROL PACK ICP.
a. Removal.
(1) Remove control panel cover (para 628).
(6) Remove two terminals covers from
steering column and disconnect harness lead 83 and 84
from screw-type horn button terminals.
(7) Disengage plug on harness (containing
leads 63, 64, 65, 71, 72 and 74) from receptacle on
cable extending from direction control switch.
(2) Disconnect and tag all electrical leads on
control pack (7, figure 7-10).
(8) Disengage harness terminals on leads 92
and 93 from push-on terminals of panic switch.
(3) Remove four mounting screws and
remove pack.
b. Installation. Reverse procedure in paragraph
a. above.
c.
6-103.
a.
(9) Disengage harness terminals on leads
13A-4 and 82 from screw-type terminals on light switch.
Adjustment. See paragraph 6-240.
CAPACITOR IC.
Removal.
(1) Remove control panel cover (para 6-28).
(10) Disconnect harness leads 19, 86-1, 86-2
and 99 from screw-type terminals on light switch.
(11) Disengage plug on wiring harness
(containing leads 27, 28, 29, 45, 46, 70, and 71) from
receptacle on cable extending from accelerator master
switch.
(2) Disconnect and tag electrical leads on
capacitor (19. figure 7-10).
(3) Remove mounting brackets and remove
capacitor.
b. Installation. Reverse procedure in paragraph
a. above.
6-104. TRANSFORMER IT.
a. Removal.
(1) Remove control panel cover (para 6-28).
(12) Disengage plug on wiring harness
(containing leads 35, 70, 86-1 and 94) from plug on
cable extending from brake and stoplight switch.
(13) Disconnect wiring harness leads 13A-1
and 84 from screw-type terminals on horn.
(2) Disconnect and tag leads on transformer
(18, figure 7-10).
(14) Disconnect wiring harness leads 91 and
92 from screw-type terminals on seat switch.
(3) Remove two mounting screws and
remove transformer.
b. Installation. Reverse procedure in paragraph
a. above.
6-105. WIRING HARNESS.
a. Removal. Removal of tile wiring harness (37,
figure 7-2) is not ordinarily required during overhaul of
the truck Usually, repair of the harness can be
accomplished with the harness in place. However, if
repair is required in an inaccessible place, the harness
may be removed from the truck and reinstalled as
follows:
(1) Release handle on battery connector and
disengage battery connector.
(15) Disconnect wiring harness leads 78 and
98 from screw-type terminals on seat switch.
(2)
(16) Disconnect wiring harness leads 69-1 and
93 from screw-type terminals on battery connecting
switch.
(17) Remove three clamps which secure
thermal relays to hydraulic oil tank to steering pump
motor, to travel motor frame and to pump motor frame.
After disengaging thermal relays, replace clamps to
prevent loss of parts.
(18) Starting at front of truck, remove all
clamps and clips which secure wiring harness branches
and main trunk to structural members.
After
disengaging harness from clamps and clips, re-attach
clamps and clips to prevent loss of parts.
Remove floor plate (para 6-27).
(3) Remove valve cover (para 6-30).
(4) Remove seven screws, nuts and flat
washers which secure cover to bottom of truck frame
(19) Remove control panel cover (para 6-28).
6-30
assembly.
(3) Free retaining ring (5) holding collar (4).
Slide collar down, and remove cushions (1) and sleeve
(6) on axle side coupling half (7). Remove sleeve from
motor side coupling half and any cushions that may
have remained with motor when separated.
(4) Remove cotter pin (3) and nut (2) from
pinion gearshaft (20). Take coupling half from pinion
gearshaft and remove collar and retaining ring.
(5) Remove six screws (14) and washers
(15). Remove oil seal and retainer (13), thrust washers
(16), spacers(18) and gaskets ( 17) from cage.
(6) Remove double row roller bearing (19)
from cage. Remove retaining ring, and take pinion
gearshaft (20) with race and retaining ring from cage.
Take single row bearing (21) from cage.
(20) Disengage two plugs on wiring harness
from receptacles connected to internal wiring of control
panel.
(21) Unscrew conduit fitting (through which
wiring harness passes) from front wall of control panel
compartment. Fitting is located in lower left hand corner
of control panel compartment.
(22) Carefully withdraw wiring harness from
control panel compartment. Straighten out branches in
harness as required and work bulky items through holes
and around corners as required. Avoid undue strain on
plugs, terminals and terminal relays.
b. Installation. Installation of the wiring harness is
essentially the reverse of the removal procedure. Plugs
are keyed to prevent improper orientation.
After
securing harness with clips and clamps, assure that
sufficient clearance is maintained between harness and
all moving parts. Hand form harness where required to
obtain clearance. Apply silicone rubber to exposed
screw-type terminals on seat switch, pump motor switch
and on brake stoplight switch. Insulate other exposed
terminals with vinyl tubing.
6-106. OVERHAUL OF MAJOR COMPONENTS AND
AUXILIARIES.
6-107.
6-111. DRIVE AXLE DISASSEMBLY. Refer to figure
7-35, except where indicated, and proceed as follows:
(1) Remove drive axle (para 6-90).
(2) Drain lubricant from axle (figure 5-1).
(3) Remove drive wheels (para 6-76).
(4) Remove screws (44 and 45) and washers
(46) and remove gear case (58) with brake assembly
from axle housing (79). Remove gasket (66 and oil seal
59).
(5) Remove hub cap (52), cotter pin (53),
spindle nut (54) and washer (55) from spindle (63).
Take final drive gear (60), bearing cups (61) and cones
and rollers (62) from spindle.
(6) Remove four nuts (64) and washers (65)
holding spindle (63) to axle housing (79) and remove
spindle.
(7) Draw axle gearshaft (69) with bearing (68)
and collar (67) from housing. If they are to be replaced,
press off bearing and collar.
(8) Remove nuts (70) and washers (71 and
74) from studs (73) in differential housing (94). Don't
remove studs unless damaged. Tap axle housings (78
and 79), if necessary, to free tapered dowels (72) on
studs.
Separate housings and remove tapered
bushings.
NOTE
Differential bearing cups (80) will remain with
axle housing, causing differential assembly to
drop slightly within its housing when axle
housings are removed.
(9) Carefully remove gaskets (81 and 82)
from studs. Before discarding these gaskets, measure
and note total gasket thickness removed at each side.
Same thickness of new gaskets is to be used as a
starting point in making pinion and drive gear
adjustments at assembly.
DRIVE AXLE AND ADAPTER.
6-108. The adapter provides a gear reduction between
the travel motor and pinion and the drive axle pinion
gearshaft. The gears are mounted in a gear case
having flanges for mounting the travel motor and for
mounting to the drive axle differential housing. The
travel motor drives a bearing-mounted gear cluster
which in turn drives an input driven gear. The pinion
gearshaft is spline engaged in the input driven gear.
6-109. The drive axle contains a differential gear
arrangement which is driven by the adapter pinion
gearshaft. The pinion gearshaft engages a ring gear
secured to the differential case. The two axle housings
provide mounting for the front wheel brake assemblies.
Many parts which comprise the drive axle can be
removed without removal of the axle from the truck.
However, for general overhaul, the axle requires
removal.
6-110. ADAPTER DISASSEMBLY. Refer to figure 737 and proceed as follows:
(1) Remove the adapter from the truck (para
6-90).
(2) Remove screws (9), nuts (8) and washers
(11) holding gearshaft bearing cage (22) to adapter
housing (24).
Remove housing and gasket (23).
Measure and record gasket thickness for reference at
6-31
bearing bores in spider pinions for scoring and for wear
resulting in loose fit.
6-114. REPAIR. Repair adapter and drive axle parts
as follows:
(1) Repair slight thread damage with tap or
thread chaser. Repair stripped threads in castings by
installing thread inserts.
(2) Repair slight axle shaft runout by pressing
or hammering to bring runout within limits of 0.01 (-inch
total indicator reading.
6-115. REPLACEMENT. Replace adapter arid drive
axle parts as follows:
(1) Replace all damaged, worn or defective
parts that cannot be made serviceable by repair
procedures outlined above.
(2) Replace all seals with new parts at each
overhaul.
(3) Always replace thrust washers in sets
only.
6-116. ADAPTER ASSEMBLY. Refer to figure 7-37
and proceed as follows:
(1) Press single row bearing (21) into recess
cage (22). Install race, retaining ring, and pinion
gearshaft (20). In all double row bearing (19) in cage
and on pinion gearshaft.
(10) Remove bearing cups (80) from axle
housing (78 and 79) and cone and roller bearings from
case halves (87). The cups (80) will probably have
remained in the bore of axle housings during removal
operation.
(11) Punch mark differential case halves (87)
for alignment on assembly. Separate differential case
halves by removing screw (88). Washers (90) and side
gears (89) will be loose when separating differential
case halves. Remove them.
(12) Remove thrust washers (91 ) and spider
pinions (92) from spider (93). Center punch rivet heads
(86), drill through heads and press out rivets. Remove
gear (85) from case (87).
6-112. CLEANING DISASSEMBLED PARTS. Clean
parts of disassembled adapter and drive axle as follows:
(1) Clean all housings, shafts, gears and
shims with SD and dry with compressed air under
moderate pressure. Be sure to clean parts thoroughly to
facilitate inspection.
(2) Clean brake assemblies with compressed
air under moderate pressure.
(3) Clean bearing cups and cones and rollers
in SD. Do not rotate cones and rollers prior to cleaning.
Dry parts with compressed air under moderate pressure.
(2) Install spacers ( 8) arid gaskets ( 17),
thrust washer (16) and oil seal and retainer (13) in cage.
Retain with six screws (14) and washers ( 5).
6-113. INSPECTION.
Inspect cleaned parts of
adapter and drive axle as follows:
(1) Inspect all bearings for roughness, pitting
of rollers, cones, and cups, cracked cones or cups. To
inspect for roughness, place cones and rollers in
associated cups and rotate cups slowly with axis of
bearing vertical. If roughness is detected, check for
metallic chips or other foreign matter between cones
and rollers.
(3) Assemble collar (4) and retaining ring (5)
to coupling half (7), and attach coupling half to pinion
gearshaft with nut (2).
(4) Install sleeve (6) and cushions (I) in
coupling half (7).
(5) Install bearing cage (22) and gasket (23)
to adapter housing. If adapter is not to be installed
immediately secure a package of gaskets (1 2) totaling
thickness of' gaskets removed to adapter, For use when
it is installed.
6-117. DRIVE-AXLE ASSEMBLY. Refer to figure 735, except where noted, and proceed as follows:
(1) If differential bearing cones arid rollers
(75) have been removed, press new ones onto trunnions
of case halves (87).
(2) Rivet bevel gear (85) to case half (87)
with new rivets (86). If a new gear or differential case is
to be used in the assembly, the rivet holes in the gear
and case should be checked for alignment and line
reamed if necessary. The gear must be tight on the
case pilot and riveted flush with the differential case
flange. Check with a 0.002-inch feeler gage. Rivets
should not be heated, but should be upset cold. When
the correct rivet and rivet set is used the head being
formed will be at least 1/8 inch larger in diameter than
the rivet hole. The head will then be approximately the
same
(2) Inspect all threaded parts and tapped
holes for stripping or other damage.
(3) Check axle shafts for runout in excess of
0.01 0-inch total indicator reading.
(4) Inspect bearing mounting surfaces on axle
shafts, on differential case halves and on pinion
gearshaft for wear as a result of bearing failure. Also
check bearing cone bores in adapter case, in axle
housings and in differential housing for wear as a result
of bearing failure.
(5) Inspect all gears and pinions for worn,
chipped or rough teeth.
(6) Inspect adapter case, axle housings,
differential housing and differential case halves for
cracks and distortion.
(7)
Inspect bearing surfaces on cross and
6-32
after replacement of parts. These are the differential
bearing preload adjustment (to be made first), the drive
gear and pinion backlash adjustment, and the tooth
contact adjustment. Adjust differential bearing preload
to be between 0.000-inches and 0.003-inch loose as
follows:
NOTE
The latter two adjustments are so related that a
change in either one causes a change of the
other adjustment.
(1) Install both axle housings (78 and 79) with
same thickness of gaskets (81 and 82) at each side as
was removed at disassembly.
(2) Turn drive gear (85) by hand, testing for
noticeable drag due to trial preload condition of bearings
(75 and 80). If no drag exists, remove axle housings,
remove one or more gaskets (82 or 81) and repeat test
until drag is noticed. Gaskets 0.005-inch thick and
0.0075-inch thick are used. Decrease total gasket
thickness in 0.0025-inch steps by removing two 0.005inch gaskets and adding one 0.0075-inch gasket.
(3) If drag is noticeable on first trial, reverse
procedure for decreasing gasket thickness given above
until no drag is present, then decrease total gasket
thickness until drag is felt. Preload will now be between
0.000-inch and 0.003-inch loose, as required.
(4) Install three adapter-to-axle gaskets (12,
figure 7-37) and install adapter to assembled axle.
(5) Remove drain plug (83, figure 7-35) from
differential housing. Install plug (3/4-14 NPT threads)
with slightly longer reach, to contact and lock bevel gear
(85) from rotation.
(6) Install a dial indicator on the adapter
flange, to take a reading at a tangent point 1.10-inches
from the center of the coupling half. Rotate coupling
half through freedom permitted by pinion and ring gear
backlash. Reading is to be 0.005-inch to 0.015-inch.
Adjustment to correct is given in step 7. below.
NOTE
Several adjustments of both pinion and ring
gear setting may be necessary in the following
procedure before the correct adjustment is
achieved. It is not possible to specify the exact
thickness of gaskets to be added, removed, or
exchanged at any stage This must be
determined by trial and error.
(7) Apply a thin coating of red lead to drive
face of ring gear teeth, and reinstall adapter to axle,
adding gaskets (12, figure 7-37) to increase backlash, or
using fewer gaskets to decrease backlash.
height as the preformed head. The formed head should
not exceed 1/16 inch less than the preformed head as
excessive pressure will cause distortion of the case
holes and result in gear eccentricity.
(3) Put spring thrust washers (91) and spider
pinions (92) on spider (93); replace thrust washers (90)
and side gears (89) in case halves (87).
(4) Place spider with washers and pinions in
position in one case half, position other case half with
side gear and washers installed, so mating marks
(punched at disassembly) are aligned and install screws
(88). Tighten all bolts equally and check for freedom
from binding by turning one side gear (89) at a time
using an axle gearshaft (69) temporarily inserted in side
gear splines.
(5) With differential assembly installed in
housing, pass a three-foot long piece of rod or pipe
through the differential case and spider, as a handle to
aid in positioning it.
(6) Install new gaskets (82 and 81) on studs
of differential housing (94) to total the same thickness at
each side as was removed and noted at disassembly.
(7) Install differential case bearing cups (80)
in base of housings (78 and 79). Positioning differential
with rod, install axle housings on studs of differential
housing. Replace nuts (70), washers '71) and alignment
dowels (72).
(8) Adjust differential assembly bearing
preload (para 6-118).
(9) Replace pinion gear adapter (8) using
attached gaskets (para 6-116). Install screws (9 and 10,
figure 7-37), lock washer (I1, figure 7-37) and nuts (8,
figure 7-37).
(10) Adjust for drive gear and pinion backlash
and for the tooth contact pattern (para 6-1 18).
(11) Press bearing (68) and collar (67) onto
axle gearshaft (69) and install gearshaft through axle
housing (79) so splines enter splines in differential side
gear (89).
(12) Replace spindle (63) on housing (79),
studs (77) and secure with washers (65) and nuts (64).
(13) Replace cone and rollers (62) on spindle,
and cup (61) in final drive gear (60). Put final drive gear
on spindle and replace cup (57), cone and rollers (56),
washer (55), nut (54) and cotter pin (53).
(14) Using new gasket (66) and oil seal (59),
install final drive gear case (58) (with brake assembly
attached) on axle housing.
(15) Replace front wheel, hubcap, and brake
lines and fittings.
6-118. ADJUSTMENTS. Three basic adjustments are
to be made when the differential has been reassembled
6-33
(8) Engage adapter coupling half (7) with a
pry bar, and turn it until differential has made one
revolution in the forward direction.
(9) Remove adapter from axle. Examine
teeth of ring gear, and compare marks in red lead from
pinion gear contact.
NOTE
Ring gear is on left side of pinion when installed.
References to follow will be on this basis.
(10) If marks in red lead indicate high, narrow
tooth contact (pinion too far out), adjust by removing
one or more adapter-to axle gaskets to move pinion in
direction, and transfer one or more axle housing-todifferential housing gaskets from left side of differential
housing to right side. Repeat above to check results of
adjustment.
NOTE
Do not change total thickness of side gaskets
used; merely change them from one side to the
other as needed, so the differential bearing
preload will not be changed.
(11) Lubricate drive axle (figure 5-1).
6-119. STEERING AXLE.
washers (40).
6-122. CLEANING. Clean disassembled parts as
follows:
(1) Wash all metallic parts in SD and dry with
compressed air under moderate pressure. Be sure to
clean parts thoroughly to facilitate inspection.
(2) Clean neoprene axle blocks with cloth or
cotton waste moistened with SD.
6-123.
INSPECTION. Inspect parts as follows:
(1) Inspect neoprene axle blocks for cracking,
deformation, splitting and deterioration.
(2) Inspect threaded parts for stripped or
damaged threads.
(3) Inspect tie rods for damaged ends. Also
check that tie rods are not bent or deformed.
(4) Inspect axle, bell crank, spindle pins and
steering arms for cracks and distortion.
(5) Inspect bearings in bell crank and
bearings in steering arms and bearings in axle forging
for wear.
6-124 REPAIR AND REPLACEMENT. Replace parts
removed from steering axle as follows:
(1) If practicable, repair damaged threads
with a lap or thread chaser.
(2) Replace all parts that are cracked, worn,
distorted or deteriorated.
6-120. The steering axle comprises a forged axle, two
steering arms (to which the rear truck wheels mount), a
bellcrank and axle mounting blocks. The bellcrank
connects to the steering gear by means of a drag link.
Conventional tie rods connect the bellcrank to the two
steering arms.
6-125. REASSEMBLY. Reassembly steering axle as
follows:
(1) Install washers (40), bearings (41 ) and
pullcrank (38) on axle (42). Secure with ring (39).
(2) Pack bearings (36) with automotive
grease and install bearings (36), knuckles (29 and 30),
pins (35), washers (33), screws (31) and nuts (32).
(3) Replace tie rod ends (17 and 20) on tie
rods (23). Do not tighten clamps (24) until after
adjustment of wheel alignment.
(4) Install tie rod assemblies to connect
bellcrank to steering knuckles.
(5) Replace seals (13) on spindles of steering
knuckles (29 and 30). Put one bearing cone and roller
(6) on spindle of knuckle. Press both bearing cups (10)
into wheel and put wheel on spindle, followed by second
bearing cone, washer (9), nut (8) and cotter pin (7).
Replace cap (5). Repeat for second wheel.
6-121. DISASSEMBLY. Refer to figure 7-34 and
proceed as follows:
(1) Remove hub cap (5). Remove tire (II)
and wheel (12) as an assembly by removing cotter pin
(7), nut (8) and washer (9). Carefully pull wheel from
steering knuckle (29 or 30) to avoid damaging oil seal
(13). The inner bearing cone and rollers (6) may remain
with the knuckle. The outer bearing cone and rollers
and bearing cups (10) will remain in the wheel. Remove
bearing cups, cone and rollers.
(2) Remove seals (13) from steering knuckles
(29 and 30). Remove axle blocks (4) from axle (42).
(3) Remove two tie rod assemblies attached
with cotter pins (18 and 21) and nuts (19 and 22).
(4) Loosen clamps (24) secured with bolt
(25), nut (26) and washer (27). Unscrew tie rod ends
(17 and 20) from tie rod (23).
(5) Remove bearings (34) steering knuckles
(29 and 30) attached with screws (3 1), nuts (32 and
washers (33).
(6) Remove bellcrank lever (38) and two
bearings (41) secured with retaining ring (39) and two
6-126. ADJUSTMENT. The following adjustment can
be made most conveniently before installation of the
steering axle. However, the adjustment can be made
with the axle installed, as well. Adjust as follows:
6-34
brake shoes and springs. Secure rod in place with selflocking nut (9).
(4) Secure link (3) between clevis on lower
brake shoe with anchor pin (4). Insert cotter pin (7)
through end of anchor pin to secure anchor pin.
(1) With axle level fore and aft, measure
distance between inside tires at hub height, first at front,
then at rear. If measurements are within 1/16-inch of
each other, no adjustment is needed. Tighten tie rod
end clamps (24) on tie rods. If readings are outside
limits, proceed to step below.
(5) Insert link pin through clevis (38. figure 728) on rod (36) and through link: then. insert cotter pin
(42) through link pin to secure pin.
(2) Turn each tie rod (17 and 20) an equal
amount (with clamps (24) still not tightened) until wheels
are parallel, as measured in step (1) above.
6-132.
(3)
6-127.
SERVICE BRAKES.
Tighten tie rod end clamps.
6-133.DISASSEMBLY (figure 7-35).
(1) Remove front wheels from drive axle
(para 6-76).
HAND AND SEAT BRAKE.
6-128. The hand-motor brake system incorporates a
hand brake lever and a mechanical seat linkage to apply
brake shoes to the brake drum attached to the travel
motor armature shaft. This braking system is applied
automatically when the operator leaves the seat or may
be applied by the operator by means of the brake lever.
(2)
Remove wheel hubs.
(3) Disconnect both brake tubing (15) from
adapters (19) on each wheel cylinder (41). Use care to
prevent kinking or denting tubing and to avoid entrance
of foreign matter.
6-129. REMOVAL. Remove motor brake shoes and
drum as follows:
(1) Remove clevis rod (38, figure 7-28) at link
(3, figure 7-36) secured with pins (41 and 42, figure 728).
(4) Remove screw (49) and washers (50)
securing brake assemblies and spacer (42).
(5) Use brake servicing tool's to remove
retaining spring (28) and return spring(27), then. lift off
brake shoes.
(2) Remove nut (9, figure 7-36) and two
springs (10) mounted on rod (8).
(6) Remove bolts (35) and washers (36)
which secure wheel cylinders to backing plate; then,
withdraw wheel cylinders.
NOTE
If wheel cylinders show evidence of fluid
leakage, repair cylinder or replace.
(3) Remove brakeshoes (] 7) attached to
motor with nut (56), washer (57) and stud(58). Remove
bushings (16) from brakeshoes.
(4) Remove brake drum (18) attached with
woodruff key, nut (20) and cotter pin (21) from motor
shaft.
6-134. CLEANING. Remove dust from parts with
compressed air and a stiff bristle brush. If brake fluid
has leaked onto brake shoe linings, replace linings and
clean other parts with alcohol. If grease from axle has
contaminated parts, wash parts (except wheel cylinders)
in SD, and replace linings on brake shoes.
CAUTION
Do not allow SD to come in contact with rubber
parts. SD will cause rubber to swell and rot.
6-130. REPAIR AND REPLACEMENT OF MOTOR
BRAKE PARTS. Repair of motor brake parts is limited
to removal and replacement of bushings In brake shoes.
Press bushings out of shoes and install new bushings.
Replace brake shoes. If brake linings are worn to less
than 1/I6inch at any point, replace brake shoes.
Replace brake drum if scored, corroded or pitted.
Replace any other parts that are distorted or excessively
worn.
6-135.
INSPECTION.
(1) Inspect wheel cylinders for evidence of
fluid leakage.
6-131. INSTALLATION OF MOTOR BRAKE SHOES
AND DRUM.
(1) Place motor brake drum (18, figure 7-36)
with woodruff key on motor shaft and secure with nut
(20) and cotter pin (21).
(2) Inspect
excessive wear.
linings
on
brake
shoes
for
(3) Inspect backing plates for distortion or
other damage.
(2) Place brake shoes on mounting stud (58)
and secure with washer (57) and nut (56).
(4) Inspect tapped holes and threaded parts
for stripping of threads or other thread damage.
(3) Place compression springs (10) between
ends of brake shoes; then, insert rod cup (8) through
6-35
6-140. INSPECTION AND REPAIR.
Proceed as
follows (figure 7-29).
(1) Remove filler cap and gasket from
cylinder (32) and discard fluid in reservoir.
(2) Pull push rod (34) free of bellows (33) and
remove bellows.
(3) Remove retaining ring and withdraw
piston stop, piston, primary cup, spring, and check
valve, from inside bore of body.
(4) Inspect all rubber parts for swelling,
distortion or wear. Check that edges of primary cup,
and secondary cup on piston are sharp and not flared.
NOTE
If either cup shows any sign of damage, install
the complete master cylinder repair parts kit.
(5) Inspect bore of master cylinder for
scratches, rust spots or pitting. Remove minor surface
defects with a brake cylinder hone.
6-136.
REPAIR.
(1) If linings on brake shoes are worn to less
than 1/16-inch at the thinnest point, install new bonded
linings. Install linings in accordance with good practice
and instructions for use of equipment available.
(2) Repair
minor
thread
practicable) with tap or thread chaser.
(3)
damage
(if
Replace all distorted or damaged parts.
6-137.
ASSEMBLY.
(1) Install wheel cylinder assembly on
backing plates with spacer (42, figure 7-35), bolts (35)
and washers (36).
(2) Place brake shoes on backing plate studs
and install return springs and retaining springs with
brake service tools.
(6) Inspect check valve for cleanliness, firm
spring action, and tight sealing when closed.
(3) Install backing plates (43) on axle
housings and secure with screws (49) and washers (50).
(7) Probe ports visible through reservoir fill
hole with fine wire to be sure they are clean. If
necessary to flush reservoir, use only pure denatured
alcohol.
(4) Connect brake tubings (15) to adapters
(19) in wheel cylinders.
(5) Adjust brake shoes for proper shoe to
brake drum clearance (para 6-36).
(8) Install check valve in bore of cylinder, to
bottom, followed by spring, primary cup, piston and
piston stop.
6-138. WHEEL CYLINDER REPAIR. Proceed as
follows:
(1) Remove rubber boots (37) from ends of
wheel cylinder.
(9)
(10) Slide push rod into small end of bellows,
then install bellows on master cylinder. If unit is not to
be installed immediately, cap or plug all openings to
keep out dirt.
(2) Remove pistons (38), cups (39) and
spring (40) from wheel cylinder.
(3) Clean metal parts in alcohol. Wipe rubber
parts with clean soft lint-free cloth.
6-141.
(4) Inspect bore in cylinder and pistons for
scoring or pitting.
(6) Discard parts for which new parts are
supplied in wheel cylinder repair kit.
6-143. TIRE
REPLACEMENT
PROCEDURE.
Proceed as follows:
(1) Remove wheel from truck.
(2) Support felloe of wheel with a ring slightly
smaller in diameter than wheel felloe and at least as
wide as tire to be pressed off.
(3) Place new tire over old and center
carefully.
(4) Slowly lower press ram, check alignment, and
proceed with pressing operation.
(7) Insert spring (40), cups (39) and pistons
(38) into bore in wheel cylinder.
Snap boots (37) onto ends of wheel
(9)
Install wheel cylinders on truck.
cylinder.
6-139.
TIRE REPLACEMENT.
6-142 GENERAL. Replacement of tires is usually
made by pressing off old tire simultaneously with
pressing on new tire. Force required to replace a tire is
5,000 pounds for each inch of wheel diameter. For
example, a tire used on a wheel 18 inches in diameter
requires 18 x 5,000 pounds or 90,000 pounds (45 tons)
press capacity.
(5) Remove minor pitting or scoring by
honing.
If piston or cylinder cannot be made
serviceable by honing, replace entire wheel cylinder
assembly.
(8)
Install retaining ring to hold these parts in
place.
MASTER CYLINDER.
6-36
to be flush with bottom surface of stub shaft seal (61)
bore.
(2) Lubricate new stub shaft seal with
automatic transmission fluid, TYPE "A", and install far
enough to provide clearance for dust seal (60) and
retaining ring (63). Lubricate new dust seal with engine
oil and install with rubber surface outward. Install
retaining ring (63), making certain that the ring is
properly seated.
(5) Be sure that force is always applied
through metal base band and that there is no
interference with the rubber. Never hammer tire. Use
ring rather than block for supporting wheel and applying
force to tire.
NOTE
In some cases removal of old tire may be
difficult due to peened-over condition of base
band or felloe. In such cases, remove old tire
by burning or cutting through base band. In
mounting tires on wheels without old tires, use
care to insure that felloes are smooth and free
of burrs. Also carefully check alignment to
assure that new tire starts on squarely and is not
cocked on wheel.
(6) Reinstall wheel on truck.
6-144.
(3) Lubricate packing (62) with automotive
grease, and install on adjuster plug. Assemble large
thrust bearing face (66), thrust bearing (70), small thrust
bearing race (68), and thrust bearing spacer (69) on
adjuster plug. Press new bearing retainer (70) into
needle bearing bore, using thrust bearing retainer
installer.
STEERING GEAR REPAIR.
6-148. ADJUSTER PLUG INSTALLATION. Proceed
as follows:
(1) Place tool to protect seal over end of stub
shaft (88, figure 7-33).
6-145. GENERAL.
Complete disassembly of the
steering gear at one time is not an overhaul operation.
The instructions in following paragraphs present
complete information necessary to correct any
malfunction of the gear. Before beginning repairs,
diagnose the probable cause of the malfunction by
referring to the troubleshooting chart for the steering
gear (figure 6-8) at the end of the steering gear
instructions. Limit disassembly to necessary operations.
(2) Install adjuster plug assembly in gear
housing. Adjust thrust bearing preload according to
paragraph 6 below, and tighten locknut to 50 to 110 foot
pounds.
6-149. STEERING GEAR VALVE REMOVAL. The
complete valve in each steering gear is a precision unit
with selective fitted parts and is hydraulically balanced
at assembly. Only those parts which are service items
are replaceable and interchangeable. No other valve
parts are individually interchangeable. If replacement of
any nonserviceable valve part is necessary, the
complete rotary valve assembly must be replaced. Do
not disassemble the valve unless necessary since this
may result in damaging the assembly. If the valve spool
dampener packing requires replacement, remove valve
spool only, replacing packing, and reinstall spool
Immediately. Do not disassemble further. Proceed as
follows:
NOTE
It is very uncommon to have to make any
service repairs to the valve assembly, with the
exception of the valve spool dampener packing.
(1) Remove adjuster plug assembly as
outlined under paragraph 6-143.
6-146. ADJUSTER PLUG DISASSEMBLY. Proceed
as follows:
(1) Loosen adjuster plug locknut (59, figure 733).
(2) Remove the thrust bearing retainer (70)
with a screwdriver, being careful not to score the needle
bearing bore, and discard. Remove thrust bearing
spacer (69), thrust bearing (67) and thrust bearing races
(66 and 68).
(3)
Remove adjuster plug packing (62) and
discard.
(4) Remove stub shaft seal retaining ring
(63), with snap ring pliers, and remove stub shaft dust
seal (60).
(5) Remove stub shaft oil seal (61) by prying
out with screwdriver and discard.
(2) Remove valve assembly from gear by
grasping stub shaft (88, figure 7-33) and pulling out
valve assembly and stub shaft.
(6) Inspect adjuster plug needle bearing (64),
and if rollers are broken or pitted, remove needle
bearing from adjuster plug by pressing from thrust
bearing end using piloted driver. Discard bearing.
6-150.
VALVE DISASSEMBLY. Proceed as follows:
(1) Remove packing (92) and discard.
(2) Remove spool spring (82) by prying small
coil, using small screwdriver. Do not pry against the
valve body (87) as this may result in a sticky valve.
Work spring onto bearing diameter of the stub shaft
(88). Slide the spring off the stub shaft.
6-147. ADJUSTER PLUG ASSEMBLY. Proceed as
follows:
(1) Assemble needle bearing (64, figure 7-33)
by pressing from thrust bearing end of adjuster plug (65)
against identification end of bearing. End of bearing is
6-37
(88). If it is worn badly, cracked, or broken, replace the
entire valve assembly.
(3) Remove valve spool (84) with extreme
care. To remove valve spool (84), hold valve assembly
in both hands with stub shaft pointing downward. Push
lightly on valve spool with a small rod by inserting rod
through openings in valve cap (91) until spool Is far
enough out of valve that it may be grasped by the hand.
Withdraw spool with a steady oscillating pull to prevent
jamming. If slight sticking occurs, make a gentle
attempt to reverse withdrawal procedure. If this does
not free the spool, it has become cocked in the valve
body bore. Do not attempt to force the spool in or out if
it becomes cocked.
In this case, continue to
disassemble the valve assembly as follows and return to
the spool as described below.
(5) Examine the spool (84) surface for nicks
and burrs. If any are found, they may be removed with
a very fine hone. A slight polishing is normal on the
valving surfaces.
(6) Examine the valve body bore for nicks or
burrs. If any are found, they can be removed with light
crocus cloth until the spool turns freely in the body. Be
careful not to remove any stock from the surface of the
body. As on the spool, a slight polishing is normal on
the valving surfaces.
6-152.
VALVE ASSEMBLY. Proceed as follows:
(1) Lubricate three valve ring back-up
packings (86) in SAE 10 engine oil. Assemble in three
ring grooves on the valve body (87). Assemble the
valve rings (85) in the ring grooves over the back-up
packings by carefully slipping the rings over the valve
body. The rings may appear loose or twisted in the
grooves, but the heat of the oil after assembly will cause
them to tighten.
CAUTION
The diametrical clearance between the valve
body and the spool may be as low as 0.004
Inch. The slightest cocking of the spool may
jam it in the valve body.
(4) Remove the stub shaft (88), torsion bar
and valve cap assembly (91) by holding the valve
assembly in both hands as before, only with thumbs on
valve body. Rap torsion bar lightly against the work
bench. This will dislodge the cap from the valve body.
If the valve spool has become cocked as described
above, it can now be freed. By visual inspection on a
flat surface it can be determined in which direction the
spool is cocked. A few very light taps with a Iight soft
plastic or rawhide mallet should align the spool in tile
bore and free it.
(2) Install new valve spool dampener packing
(83) in valve spool (84) groove.
(3) Assemble the stub shaft in the valve
body. Align groove in valve cap (91) with pin in valve
body. Tap lightly on cap with plastic or rawhide mallet
until cap is against shoulder in valve body with valve
body pin in cap groove.
CAUTION
Make sure groove and pin are in line before
tapping on cap. Hold these parts together
during the rest of the assembly.
CAUTION
Do not tap with anything metallic. If spool can
be rotated, it can be removed.
(5) Remove dampener seal packing (83) from
spool and discard.
(4) Lubricate valve spool with SAE 10 engine
oil. Slide spool over stub shaft with notch toward valve
body. Align notch with spool drive pin in stub shaft and
carefully engage spool in valve body bore. Push the
spool evenly and slowly with a slight oscillating motion
until spool reaches drive pin. Rotate the spool slowly
with pressure until the notch engages the pin. Before
pushing the spool completely in, make sure the
dampener packing is evenly distributed in the spool
groove. Slowly push the spool completely In. Take
extreme care not to cut or pinch the packing.
CAUTION
Because the clearance between the spool and
the valve body is very small, extreme care must
be taken when assembling these parts.
(6) Where the valve rings (85) show evidence
of excessive wear, carefully cut rings and ring back-up
packing (86), remove and discard. The valve rings are
made of filled teflon and it is very unusual that
replacement is required.
6-151.
VALVE INSPECTION. Proceed as follows:
(1) If the valve assembly leaks externally
around the torsion bar (91) replace the entire assembly.
(2) Check the pin in the valve body (87)
which engages the cap. If It is badly damaged, replace
the entire valve assembly.
(5) Place seal protecting tool over stub shaft.
Slide spool spring over seal protector and work spool
spring (82) down until it is seated in stub shaft groove.
Take care not to mar sealing surface of stub shaft.
(3) Check the worm pin groove (the smaller
of the two) in the valve body). If It is damaged, replace
the entire valve assembly.
(4)
Check the spool drive pin in the stub shaft
6-38
INSPECTION. Proceed as follows:
(1) Inspect the sleeve bearing (41) in the side
cover (42) for excessive wear or scoring. If badly worn
or scored, replace the side cover and bearing as an
assembly.
(2) Check the sector gearshaft teeth and the
bearing and seal surfaces. If badly worn, pitted, or
scored, replace the gearshaft assembly.
(3) Check the needle bearing (94) in the
housing.
(6) Lubricate a new cap-to-worm packing (92)
with SAE 10 engine oil, and install in valve assembly.
(7) If during the assembly of the valve, the
stub shaft and cap assembly is allowed to slip out of
engagement with the valve body pin, the spool may
enter the valve body too far. The dampener packing will
expand into the valve body oil grooves, preventing
withdrawal of the spool. Attempt to withdraw the spool
with slight pulling and much rotary motion. If this does
not free the spool after several tries, make sure spool is
free to rotate, place valve body on flat surface with
notched end up, and tap spool with wooden or plastic
rod until packing is cut and spool can be removed.
Replace packing and proceed with assembly as before.
6-157.
SECTOR GEARSHAFT AND SIDE COVER
ASSEMBLY. Proceed as follows:
(1) Assemble new needle bearing (94) into
the gear housing (97) bore from seal bore end, pressing
against stamped Identification end.
Press in until
bearing clears shoulder in gear housing 0.030 inch
maximum.
(2) Lubricate new gearshaft seals in SAE 10
engine oil. Install the single lip seal (54) first, then a
back-up washer (52). Drive the seal and washer in far
enough to provide clearance for the other seal, and
back-up washer, and retaining ring. Seal must not
bottom on end of counterbore. Install double lip seal
(53) and second back-up washer. Drive seal and backup washer in only far enough to provide clearance for
the retaining ring. Install sector gearshaft retaining ring
(51), making certain that the ring is seated properly.
(3) Assemble side cover (42) and bearing
(41) assembly on the sector gearshaft assembly. Screw
the lash adjuster (47) through the side cover until the
side cover bottoms on the gearshaft, and back off 1/2
turn.
6-153.
VALVE INSTALLATION. Proceed as follows:
(1) Align valve body drive pin in the worm
(71) with the narrow pin slot on the valve body (87).
Insert the valve assembly into the gear housing (97).
Do not push against stub shaft as this may cause stub
shaft and cap to pull out tilt the valve body, allowing
spool seal to slip into valve body oil grooves. Valve
assembly should be pushed in by pressing against valve
body with finger tips. Be sure valve is properly seated
before assembling adjuster plug assembly. Return hole
in gear housing should be fully visible at this time.
(2) lnstall adjuster plug (65) assembly as
outlined in paragraph 6 148.
6-154.
SECTOR GEARSHAFT AND SIDE COVER
REMOVAL. Proceed as follows:
(1) Rotate stub shaft (88) until sector
gearshaft (49) is in cover position and remove side
cover retaining screws (39). Tap the end of gearshaft
with soft mallet and slide gearshaft out of housing.
(2) Remove side cover packing (43) from
side cover and discard.
6-158.
SECTOR GEARSHAFT AND SIDE COVER
INSTALLATION. Proceed as follows:
(1) Lubricate the new side cover packing (43)
and install in the groove in the face of the side cover
(42).
(2) Turn the stub shaft (88) as necessary until
the middle rack groove is aligned with the center of the
gearshaft needle bearing (94).
(3) Install the gearshaft (49) so that the center
tooth in the sector meshes with the center groove of the
rack on the ball nut (77). Make sure that the side cover
packing is in place before pushing the side cover down
on the gear housing.
(4) Install the side cover screws (39) and
tighten to 30 to 35 foot pounds.
(5) Install lash adjuster nut (44) on lash
adjuster without tightening. Adjust gearshaft (refer to
paragraph 6-168). Hold lash adjuster from rotating with
a hex key wrench and tighten lash adjuster nut to 20 to
30 foot pounds.
6-155.
SECTOR GEARSHAFT AND SIDE COVER
DISASSEMBLY. Proceed as follows:
(1) Hold lash adjuster (47) with a hex key
wrench and remove the lash adjuster nut (44) and
discard. Screw lash adjuster out of side cover (42).
(2) Remove the sector gearshaft seal
retaining ring (51), and then remove the outer back-up
washer (52). Tap a screwdriver between the outer seal
and the inner back-up washer and pry out the seal. Tap
the screwdriver between the inner seal and the shoulder
in the gear housing and pry out the seal. Be careful not
to damage the seal bore. Discard seals.
(3) Remove needle bearing (94) from gear
housing bore by
pressing on
the
stamped
identification end of the bearing. Discard bearing.
6-156.
SECTOR GEARSHAFT AND SIDE COVER
6-39
(4) Insert rack-piston arbor in end of worm
(71). Rotate stub shaft to left turn, which will force rackpiston ball nut (77) onto arbor, and remove rack-piston
ball nut from gear housing, taking card to keep arbor in
place in the rack-piston nut or the balls will fall out. If
rack-piston ball nut is being removed to replace the
piston ring (72) and back-up
packing
(73),
reassemble without further disassembly.
(5) Remove valve assembly as outlined in
paragraph 6-149.
(6) Remove worm, lower thrust bearing and
races.
6-159. HOUSING END PLUG REMOVAL. Proceed
as follows:
(1) Rotate end plug retainer ring (56) so that
one end of the ring is over the hole in the housing.
Spring one end of ring with punch to allow screwdriver
to be inserted to lift ring out.
(2) Rotate stub shaft (88) with 3/4 inch box
end or socket wrench to left turn corner position and
force end plug (55) out of housing.
CAUTION
Do not rotate further than necessary, or the balls
from the rack and worm assembly will fall off the
end of the worm.
6-164. RACK-PISTON AND WORM ASSEMBLY AND
GEAR HOUSING DISASSEMBLY. Proceed as follows:
(1) Cut piston ring (72) and packing (73)
back-up seal, remove from rack-piston ball nut (77) and
discard.
(2) Remove screws and lock washers (75)
from rack-piston nut with screwdriver.
(3) Remove ball return guide clamp (74).
(4) Place the assembly on a clean cloth and
remove ball return guides (76) and arbor. Make sure all
of the balls (78) are caught on the cloth.
(3) Remove and discard housing end plug
packing (57).
6-160. HOUSING END PLUG INSTALLATION.
Proceed as follows:
(1) Lubricate new housing end plug packing
(57) with SAE 10 engine oil, and install in gear housing
(97).
(2) Insert housing end plug (55) into gear
housing and seat against packing.
(3) Install end plug retainer ring (56) with
fingers. Install one end of ring and work ring into groove
until seated. Slight tapping may be required to securely
bottom retainer ring in gear housing.
6-165. RACK-PISTON AND WORM ASSEMBLY AND
GEAR HOUSING INSPECTION. Proceed as follows:
(1) Inspect housing assembly. If bore is
badly scored or worn, replace housing. If connectors
(95 and 96) are badly brindled or scored, replace them.
To remove connectors, tap threads in connectors, using
a 5/16-18 tap. Thread a bolt with nut and flat washer
attached into tapped hole. To pull connector, hold bolt
from rotating while turning nut off bolt. This will pull
connector from gear housing. Discard connectors.
(2) Inspect ball plug (93) in housing. If it is
leaking or raised above housing surface, drive it in flush,
to 1/16 inch below the surface. Tighten ball by staking
the housing. If leakage cannot be stopped, housing
must be replaced.
(3) Inspect all seal surfaces and retaining ring
grooves for defects. If any defects are found, housing
must be replaced.
(4) At initial assembly, the rack-piston nut,
worm and balls are selected to obtain a preload of I to 4
inch pounds measured on center through an angle of 90
degrees. This preload may drop during service, without
having any noticeable effect on steering.
Upon
complaint of loose or hard steering, thrust bearing
adjustment and overcenter adjustment will correct the
problem if it lies in the steering gear adjustments. If
not, check the rack-piston nut and
6-161. RACK-PISTON END PLUG REMOVAL.
Proceed as follows:
(1) Remove housing end plug as outlined in
paragraph 6-159.
(2) Remove rack-piston end plug (58) by
inserting a 1/2 inch drive socket extension into the
square hole in the plug and turning counterclockwise.
6-162. RACK PISTON END PLUG INSTALLATION.
Proceed as follows:
(1) Turn plug into rack-piston and tighten to
50 to 100 foot pounds.
(2) Install housing end plug as outlined In
paragraph 6-160.
6-163. RACK-PISTON AND WORM ASSEMBLY AND
GEAR HOUSING ASSEMBLY REMOVAL. Proceed as
follows:
(1) Remove housing end plug as outlined in
paragraph 6-159.
(2) Remove rack-piston end plug as outlined
in paragraph 6-161.
(3) Remove sector gearshaft assembly as
outlined in paragraph 6-154.
6-40
install two screw and lock washer assemblies and
tighten to 8 to 12 foot pounds.
(9) Insert rack-piston arbor tool into worm.
Turn rack-piston onto the arbor. Do not allow arbor to
separate from worm until rack-piston nut is fully on
arbor.
worm assembly for excessive lash or excessive load
overcenter and also for roughness at any point along the
worm. If any of these conditions is found, disassemble
the assembly and inspect worm and rack-piston nut
grooves and all the balls for excessive wear or scoring.
If either worm or rack-piston nut need replacing, both
must be replaced as a matched assembly. The lash or
heavy load may be corrected by replacing the standard
balls with a larger or smaller size. Black balls need not
be replaced unless they are defective. In event the
black balls cannot be distinguished from the standard
balls, replace with new balls.
NOTE
The black balls are 0.0005 inch smaller than the
silver balls. The black and silver balls must be
installed alternately into the rack-piston nut and
return guide.
(5) Inspect ball return guides (76), making
sure that the ends where the balls enter and leave the
guides are not damaged.
(6) Inspect lower thrust bearing (80) and
races (79).
(7) Inspect rack-piston ball nut (77) teeth for
wear and chipping. Inspect rack-piston nut surface for
scoring or burrs.
6-167. RACK-PISTON AND WORM ASSEMBLY AND
GEAR HOUSING INSTALLATION. Proceed as follows:
(1) Assemble thrust bearing (80) and races
(79) on worm (71). Assemble valve assembly to worm
by aligning small slot in valve body (87) with pin on
worm. Be sure to install packing (92) between body and
worm head.
(2) Install valve assembly and worm in
housing (97) as integral unit and continue valve
assembly as outlined in paragraph 6-166. Adjust thrust
bearings.
(3) Install piston ring compressor in gear
housing (97). Hold it tight against shoulder in housing.
Insert rack-piston ball nut (77) into housing until arbor
engages worm. Turn stub shaft (88) clockwise, drawing
rack-piston nut into the housing. When piston ring is in
housing bore, withdraw arbor from rack-piston nut.
Remove ring compressor.
(4) Install rack-piston plug as outlined in
paragraph 6-162.
(5) Install housing end plug as outlined in
paragraph 6-160.
(6) Install sector gearshaft and side cover as
outlined in paragraph 6-159.
6-166. RACK-PISTON AND WORM ASSEMBLY AND
GEAR HOUSING ASSEMBLY. Proceed as follows:
(1) Thoroughly clean the parts and lubricate
the internal parts with SAE 10 engine oil.
(2) Drive new connectors (95 and 96) in place
with piloted driver.
(3) Lubricate a new back-up packing (73) with
SAE 10 engine oil. Assemble in piston ring groove on
rack-piston nut (77). Install new piston ring (72) in the
ring groove over the packing by carefully slipping ring
over the rack-piston nut. The ring may be slightly loose
after assembly. This is normal. It will tighten when
subjected to the hot oil in the system.
(4) Insert worm (71) into rack-piston nut, to
bearing shoulder.
(5) Align the ball return guide holes with the
worm groove. Load 24 balls (78) into the guide hole
nearest the piston ring, while slowly rotating the worm
(71) counterclockwise to feed the balls through the
circuit. Alternate the black balls with the standard balls.
(6) Fill one of ball return guides with
remaining six balls. Place other guide over balls and
plug ends with automotive grease to prevent balls falling
out when installing guide into rack-piston nut.
(7) Insert guides into guide holes of rackpiston nut. Guides should fit loosely.
(8) Place return guide clamp over guides,
6-168. STEERING GEAR LASH ADJUSTMENT.
Proceed as follows:
(1) Disconnect the steering arm from the
sector gearshaft and remove the horn button.
(2) Turn the steering wheel 1/2 turn off center
(either direction). Using a 24 inch pound torque wrench
on the steering wheel nut, determine the torque required
to rotate the shaft slowly through a 20 degree arc.
(3) Turn the gear back to center and
repeating the method of reading torque as in step b.
above, loosen lash adjuster locknut (44), turn screw (47)
in until the reading is equal to six inch pounds in excess
of reading obtained in step b. above, and retighten the
locknut while holding the screw in place.
(4) Recheck the readings and replace
steering arm and horn button.
6-169. THRUST BEARING ADJUSTMENT.
This
adjustment is to be made after the worm, thrust
bearings,
6-41
valve assembly, adjuster plug assembly, and locknut
are assembled in the housing assembly. Proceed as
follows:
(1) Before adjusting preload, tighten adjuster
plug up snug, back off slightly (1/8 turn) and measure
valve assembly drag.
(2) Turn adjuster plug in so that preload is I to
3 Inch pounds in excess of valve assembly drug.
Tighten locknut. Total thrust bearing adjustment and
seal drag is riot to exceed 8 inch pounds.
holes for stripped threads or other damage.
(2) Inspect mounting flange cover, housing
drive gear shaft and driven gear shaft for cracks and
distortion.
(3) Inspect bores in bearings [or scoring and
pitting and for excessive wear as indicated by loose fit
on bearing surfaces of drive gear shaft and driven gear
shaft.
(4) Inspect teeth on drive gear shaft and
driven gear shaft for pitting, chipping and excessive
wear.
(5) Inspect interior surfaces of pump housing
for scoring, pitting and other damage.
6-170. OVERCENTER OR SECTOR GEARSHAFT
ADJUSTMENT. This adjustment is to be made after the
gear is completely assembled. Proceed as follows:
(1) With gear on center and last adjuster
screw backed off, measure total drag.
(2) With gear on center adjust lash adjuster
so that preload is 4 to 8 inches in excess of total preload
and drag. Readings are to be made through an arc not
exceeding 20 degrees with gear on center.
(3) Tighten lash adjuster locknut.
6-171.
6-176. REPAIR. Repair hydraulic pump parts as
follows:
(1) Repair minor thread damage with tap or
thread chaser.
(2) Replace parts that are cracked or
distorted, or that are excessively worn.
(3) Replace all packings and seals at each
reassembly.
HYDRAULIC PUMP.
6-177. REASSEMBLY. Reassemble, hydraulic pump
parts as follows:
(1) If removed, press pins (16, figure 7-16)
into housing (17). Fit all packings (5, 6, and 8) neatly
into recesses in housing (17) and flange cover (2).
(2) Fit bushings (9 and 12) together, using
pins (13) for alignment, install them on gearshafts (10
and 11) and replace this assembly in housing.
(3) Press new seal (4) into cover (2), install
retaining ring (I) and replace cover on housing. Secure
with screws (3).
CAUTION
Tighten cover screws gradually, alternating from
side to side of cover, to avoid warping cover by
uneven pressure from screws in one area.
(4) If pump is not to be installed immediately,
plug inlet and outlet parts to keep dirt out during storage
period.
6-172. DESCRIPTION. The hydraulic pump is driven
by the electric pump motor and provides hydraulic fluid
pressure for extending the tilt cylinders and the hoist
cylinder. The pump is a positive displacement type
having a rated capacity of X.7 gallons per minute at
1.200 rpm and 1.000 psi. Removal of the hydraulic
motor is required for repair.
6-173.
DISASSEMBLY. Proceed as follows:
(1) Remove retaining ring (1, figure 7-16) and
eight screws (3) securing mounting flange cover (2) to
housing (17). Press seal (4) out of mounting flange
cover.
(2) Remove driven
gearshaft (10, drive
gearshift (11), four bushings (9 and 12) and two pins
(13).
(3) Remove two packing retainers (7) and
packings (5, 6 and 8). Do not remove two pins (16)
from housing (17) unless necessary.
6-178
6-174. CLEANING.
Clean disassembled parts of
hydraulic pump as follows:
(1) Wash all parts in SD and dry with soft
cloth or with compressed air under moderate pressure.
(2) Ensure that fluid passages in housing are
free of obstructions.
6-179.
POWER STEERING PUMP.
DISASSEMBLY. Proceed as follows:
(1) Remove pump manifold (I, figure 7-31)
and gasket (4) from steering pump attached with three
screws (2) and washers (3).
(2) Remove body (10) attached with four
screws (I 11). Remove packings ( 1 2 and 13).
(3) Remove vanes (19) and rotor (20) and
separate vanes from rotor.
6-175
INSPECTION. Inspect hydraulic pump parts
as follows:
(1) Inspect all threaded parts and tapped
6-42
(4) Remove relief valve assembly consisting
of plug (15), packing (16), valve (17) and spring (18) by
pressing out pin (14) from boss on side of cover (25).
NOTE
Some valve parts are under spring pressure.
Take care to prevent their being lost when the
pin is removed. Do not disassemble valve (17).
(5) Separate pumpshaft (5), washer (6), seal
(7) and bearing (8) from body (10).
(6) Remove pins (22) from ring (21) and
remove ring, plate (23) and spring (24) from body (10).
(7) Install cover (25). Tighten cover screws
(11) to 25 to 30 foot pounds torque.
(8) Install pressure control valve spring (18)
in relief valve bore. Insert valve (17) with hex toward
spring. Install plug (15) with packing (16) in bore and
hold it in position while driving in a new retaining pin
(14).
(9) Install gasket (4) and manifold (I) with
washers (3) and screws (2).
6-180. INSPECTION AND REPAIR.
Proceed as
follows:
(1) Inspect surfaces of all parts which are
subject to wear. Light scoring may be removed from
faces of body (10) with crocus cloth (by placing cloth on
flat surface), medium India stone or by lapping. Check
edges of vanes (19) for wear. Vanes must not have
excessive play in slots or burrs on edges. Replace if
necessary. Check each rotor (20) slot for sticky vanes
or wear. Vanes should drop in rotor slots by their own
weight when both slot and vane are dry.
(2) Replace pumpshaft seal (7) at each
overhaul to prevent oil leakage. Check pumpshaft seal
diameter for wear and scoring. Do not install a new seal
on a pumpshaft (5) which is worn or damaged at seal
diameter. Replace pumpshaft if worn. Stone and polish
sharp edges of pumpshaft to prevent damage to seal.
(3) Stone all mating surfaces of body (10 and
cover (25) with a medium India stone, if necessary, to
remove all burrs and sharp edges. Rewash all parts
after stoning.
6-183.
6-182.
CONTROL VALVE ASSEMBLY.
DISASSEMBLY. Proceed as follows:
CAUTION
This
valve
contains
numerous
similar
appearing, but not interchangeable, parts.
Before
disassembly,
arrange
separate
containers for parts related to each spool, to
avoid problems at assembly. Equivalent parts
with different index numbers on figure 7-22 are
not interchangeable.
(1) Unscrew plugs and seals (36 and 37,
figure 7-22). Remove nut (1), nut (3) and seals (2).
Back out setscrew (4), and remove spring (9) and
plunger (10). Remove safety relief valve cap (5) and
packing (8).
(2) Remove packing (6) and retainer (7), seat
(11) spring (12), screen (13), plunger (14) and seat (l5).
(3) Remove check valve cap (16), packing
(17), spring (18) and poppet (19).
(4) Remove screws (22) and retainer plates
(21) from both TILT and HOIST valves. Remove wiper
rings (23), packing retainers (24) and packings (25).
(5) Take off both spool caps (20), and
remove retaining rings (26), four spring retainers (27),
springs (29), and washers (28).
(6) Remove packing retainers (30) and
packings (31).
(7) Remove spool (33) and spool (32) from
body (38).
(8) If identification plate (34) must be
replaced, remove drive screws (35).
6-181.
ASSEMBLY.
Liberally coat all parts with
automatic transmission fluid and assemble as follows:
(1) Carefully install new seal (7) and pump
shaft (5) in body (10). Avoid damaging bushing in body,
and seal.
(2) Install locating pins (22) in pump body.
Install ring (21) over pins in correct direction of rotation.
(3) Install rotor (20) with chamfered edge of
splined hole toward pump body. The chamfer facilitates
assembly.
(4) Install vanes (19) with their radius edge
toward the inner ring contour. packings (12 and 13) in
grooves of pump body.
(5) Install packings (12 and 13) in grooves of
pump body.
(6) Install pressure plate (23) and pressure
plate spring (24).
6-184. CLEANING. Cleaning parts of control valve as
follows:
(1) Wash parts thoroughly in SD. Dry parts
with soft lintfree cloth or with compressed air under
moderate pressure.
(2) Assure that all fluid passages are free of
obstructions.
6-43
CAUTION
Do not use wire or metallic rod or pick to clean
fluid passages since such procedure could
result in irreparable damage to parts.
6-185.INSPECTION.
follows.
6-188.
ADJUSTMENT. Adjust valve as follows:
(1) Connect pressure part of control valve to
a hydraulic test pressure source of 2,000 psig with a flow
rate of 4 gallons per minute (or greater).
(2) Connect hydraulic test source return hose
to return port on control valve and temporarily plug
unused ports in valve body.
(3) Raise either plunger and note test
pressure. If test pressure is not within the range of
1,600 to 1,700 psig, turn adjusting setscrew clockwise to
increase pressure or counterclockwise to decrease
pressure.
(4) When relief valve pressure is properly set,
tighten jam nut on adjusting setscrew and install relief
valve nut over end of setscrew.
(5) Disconnect control valve from test
pressure source and remove temporary plugs.
Inspect control valve parts as
(1) Inspect valve body for cracks and for
scoring or other damage to plunger bores.
(2) Inspect threaded parts and tapped holes
for stripping or other damage to threads.
(3) Carefully inspect plungers for surface
defects such as scoring, pitting or excessive wear.
(4) Inspect poppet and bearing for wear and
scoring.
6-180.
REPAIR. Repair control valve parts as follows:
(1) Replace all parts found to be defective
during disassembly and Inspection.
6-189.
TILT CYLINDER.
6-190.
DISASSEMBLY. Proceed as follows:
(1) Remove rod end (1, figure 7-17) secured
with nut (4), screw (2) and washer (3).
(2) Remove packing retainer (5) attached
with two screws (6) and washers (7). Remove wiper ring
(8) from inside packing retainer.
(3) Unscrew stuffing box (9) and remove
packing set (I1), packing (12), ring (13) spacer (14) and
rings (15 and 16) from stuffing box.
(4) Pull piston and rod assembly (17) from
cylinder (18). Remove ring (15) from piston and rod
assembly.
NOTE
If either of tie plungers or the valve body is
defective to extent of being unserviceable,
replace entire control valve assembly.
(2) Repair minor thread damage with tap or
thread chaser.
(3) Remove minor surface defects from parts
with crocus cloth (Specification P-C458).
(4) Replace all packings with new parts at
each reassembly.
6-187. ASSEMBLY. Reassemble control valve as
follows:
(1) Install packings for plungers in valve body
bores; then, insert plungers.
(2) Place washers on ends of plungers.
Then, install springs using spring retainer and screws.
(3) Screw plugs to which gaskets have been
applied into valve body to cover springs and tighten
securely.
(4) Insert bearing into valve body and screw
associated plug into valve body.
(5) Place packing in groove of poppet and
insert poppet into bearing. Place spring on poppet and
spring seat on spring.
(6) Screw relief valve plug into valve body
and screw adjusting setscrew into relief valve plug.
Install jam nut on adjusting setscrew but leave loose.
(7) Install remaining plugs in valve body.
6-191. CLEANING. Cleaning disassembled parts of
tilt cylinder as follows:
(1) Wash metallic parts in SD and dry with
compressed air under moderate pressure or with clean
cloth.
(2) Be sure to clean parts thoroughly to
facilitate inspection.
6-192. INSPECTION. Inspect tilt cylinder parts as
follows:
(1) Inspect all threaded and tapped parts for
stripped threads or other thread damage.
(2) Inspect packing retainer, stuffing box,
piston and rod, and cylinder for cracks and distortion.
(3) Inspect bore in cylinder for scratches,
scoring, pitting and other surface defects.
6-44
(7) Pull cylinder (22) from plunger (29) and
remove bearing (25) from cylinder and bearing (20) from
inside of plunger (29).
6-193. REPAIR. Repair tilt cylinder parts as follows:
(1) Repair minor thread damage with tap,
thread file or thread chaser.
(2) Remove minor surface defects from bore
of cylinder by carefully honing. Remove all traces of
abrasive after honing.
(3) Replace all cracked or distorted parts with
serviceable parts.
(4) Replace wiper ring, packings, backup ring,
piston packings and piston guide with new parts at each
reassembly.
6-197. CLEANING. Clean disassembled parts of hoist
cylinder as follows:
(1) Clean all removed metallic parts with SD
and dry with soft lint-free cloth.
(2) Slide secondary cylinder out of primary
cylinder as far as possible and carefully clean exposed
surface of secondary cylinder with cloth moistened with
SD.
6-194. ASSEMBLY. Thoroughly wet all internal parts
with hydraulic fluid before installation. Take particular
care to keep parts clean during assembly. Proceed as
follows:
(1) Install piston and rod (17) with ring ( 5) in
cylinder (18). Fit (12, 13, 14, 15 and 16) into recess in
cylinder, and install stuffing box (9) in cylinder snugly
with spanner wrench.
(2) Slide packing set (11) down piston rod,
carefully entering it into recess of stuffing box.
(3) Lubricate and install wiper ring (8) in
recess of packing retainer (5) and install packing
retainer (loosely at first) with screws (6) and washers (7).
(4) Install rod end (I) on piston rod, and
replace screw (2), washer (3) and nut (4), but do not
tighten, as rod end final position must be adjusted when
tilt cylinder is installed.
6-198. INSPECTION. Inspect hoist cylinder parts as
follows:
(1) Inspect all threaded parts and parts with
tapped holes for stripped threads or other thread
damage.
(2) Inspect packing retainers for scratches,
burrs and upset metal.
(3) Inspect cylinders and plunger for cracks
and distortion.
(4) Inspect external surfaces of secondary
cylinder and secondary plunger for scratches, pitting,
scoring, upset metal and other surface damage.
(5) Inspect check valve for free return flow.
6-199. REPAIR. Repair parts as follows:
(1) Replace all cracked or distorted parts.
(2) Repair minor thread damage with a tap,
thread file or thread chaser.
(3) Remove minor surface defects on
surfaces of secondary cylinder and secondary plunger
with crocus cloth or with minor honing.
(4) Replace all packings and wiper rings with
new parts at each assembly.
6-195. HOIST CYLINDER.
6-196. DISASSEMBLY. Proceed as follows:
(1) Remove screws (1, figure 7-24) and
washers (2). Unscrew cylinder end (3). Remove
packing (5) and washer (4) from cylinder end.
(2) Unscrew packing nut (6) from plunger
(28). Remove wiper ring (7), packing retainer (8) and
five packings (9).
(3) Unscrew packing nut (11) from cylinder
(21). Remove wiper ring (12), retainer (13) and five
packings (14).
(4) Unscrew packing nut (16) from cylinder
(22). Remove wiper ring (17), packing retainer (18) and
five packings (19).
(5) Unscrew and remove cylinder (21) from
cylinder (22) and remove bearing (15) from inside of
cylinder.
(6) Remove plunger (28) and remove bearing
(10) from inside plunger. Remove plunger guide (26)
secured in position with retaining ring (27). Remove
packing (23) and washers (24) from cylinder (22).
6-200. ASSEMBLY. Take special care to keep all parts
of the hoist cylinder clean during reassembly. Wet
interior parts with clean hydraulic oil, before installing
them. Reassemble as follows:
(1) Install new bearings (25) over secondary
plunger (29). Push plunger into secondary cylinder (22)
from bottom and install new packing (23) and washer
(24) in groove in base of secondary cylinder. Screw
cylinder end (3) into secondary cylinder.
(2) Install bearing (20) in base of secondary
cylinder and install packing (19) against base of bearing.
Insert packing retainer (18). Insert wiper ring (17) in
packing nut (16) and install packing nut in bottom of
secondary cylinder.
6-45
surface smoothness to less than 33 micro-inches. This
finish may be obtained, after lathe turning, with a
commutator stone.
(3) Install bearing (10) in top end of plunger
(28). Install bearing (15) in primary cylinder (21). Install
guide (26) and retaining ring (27).
(4) Install cylinder (22) with assembled items
through bottom of primary plunger (28) and install both
in primary cylinder (21).
(5) lnstall new packing (14) and retainer (13).
Put wiper ring (1 2) in packing nut ( 1) and install
packing nut in end of primary cylinder (21).
(6) Place packing (9) over plunger (29) and
install packing retainer (8). Put wiper ring (7) in packing
nut (6); lnstall nut over plunger (29) and thread into
plunger (28). Install two new washers (2) and replace
screws (1).
(3) Check brush length of used brushes by
comparing them with new brush. If brushes have less
than one-half length of new brushes, replace them, as
they probably will not last until next disassembly.
(4) Inspect bearings. Replace if necessary.
6-205. ASSEMBLY. Reverse procedures in paragraph
6-202.
6-206. TEST. Test as follows:
(1) Excite the field with rated current and
voltage.
(2) Seat the brushes, and run the motor with
low (6 or 12 volts DC) voltage on the armature
terminals. Armature must now turn clockwise, viewed
from commutator end.
(3) After brushes have been seated and
motor has run for four minutes, check bearing housings
for head caused by motor yoke misalignment or bad
bearings.
Observe commutator and brushes for
sparking at this time.
(4) Make a high potential test above ground
on all windings, using a 115 volt AC test light.
6-201. TRAVEL MOTOR.
6-202. DISASSEMBLY. Clean exterior thoroughly, then
disassemble only as far as necessary to repair, as
follows:
(1) Remove screws (5 1 and 54, figure 7-36)
washers and nuts, and take off covers (50).
(2) Disconnect leads (37 and 38) at brush
holders (43). Remove brushes (42) from motor.
(3) Remove screws (28) and washers (29).
Take off rear motor yoke (27). Remove screws (23),
washers (24), bearing retainer (22), washer (25) and
bearing (26).
(4) Remove socket head screws inside brush
inspection holes, which attach front motor yoke (49) to
motor ring (7 1) and separate ring, armature (59) and
yoke (49). Take nut (60), washers (36, 61 and 62),
insulator (35) and leads (37-38) from yoke.
(5) Remove screws (70) to free pole pieces
(69), insulators and field coils (66).
6-207. HYDRAULIC PUMP MOTOR.
6-208.
DISASSEMBLY.
Clean motor exterior
thoroughly with solvent, and disassemble as follows:
(1) Remove both covers (4, figure 7-15),
remove screws (13) and washers, and take brushes (12)
from motor.
(2) Remove screws (9) and take grease cap
(8), retaining ring (11) and bearing (10) from end bell
(39).
(3) Remove screws (40) and take front end
bell (39) from motor housing (53).
(4) Remove nuts (23), washers (24 and 25),
studs (28) and connectors (34 and 35), and insulators
(27, 36, 22 and 38).
NOTE
Tag wires to insure correct assembly and proper
rotation of motor.
(5) Remove brush holders (16) and insulators
(21 and 20).
(6) Remove screws (43) and retaining ring
(46). Separate end bell (42) from motor housing (53). If
bearing (45) remained in bell housing, remove.
(7) Remove armature (47) from motor
housing. Pull bearing from shaft if necessary.
6-203. CLEANING. Clean parts as follows:
(1) Remove as much dirt as practical from
parts with compressed air.
(2) Wipe remaining dirt from parts with a
cloth slightly moistened with solvent. Do not wet
armature or field windings.
(3) Clean commutators to bright finish with a
commutator stone. Do not use emery cloth.
6-204.
INSPECTION AND REPAIR.
Proceed as
follows:
(1) If balancing machine is available, check
that armature dynamic balance is within 1 inch- ounce,
at 3000 revolutions per minute.
(2) Measure commutator runout. If in excess
of 0.002 inch total indicator reading, turn in lathe, truing
commutator within above limits, and holding copper
6-46
(8)
Remove pole piece screws (51, pole pieces (50), strips (49) and fields (52).
6-209. CLEANING. Clean as follows:
(1) Remove as much dirt as practical from parts, with compressed air.
(2) Wipe remaining dirt from parts with a cloth slightly moistened with solvent. Do not wet armature or field
windings.
(3) Clean commutator to bright finish with commutator stone. Do not use emery cloth.
6-210. INSPECTION AND REPAIR. Inspect and repair as follows:
(1) If balancing machine is available, check that armature dynamic balance is within one inch-ounce, at 3000
revolutions per minute.
(2) Measure commutator runout. If in excess of 0.002 inch total indicator reading, turn in lathe, truing
commutator within above limits, and holding copper surface smoothness to less than 33 micro-inches. This finish may
be obtained, after lathe turning, with commutator stone.
(3) Check brush length of used brushes by comparing them with new brush. If brushes have less than onehalf length of new brushes, replace them, as they probably will not last until next disassembly.
(4) Make a high potential test above ground on all windings, using I 15 volt test light or ohmmeter.
(5) With motor on test operation for five minutes, check for bearing heating, unusual noises from bearings or
brushes, and for vibration.
(6) Watch action of brushes on commutator. Excessive sparking of brushes indicates worn or sticking
brushes, weak brush springs, defective armature or commutator.
(7) Inspect area around commutator and brush covers for thrown solder from commutator, indicating that
motor has been overheated in operation, or armature is shorted. If this condition is found, replace armature.
(8) Repair is limited to soldering loose solder joint connections, truing commutator in a lathe, and replacing
defective parts.
6-211. ASSEMBLY. Reverse procedure in paragraph 6-207.
6-212. STEERING PUMP MOTOR.
6213. DISASSEMBLY. Clean motor exterior thoroughly with solvent before beginning disassembly. Disassemble only
as far as necessary, as follows:
(1) Relieve pressure of brush springs (8, figure 7-32) on brushes (15) and remove brushes.
CAUTION
Do not pull brushes out by leads if they might be serviceable. Leads may be damaged.
(2) Remove screws (3) from both end bells (1 and 2). Separate end yokes from field frame (14). Remove
armature (l 3).
(3) Remove screws (16), washers (17), and remove brush holder (5) from commutator end bell. If they are to
be replaced, pull bearings (9 and 10) from end bells..
(4) Remove screws, nuts and washers attaching terminal poles, and field windings (21, 22, 23 and 24), and
remove poles and field windings.
6-214. INSPECTION. Inspect as follows:
(1) With motor on test operation for five minutes at 6 to 12 volts, check for bearing heating, unusual noises
from bearings or brushes, and for vibration.
(2) Watch action of brushes on commutator. Excessive sparking of brushes indicates worn or sticking
brushes, weak brush springs, defective armature or commutator.
(3) Compare used brush length with a new brush from stock. If less than half length of new brush, install new
brushes.
(4) Inspect area around commutator and brush covers for thrown solder from commutator, indicating that
motor has been overheated in operation, or armature is shorted. If this condition is found, replace armature.
6-215. REPAIR. Repair is limited to soldering loose solder joint connections, truing commutator in a lathe, and replacing
defective parts.
6-216. ASSEMBLY. Reverse procedures in paragraph 6212.
6-217. TEST.
(1) With motor installed and pump connected for operation, disconnect one lead and connect an ammeter in
series between the lead and the motor terminal from which the lead was disconnected.
(2) Operate motor and check for current draw of about 18 amperes unloaded (not steering) at truck battery
voltage.
6-218. SC RELAY.
6-219. DISASSEMBLY. Disassemble only as far as necessary to perform necessary repairs, as follows:
6-47
(1)
reversing the disassembly procedure.
6-227.
MASTER SWITCH AND PUMP MOTOR
RELAYS.
a. General. All trucks have one pump contactor
fitted with a circuit interlock which energizes the
hourmeter. If a truck has a second (optional) pump, the
number two pump contactor will not have an interlock.
Otherwise both contactors will be the same.
Disconnect all external leads to contactor.
(2) Remove snap switch (1, figure 7-7) from
hinge bracket (I 11).
(3) Disconnect
connector
(7),
remove
retaining snap ring and take off rocker arm lever (25)
with movable contact (20). Take contact from rocker
arm lever. Take washer, timing actuator (28) from base
assembly (29).
(4) Remove screws
contacts (15) from base (29).
and
take
6-228. DISASSEMBLY. Disassemble only as far as
necessary to repair, as follows:
(1) Disconnect all external leads to contactor.
Remove contactor only if necessary.
stationary
(2) To replace finger contact (figure 74),
remove special nuts and lock washers and remove
contact tops.
(5) Remove screw which holds coil (42) to
magnet frame (45). Remove coil.
6-220.
ASSEMBLY.
Assemble the contactor by
reversing the disassembly steps.
(3) To replace coil (18), remove spring guide
(14), spring (12) and armature (11). Take out screw
above coil and remove two spring washers, pole face
and assembly, and coil.
6-221. FORWARD AND REVERSE RELAYS.
6-222. DISASSEMBLY. Disassemble contactor only
as far as necessary to make repairs as follows:
(1) Disconnect all external leads.
6-229. ASSEMBLY. Assemble contactor by reversing
steps above, observing the following recommendations.
6-230. STEERING RELAY.
6-231. DISASSEMBLY. Proceed as follows:
(1) Disconnect leads to contactor. Remove
screw and washer (2, figure 7-6), and stationary contact
(1).
(2) Remove nut (5) and insulator (10).
Remove contact bar (4).
(3) Remove leads to coil (19). Remove nut
(5) and screws (17), carefully lift interfering parts out of
way and remove coil.
6-232. ASSEMBLY. Reverse procedure above.
6-233. ACCELERATOR CONTROL.
6-234. POTENTIOMETER REPLACEMENT. Proceed
as follows: (figure 7-11).
(1) Remove
potentiometer
wires
from
terminal strip (19).
(2) Disconnect connector (I, figure 7-8),
remove snap ring and take off rocker arm lever (16).
Remove both movable contacts (14).
(3)
base (20).
Take washer, timing actuator (19) from
(4) Remove screws, and take stationary
contacts (9) from base.
(5) Remove screw which holds coil (33) to
magnet frame (36) and remove coil.
6-223.
ASSEMBLY.
Assemble the contactor by
reversing the disassembly procedure.
6-224. FIELD WEAKENING RELAY.
6-225. DISASSEMBLY. Disassemble only as far as
required to perform needed repairs as follows:
(1) Disconnect all external leads to contactor.
(2) Loosen allen set screw (22) which secures
potentiometer (21) to potentiometer drive and remove
potentiometer.
(3) Before installing new potentiometer
connect an ohmmeter or continuity tester between single
terminal on top of potentiometer and center terminal of
bottom three terminals.
Adjust potentiometer for
minimum resistance (ohmmeter) or maximum
brightness (continuity tester).
(2) Remove connector (1, figure 7-9), and
movable contact (14). Take off snap ring and take
rocker arm lever (19) from base (23).
(3) Remove
contact (9) from base.
screw
and
take
stationary
(4) Install potentiometer and tighten allen set
screw. (Make sure tab on side of potentiometer is in
notch in bracket). Recheck potentiometer adjustment.
The potentiometer should exhibit minimum resistance
(4) Remove screw, and take coil (36) from
magnet frame (39).
6-226.
ASSEMBLY.
Assemble the contactor by
6-48
6-240. ELECTRICAL CONTROL ADJUSTMENTS.
6-241. GENERAL. The SCR control pack which
controls creep speed, acceleration time, the shorting
contactor time delay, current limit, and plugging severity
is adjusted for each truck during manufacture.
Replacement of control components or motors may
require readjusting of the control pack (7, figure 7-10)
for proper truck operation. Adjustment may also be
required when the nature of operation or type of
materials handled change. The change from a lead-acid
to a nickel-iron alkaline battery will require adjustment
(para 6-250).
6-242. ADJUSTMENTS. The SCR control pack cover
is removed and exposes five trimmers. Clockwise
rotation will provide an increase in the function being
adjusted and counterclockwise a decrease. The SCR
trimmers provide fifteen turn to go from one end of the
trimmer range to the other. At each end the adjusting
screw will "slip" to prevent damage to the threads. The
field weakening pack (20, figure 7-3) is provided with
drop-out and pick-up single turn trimmers, each having
a locknut.
NOTE
Make all adjustments except where noted in the
following sequence. Adjustments must be made
with a fully charged battery.
6-243. PREPARATION OF TRUCK. Make adjustments
to the electrical control circuits as follows:
(1) Raise drive wheels of truck off floor.
Support securely.
(ohmmeter) or maximum brightness (continuity tester)
when in the neutral position.
6-235. CONTACTS. The contacts are silver and need
only be replaced when worn thin. Do not file contacts;
discoloration and slight pitting of the contacts is not
harmful. When contacts need replacing, the contact
module is replaced as a unit, along with its cam.
Proceed as follows:
(1) Remove the module retaining screw (24),
and remove the individual modules and cams, keeping
the parts in order to facilitate reassembly.
(2) When reassembling, make sure the cams
and contact modules are replaced in order. Also make
sure the orientation of the index line on the cams and
contact modules is the same as in the above diagram.
6-236. RETURN SPRING. Proceed as follows:
(1) To replace a broken return spring,
proceed with the disassembly as in the contacts section.
(2) Gently pry off detent cam housing (35)
and cover (33), and the spring return housing (26).
(3) Slide off the shaft bearing (36), spring
drive (37) and defective spring (39).
(4) With the shaft oriented so the spring
is directly opposite the detent cam housing
protrusion, slide the new return spring (39) on the
so that both spring ends are above the detent
housing (35) protrusion.
drive
(35)
shaft
cam
(2)
Remove rear control panel cover (para 6-
(5) Using a screwdriver, load the spring by
placing the top end of the return spring below the detent
cam housing protrusion. Replace the spring drive (37)
so its hub is adjacent to the detent cam protrusion.
28).
(6) Replace the shaft bearing (36), spring
return housing (26), detent module and cover.
6-237. DIRECTIONAL CONTROL SWITCH.
6-238. DISASSEMBLY. Proceed as follows:
(1) Remove cover (11, figure 7-12) attached
with two screws ( 12), washers (13), and liner (14).
(4) Disconnect the heavy cable connecting
the hydraulic pump relay IMP (2, figure 7-3) and the
shorting contactor SC relay (17).
Connect a DC
ammeter and a shunt between the end of the removed
cable and the terminal from which it was removed.
(3) Remove the SCR control pack cover (7,
figure 7-10).
(5)
(2) Remove screws attaching sensitive
switches (18) to bracket (19) and remove switches.
Remove truck floor plate (para 627).
(6) Disconnect wiring harness at the master
cylinder brake light switch (9, figure 7-29) connector
plug. The plug contacts are arranged in two rows of
three contacts. Connect, with a jumper wire, the outer
contacts of one row in the harness end plug. With all
switches in operating position, check for stoplight. If
stoplight lights, remove jumper and connect to outer
contacts of other row. The jumper in correct location will
lock out the brake switch in the travel motor circuit.
NOTE
If wire harness leads are numbered, jump wire
70 to wire 94. See wiring schematic (figure 41).
(3) Remove screws holding housing bracket.
Remove housing bracket (10).
(4) Remove springs (20). Remove two clips
(22) attached with screws, and remove pins (21) and
arm assemblies (23).
(5) Remove screw and washers securing
carrier assembly to shaft (24). Remove shaft and
spacer (26) from housing (28).
6-239. ASSEMBLY. Reverse disassembly procedures.
6-49
(5)
6-244. FIELD WEAKENING ADJUSTMENT.
a. Field weakening provides for maximum truck
speed and is controlled through the shorting contactor
SC relay (17, figure 7-3).
Repeat steps above until drop-out is
correct.
(6) Again accelerate until the SC and FW
relays close and gently apply brake until FW relay drops
out.
b. Field weakening relay is adjusted to operate at
the following amperes:
(1)
amperes.
Relay
150
(7) Gradually release brake until the FW relay
picks up and note current draw on ammeter.
(2)
amperes.
Relay opens (drops out) 350 to 365
(8) If not 125 to 150 amperes, release both
brake and accelerator.
Adjust or pick-up and drop-out as follows:
(1) With direction control in forward direction,
depress accelerator pedal slowly until two clicks of the
shorting contactor SC (17) and the field weakening FW
(19) relays are heard or the contacts are seen to close.
Hold this accelerator position.
(9) Adjust field weakening pack pick-up
trimmer (figure 6-2) similar to (4) above.
CAUTION
Avoid excessive operation of loading motor by
applying service brakes with the brake switch
jumped. This will cause extreme motor heat
and excessive wear of brake lining.
closes
(pick-up)
125
to
c.
(2) Gently apply fool service brake while
holding motor speed until the field weakening relay
drops out. Note current draw on ammeter.
6-245. CURRENT LIMIT ADJUSTMENT.
a. The current limit prevents excess current from
damaging the system. The limit must be adjusted when
changing from a lead-acid to a nickel-iron alkaline
battery. See para 6251.
(3) If not 350 to 365 amperes, release both
brake and accelerator.
b. The current limit must be adjusted to a
maximum of 200 amperes.
(4) Adjust field weakening pack (20) drop-out
trimmer (figure (-2). Loosen locknut and turn clockwise
to decrease current draw. Lock locknut.
Figure 6-2. Electrical Control Trimmer Locations
6-50
c.
Adjust the current limit as follows:
(1) Prepare truck according to para 6-243.
(2) Disconnect wire No. S from the No. 5
terminal of the anti-rollback pack ARP (12, figure 7-3).
NOTE
Truck may reach maximum SCR controlled
speed prior to covering 22 feet.
(2) Run test several times to get accurate
reading if necessary.
(3) With direction control in forward position,
depress accelerator fully until maximum speed is
obtained and hold position.
(3) To reduce time to cover 22 feet, faster
acceleration, rotate SCR control pack No. 2RH trimmer
(figure 6-2) counterclockwise.
(4) Gently apply foot service brake until drive
motor stalls. Note current draw on ammeter.
(4) To increase time, slower acceleration,
rotate trimmer clockwise.
(5) If reading is not 200 amperes, adjust the
SCR control pack No.
4RH trimmer (figure 6-2)
clockwise to increase amperes to 200 or
counterclockwise to decrease limit.
(5) Reconnect wire No. 5 to the No. 5
terminal of the anti-rollback pack (1 2, figure 7-3)
removed in para 6-245.
6-248. SHORTING CONTACTOR TIME DELAY.
a. The shorting contactor timing delay is required
to provide a fraction of a second delay between the
point of maximum SCR speed control range and when
the circuitry switches to the field weakening pack for
maximum speed. The shorting contactor also cuts out
tile SCR controlled acceleration.
(6) Repeat steps 3, 4 and 5 above until
correct setting is obtained.
(7) Remove ammeter and shunt. Connect
cable removed in para 6-243(4). Remove brake switch
jumper and connect plugs. Attach floor.
6-246. CREEP SPEED. Adjust as follows:
(1) Place direction control in either forward or
reverse position and lightly depress accelerator until
forward or reverse relays (I8, figure 7-3)just close.
b. The shorting contactor relay (l17, figure 7-3) is
adjusted to close in approximately the same time that
was established for acceleration time (para 6-247).
(3) If truck moves too fast, adjust trimmer
counterclockwise.
NOTE
For smooth operation of truck, the shorting
contactor time delay should never be set to a
value less than tile acceleration time.
c. Adjust time delay as follows:
(1) Rotate SCR control pack No.
3RII
trimmer (figure 6-2) fully clockwise until the screw slips.
6-247. ACCELERATION TIME.
a. The acceleration time is that time required for
the truck to progress in speed from a standstill to the
maximum SCR controlled speed.
(2) Operate truck full speed forward and
observe when shorting contactor closes. The relay will
snap with a loud snap, followed immediately by the field
weakening relay pick-up.
NOTE
The maximum unloaded forward speed is 5.8
mph when the shorting contactor and field
weakening pack are connected.
b. Acceleration time is adjusted to provide 22 feet
of forward movement from standstill in 6 seconds.
(3) Rotate trimmer counterclockwise in small
steps and repeat (2) above.
(2) If truck falls to move on level floor, adjust
the SCR control pack No. 1 Rh trimmer (figure 62)
clockwise until truck begins to move.
(4) Continue adjusting until shorting contactor
relay closes in approximately the same time that was
derived in the acceleration time adjustment.
c.
Adjust acceleration rate as follows:
(1) Using a watch with a sweep second hand
or stop watch, accurately time the time required to travel
22 feet. From standstill with direction control in forward
position, depress accelerator fully.
6-249. PLUGGING SEVERITY.
a. Plugging is the act of switching the direction
control while moving in one direction at maximum speed
without use of the service brakes. In plugging, the
motor will act as a braking force.
b.
6-51
Adjustment is made for feel of operation.
Conversely, a lead-acid battery installed in the truck
calibrated and run from a nickel-iron alkaline battery will
pass excessive current. The current limit must be set
for a maximum of 200 amperes for either battery.
Excess current will cause a lurch in speed as the
acceleration passes from the SCR controlled
acceleration to the field weakening controlled maximum
speed.
CAUTION
Replace the battery with a similar battery or
recalibrate current limit (para 6-245) to prevent
truck lurch. Excess current may also damage
the SCR control pack.
c.
Adjust plugging severity as follows:
(1) Operate the truck at a maximum forward
speed. If previous adjustments (para 6-244 through 6248) have been properly made, truck will come to
maximum speed smoothly.
(2) Move direction control lever (82, figure 72) to reverse position without releasing accelerator or
applying service brakes. Determine severity of direction
change.
(3) If plugging reaction is too severe, adjust
SCR control pack No. 5RH trimmer (figure 62)
counterclockwise to reduce severity. If plugging is too
soft, adjust clockwise. Repeat step (2) above until
correctly adjusted.
(4) Replace SCR control pack cover and
control panel cover.
6-253. BATTERY DESCRIPTION. Batteries differ in
appearance as follows:
a. Lead-Acid Battery. The lead-acid battery is
constructed with all cells built into one case. The battery
case top is filled and sealed between the cells.
6-250.
INDIVIDUAL ADJUSTMENTS.
When
necessary, any one or more of above adjustments can
be made without completing the complete sequence.
The following chart is a summary of adjustment steps
and preparation required (para 6-243).
b. Nickel-Iron Alkaline Battery. This battery is
composed of individual separate cells arranged in a
carrying tray or case. Each cell is joined by a connector
cable with cells hooked in series. Cells are separated
from each other within the case.
6-251. BATTERY TYPES.
6-254. BATTERY COMPARTMENT. Each truck is
constructed with battery clamps welded to the truck in a
location permitting installation of only one type battery.
If the battery is to be changed to the other style, the
brackets must be relocated.
6-252. GENERAL. This truck may be operated from
either a lead-acid or nickel-iron alkaline battery. Either
battery will provide the required voltage but due to its
construction and materials, the current limit must be
calibrated for the type battery installed. The current
output of the nickel-iron alkaline battery will not provide
sufficient current to satisfactorily operate the truck that
has been calibrated and run on a lead-acid battery.
6-255. DEFECTIVE MATERIAL. Return unserviceable
items to supporting maintenance units for determination
of feasibility of action under warranty.
Para
Adjustment
1.
Field Weakening
2.
Current Limit
3.
Creep Speed
4.
Acceleration Time
5.
6.
Shorting Contactor Time Delay
Plugging
Preparation
a.
b.
c.
a.
b.
c.
d.
a.
b.
a.
b.
a.
a.
Lift drive axle
Connect ammeter and shunt
Jump brake switch
Lift drive axle
Connect ammeter and shunt
Jump brake switch
Disconnect ARP no. 5 lead
Disconnect ARP no. 5 lead
Operate truck
Disconnect ARP no. 5 lead
Operate truck
Operate truck
Operate truck
6-52
Ref
6-244
6-245
6-246
6-247
6-248
6-249
SECTION 7
ILLUSTRATIONS
7-1.
General. This section illustrates the major equipment groups, assemblies, subassemblies, and detail parts of the
Model FTD-04O-EE Electric Fork Lift Truck.
7-2.
Arrangement of Illustrations. The complete equipment is illustrated in figure 7-1. The list accompanying
figure 7-1 refers (by figure numbers) to subsequent illustrations where breakdowns of the equipment may be found.
7-1
INDEX
NO.
1
2
3
4
5
6
7
8
9
DESCRIPTION
FIGURE NO.
Electrical System
Hydraulic System
Uprights, Backrest, Fork and Carriage Arrangement
Seat, Individual
Mechanical Controls Arrangement
Steering
Steering Axle Arrangement
Drive Axle, Adapter, Drive Motor, Wheels and Tires
Body and Chassis Arrangement
2 thru 12
13 thru 22
23 thru 26
27
28 thru 29
30 thru 33
34
35 thru 37
38
Figure 7-1. Model FTD-040-EE, 4000 Pound Capacity, Fork Lift Truck
7-2
Figure 7-2. Electrical System Arrangement
7-3
Key to figure 7-2
1
Panel, electric control
2
Screw, tapping
3
Washer, lock
4
Clamp
5
Screw, machine
6
Nut, plain, hex
7
Washer, lock
8
Clamp, loop
9
Nut, plain, hex
10
Washer, lock
11
Clamp, loop, lead attaching
12
Nut, plain, hex
13
Washer, lock
14
Washer, flat
15
Clamp, loop
16
Nut, flat
17
Washer, flat
18
Clamp, loop
19
Screw, cap, hex head
20
Nut, plain, hex
21
Washer, lock
22
Lead, electrical
23
Lead, electrical
24
Lead, electrical
25
Lead, electrical
7-4
26
Lead, electrical
27
Lead, electrical
28
Lead, electrical
29
Lead, electrical
30
Nut, plain, hex
31
Washer, lock
32
Washer, flat
33
Insulator
34
Insulator
35
Insulator
36
Lead, electrical
37
Wiring harness
38
Relay, thermal
39
Bonnet
40
Guard, headlight
41
Screw, cap, hex head
42
Nut, plain, hex
43
Lamp incandescent
44
Cable assembly
45
Housing, lamp
46
Screw, cap, hex head
47
Nut, plain, hex
48
Washer, lock
49
Connector, plug
50
Guard
Key to figure 7-2 (cont'd)
51
Screw, tapping
52
Washer, lock
53
Lens
54
Lamp, incandescent
55
Connector, plug
56
Screw, cap, hex head
57
Washer, lock
58
Housing, plunger
59
Plunger
60
Switch, sensitive
61
Screw, machine
62
Washer, lock
63
Bracket
64
Screw, cap
65
Nut, plain, hex
66
Washer, lock
7-5
67
Insulator
68
Tubing,
69
Suppressor
70
Horn, electrical
71
Screw, cap
72
Washer, lock
73
Clamp, suppressor
74
Suppressor
75
Meter
76
Switch, toggle
77
Plate
78
Switch, push
79
Switch assembly
80
Screw, cap, hex head
81
Washer, lock
82
Switch assembly
Figure 7-3. Panel, Electric Control
7-6
Key to figure 7-3
1
Relay armature
2
Relay, armature
3
Fuse, cartridge
4
Fuse, cartridge
5
Fusetron
6
Fusetron
7
Fuseholder
8
Bracket
9
Resistor
10
Engine hour pack
11
Capacitor
12
Anti-rollback pack
13
Barrier
14
Capacitor
15
Relay armature
16
Bus bar
17
Relay, armature
18
Relay, armature
19
Relay, armature
20
Field weakening pack
21
Resistor
22
Control pack
23
Power panel
7-7
Figure 7-4. Relay Armature, MS
7-8
Key to figure 7-4
1
Guide, spring
2
Spring, helical
3
Clip, flex connector
4
Screw, cap, hex head
5
Washer, lock
6
Contact, electrical
7
Support, stationary contact
8
Screw, cap, hex head
9
Washer, lock
10
Post, contact
11
Screw, cap
12
Washer, lock
13
Stop, contact
14
Finger, contact
15
Armature, relay
16
Spring, helical
17
Washer
18
Guide
19
Post, contact stop
20
Pole face assembly
21
Washer
22
Coil, relay
23
Frame assembly
24
Spacer, panel
25
Panel assembly
7-9
Figure 7-5. Relay, Armature, IMP.
7-10
Key to figure 7-5
1
Guide, spring
2
Spring, helical
3
Clip, flex connector
4
Screw, cap, hex head
5
Washer, lock
6
Contact, electrical
7
Support
8
Screw, cap, hex head
9
Washer, lock
10
Post, contact
11
Screw, cap, hex head
12
Washer, lock
13
Stop, contact
14
Finger, contact
15
Armature, relay
16
Spring, helical
17
Washer, cup
18
Guide, return spring
19
Post, contact stop
20
Pole face assembly
21
Washer
22
Coil, relay
23
Frame assembly
24
Spacer, panel
25
Panel assembly
7-11
Figure 7-6. Relay, Armature, IS
7-12
Key to figure 7-6
1
Contact, electrical
2
Screw, cap, hex head
3
Washer, lock
4
Contact bar assembly
5
Nut, plain, hex
6
Washer, lock
7
Washer, flat
8
Screw, cap
9
Washer, lock
10
Bushing, Insulator
11
Lug, bottom
12
Block assembly, contact
13
Screw, assembled washer
14
Bushing, insulator
15
Washer, armature rod
16
Frame assembly
17
Screw, assembled washer
18
Washer
19
Coil, relay
20
Spring, helical
21
Plunger assembly
22
Plate, bottom
7-13
Figure 7-7. Relay, Armature SC
7-14
Key to figure 7-7
23
Screw, machine
1
Switch, sensitive, interlock
24
Washer, lock
2
Screw, machine
25
Arm assembly, rocker
3
Washer, lock
26
Ring, retaining
4
Hinge bracket and pin
27
Washer, flat
5
Screw, tapping
28
Actuator, interlock
6
Lever, operator, switch
29
Base assembly
7
Connector, flexible
30
Screw, machine
8
Screw
31
Hinge, moveable
9
Washer, lock
32
Screw, machine
10
Nut, plain, hex
33
Arm and crank assembly
11
Washer
34
Rod, push
12
Support, flexible connector
35
Ring retaining
13
Screw, machine
36
Spring, helical
14
Washer, lock
37
Shim, push rod
15
Contact, electrical
38
Bushing, push rod
16
Screw, contact
39
Clamp, wire, coil
17
Washer, lock
40
Screw, machine
18
Screw, machine
41
Washer, lock
19
Washer, lock
42
Coil, relay
20
Contact electrical
43
Screw, machine
21
Screw, moveable
44
Washer, lock
22
Stop, moveable contact
45
Frame assembly
7-15
Figure 7-8. Relay, Armature, Forward and Reverse
7-16
Key to figure 7-8
1
Connector, flexible
2
Screw
3
Washer, lock
4
Nut, plain, hex
5
Washer, spring tension
6
Support, flexible
7
Screw, machine
8
Washer, lock
9
Contact, electrical
10
Screw, contact
11
Washer, lock
12
Screw, machine
13
Washer, lock
14
Contact, electrical
15
Screw, moveable
16
Arm assembly, rocker
17
Ring, retaining
18
Washer, flat
7-17
19
Actuator, interlock
20
Base assembly
21
Screw, machine
22
Hinge, moveable
23
Screw, machine
24
Arm and crank assembly
25
Rod, push
26
Ring, retaining
27
Spring, helical
28
Shim, push rod
29
Bushing, push rod
30
Clamp, wire coil
31
Screw, machine
32
Washer, lock
33
Coil, relay
34
Screw, machine
35
Washer, lock
36
Frame assembly
Figure 7-9. Relay, Armature, Field Weakening.
7-18
Key to figure 7-9
20
Ring, retaining
1
Connector, flexible
21
Washer, flat
2
Screw
22
Actuator, Interlock
3
Washer, lock
23
Base assembly
4
Nut, plain, hex
24
Screw, machine
5
Washer, spring
25
Hinge, moveable
6
Support, flexible connector
26
Screw, machine
7
Screw, machine
27
Arm and crank assembly
8
Washer, lock
28
Rod, push
9
Contact, electrical
29
Ring, retaining
10
Screw
30
Spring, helical
11
Washer, lock
31
Shim push rod
12
Screw, machine
32
Bushing, push rod
13
Washer, lock
33
Clamp, wire, coil
14
Contact, electrical
34
Screw, machine
15
Screw
35
Washer, lock
16
Stop, moveable contact
36
Coil, relay
17
Screw, machine
37
Screw machine
18
Washer, lock
38
Washer, lock
19
Arm assembly, rocker
39
Frame assembly, magnet
7-19
Figure 7-10. Power panel, SCR
7-20
Key to figure 7-10
1
Semiconductor device
2
Semiconductor device
3
Heat sink
4
Heat sink
5
Semiconductor device
6
Semiconductor device
7
Control pack
8
Thermistor
9
Heat sink
10
Semiconductor device
11
Fuse, cartridge
12
Fuse, cartridge
13
Fuse, cartridge
14
Suppressor
15
Resistor
16
Bracket
17
Suppressor
18
Transformer
19
Capacitor
20
Bracket, capacitor
21
Resistor
7-21
Figure 7-11. Switch Assembly, Accelerator Control
7-22
Key to figure 7-11
1
Ball joint, rod end
2
Washer, lock
3
Bracket, accelerator switch
4
Screw, machine
5
Washer, lock
6
Connector, receptacle
7
Wiring harness
8
Rivnut, enclosure mounting
9
Arm, operating
10
Screw, machine
11
Washer, lock
12
Cover, enclosure
13
Screw, machine
14
Gasket, cover
15
Enclosure
16
Bracket, mounting
17
Screw, machine
18
Retainer, shaft
19
Terminal Board
20
Barrier
7-23
21
Potentiometer assembly
22
Setscrew
23
Bracket, potentiometer mounting
24
Screw, machine
25
Washer, lock
26
Housing, spring return
27
Drive coupling potentiometer
28
Screw, machine
29
Strip, marker
30
Contact assembly
31
Cam
32
Cam
33
Cover, detent housing
34
Cam, detent
35
Housing, detent cam
36
Bearing, shaft
37
Drive, spring
38
Support, spring
39
Spring, return
40
Shaft
Figure 7-12. Switch Assembly, Directional Control
7-24
Key to figure 7-12
1
Connector, receptacle
2
Conduit, electrical
3
Connector, conduit
4
Clamp, direction control switch
5
Screw, cap
6
Washer, lock
7
Handle assembly
8
Knob, operating handle
9
Wiring harness
10
Bracket, housing
11
Cover
12
Screw, machine
13
Washer
14
Liner, cover
15
Shaft assembly
16
Lever, trip
17
Operating lever
18
Switch
19
Bracket
20
Spring, helical
21
Hinge pin
22
Clip
23
Arm assembly
24
Shaft assembly
25
Washer
26
Spacer
27
Carrier assembly
28
Housing and bearing assembly
7-25
Figure 7-13. Hydraulic Assembly
7-26
Key to figure 7-13
15
Motor and pump arrangement
1
Hose assembly
16
Fitting, lubrication
2
Hose assembly
17
Fitting, lubrication
3
Hose assembly
18
Cylinder assembly
4
Hose assembly
19
Cylinder assembly
5
Hose assembly
20
Pin, tilt cylinder, rear
6
Adapter, straight
21
Pin, tilt cylinder, front
7
Adapter, straight
22
Screw, lock,
8
Tee, tube
23
Reservoir assembly hydraulic
9
Tube assembly
24
Hydraulic controls
10
Tube assembly
25
Tube assembly, metal
11
Hose and tube assembly
26
Tube assembly, metal
12
Hose, rubber
27
Tube assembly, metal
13
Hose, rubber suction
28
Elbow, wheel cylinders
14
Clamp, hose
29
Tee, strap, brake,
7-27
Key to figure 7-14
1
Adapter, straight
2
Adapter, straight
3
Elbow, pipe, street, 90 deg.
4
Elbow, pipe, street, 45 deg.
5
Adapter, straight
6
Screw, machine
7
Motor, dc hydraulic pump
8
Pump, rotary
9
Nut, plain, hex
10
Washer, lock
11
Coupling half, shaft
12
Coupling half, shaft
Figure 7-14. Motor and pump arrangement
7-28
Figure 7-15. Motor, DC, Hydraulic Pump.
7-29
Key to figure 7-15
27
Insulator, bushing, end bell
1
Stud, plain
28
Stud, terminal end bell
2
Plate, ident
29
Terminal, stud
3
Screw, drive
30
Terminal, electrical lead
4
Cover, brush access
31
Screw, machine
5
Screw, machine
32
Nut, plain, hex
6
Nut, plain, hex
33
Washer, lock
7
Washer, lock
34
Lead, electrical brush
8
Cap, grease
35
Lead, electrical brush
9
Screw, machine
36
Insulator
10
Bearing, ball, annular
37
Pin, straight
11
Ring, retaining
38
Insulator, external
12
Brush, electric contact
39
End bell
13
Screw, machine
40
Screw, cap
14
Washer, lock
41
Washer, lock
15
Spring, helical
42
End bell
16
Holder, electric contact
43
Screw, cap
17
Screw, machine
44
Washer, lock
18
Washer, lock
45
Bearing, ball, annular
19
Washer, flat
46
Ring, retaining
20
Insulator, bushing
47
Armature, motor
21
Insulator, plate holder
48
Key, woodruff
22
Insulator, external, end bell
49
Filler strip, motor field winding
23
Nut, plain, hex
50
Pole piece, magnet
24
Washer, lock
51
Screw, cap
25
Washer, flat
52
Winding, motor field
26
Insulator, washer, end bell
53
Housing, electrical rotating
7-30
Key to figure 7-16
9
Bushing, pump
1
Ring, retaining, seal
10
Gearshaft, spur
2
Cover, mounting flange
11
Gearshaft, spur
3
Screw, cap
12
Bushing, pump
4
Seal, plain
13
Pin, straight
5
Packing, preformed
14
Plate, ident
6
Packing, preformed
15
Screw, drive
7
Retainer, packing
16
Pin, straight
8
Packing, preformed
17
Housing, pump
Figure 7-16. Pump, rotary, power driven, hydraulic
7-31
Figure 7-17. Cylinder Assembly, Actuating, Linear, Tilt
7-32
Key to figure 7-17
1
Clevis, rod end
2
Screw, cap
3
Washer, lock
4
Nut, plain, hex
5
Retainer, packing
6
Screw, cap
7
Washer, lock
8
Ring, wiper
9
Stuffing box, tilt cylinder
10
Plug, lock
11
Packing set
12
Packing, preformed
13
Ring, back-up
14
Spacer, piston
15
Ring, U, Piston
16
Ring, T, piston
17
Piston assy
18
Cylinder tube
7-33
Figure 7-18. Reservoir Assembly, Hydraulic
7-34
Key to figure 7-18
1
Adapter, straight
2
Elbow, pipe, street
3
Filter, fluid, pressure
4
Bushing
5
Nipple, pipe
6
Plug, pipe
7
Tee, pipe
8
Nipple, pipe
9
Elbow, pipe
10
Bushing, pipe reservoir
11
Reservoir, hydraulic oil
12
Screw, cap
13
Nut, plain, hex
14
Washer, lock
15
Washer, flat
16
Filter, hydraulic-reservoir
17
Dipstick, hydraulic reservoir
7-35
Key to figure 7-19
1
Housing, filter element
2
Packing, preform
3
Filter, element
4
Packing, preform
5
Head, filter
6
Valve, by-pass
Figure 7-19. Filter, fluid, pressure, pump intake.
7-36
Figure 7-20. Hydraulic Controls
7-37
Key to figure 7-20
22
Spring, helical
1
Lever, control valve
23
Pin, spring retainer
2
Lever, control valve
24
Clip, spacer
3
Pin, cotter
25
Screw, self-tapping
4
Ring, retaining
26
Hinge
5
Pin, straight
27
Bracket
6
Rod, connecting
28
Elbow
7
Sleeve, control valve
29
Elbow
8
Setscrew
30
Adapter
9
Nut, plain
31
Elbow, pipe
10
Clevis, rod end
32
Plug, pipe
11
Pin, cotter
33
Elbow
12
Pin, straight
34
Bushing
13
Bracket, lever
35
Tee, pipe
14
Screw, cap
36
Filter, fluid
15
Nut, plain
37
Nipple
16
Washer, lock
38
Elbow, pipe street
17
Actuator assembly
39
Adapter
18
Screw, cap
40
Control valve assembly
19
Nut, plain
41
Screw, cap
20
Washer, lock
42
Nut, plain
21
Disk, spring retainer
43
Washer, lock
7-38
Key to figure 7-21
1
Screw, machine valve
2
Nut, self-locking hexagon
3
Spring, helical
4
Spacer
5
Guide
6
Valve, by-pass
7
Filter element
8
Head, filter
Figure 7-21. Filter, fluid, pressure
7-39
Figure 7-22. Control Valve Assembly
7-40
Key to figure 7-22
1
Nut, acorn
2
Packing, preform
3
Nut, plain
4
Setscrew
5
Cap, relief valve
6
Packing, preform
7
Ring, backup
8
Packing, preform
9
Spring, helical
10
Plunger, pilot
11
Seat, pilot
12
Spring helical
13
Screen, plunger
14
Plunger, poppet
15
Seat, poppet
16
Cap, check valve
17
Packing, preform
18
Spring, helical
19
Poppet, check valve
7-41
20
Cap, spool
21
Plate, retainer
22
Screw, assembled washer
23
Ring, wiper spool
24
Retainer, spool
25
Packing, preform
26
Ring, retaining
27
Spacer, spool
28
Washer, flat
29
Spring, helical
30
Retainer, preformed packing
31
Packing, preform
32
Spool, hydraulic control
33
Spool, hydraulic control
34
Plate, identification
35
Screw, drive
36
Plug, pipe
37
Plug, pipe
38
Body
Figure 7-23. Uprights, Backrest, Fork and Carriage Assembly
7-42
Key to figure 7-23
1
Fork, lift truck
2
Handle, fork pin retainer
3
Pin, spring handle
4
Spring, helical
5
Pin, fork retaining
6
Backrest, load
7
Elbow
8
Regulator, flow
9
Nipple, pipe
10
Elbow, pipe
11
Screw, cap
12
Nut, self-locking
13
Bar, chain retainer
14
Bar, chain retainer
15
Screw, cap,
7-43
16
Washer, lock
17
Fitting, lubrication
18
Lever, upright
19
Pin, cotter
20
Washer, flat
21
Pin, cotter
22
Washer, flat
23
Pin, spring
24
Shaft
25
Spring, helical
26
Lever, upright
27
Setscrew
28
Nut, plain
29
Screw, adjusting chain
30
Nut, plain
Key to figure 7-23 (cont)
46
Hoist cylinder, assembly
31
Nut, plain
47
Ball, bearing
32
Chain, rollers
48
Plug, lock
33
Ring, retaining
49
Setscrew
34
Washer, flat
50
Setscrew
35
Bearing, sleeve roller
51
Roller, carriage
36
Roller, crosshead
52
Bearing, ball
37
Brace, hoist cylinder
53
Shim, carriage roller
38
Nut, self-locking
54
Fitting, lubrication
39
Washer, flat
55
Bearing half
40
screw, cap
56
Pin, straight
41
Washer, lock
57
Insert, bronze
42
Block, striker carriage
58
Upright, inner
43
Setscrew
59
Upright, outer
44
Fitting, lubrication
60
Carriage, upright
45
Crosshead, hoist cylinder
61
Trunnion, carriage
7-44
Figure 7-24. Hoist Cylinder Assembly, Actuating, Linear
7-45
Key to figure 7-24
15
Bearing, sleeve
1
Screw, cap
16
Packing nut
2
Washer, nonmetallic
17
Ring, wiper
3
End, cylinder
18
Retainer, packing
4
Washer, nonmetallic
19
Packing, preformed
5
Packing, preformed
20
Bearing, sleeve
6
Packing nut
21
Cylinder, primary
7
Ring, wiper
22
Cylinder, secondary
8
Retainer, packing, nut
23
Packing, preformed
9
Packing, preformed
24
Washer, nonmetallic
10
Bearing, sleeve
25
Bearing, sleeve
11
Packing nut
26
Guide, plunger
12
Ring, wiper
27
Ring, retaining
13
Retainer, packing, nut
28
Plunger, primary
14
Packing, preformed
29
Plunger, secondary
7-46
Figure 7-25. Uprights, Backrest, Fork and Carriage Assembly
7-47
Key to figure 7-25
1
Fork, lift truck
2
Handle, fork pin retainer
3
Pin, spring handle
4
Spring, helical
5
Pin, fork retaining
6
Backrest, load
7
Fitting, lube rollers
8
Chain, mast
9
Nut, plain
10
Anchor
11
Pin, mast and carriage
12
Chain, carriage
13
Anchor
14
Turnbuckle
15
Bolt
16
Nut, plain
17
Pin, connection
18
Pin, cotter
19
Anchor
20
End fitting, truck
21
Hose assembly
22
Elbow
23
Tube assembly
24
Adapter, cylinder base
25
Nut, lock
7-48
26
Screw
27
Ring, retaining
28
Plug, carriage roller
29
Stud, carriage roller
30
Roller, carriage roller
31
Carriage assembly
32
Anchor plate
33
Screw, cap
34
Washer, lock
35
Screw
36
Washer, lock
37
Pin, straight
38
Screw, special
39
Washer, flat
40
Bearing, inner race
41
Bearing
42
Roller, cylinder
43
Washer, flat
44
Cylinder assembly
45
Pin, straight
46
Screw, machine
47
Spacer
48
Channel, inner
49
Channel, center
50
Channel, outer
Key to figure 7-26
1
Screw, bleeder
2
Gasket
3
Packing, preform
4
Ring
5
Head, plunger
6
Ring, retaining
7
Stuffing box
8
Gland, packing
9
Ring, wiper
10
Packing, preform
11
Packing set
12
Ring, packing
13
Ring, wear
14
Spacer, rod
15
Rod, cylinder
16
Ring, wiper
17
Gland, packing
18
Packing, preform
19
Packing set
20
Cylinder, outer
21
Ring, wiper
22
Gland, packing
23
Setscrew
24
Ring, wear
25
Packing set
26
Packing, preform
27
Piston, outer
28
Cylinder
Figure 7-26. Cylinder assembly
7-49
Key to figure 7-27
1
Cushion, backrest
2
Screw, machine
3
Nut, self-locking
4
Washer, flat
5
Cushion, seat
6
Frame, seat
Figure 7-27. Seat, individual
7-50
Figure 7-28. Mechanical Controls Arrangement
7-51
Key to figure 7-28
1
Clip, retaining
2
Screw, cap
3
Nut, plain
4
Washer, lock
5
Screw, cap
6
Nut, plain
7
Washer, lock
8
Cable
9
Connector
10
Washer, flat
11
Screw, machine
12
Clamp
13
Nut, plain
14
Washer, lock
15
Washer, flat
7-52
16
Bar
17
Grommet
18
Brake lever
19
Screw, cap
20
Nut, plain
21
Washer, lock
22
Bracket
23
Screw, cap
24
Washer, lock
25
Rod
26
Nut, plain
27
Strip, switch support
28
Screw, cap
29
Washer, flat
30
Rail, seat guide
Key to figure 7-28 (cont)
45
Pedal, accelerator
31
Hinge pin
46
Screw, cap
32
Cap
47
Nut, self-locking
33
Nut, plain
48
Screw, cap
34
Stop, rod
49
Nut, plain
35
Spring, helical
50
Spring, helical
36
Rod
51
Screw, cap
37
Nut, plain
52
Nut, plain
38
Clevis
53
Washer, lock
39
Lever, brake
54
Rod
40
Clevis
55
Nut
41
Pin, straight
56
Cylinder assy, master brake
42
Pin, cotter
57
Screw, cap
43
Rod, brake
58
Nut, plain
44
Nut, plain
59
Washer, lock
7-53
Figure 7-29. Cylinder Assembly, Master Brake
7-54
Key to figure 7-29
1
Wiring harness
2
Pad, pedal
3
Nut, plain
4
Washer, lock
5
Spring, helical
6
Screw, cap
7
Nut, plain
8
Plug, pipe
9
Switch, push
10
Screw, machine
11
Nut, plain
12
Washer, lock
13
Insulator
14
Yoke end
15
Nut, plain
16
Pin, straight
17
Pin, cotter
7-55
18
Lever
19
Screw, cap
20
Nut, plain
21
Washer, lock
22
Bushing, sleeve
23
Bracket
24
Bracket
25
Screw, cap
26
Nut, plain
27
Washer, lock
28
Bolt, connector
29
Gasket
30
Fitting, tube
31
Gasket, tube
32
Cylinder assembly
33
Boot
34
Rod, push
Figure 7-30. Steering Control System
7-56
Key to figure 7-30
1
Fitting, lubrication
2
Fitting, lubrication
3
Pin, cotter
4
Tie rod end
5
Tie rod end
6
Clamp
7
Draglink, steering
8
Hose assembly
9
Hose, rubber
10
Clamp, hose
11
Hose assembly
12
Screw, cap
13
Nut, plain
14
Washer, lock
15
Adapter, hose
16
Elbow, hose
17
Clamp, hose
18
Pump, hydraulic
19
Cover, fan
20
Bracket, cover
21
Fan, electrical
22
Motor, direct current
23
Steering unit
24
Screw, cap
7-57
Figure 7-31. Pump, hydraulic, Power Steering
7-58
Key to figure 7-31
1
Manifold, pump
2
Screw, cap
3
Washer, flat
4
Gasket, manifold
5
Shaft, pump
6
Washer, flat
7
Seal, shaft
8
Bearing, sleeve shaft
9
Plug, body
10
Body, pump
11
Screw, cap
12
Packing, preform
13
Packing, preform
14
Pin, control valve retaining
15
Plug, control valve
16
Packing, preform
17
Control valve
18
Spring, helical
19
Vane kit, pump
20
Rotor, pump
21
Ring, pump
22
Pin, straight
23
Pressure plate
24
Spring, helical
25
Cover, pump
7-59
Figure 7-32. Motor, Direct Current
7-60
Key to figure 7-32
1
End bell
2
End bell assembly
3
Screw, machine
4
Washer, lock
5
Holder, electric
6
Screw, cap
7
Washer, lock
8
Spring, spiral
9
Bearing, ball
10
Bearing, ball
11
Washer, thrust
12
Washer, thrust
13
Armature, motor
14
Field and frame assembly
15
Brush set, electric contact
16
Screw, machine
17
Washer, lock
18
Nut, plain
19
Washer, lock
20
Washer, flat
21
Winding, motor
22
Winding, motor
23
Winding, motor
24
Winding, motor
7-61
Figure 7-33. Steering Unit
7-62
Key to figure 7-33
1
Grommet
2
Plate, mounting
3
Screw, cap
4
Screw, cap
5
Washer, lock
6
Cover, connector
7
Screw, machine
8
Washer, lock
9
Connector, horn
10
Screw, tapping
11
Screw, machine
12
Button, horn
13
Cover, button
14
Contact, horn
15
Spring, helical
16
Insulator, horn
17
Contact, base, plate
18
Separator, horn
19
Steering wheel
20
Nut, plain, hex
21
Key, woodruff
22
Arm, steering
23
Nut, plain
24
Washer, lock
25
Bolt, shoulder
7-63
26
Bolt, shoulder
27
Reinforcement, coupling
28
Seal, dust
29
Retainer, lower
30
Ring, retaining
31
Spring, helical
32
Seat, spring
33
Bearing assembly
34
Bearing assembly
35
Jacket and adapter
36
Shaft assembly
37
Contact assembly
38
Shaft, steering
39
Screw, cap
40
Washer, lock
41
Bearing, sleeve
42
Cover, housing side
43
Packing, preform
44
Nut, plain
45
Washer, thrust
46
Retainer, lash
47
Adjuster, lash
48
Washer, thrust
49
Gearshaft
50
Spring, helical
Key to figure 7-33 (cont)
74
Clamp, ball
51
Ring, retaining
75
Screw, assembled
52
Washer, backup
76
Guide, ball
53
Seal, plain
77
Ball nut
54
Seal, plain
78
Ball seat, recirculating
55
Plug, housing
79
Race, lower
56
Ring, retaining
80
Bearing, roller
57
Packing, preform
81
Pin, torsion bar
58
Plug, rack
82
Spring, helical
59
Nut
83
Packing, preform
60
Seal, plain
84
Spool, valve
61
Seal, plain
85
Ring, valve
62
Packing, preform
86
Packing, preform
63
Ring, retaining
87
Body, valve
64
Bearing, roller
88
Shaft assembly
65
Plug, adjuster
89
Packing, preform
66
Race, upper
90
Sleeve, torsion bar
67
Bearing, roller
91
Cap and torsion bar
68
Race, upper
92
Packing, preform
69
Spacer, thrust
93
Ball, bearing
70
Retainer, spacer
94
Bearing, roller
71
Worm assembly
95
Connector, housing
72
Ring, piston
96
Connector, housing
73
Packing, preform
97
Housing, steering
7-64
Figure 7-34. Steering Axle Arrangement
7-65
Key to figure 7-34
1
Plate, axle retaining
2
Screw, cap
3
Washer, lock
4
Block, axle
5
Cap, grease
6
Cone and rollers
7
Pin, cotter
8
Nut, castellated
9
Washer, flat
10
Cup, tapered
11
Tire, solid rubber
12
Wheel
13
Seal, plain
14
Fitting, lubrication
15
Bolt
16
Nut, plain
17
Tie rod end
18
Pin, cotter
19
Nut, slotted
20
Tie rod end
21
Pin, cotter
7-66
22
Nut, slotted
23
Rod, aligning
24
Clamp
25
Bolt, machine
26
Nut, plain
27
Washer, lock
28
Fitting, lubrication
29
Knuckle, steer
30
Knuckle, steer
31
Screw, cap
32
Nut, plain
33
Washer, flat
34
Bearing, roller
35
Pin, hollow
36
Bearing, roller
37
Fitting, lubrication
38
Lever, bellcrank
39
Ring, retaining
40
Washer, flat
41
Bearing, roller
42
Axle, vehicular
Figure 7-35. Drive Axle, Adapter, Drive Motor and Tire
7-67
Key to figure 7-35
1
Tire, solid rubber
2
Motor, direct current
3
Screw, cap
4
Washer, lock
5
Screw, cap
6
Nut, self-locking
7
Washer, flat
8
Adapter arrangement
9
Plug, pipe
10
Plug, pipe
11
Brake drum
12
Nut, plain
13
Washer, wheel
14
Bushing, tapered
15
Tube assembly
16
Tube assembly
17
Fitting, brake
18
Elbow, fitting
19
Adapter, wheel
20
Gasket, adapter
21
Adapter, bleeder
22
Fitting, bleeder
23
Fitting, bleeder
24
Washer, fitting
25
Nut, jam
7-68
26
Plug, pipe
27
Spring, return
28
Spring
29
Brake shoe
30
Retainer, brake
31
Washer, flat
32
Spring, helical
33
Pin, antirattle
34
Rod, push, wheel
35
Screw, cap
36
Washer, lock
37
Boot, dust
38
Piston, wheel
39
Cup, hydraulic
40
Spring, helical
41
Body, cylinder
42
Spacer, wheel cylinder
43
Backing plate
44
Screw, cap
45
Screw, cap
46
Washer, lock
47
Stud, plain
48
Dowel
49
Screw, cap
50
Washer, lock
Key to figure 7-35 (cont)
51
Stud, plain
52
Cap, grease
53
Pin, cotter
54
Nut, slotted
55
Washer, flat
56
Cone and roller
57
Cup, tapered
58
Case, gear
59
Seal, plain
60
Gear, final
61
Cup, tapered
62
Cone and roller
63
Spindle, wheel
64
Nut, plain
65
Washer, lock
66
Gasket, wheel
67
Collar, axle
68
Bearing, ball
69
Shaft, axle
70
Nut, plain
71
Washer, lock
72
Dowel, axle
7-69
73
Stud, plain
74
Washer, axle
75
Cone and rollers
76
Stud, plain
77
Stud, plain
78
Housing and cup
79
Housing and cup
80
Cup, tapered
81
Gasket, axle
82
Gasket, axle
83
Plug, pipe
84
Plug, pipe
85
Gear, bevel
86
Rivet, solid
87
Differential case
88
Screw, cap
89
Gear, bevel
90
Washer, thrust
91
Washer, spring
92
Gear, pinion
93
Spider
94
Housing
Figure 7-36. Motor Drive Assembly
7-70
Key to figure 7-36
1
Plate, identification
2
Screw, drive
3
Link, brake
4
Pin, straight
5
Pin, cotter
6
Pin, straight
7
Pin, cotter
8
Rod, brake shoe
9
Nut, self-locking, hex
10
Spring, compression
11
Seat, spring
12
Screw, cap
13
Washer, lock
14
Pin, groove
15
Lining, friction
16
Bushing, sleeve
17
Brake shoe
18
Brake drum
19
Coupling, motor to adapter
20
Nut, slotted
21
Pin, cotter
22
Retainer, bearing
23
Screw, cap
24
Washer, lock
25
Washer, flat
7-71
26
Bearing, ball
27
Yoke, rear
28
Screw, cap
29
Washer, lock
30
Screw, cap
31
Washer, lock
32
Nut, plain
33
Washer, flat
34
Washer, insulating
35
Washer, sleeve
36
Washer, Insulating
37
Connector, brush
38
Connector, brush
39
Screw, machine
40
Washer, lock
41
Spring, helical
42
Brush, electrical
43
Brush holder
44
Screw, machine
45
Washer, lock
46
Washer, flat
47
Bushing, insulating
48
Insulator
49
Yoke, motor
50
Cover
Figure 7-36 (cont)
51
Screw, cap
52
Nut, plain
53
Washer, lock
54
Screw, machine
55
Washer, lock
56
Nut, self-locking
57
Washer, flat
58
Stud, brake shoe
59
Armature, motor
60
Nut, plain
61
Washer, flat
62
Washer, insulator
63
Terminal motor
64
Washer, Insulator
65
Bushing, insulating
66
Coil, field
67
Insulation, pole
68
Insulator, pole
69
Pole piece, magnet
70
Screw, cap
71
Frame, field
7-72
Figure 7-37. Adapter Arrangement
7-73
Key to figure 7-37
1
Cushion, load
2
Nut, slotted
3
Pin, cotter
4
Collar, outside
5
Ring, retaining
6
Sleeve, inside
7
Coupling half
8
Nut, plain
9
Screw, cap
10
Screw, cap
11
Washer, lock
12
Gasket, cage to differential
13
Cap, oil seal retainer
14
Screw, cap
15
Washer, lock
16
Washer, thrust gearshaft
17
Gasket, oil seal retainer
18
Spacer, gearshaft bearing cap
19
Bearing, roller
20
Gearshaft, helical
21
Bearing, roller
22
Cage, gearshaft
23
Gasket, housing to cage
24
Housing, adapter
7-74
Figure 7-38. Body and Chassis Arrangement
7-75
Key to figure 7-38
1
Plate, identification
2
Plate designation, hoist
3
Plate designation, tilt
4
Plate designation, lights
5
Plate designation, direction
6
Overhead guard
7
Cover, battery compartment
8
Cover, battery
9
Cover, fuse
10
Cover, scr
11
Cover, battery connector
12
Cover, wiring harness
13
Cover, travel motor
14
Strap, static drag
15
Cover, hydraulic control valve
7-76
16
Floor plate
17
Cover, front
18
Angle, battery holder
19
Screw, cap
20
Washer, lock
21
Washer, flat
22
Bolt, machine
23
Washer, flat
24
Washer, lock
25
Nut, plain, hex
26
Extinguisher, fire
27
Screw, machine
28
Nut, plain, hex
29
Washer, lock
30
Frame assembly
APPENDIX A
MAINTENANCE ALLOCATION CHART
Section I. INTRODUCTION
A-1.
General
a.
This section provides a general explanation of all maintenance and repair functions authorized at various
maintenance levels.
b.
Section II designates overall responsibility for the performance of maintenance functions on the identified end
item or component. The implementation of the maintenance functions upon the end item or component will be consistent
with the assigned maintenance functions.
c.
Section III contains supplemental Instructions, explanatory notes and/or illustrations required for a particular
maintenance function.
d.
A-2.
Section IV is not applicable.
Explanation of Columns in Section II
a.
Group Number. Column 1. The assembly group is a numerical group assigned to each assembly in a top
down breakdown sequence. The applicable assembly groups are listed on the MAC in disassembly sequence beginning
with the first assembly removed in a top down disassembly sequence.
b.
group.
Assembly Group. Column 2.
This column contains a brief description of the components of each assembly
c.
Maintenance Functions. Column 3. This column lists the various maintenance functions (A through K) and
indicates the lowest maintenance category authorized to perform these functions. The symbol designations for the
various maintenance categories are as follows:
C - Operator or crew
O - Organizational maintenance
F - Direct support maintenance
H - General support maintenance
D - Depot maintenance
The maintenance functions are defined as follows:
A - INSPECT. To determine serviceability of an item by comparing its physical, mechanical, and electrical
characteristics with established standards.
B - TEST. To verify serviceability and to detect electrical or mechanical failure by use of test equipment.
C - SERVICE. To clean, to preserve, to charge, and to add fuel, lubricants, cooling agents, and air. If it is desired
that elements, such as painting and lubricating, be defined separately, they may be so listed.
A-1
D - ADJUST. To rectify to the extent necessary to bring into proper operating range.
E - ALIGN. To adjust specified variable elements of an item to bring to optimum performance.
F - CALIBRATE. To determine the corrections to be made in the readings of instruments or test equipment
used in precise measurement. Consists of the comparison of two Instruments, one of which is a certified standard of
known accuracy, to detect and adjust any discrepancy in the accuracy of the instrument being compared with the certified
standard.
G - INSTALL. To set up for use in an operational environment such as an emplacement, site, or vehicle.
H - REPLACE. To replace unserviceable items with serviceable like items.
I - REPAIR. Those maintenance operations necessary to restore an item to serviceable condition through
correction of material damage or a specific failure. Repair may be accomplished at each category of maintenance.
J - OVERHAUL. Normally, the highest degree of maintenance performed by the Army in order to minimize
time work in process Is consistent with quality and economy of operation. It consists of that maintenance necessary to
restore an item to completely serviceable condition as prescribed by maintenance standards in technical publications for
each item of equipment. Overhaul normally does not return an item to like new, zero mileage, or zero hour condition.
K - REBUILD. The highest degree of materiel maintenance. It consists of restoring equipment as nearly as
possible to new condition in accordance with original manufacturing standards. Rebuild is performed only when required
by operational considerations or other paramount factors and then only at the depot maintenance category. Rebuild
reduces to zero the hours or miles the equipment, or component thereof, has been in use.
d.
Tools and Equipment. Column 4. This column is not applicable.
e.
Remarks. Column 1. This column is provided for referencing by code the remarks (Section III) pertinent to the
maintenance functions.
A-3.
Explanation of Columns in Section T1
a.
Reference Code. This column consists of two letters separated by a dash, both of which are references to
Section II. The first letter references column 5 and the second letter references a maintenance function, column 3, A
through K.
b.
Remarks. This column lists information pertinent to the maintenance function being performed, as indicated
on the MAC, Section II.
A-2
(1)
GROUP
NUMBER
01
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
ELECTRICAL SYSTEM
Hour meter
0
0
Switch, light
0
0
Switch, emergency stop
0
0
Switch, stoplight
0
0
Lamps
0
0
Lights Head, stop & tail
0
0
Lights
Resistors, lights
0
0
Horns
Button, horn
Horn assembly
0
0
0
A-3
0
A
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
Horn (Cont'd)
Horn wiring
0
0
Receptacle, Charging
0
0
Battery, Storage
0
Cables, battery
0
0
0
F
0
F
F
Batteries
0
0
F
0
D
Hull or chassis wiring
Harness, wiring
02
FRONT AXLE
Front axle assembly
Axle assembly, driving
0
0
A-4
H
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
FRONT AXLE (Cont'd)
Differential
Differential assembly
03
F
0
F
F
F
REAR AXLE
Rear axle assembly
Axle assembly, steering
0
0
F
0
F
F
Steering
Arm, steering
Axle, steering
F
A-5
H
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
04
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
BRAKES
Handbrakes
Brakeshoe assembly motor
0
Cable, handbrake
0
Control linkage
Drum, brake
F
0
0
0
0
0
0
F
F
Lever, handbrake
0
Service brakes
Brake assembly
0
0
F
Shoe assembly
0
0
0
A-6
F
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
BRAKES (Cont'd)
Hydraulic brake system
05
Master cylinder
0
0
0
Tube assembly, metal
0
0
Wheel, cylinder
0
0
WHEELS
Wheels assembly
Bearing and seals, rear
wheels
0
0
0
0
Wheel assembly
0
Tires
Tires, solid
0
F
A-7
F
B
F
C
(1)
GROUP
NUMBER
06
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
STEERING
Steering assembly
Bearing, bellcrank
F
Bellcrank
F
Drag, link
0
Rod assembly, tie
Steering gear assembly
0
F
F
0
F
0
F
Wheel, steering
07
0
BODY, CAB, HOOD AND HULL
Body, cab, hood, hull
assemblies
Covers (Battery compartment)
0
Overhead guard
0
A-8
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
Body, cab, hood, hull assy
(cont'd)
Floor
Plate, floor
0
Seats
Seat assembly
08
0
0
0
0
F
F
0
F
F
HYDRAULIC LIFT COMPONENTS
Hydraulic pump
Pump, rotary, power driven
hydraulic
Hydraulic control valve
Valve, directional control
Hydraulic control levers
and linkage
A-9
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
Hydraulic control levers
and linkage (Cont'd)
Bracket, control valve
0
Levers, control
0
Hydraulic tilt cylinders
Cylinder assembly, tilt
0
0
F
0
0
F
F
F
F
Hydraulic mast column
Chain assembly
0
0
0
Crosshead
Cylinder assembly,
actuating, hoist
0
Forks
0
Roller assembly
F
Upright assembly
0
0
0
F
A-10
H
H
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
Hydraulic lines and fittings
Cap, oil breather
0
0
0
Filter element
0
0
Hoses assembly, rubber
0
0
Tank, oil
0
0
F
Valve, regulating
09
0
0
ELECTRIC MOTORS
Motor assembly
Motor assembly, travel
F
F
F
F
H
Motor assembly, pump
F
F
F
F
H
Motor assembly, steering
F
F
F
F
H
Brush holders
Brush, electrical contact
0
F
A-11
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
Brush holders (cont'd)
Holder, electrical contact
brush
F
F
Endbell
F
F
F
F
Frame supports and housings
Bearing, ball annular,
drive motors
10
DRIVE COMPONENTS
Adapter assembly, gear
reduction
0
0
F
F
Accelerator control assembly
Potentiometer
F
F
Control, accelerator
0
F
Switch, sensitive
F
A-12
F
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
Accelerator control
assembly (Cont'd)
11
Contacts electrical
0
F
Contacts stationary
0
F
Contacts finger
0
F
0
0
FUSE AND CIRCUIT BREAKER
Fuse, cartridge
Fuse holder
F
Link, fuse
F
Oscillator module
12
F
F
F
SWITCHES
Lever, switch
Switch, directional control
F
0
F
A-13
F
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
(1)
GROUP
NUMBER
(2)
FUNCTIONAL GROUP
COMPONENT ASSEMBLY
SECTION II. MAINTENANCE ALLOCATION CHART
(3)
MAINTENANCE FUNCTIONS
Resistor
Resistor, fixed
0
0
Relay
Relay, armature
0
F
F
Contact, relay
0
Relay, thermal
0
0
0
F
F
F
0
Rectifier, transformer
SCR assembly
Radio interference
suppression
Strap, static drag
F
A-14
F
(4)
TOOLS AND
EQUIPMENT
(5)
REMARKS
SECTION III
MAINTENANCE ALLOCATION CHART
REFERENCE
CODE
REMARKS
A-1
Repair includes installing repair kit.
B-1
Repair includes installing repair kit.
C-1
Repair includes installing repair kit.
A-15
APPENDIX B
BASIC ISSUE ITEMS LIST
Section I. INTRODUCTION
B-1.
Scope
This appendix lists items which accompany the Fork Lift Truck or are required for installation, operation, or operator's
maintenance.
B-2.
General
This Basic Issue Items List is divided into the following sections:
a. Basic Issue Items - Section II. A list of items which accompany the Fork Lift Truck and are required by the
operator/crew for installation, operation, or maintenance.
b. Maintenance and Operating Supplies - Section Ill. A listing of maintenance and operating supplies required for
initial operation.
B-3.
Explanation of Columns
The following provides an explanation of columns in the tabular list of Basic Issue Items, Section II.
a.
Source, Maintenance, and Recoverability Codes (SMR).
(1)
Code
Source code, Indicates the source for the listed item. Source codes are:
Explanation
P
Repair parts which are stocked in or supplied from the GSA/DSA or Army supply system and
authorized for use at indicated maintenance categories.
M
Repair parts which are not procured or stocked, but are to be manufactured in indicated
maintenance levels.
A
Assemblies which are not procured or stocked as such, but are made up of two or more units. Such
component units carry individual stock numbers and descriptions, are procured and stocked
separately and can be assembled to form the required assembly at indicated maintenance
categories.
X
Parts and assemblies which are not procured or stocked and the mortality of which normally is
below that of the applicable end item or component. The failure of such part or assembly should
result in retirement of the end item from the supply system.
B-1
Code
Explanation
X1
Repair parts which are not procured or stocked. The requirement for such items will be filled by use
of the next higher assembly or component.
X2
Repair parts which are not stocked. The indicated maintenance category requiring such repair parts
will attempt to obtain them through cannibalization, requirements will be requisitioned, with
accompanying justification, through normal supply channels.
G
Major assemblies that are procured with PEMA funds for initial Issue only as exchange assemblies at
DSU and GSU level. These assemblies will not be stocked above GS and OS level or returned to
depot supply level.
(2) Maintenance code, indicates the lowest category of maintenance authorized to install the listed item. The
maintenance level code is:
Code
C
Explanation
Operator/crew
(3) Recoverability code, indicates whether unserviceable items should be returned for recovery or salvage. Items
not coded are expendable. Recoverability codes are:
Code
Explanation
R
Repair parts (assemblies and components) which are considered economically reparable at direct
and general support maintenance levels. When the maintenance capability to repair these items
does not exist, they are normally disposed of at the GCS level. When supply considerations dictate,
some of these repair parts may be listed for automatic return to supply for depot level repair as set
forth in AR 710-50. When so listed, they will be replaced by supply on an exchange basis.
S
Repair parts and assemblies which are economically reparable at DSU and GSU activities and which
normally are furnished by supply on an exchange basis. When items are determined by a GSU to be
uneconomically reparable they will be evacuated to a depot for evaluation and analysis before final
disposition.
T
High dollar value recoverable repair parts which are subject to special handling and are issued on an
exchange basis. Such repair parts normally are repaired or overhauled at depot maintenance
activities.
U
Repair parts specifically selected for salvage by reclamation units because of precious metal
content, critical materials, or high dollar value reusable casings or castings.
B-2
b. Federal Stock Number. This column indicates the Federal stock number assigned to the item and will be used
for requisitioning purposes.
c.
Description. This column Indicates the Federal item name and any additional description of the item required.
d. Unit of Measure (U/M). A 2 character alphabetic abbreviation indicating the amount or quantity of the Item upon
which the allowances are based, e.g., ft, ea, pr, etc.
e.
Quantity Incorporated In Unit. This column Indicates the quantity of the item used in the assembly group.
f.
Quantity Furnished With Equipment.
equipment.
g.
B-4.
This column Indicates the quantity of an item furnished with the
Illustration. This column is not applicable.
Explanation of Columns in the Tabular List of Maintenance and Operating Supplies - Section III.
a. Component Application. This column identifies the component application of each maintenance or operating
supply item.
b. Federal Stock Number. This column Indicates the Federal stock number assigned to the item and will be used
for requisitioning purposes.
c.
Description. This column indicates the item name and brief description.
d. Quantity Required for Initial Operation, This column indicates the quantity of each maintenance or operating
supply item required for initial operation of the equipment.
e. Quantity Required for 8 Hours Operation.
average 8 hours of operation.
f.
This column indicates the estimated quantities required for an
Notes. This column indicates Informative notes keyed to data appearing in a preceding column.
B-3
Section II. BASIC ISSUE ITEMS
(1)
(2)
SMR
Code
Federal Stock
Number
PC
PC
(3)
Description
(4)
Unit
of
Meas
(5)
Qty
inc
in
Unit
(6)
Qty
furn
with
equip
ARMY LUBRICATION ORDER
LO 10-3930-615-12
EA
1
1
ARMY TECHNICAL ORDER
TM 10-3930-615-15
EA
1
1
Ref no. & mfr
Code
Usable
on code
PC
7510-889-3494
BINDER, Looseleaf
EA
1
1
PC
7520-559-9618
CASE, Operator and maintenance
publications
EA
1
1
EXTINGUISHER, Fire
EA
1
1
PC
4210-889-2221
B-4
(7)
Illustration
(A) (B)
Fig Item
no.
No.
SECTION III. MAINTENANCE AND OPERATING SUPPLIES
(1)
(2)
COMPONENT
FEDERAL
APPLICATION
STOCK NUMBER
BRAKE MASTER
CYLINDER
(3)
DESCRIPTION
(4)
(5)
QUANTITY
QUANTITY
REQUIRED
REQUIRED
F/INITIAL
F/8 HRS
OPERATION
OPERATION
BRAKE FLUID, AUTOMOTIVE:
gal can as follows:
9150-231-9071
(1)
DIFFERENTIAL
DRIVE AXLE
9150-577-5844
(1)
9150-257-5440
(1)
HYDRAULIC
SYSTEM
9150-265-9428
(1)
9150-242-7603
(1)
LUBRICATION
FITTINGS
9150-190-0904
(1)
HB
1 pt
(2)
LUBRICATING OIL, GEAR:
5 gal drum as follows:
GO-90
1 qt
(2)
GOS
20 qt
(2)
OIL, LUBRICATING: 5
gal pails as follows:
OE-10
1 qt
(2)
20 qts
(2)
1 lb
(2)
OES
GREASE, AUTOMOTIVE AND
ARTILLERY: 1 lb can as
follows:
GAA
B-5
(6)
NOTES
(1) See C9100-IL for additional data and requisitioning procedure.
(2) See current LO for
grade, application and
replenishment intervals.
By Order of the Secretary of the Army:
Official:
W. C. WESTMORELAND,
General, United States Army,
Chief of Staff.
KENNETH G. WICKHAM,
Major General, United States Army,
The Adjutant General.
Distribution:
To be distributed in accordance with DA Form 12-25, Section I, (qty rqr block No. 190) organizational maintenance
requirements for Truck, Fork Lift: Electrical.
P U S. GOVERNMENT PRINTING OFFICE: 1994 - 300-421/81947
PIN: 088297-000
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