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TM10-3930-242-12

TECHNICAL MANUAL

OPERATOR AND ORGANIZATIONALMAINTENANCE MANUAL

FOR

TRUCK, LIFT, FORK, DIESEL ENGINE,

PNEUMATIC TIRED WHEELS,

ROUGH TERRAIN 6,000 LB. CAPACITY,24 INCH LOAD CENTER

(ANTHONY MODEL MLT-6,

ARMY MODEL MHE-200)

NSN 3930-00-903-0900,

(CHRYSLER MODEL MLT-6CH,ARMY MODEL MHE-202)

NSN 3930-00-937-0220,

(ATHEY MODEL ARTFT-6,ARMY MODEL MHE-222)

NSN 3930-00-419-5744This copy is a reprint which includes current

pages from Changes 1 through 3.

HEADQUARTERS, DEPARTMENT OF THE ARMYJULY 1980

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TM 10-3930-242-12

W A R N I N G

Death or severe injury may result if forklift truck engine is operated in an enclosed area withoutproviding adequate ventilation. Exhaust fumes contain carbon monoxide, a colorless, odorless,

poisonous gas.

W A R N I N G

Do not smoke or use open flame in vicinity where batteries are being charged. The charging process

generates hydrogen, a highly explosive gas.

W A R N I N G

Do not remove radiator cap unless engine has stopped and cooled to reduce pressure.

W A R N I N G

Always be alert for personnel in the area during operation of the forklift truck.

W A R N I N G

Always bleed off the pressure before operating any part of the hydraulic brake system by operatingthe brake pedal several times with the engine not running. Failure to observe this warning mayresult in severe injury to personnel.

W A R N I N G

Operation of this equipment presents a noise hazard to personnel in the area. The noise level ex-

ceeds the allowable limits for unprotected personnel. Wear ear muffs or ear plugs.

W A R N I N G

Drycleaning solvent, P-D-680, used to clean parts, is potentially dangerous to personnel and

property. Do not use near an open flame or excessive heat. The flash point of solvent is 138F.

W A R N I N G

Compressed air used for cleaning purposes will not exceed 30 psi. Use only with effective chipguarding and personal protective equipment (goggles/shield, gloves, etc.)

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CHANGE

No. 3

TM1O-393O-242-12

C3

HEADQUARTERS

DEPARTMENT OF THE ARMY

Washin gton D. C., 26 Ju ly 1991

OP ER ATOR AND ORGANIZATIONAL

MAINTENANCE MANUAL

(NSN 3930-00-327-1575)

TRUCK, LlFT, FORK; DIESEL ENGINE, PNEUMATIC TIRED WHEELS,

R O U G H T E R R A I N , 6 , 0 0 0 L B C A P A C I T Y , 2 4 I N C H L O A D C E N T E R

ANTHONY MODEL MLT 6-2 ARMY MODEL MHE-230

C u r r e n t a s o f

TM 10-3930-242-12, 30 January 1987 is changed as follows:

1. Inside Front Cover. Add the following warning:

WARNING

If NBC exposure is suspected, all air filter media should be handled by personnel wearing

protective equipment. Consult your unit NBC Officer or NBC NCO for appropriate hand

Iing or disposal instructions.

2. Remove old pages and insert new pages.

3. New or chan ged mater ial is indicated by a vertical bar in t he ma rgin of the page.

R e m o v e P a g e s I n s e r t P a g e s

Pages 2-13 Pa ges 2-13

Pages 3-7 Pa ge 3-7

Pages 3-7.0 thru 3-7.3. Add pages 3-8 th ru 3-8.3

Pa ge 3-9 th ru 3-10 Page 3-9 th ru 3-10

Pa ge 4-4 Pa ge 4-4

Page 4-9 thru 4-14 Page 4-9 th ru 4-14

4. File this change sheet in front of the publication for reference purposes.

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By Order of th e Secretar y of the Army:

GORDON R. S ULLIVAN

General, United States Army

Chief of Staff

Official:

PATRICIA P. H ICKERSON

Brigadier General, United S tates Arm y

The Ajutant General

Distribution:

To be distributed IAW DA Form 12-25-E (Block No. 2227) Operator and Unit maintenance

requir ement s for TM 5-2410-223-24.

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C h a n g e s I n f o r c e : C 1 a n d C 2

C H A N G E

No. 2

TM 10-3930-242-12

C 2

HEADQUARTERSDEPARTMENT OF THE ARMY

Washington, D.C., 18 July 1989

OP ER ATOR AND ORGANIZATIONAL MAINTENANCE MANUAL

F OR

TRUCK, LIFT, FORK, DIESEL ENGINE, PNE UMATIC TIRE D WHEELS,

ROU GH TE RR AIN; 6,000 LB CAPACITY, 24 INCH LOAD CEN TER

(ANTHONY MODEL MLT-6, ARMY MODEL MHE-200)

(NSN 3930-00-903-0900),

(CHRYSLER MODEL MLT-6CH, ARMY MODEL MHE-202)

(NSN 3930-00-937-0220),

(ATH EY MODEL ARTF T-6, ARMY MODEL MHE -222)

(NS N 3930-00-419-5744)

TM 10-3930-242-12, 31 July 1980, is changed as follows:

1. Remove old pages and insert new pages as indicated below.

2. New or changed material is indicated by a vertical bar in the margin of the page and by a vertical baradjacent to the illustration identification number.

R e m o v e P a g e s I n s e r t P a g e s

i and ii

1-1 and 1-2

2-5 through 2-10

3-5 through 3-8

3-11

4-1 through 4-4

4-41 and 4-42

A-1

C-1

D-9 a nd D-10

i and ii

1-1 and 1-2

2-5 through 2-10

3-5 through 3-8

3-11/(3-12 blank)

4-1 through 4-4

4-41 and 4-42

A-1/(A-2 blank)

C-1/(C-2 blank)

D-9 a nd D-10


1

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By Order of the Secretary of the Army:

Official:

CARL E. VUONO

General, United States ArmyChief of S taff

WILLIAM J. MEEHAN II

Brigadier General, United States ArmyTh e Adjutant General

Distribution:

T o b e d i s t r i b u t e d i n a c c o r d a n c e w i t h D A F o r m 1 2 - 2 5 F , O p e r a t o r a n d U n i t

m a i n t e n a n c e r e q u i r e m e n t s f o r F o r k L i f t , 6 0 0 0 L B C a p a c i t y , R o u g h T e r r a i n ,

P n e u m a t i c T i r e , D i e s e l ( M o d e l M H E - 2 0 0 , 2 0 2 , 2 2 2 ) C u m u l a t i v e .

2

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Change in force: C1 TM10-3930-242-12

C1

CHANGE HEADQUARTERS


NO. 1 Washington, D. C., 30 January1987

TECHNICAL MANUAL

OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL

FOR

TRUCK, LIFT, FORK, DIESEL ENGINE, PNEUMATIC TIRED WHEELS,

ROUGH TERRAIN 6,000 LB CAPACITY, 24 INCH LOAD CENTER


NSN 3930-00-903-0900,

(ANTHONY MODEL MLT-6 WITH ROPS)

NSN 3930-01-054-3831,


NSN 3930-00-937-0220,

(CHRYSLER MODEL MLT-6CH WITH ROPS

NSN 3930-01-053-4823,(ATHEY MODEL ARTFT-6, ARMY MODEL MHE-222)

NSN 3930-00419-5744,

(ATHEY MODEL ARTFT-6 WITH ROPS)

NSN 3930-01-054-3830

TM 10-3930-242-12, July 1980 is changed as follows:

1. Remove old pages and insert new pages as indicated below.

Remove pages Insert Pages

Pages D-1 through D-7, APPENDIX D Pages D-1 through D-14, APPENDIX D


B y O r d e r o f t h e S e c r e t a r y o f t h e A r m y :

J OHN A. WICKHAM, J R.

G en e r a l , U n i t ed S t a t e s A r m y

C h i e f o f S t a f f

Official:

R.L. DILWORTH

Brigadier General, United Sta tes Army

The Adjutant General

D i s t r i b u t i o n :

T O be distr ibuted in accordance with DA Form 12-25 , Operator and Organizat ionalM a i n t e n a n c e r e q u i r e m e n t s f o r T r u c k , L i f t , F o r k , D i e s e l E n g i n e , R o u g h T e r r a i n ,

6,000 lb. capacity, Model MHE-200, 202, 222.

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*TM 10-3930-242-12

TECHNICAL MANUAL HEADQUARTERS


NO.10-3930-242-12 WASHI NGTON, DC, 31 July 1980

OP ER ATOR AND ORGANIZATIONAL MAINTENANCE MANUALF O R

T RU CK , L I F T , F O RK , D I E S E L E N G I N E ,

PNEUMATIC TIRED WHEELS, ROUGH TERRAIN

6,000 LB CAPACITY, 24 INCH LOAD CENTER


NSN 3930-00-903-0900


NSN 3930-00-937-0220

(ATHEY MODEL ARTFT-6, ARMY MODEL MHE-222)

NSN 3930-00-419-5744

REP ORTING ERRORS AND RECOMMENDING IMPR OVEMENTS

You can help improve this manual. If you find any mistakes or if you know of a way toimprove th e pr ocedures, please let us know. Mail your letter, DA Form 2028(Recommended Changes to Publications and Blank Forms), or DA Form 2028-2,l oca t e d in t h e ba c k of t h i s m a n u a l , d i r ect t o: C om m a n de r , U.S . Ar m yTank-Automotive Command, ATTN: AMSTA-MB, Warren, Ml 48397-5000. A replywill be furn ished t o you.

ParagraphCHAPTER 1. INTRODUCTION

Section I. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .II. Des cript ion an d da ta . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 2. OPERATING INSTRUCTIONSSection I. Operating procedures, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II. Oper at ion u nd er u nu su al condit ions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 3. OPERATOR/CREW MAINTENANCE INSTRUCTIONSSection I. Lu bricat ion in st ru ctions ........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II. Pr eventive ma inten an ce checks an d ser vices . . . . . . . . . . . . . . . . . . . . . . . . . . .III. Troubleshooting ............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV. Maint ena nce pr ocedur es....... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CHAPTER 4. ORGANIZATIONAL MAINTENANCE INSTRUCTIONSSection I. Service upon receipt of material.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

II. Movement toa new worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .III. Repair pa rt s, special tools an d equipm ent . . . . . . . . . . . . . . . . . . . . . . . . . . . . .IV. Preven tive ma inten ance checks an d services . . . . . . . . . . . . . . . . . . . . . . . . . . .V. Trou bles hootin g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1-1-5-1-6-1-8

2-1-2-52-62-13

3-1,3-23-3,3-4

3-53-6 3-13

4-1, 4-24-3, 4-44-5,4-64-7,4-8

4-9,4-10

l Tbis man ua l super sedes TM 10-3930-242-12, 24 December 1973, inc lud ing a l l cha nges .

C h a n g e 2

Page

1-11-1

2- 12-12

3-13-63-8

3-10

4-14- 14-24-24-4

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VI.VII.

VIII.IX.X.

XI.XII.

XIII.XIV.

XV.XVI.

XVII.XVIII.

APPENDIX A.B.C.D.E.F.

INDEX

Main ten an ce of lubr ication syst em. . . . . . . . . . . . . . . . . . . . .Main ten an ce of Exha ust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maint enan ce of fuel sys tem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ma int ena nce of cooling s yst em . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main ten an ce of electr ical sys tem ... . . . . . . . . . . . . . . . . . . . . .Maint ena nce of cont rols and inst ru ment s. . . . . . . . . . . . .Main ten an ce of tra nsm ission. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Main te na nce of pr opeller sh aft . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Main ten an ce of whee ls . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . . . .Maintenance of steering system. . . . . . . . . . . . . . . . . . . .. . . . . . . . .Main ten an ce of hood an d body... . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .Maintenance of hydraulic lift, pump, and tubing . . . . . . . . . . . . .

Refer en ces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Components of end items list. . . .. . . . . . . . . .. (None Authorized)Additional a ut horiza tion list ... . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance allocation chart. . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair par ts an d special t ools list . . . . . . . . . . . . . . . . (None Aut horized)Expen dable su pplies an d m at erials list . . . . .. . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P a r a g r a p h

4-114-154-16,4-17

4-184-224-234-314-324-424-434-524-534-56

4-574-584-62

4-634-644-674-684-704-714-77

A-1B-1C-1D-1E-1F-1

P a g e

4-54-84-9

4-144-214-314-354-374-38

4-414-424-434-48

A-1B-1C-1D-1E-1F-1

I-1

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C H A P T E R 1

I N T R O D U C T I O N

S e c t i o n I .

1-1. S c o p e

This manual is for your use in operating and

maintaining rough terrain forklift trucks, Army

models MHE-200, MHE-202, and MHE-222.

1-2. M a i n t e n a n c e F o r m s a n d R e c o r d s

Equipment maintenance forms, and procedures for

th eir use a re cont ained in DA Pam 738-750.

1-3. Admin i s t r a t i ve S to r age

a . S t o r e e q u i p m e n t t o p r o v i d e m a x i m u m

protection from the elements and to provide access

for inspection, maintenance, and exercising. An-

ticipate removal or deployment problems and take

suitable precautions.

b. Take into account environmental conditions

such as extreme heat or cold, high humidity,

blowing sand, dust, loose debris, soft ground, mud,

heavy snows, and take adequate precautions.

G E N E R A L

C. Establish a fire plan and provide for adequate

fire fighting equipment and personnel.

d. Additional information can be found in TM

740-90-1.

1-4. D es t ruc t ion o f A rm y M ate r i e l t o P reven t

E n e m y U se

Procedures for the destruction of Army materiel to

prevent enemy us e ar e explained in TM 750-244-6.

1-5. R e p o r t i n g E q u i p m e n t I m p r o v e m e n t R e co m -

men d a t io n s (E IR )

If your Rough Terrain Fork Lift Truck needs im-provement, let us know. Send us an EIR. You, the

user, are the only one who can tell us what you dontlike about your equipment. Let us know why you

dont like the design or performance. Put it on an SF

368 (Quality Deficiency Report). Mail it to us at:Commander, U.S. Army Tank-Automotive Com-

m a n d , A T T N : A M S T A - Q R D , W a r r e n , M I48397-5000. Well send you a reply.

S e c t i o n I I . D E S C R I P T I O N A N D D AT A

1-6. Desc r ip t ion

The rough terrain forklift truck (fig. 1-1 and 1-2) is

capable of operating over all types of terrain. It hasfront and rear axle steering which enables it to move

sideways at 20 angles and gives the forklift a

shorter turning radius. The forklift can be operated

in two-wheel or four-wheel drive, enabling it to

travel through mud, snow, sand, and up steep

grades with equ al mobility. The forklift ha s fording

capability up to five foot waves. The body and forks

for t he forklift may be t ilted right or left in relat ion

to the front axle. The forks are extended by

hydraulically operated telescoping arms which

reach out, up, or down to handle loads. A hydraulic

cylinder m oves th e forks right or left from center to

lift off-center loads. Th e forklift ha s expan ding tu betype hydra ulic brak es, hydrau lically opera ted power

steering, and a torque converter. The maintenance

paragraphs o f t h i s m anua l con ta in de t a i l ed

descriptions of its components.

1-7. T a b l u a t e d D a t a

a. Identification. The forklift ha s a n iden tification

plate mounted on the left side of the hull which

specifies the nomenclature, shipping dimensions,

model number, and engine manufacturer. The data

for this plate is listed under tabulated data (bbelow).

b. Tabulated Datu

(1) Corps of En gin eers A Pla te.Nomenclature. . . . . . . . . . . . . . . . .. . Truck, forklift, diesel. pneu-

matic tired, 6,000 lb capacityat 24 inch load center

Engine manufacturer. . . . Detroit DieselModel . . . . . . . . . . . . . . . . . . . . .4 -53-N

(2) Dimensions and Weights

Cube . . . . . . . . . . . . . . . .1,763cu ftLengt h . . . . . . . . . . . . . . . . 228 in.Width . . . . . . . . . . . . . . . . . . . . 102 in.He igh t . . . . . . . . . . . . . . . . . . . 131 in.Weight:

Anthony and AtheyEm pty . . . . 23,000 lbMaximum 29,000 lb

Chrys le rEmpty . . . 24,759 lbMaximum . 30,759 lb

Front wheel weights:Em pt y . . . . . . . . . . . . . . . . 8,645 lbLoaded . . . . . . . . . . . . . . . .l6,952 lb

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Rear wheel weights:Empty . . . . . . . . . . . . . . .15,915 lbLoade d . . . . . . . . . . . . . . .13,608 lb

(3) Capacities.Fu el ta nk . . . . . . . . . . . . . . . . 80 galHydra ulic tan k . . .. . . . . . . . 200 qtTran smission . . . . . . . . . . . . 24 qtCra nk case w/filter . . . . . . . . 16 qtRadiator . . . . . . . . . . . . . . . . 25 qtPlan eta ry dr ive . . . . .. . . . 4 qt ea

Differen tia l . . . . . . . . . . . . . . 10 qt ea(4) Wirng diagram. See figure 1-3.

1-8. Di f f e r ences Among Mode l s

This manual covers the Anthony Model MLT-6

( M H E - 2 0 0 ) , t h e C h r y s l e r M o d e l M L T - 6 C H

( M H E - 2 0 2 ) , a n d t h e A t h e y M o d e l A R T F T - 6

(MHE-222). The differences among models exist in

the hydraulic cylinders and the common hardware

relative to size, length, and type. Cylinder assembly

internal parts are not interchangeable on Anthony

and Chrysler models, but are interchangeable onAnthony and Athey models. All hydraulic cylinders

are interchangeable between models.

Figu re 1-1. R ough t e r ra i n f ork l i f t t ruck , r i gh t f ron t t h ree-quar t er v i ew w i t h sh i pp i n g d i mens i ons .

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Figure 1-2. Rough terrain forkl i f t t ruck, le f t rear , three-quarter v iew.

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fgure1-3

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C H A P T E R 2

O P E R A T I N G I N S T R U C T I O N S

S e c t i o n I . O P E R A T I N G P R O C E D U R E S

WARNING

Operation of this equipment presents a

noise hazard to personnel in the area. The

noise level exceeds the allowable limits

for unprotected personnel. Wear ear

muffs or ear plus.

2-1. G e n e r a l

a. The instructions in this section are for the

informa tion a nd guidance, of personnel r esponsible

for the operation of the rough terrain forklift truck.

WARNING

When climbing into th e drivers seat , be

careful not bum p hea d on roll over

protective str ucture (ROPS).

b. The operator must know how to perform every

operation of which the forklift truck is capable. This

section gives instructions on starting, stopping,

operating, and coordinating the basic motions to

perform the specific tasks for which the forklift is

designed. Since nearly every job presents a different

problem, the operator may have to vary given

procedures to fit the individual job.

c. The outside steering radius of the forklift truck

is 32 feet in CRAMP steering mode and 43 feet in

the TWO WHEEL steering mode. If steering dif-

ficulty is experienced in the CRAMP or CRAB

modes of steering, it may be best to continue

opera tion in th e TWO WHEE L steering mode.

2-2. C o n t r o ls a n d I n s t r u m e n t .The controls and instruments and their normal

readings are illustrated in figur e 2-1.

2-1

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2-2 Figure 2-1. C on t r o l s a n d i n s t r u m e n t s .

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2-3. S t a r t i n g

a Preparation for Starting.

operat ion ser vices in ta ble 3-1.NOTE

Starting circuit is operative only when

FWD NEUT REV control lever is in

TM 10-3930-242-12

b. Starting. Refer to figure 2-2 and s tar t the

Perform the beforeforklift.

C A U T I O N

Cont inue operation only if ther e is not a n

NEUT.

STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

STEP 6:

STEP 7:

STEP 8:

apparent loss of hydraulic oil or no

unu sual noise from the hydra ulic pump t o

prevent da mage t o the forklift.

PLACE FWD-NEUT-REV LEVER IN NEUT POSITION.

ENGAGE PARKING BRAKE.

CHECK RADIATOR FAN CONTROL LEVER FOR PROPER POSITION.

PLACE IGNITION SWITCH IN ON POSITION.

PRESS ACCELERATOR PEDAL DOWN ONE THIRD DISTANCE.

PRESS STARTER BUTTON.

WARM ENGINE FOR THREE TO FIVE MINUTES AND OBSERVE INSTRUMENTS FOR

NORMAL READING (FIG. 2-1).

REMOVE FOOT FROM ACCELERATOR PEDAL.

TA072307

Figure 2-2. E n g i n e s ta r t ing i n s t r u c t i o n s .

2-3

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2-4. O p e r a t i o n o f E q u i p m e n t

WARNING

Do not attempt to cross a side slope of

30 or more wi th forkl i f t in FOURW H EEL s t ee r ing m ode because the

forklift may tu rn over.

a. General. The rough terrain forklift truck is

capable of opera ting over all types of terr ain su ch as

snow, sand, and steep grades with equal mobility.

b. Driving on Improved Surfaces. Refer to figure

2-3 for driving instructions while operating on

improved surfaces. After you pu t th e dr ive selector

lever in TWO WHEEL DR, place the CRAB,

CRAMP, and TWO WHEEL steering control lever

in the TWO WHEEL steeering position and engage

the TWO WHEEL steering lock.

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STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

STEP 6:STEP 7:

START ENGINE (REF. PARA. 2-3).

PULL FORK LIFT CONTROL LEVER TO RAISE FORKS 12 TO 18 INCHES OFF OPERATING

SURFACE.

PLACE DRIVE SELECTOR LEVER (LOCATED TO REAR OF PARKING BRAKE) IN TWO-

WHEEL DRIVE POSITION.

DISENGAGE PARKING BRAKE AND APPLY SERVICE BRAKES.

PLACE TRANSMISSION RANGE CONTROL LEVER IN DESIRED P OSITION, DEPENDING ONWEIGHT OF LOAD. PLACT FWD-NEUT-REV CONTROL LEVER IN DESIRED POSITION.

RELEASE SERVICE BRAKES.PRESS ACCELERATOR PEDAL AND PROCEED.

TA501572

Fig u re 2 -.3 Dr iv in g o n imp ro u ed su r fa ces .

c.. Driving on Unimproved Surfaces. Refer to figure 2-5 for instructions for driving in snow or

figure 2-4 for driving instructions in surf. Refer to sand.

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NOTE:

STEP 1:

NOTE:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

STEP 6:NOTE:

CAUTION:

STEP 7:

CAUTION:

N O T E :

NOTE:

NOTE:

MAKE SURE FLYWHEEL HOUSING DRAIN PLUG IS IN PLACE, AND START ENGINE (FIG. 2.2).

PULL-

FORK LIFT CONTROL LEVER TO RAISE F ORKS JUS T HIGH E NOUGH TO

CLEAR THE SURF.

IF TRANSPORTIN G A LOAD, PU LL FORK EXTENSION CONTROL LEVER BACK TO RETRACT

LOAD AS CLOSE TO CENTER OF TRUCK AS POSSIBLE TO BALANCE LOAD.

PLACE DRIVE SELECTOR LEVER (LOCATED TO REAR OF PARKING BRAKE) IN FOUR-

WHEEL DRIVE POSITION.

RELEASE PARKING BRAKE AND APPLY SERVICE BRAKES.

PLACE TRANSMISSION RANGE CONTROL LEVER IN DESIRED POSITION. NORMALLY A LOW-

SPEED POSITION IS REQUIRED FOR SURF OPERATION.

PLACE FWO-NEUT-REV CONTROL LEVER IN POSITION FOR DESIRED DIRECTION OF

TRAVEL.

RELEASE SERVICE BRAKE, PRESS ACCELERATOR PEDAL AND PROCEED.J UST BEFORE E NTERING SURF, P LACE RADIATOR FAN CONTROL LEVER IN OFF POSITION.

WHEN LEAVING SURF, PLACE RADIATOR FAN CONTROL LEVER IN ON POSITION.

DO NOT ALLOW WATER TO EXCEED 5-FOOT LEVEL MARK, MEASURED FROM CREST OF

WAVES. PROCEED SLOWLY THROUGH SURF, KEEPING CONSTANTLY ALERT FOR HOLES

AND OCEAN BOTTOM SOFTNESS. WHEN TIDE IS OUT, BOTTOM IS ESPECIALLY SOFT. IF

TRUCK BEGINS TO MIRE, DO NOT STOP: MANEUVER UNTIL FREE. DIFFERENTIAL LOCK MAY

BE USED WHEN NECESSARY TO GAIN ADDITIONAL TRACTION.

OBSERVE RAMP OF LANDING CRAFT BEFORE ENTERING. ENTER FROM CENTER OF RAMP

ON WAVE RATHER THAN BETWEEN WAVES TO COMPENSATE FOR SHIFTING. KEEP SIGHT

ON TOP OF LEFT FORK. USE FORK TILT CONTROL LEVER TO BALANCE LOAD WHEN

GOING UP OR DOWN RAMP.BRAKES ARE LESS EFFECTIVE IMMEDIATELY AFTER LEAVING SURF.

IF CONDITIONS WARRANT THE USE OF FOUR-WHEEL STEERING, ALINE FRONT WHEELS,PLACE FMD-NEUT-REV CONTROL LEVER IN FORWARD POSITION AND PLACE CRAB AND

CRAMP CONTROL LEVER IN DESIRED P OSITION:

CRAMPING IS NOT RECCMMENDED FOR SOFT TERRAIN.

AFTER OPERATION IN SURF, SEE LO 10-3930-242-12-1, NOTE 6 AND NOTE 7.

2-6

Figure 2-4. D r i v in g i n s u r f

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NOTE: START ENGINE (FIG. 2-2).

STEP 1: PULL F ORK LIFT CONTROL LEVER TO RAISE F ORKS 12 TO 18 INCHES ABOVE OPERATING

SURFACE.STEP 2: PIACE DRIVE SE LECTOR LEVER (LOCATED TO REAR OF P ARKING BRAKE) IN 4-WHEELDRIVE .

STEP 3: RELEASE PARKING BRAKE AND APPLY SERVICE BRAKE .

STEP 4: PLACE TRANSMISSION RANGE CONTROL LEVER IN POSITION FOR DESIRED SPEED,

DEPENDING ON WEIGHT OF LOAD AND TERRAIN CONDITIONS.

STEP 5: PLACE FWD-NEUT-REV CONTROL LEVER IN POSITION FOR DESIRED DIRECTION OF

TRAVEL.

STEP 6: RELEASE SERVICE BRAKE, PRESS ACCELERATOR PEDAL AND PROCEED.

NOTE: DRIVE IN TRACKS ALREADY MADE IF POSSIBLE.

STEP 7: IF FEASIBLE, APPROACH SAND DUN ES DIRE CTLY (AT RIGHT ANGLES). ATTEMPTS TOSCALE AN INCLINE SIDEWAYS AND UPWARD USUALLY RESULT IN DOWNWARD SLIPPAGE.

IF A DIRECT APPROACH CANNOT BE MADE, USE THE OSCILLATION CONTROL LEVER TOBALANCE LOAD DURING THE ASCENT.

WARNING: DO NOT ATTEMPT TO CROSS A SLOPE OF 30 OR MORE BECAUSE THE TRUCK MAYOVERTURN.

NOTE: DIFFERENTIAL LOCK MAY BE USED WHEN NECESSARY TO GAIN ADDITIONAL TRACTION INSAND OR SNOW.

TA501736

Figu re 2-.5.Driv ing in san d or snow.

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d. Picking up Load on Improved Surfaces. Refer

to figure 2-6 for instructions.

NOTE:

STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

STEP 6:

STEP 7:

LOAD CARRY POSITION SH OULD BE 20-24 INCHE S ABOVE TH E GROUND TO TH E H EEL

OF FORKS AND 21-23 INCHES FROM TREAD OF FRONT TIRE TO THE HEEL OF FORKS.

INNER AND OUTER BOOM SHOULD BE MARKED AT THIS POINT FOR QUICK OPERATOR

REFERENCE.

APPROACH LOAD SQUARELY WITH LIFT FORKS AT CORRECT HEIGHT AND SPACEDTO DIVIDE LOAD EVENLY. BE SURE LOCK ASSEMBLIES ARE SECURE IN THE CHAIN,AND THAT THE SPECIAL LOCK HANDLES ARE IN THE LOCKED POSITION.

DEPRE SS INCHIN G PE DAL ABOUT HALFWAY TO MOVE FORWARD SLOWLY UNTIL LIFTFORKS ARE COMPLETELY UNDE R LOAD.

DEPRESS INCHING PEDAL FULLY TO NEUTRALIZE TRANSMISSION.

ACCELERATE ENGINE SLIGHTLY, NOT MORE THAN 1/2 THROTTLE OR APPROXIMATE-LY 1500 RPM.

PULLBACK FORK LIFT CONTROL LEVER AND PICK UPLOAD.

PULLBACK FORK TILT CONTROL LEVER TO TILT LOAD AND PREVENT ITS SLIP PIN GFROM LIFT FORKS.

PULLBACK FORK EXTENSION CONTROLTION AND BETTER BALANCE TRUCK.

LEVER TO RETRACT LOAD TO CARRY POSI-

Figure 2-6. Picki ng up load on imp roved surfa ces.

e. Picking up Load on Unimproved Surfaces.

Refer t o figure 2-7 for instructions.

TA501573

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NOTE :

STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

STEP 6:

STEP 7:

STEP 8:

STEP 9:

LOAD CARRY POSITION SHOULD BE 20-24 INCHES ABOVE THE GROUND TO THE HEEL

OF F ORKS AND 21-23 INCHES F ROM TREAD OF FRONT TIRE TO THE HEE L OF F ORKS.

INNE R AND OUTER BOOM SHOULD BE MARKED AT THIS POINT FOR QUICK OP ERATOR

REFERENCE.

APPROACH LOAD SQUARELY AND STOP TRUCK (FIG. 2-9), LEAVING AMPLE ROOM TOMAKE F ORK ADJUSTMENTS.

PUSH FORK EXTENSION CONTROL LEVER FORWARD TO EXTEND FORKS LONGITUDIN-ALLY.

PUSH FORK TILT CONTROL LEVER FORWARD TO TILT FORK CARRIAGE TO VERTICALPOSITION.

PUSH FORK LIFT CONTROL LEVER FORWARD AND LOWER FORKS TO CORRECT HEIGHT.SEE THAT FORKS ARE SPACED TO DIVIDE LOAD EVENLY, IF NECESSARY, USE FORKSIDE SHIFT CONTROL LEVER TO PROPERLY POSITION FORKS FROM SIDE TO SIDE.

DEPRESS INCHING PEDAL ABOUT HALFWAY TO DRIVE TRUCK FORWARD SLOWLY UNTILFORKS ARE COMPLETELY UNDER LOAD.

DEPRESS INCHING PEDAL FULLY TO NEUTRALIZE THE TRANSMISSION AND ACCELERATETHE ENGINE NOT MORE THAN 1/2 THROTTLE OR APPROXlMATELY 1500 RPM.

PULLBACK FORK LIFT CONTROL LEVER AND PICK UPLOAD.

PULLBACK FORK TILT CONTROL LEVER TO TILT LOAD AND PREVENT ITS SLIPPING

FROM FORKS.PULLBACK FORK EXTENSION CONTROL LEVER TO RETRACT LOAD TO CARRY POSITIONAND BETTER BALANCE TRUCK.

TA501574

Figure 2-7. P i c k i n g u p l o a d o n u n i m p r o v e d s u r f a c es .

f. Depositin g Load .Refer to figure 2-8 for in-

structions.

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STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

STEP 6:

STEP 7:

STEP 8:

STEP 9:

STEP 10:

CAREFULLY DRIVE UP TO POSITIO WHERE LOAD IS TO BE DEPOSITED.DEPRESS INCHING PEDAL.

PUSH FORK EXTENSION CONTROL LEVER FORWARD TO EXTEND FORKS

LONGITUDINALLY.

PUSH FORK TILT CONTROL LEVER FORWARD TO TILT CARRIAGE TO VERTICAL POSITION.

IF LOAD IS TO BE DEPOSITED ON GROUND LEVEL, PUSH FORK LIFT CONTROL LEVER

FORWARD AND ALLOW LOAD TO LOWER SLOWLY TO RESTING PLACE. CONTINUE TO

LOWER FORKS UNTIL THEY CAN BE EASILY WITHDRAWN FROM PALLET. THEN PROCEED

WITH STEP 10.

IF LOAD IS TO BE DEP OSITED ON A TIERED STACK, PULL F ORK LIFT CONTROL LEVER

BACK UNTIL LOAD REACHES DESIRED HEIGHT ABOVE TIER, THEN PROCEED WITH STEPS

7 THROUGH 10.

RELEASE INCHING PEDAL ABOUT HALFWAY AND INCH TRUCK FORWARD UNTIL LOAD IS

ABOVE ITS RESTING PLACE.

DEPRESS INCHING PEDAL.

PUSH FORK LIFT CONTROL LEVER FORWARD AND LOWER LOAD CAREFULLY TO ITSRESTING P LACE. CONTINUE TO LOWER FORKS UN TIL THEY CAN BE E ASILY WITHDRAWN

FROM PALLET.

PLACE FWD-NEUT-REV CONTROL LEVER IN REV AND RELEASE INCHING PEDAL.

TA072391

Figure 2-8.Dep o si t in g lo a d .

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2-5. S t o p p i n g

a . Normal Stopping.

stopping instructions.

R efe r t o f igure 2-9 for

STEP 1:

STEP 2:

STEP 3:

STEP 4:

STEP 5:

REMOVE FOOT FROM ACCELERATOR.

DEPRESS BRAKE PEDAL SLOWLY AND BRING TRUCK TO GRADUAL STOP.

PLACE FWD-NEUT-REV CONTROL LEVER IN NEUT POSITION.

IF TRUCK IS TO BE PARKED, APPLY PARKING BRAKE, ALLOW ENGINE TO IDLE

3-5 MINUTES THEN PULL UP ON NORMAL ENGINE SHUTOFF HANDLE.

TURN OFF IGNITION SWITCH.

TA072392

Figu re 2-9. Fork l i f t s topp ing in s t ruc t ions .

b . E m e rg en c y S t o p p i n g . P u l l u p o n t h e

E M E R G E N C Y S T O P C O N T R O L t o s t o p t h e

engine in enemergency.

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NOTE

T o r e s t a r t t h e e n g in e a f t e r t h e

EMERGENCY STOP CONTROL has

b e e n u s e d , p u s h t h e E M E R G E N C Y

Sec t ion I I . OPERATION

2-6. Oper a t ion in Ex t r em e Co ld ( be low 0F .(18 C))

S T O P C O N T R O L d o w n . T h e

EMERGENCY STOP CONTROL reset

lever, located on left side of engine must

be pushed toward the cylinder block.

UNDER UNUSUAL CONDITIONS

foreign materials. If fuel filters requir servicing,report to organizational maintenance.

a. C heck coo lan t l eve l and add coo lan t a sf . L u b r i c a t e i n a c c o r d a n c e w i t h c u r r e n t

specified in table 2-1. Have organizational main-lubrication chart (fig. 3-1).

tenance perform specific gravity test to make sureg. Pull up on either primer butt on, engage starter ,

that antifreeze solution is correct for lowest tem-and with th e engine tur ning, press the ether but ton

perature expected.down. If combustion does not occur, repeat the

b. Inspect cooling system. Correct or report any priming process with the starter engaged.

leaks.h. In extremely cold weather it is advisable to

c. Keep batteries fully charged. After addinggive the engine one priming charge before engaging

distilled water to the bat teries, run t he engine for atthe starter. Then proceed as in g above.

least 15 minutes.i. Allow the engine to reach normal operating

d. Keep fuel tank full when not in operation.temperature before applying load.

e. Drain secondary fuel f i l ters of water and

Table 2-1. Freezing Points, Composition, and Specific Gravities of Military Antifreeze Material

Lowes texpecteda m b i e n t

t e m pF.

+2 0

+1 00

10

2 0 3 0 4 0 5 0 6 075

P i n t s o f inh ib i tedglycol pergallon ofcoo l an t

1

Compound , an t i f reeze2

11

/2 Issued full strength a nd ready mixed for 0 to 65 F temper atu res 1.022for both installation and losses.

223

344

Arct i can t i f reezep r e f e r r e d

1.0361.0471.055

1.0621.0671.073

E t h y l e n e g l yc oo l a n t s o l us p e c i f i c g r a

at 68 F.

1Maximu m protection is obta ined at 60 percent by volume (4.8 pint s of eth ylene glycol per gallon of solution).

2Military Specification M IL-C-11755 Arctic type, non-volatile antifreeze compound is intended for use in the cooling system of

liquid cooled internal combustion engines. It is used for protection against freezing primarily in Arctic regions where the ambienttempera tur e rema ins for extended periods of time close to 40 F., or below, to as low as 90 F.

Use an accurate hydrometer. To test hydrometer, use 1 part ethylene glycol type antifreeze to 2 part s water. This should produce ahydrometer reading of 0 F.

2-7. S t a r t i n g A id (2) perform normal starting procedures (para

a. General The s tar t ing a id i s a pressur ized 2-3).system used to inject a highly volatile fluid into teh (3) If engine fails to start, refer to

engine air intake system. This is to facil i tate troubleshooting table (table 3-2).

starting when ambient temperatures are below2-8. O p e r a t i on i n E x t r e m e H e a t

40 F. The r eplaceable pressur ized cylinder cont ains WARNINGsufficient fluid for 75-150 sta rt s.

b. Operating the Starting Aid.Be extremely careful when removing the

(1) Operate starting aid control for about 2ra diat or filler cap of a h ot engine. Release

of pressure may cause violet boiling andseconds. Wait 3 seconds before cran king en gine.

serious injury to personnel.

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a. Insur e t hat radiator filler cap seals properly.

The boiling point of the coolant is raised as the

system pressure is increased.

b. Check coolan t level frequent ly and add coolan t

as necessary. Use standard ethylene glycol mixtureas specified in ta ble 2-1.

c. Remove all obstructions and foreign material

collected on radiator fins and air passages.

d. Do not overfill fuel t an k. Make su re fuel filters

are clean.

WARNING

If NBC exposure is su spected, all air filter

media should be han dled by personnelwearing protective equipment. Consult

your unit N BC Officer or NBC NCO forappropriate ha ndling or disposal pr ocedures.

e. Have air cleaner cleaned and serviced.

2-9. o p e r a t i o n i n D u s t y o r S a n d y Ar e a

a. Clean all grease fittings after operation.

b. Lubricate in accordan ce with figure 3-1.

c. Check oil filter and engine oil frequently.

d. Have a ir cleaner ser viced often .

e. Have fuel filters cleaned and serviced.

2-10. O p e r a t i o n i n S a l t Wa t e r Ar e a

a. Keep all lubrication points clean and well

lubricated.

b. Keep all wiring and ignition terminals free of

corrosion.

c. Keep forklift as clean as possible.

d. After operation is complete, wash with freshw ate r . Lubr i ca t e i n accordance w i th f igu re

3-1. Check a ll gear cases for wat er cont am inat ion.

If contamination is found, (evidenced by a milky

color of lubricant) drain, flush, and refill.

2-11. Ope r a t i on Unde r R a i ny o r Hum i d C ond i t i ons

a. Keep fuel tank full at all times.

b. Wash forklift truck after operation.

2-12. Ope ra t i on a t H i gh Al t it ude

a. Check coolant level frequently and add coolant

as necessary.

NOTEThe engine will operate less efficiently at

high altitudes.

b. Observe engine instruments while operating

for any indication of trouble.

2-13. Ope ra t i on i n Snow

a. Keep fuel tank full at all times. Keep snow

away from filler where servicing fuel tan k.

b. Clean all snow from operating controls and

from steps.

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C H A P T E R 3

O P E R A T O R / C R E W M A I N T E N A N C E I N S T R U C T I O N S

S e c t i o n I . L U B R I C A T I O N I N S T R U C T I O N S

WARNING

Drycleaning solvent, P-D-680, used to

clean parts is potentially dangerous to

personnel and property. Do not use near

open flame or excessive heat. The flash

point of solvent is 138 F.

3-1. G e n e r a l L u b r i c a t i on I n f o r m a t i o n

This section contains information on lubrication

instructions not covered in the current lubrication

order. Refer to the current lubrication order for all

other instr uctions.

3-2. D e t a i le d L u b r i c a t i o n I n f o r m a t i o n

a. Care of Lubricants. Keep all lubricants in

closed containers and store in a clean, dry place,

away from heat. Keep container cover clean and in

good condition. Keep dust , dirt, a nd all other foreign

material out of the lubricant. Keep all lubrication

equipment clean and ready for use.

b. Cleaning. Keep all external parts, that do not

require lubrication, free of lubricants. Wipe all

lubrication points clean before lubricating the

forklift truck. Clean all lubrication points of ex-

cessive lubricant after servicing to prevent a build-

up or accumulation of foreign matter.

CAUTION

E x c e s s i ve l u b r i c a t i o n m a y ca u s e

equipment failure or damage to movable

parts .

c. Points of Lubrication. Service the forklift truck

at the int ervals given in figure 3-1.d. Intervals of Lubrication. The intervals of

lubrication specified in the lubrication order chart

(fig. 3-1) are based on operation under normal

conditions. Modifications of these recommended

intervals may be required under unusual operating

conditions.

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Figure 3-1. LO 10-3930-242-12-1/2 (Sheet 1 of 4)

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Figu re 3-1. LO 10-3930-242-12-1/-2 (Sh eet 2 of 4)

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Fig u re 3-1. LO 10-3930-242-12-1/-2 (S h eet 3 of 4)3-4

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Fig u re 3-1. LO 10-3930-242-12-1/-2 (Sh eet 4 of 4)3-5

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3-3. M a in t e n a n c e F o r m s a n d R e c or d s

SECTION II. OPERATOR/CREW PREVENTIVE MAINTENANCE

CHECKS AND SERVICES (PMCS)

Every mission begins and ends with the paperwork.

Ther e isnt m uch of it, but you ha ve to keep it up.

The forms and records you fill out have several uses.

They are a permanent record of the services, repairs,and modifications made on your equipment. They

are reports to organizational maintenance and to

your commander. They are also a checklist for you

when you want to know what is wrong with the equip-

ment after its last use, and whether those faults have

been fixed. For the information you need on forms

and records, see DA Pam 738-750.

3-4. G e n e r a l

Your Preventive Maintenance Checks and Services

Table lists the inspections and care of your equip-

ment required to keep it in good operating condition.

3-4 .1 . O pera to r /C rew Preven t ive M ain tenance

Che c ks a nd Se rv i c e s

a. The number column of your PMCS is the

source for the n umber used on th e TM Number Col-

umn on DA Form 2404.

b. The interval column of your PMCS Table tells

you when to do a certain check or service.

(1) Before you operate. Perform your before

(B) PMCS. Always keep in mind the WARNINGS

and CAUTIONS.

(2) While you operate. Perform your during

(D) PMCS Always keep in mind the WARNINGS

and CAUTIONS.

(3)After you operate. Be sure to perform your

af ter (A) PMCS. Always keep in mind the

WARNINGS and CAUTIONs.

(4) Once a week. Perform your weekly (W)

PMCS. Always keep in mind the WARNINGS and

CAUTIONS.

c. The procedure column of your PMCS Table

tells you how to do the required checks and services.

Carefully follow these instructions. If you do not have

the tools, or if the procedure tells you to, have organ-

izational maintenance do the work.

d. If your equipment does not perform as re-

quired, refer to the troubleshooting section in this

ma nu al for possible problems. Report an y malfunc-

tions or failures on the proper DA Form 2404 or

refer to DA Pam 783-750.

NOTE

The terms ready/available and mission capa-

ble refer to the same status: Equipment is on

han d an d is able to perform its combat mis-

sions (see DA Pam 738-750).

e. Equipment is not ready/available if: column.

This column tells you when and why your equipment

cann ot be u sed.

f. Always do your PMCS in the same order so it

gets t o be a h abit. Once youve ha d some pr actice,

you will spot anything wrong in a hur ry.

g. When you do your PMCS, take along a rag or

two.

h . W h i l e p e r f o r m i n g P M C S , o b s e r v c e a l l

WARNINGs and CAUTIONs preceding those opera-

tions which could endan ger your safety or result in

damage to the equipment.

WARNING

Dry cleaning solvent, P-D-680, is toxic and

flammable. Wear protective goggles and

gloves and use only in a well-ventilated area.

Avoid allowing solvent to contact skin, eyes,

an d clothes, an d dont brea th e vapors. Do

not use near open flame or excessive heat. If

you become dizzy while using cleaning sol-

vent, get fresh air immediately and get

medical aid. If solvent comes in contact with

skin or clothing, wash with water. If solvent

gets in your eyes, flush eyes with water and

get medical aid immediately. Flash point of

solvent is 100-138F (38-59C).

(1) Keep it clean. Dirt, grease, oil and debris

only get in the way and may cover up a serious prob-

lem. Clean as you work and as needed. Use dry

clean ing solvent (P-D-680) to clean meta l sur faces.

Use soap and wat er when you clean rubber or plastic

material.

(2) Bolts, nuts, and screws. Check that they

are not loose, missing, bent, or broken. You cant try

th em a ll with a tool, of cour se, but look for chipped

paint, bare metal, or rust around bolt heads. Tighten

an y bolt, nu t, or screw th at you find loose.

(3) Welds. Look for loose or chipped paint,

rust or gaps where parts are welded together. If you

find a bad weld, report it to organizational m ainte-

n a n c e .

(4) Electric wires and connectors. Look for

cracked or broken insulation, bare wires, and loose

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or broken connectors. Report dam aged or loose wir-

ing to organizational maintenance.

(5)Hoses and flu id lin es. Look for wear, dam-

age, and leaks. Make sure clamps and fittings are

tight. Wet spots show leaks, but a stain around a fit-

ting or connector can also mean a leak. If leakage

comes from a loose fittin g or conn ector, t ighten th e

fitt ing or conn ector. If someth ing is broken or worn

out, report it to organizational maintenance.

(6) Fluid level. Vehicle must be on level

ground in order to get correct fluid level measure-

m e n t .

i. It is necessary for you to know how fluid leaks

affect the status of your equipment. The following

are definitions of the types/classes of leakage you

need to know to be able to determine t he sta tus of

your equipment. Learn and be familiar with t hem,

and REMEMBER when in douubt, notify your su-

pervisor.

TM10-3930-242-12

Leakage Defini tions for Opera tor/ Crew PMCS

Class I Seepage of fluid (as indicated by wetness ordiscoloration) not great enough to formd r o p s .

Class II Leakage of fluid great enough to form drops,but not enough to cause drops to drip from theitem being checked/inspected.

Class III Leaka ge of fluId great enough to form dropsthat fall from the item being checked/in-spected.

CAUTION

Equipment operation is allowable with minor

leakages (Class I or II). Of course, consid-

eration must be given to the fluid capacity in

the item/system being checked/inspected.

When operating with Class I or II leaks, con-

tinue to check fluid levels as required on

your PMCS. Class III leaks should be re-

ported to your supervisor or to organizational

maintenance.

I t emNo.

1

2

Ta ble 3-1. O pe r a t o r /Cr e w Pr e v e n t i v e M a i n t e nan c e Che c k s an d Se r v i c es

NOTE: Within designated Interval, these checks are to be

B Before

performed in the order listed.

D D u r i n g A A f t e r W W e e k l y

Interval

D A W

I tem To Be Inspec ted

Procedure : Check for and have repa i red, f i l l ed, ora d j us t e d a s ne e de d .

IMPORTANT - PERFORM WEEKLY (W) AS

WELL AS BEFORE (B) OPERATIONS P MCS IF:

a. You are t he a ssigned operator an d ha ve not op-

erated the vehicle since the last weekly PMCS.

b. You are opera ting t he vehicle for th e first time.

E XT E RI O R O F VE H I CL E

a. Check for fuel, engine oil, coolant and hy-

draulic leaks or appearance of leakage.

b. Visually check Roll Over Pr otective Str uctu re

(ROPS) for damage, bends, or cracks in weldment.

c. Visually check forks , carria ges, and side sh if-

ter frame for cracked, bent , or br oken component s

or fram e members.

d. Visually check wiring harness and connec-

tions for frayed, broken, or bur ned wires.

TIRE S AND WHEE LS

a. Check tires for excessive wear, cuts, or abra-

sions, embedded foreign objects, and obviously low

or flat condition. (Ref TM 9-2610-200-24)

Equi pme n t i s no t Re a dy / Available If:

Class III leaks ar e evident.

Damage, bends, or cracks

in weldment.

Forks, carriage, or side

sh i f t e r f r am e c racked ,

bent, or broken.

Wiring is frayed, broken,

or burn ed.

Tires have cuts or abra-

sions which would result in

tire failure. Tires are low,

flat, or missing.

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Table 3-1. Operator/Crew Prventive Maintenance Checks and Services - Continued

NOTE: Within designated interval, these checks are to beperformed in the order listed.

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Tabel 3-1. Operator/Crew Preventive Maintenance Checks and Services - Continued


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Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - Continued


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Table 3-I. O per a t o r / C r cw p r even t i ve Main tenan ce Checks and SemitesConth wed

N O T E : Wi t h i n d e s i g n a t e d I n t e r v a l , t h e s e c h e c k s a r e t o b ep e r f o r m e d i n t h e o r d e r l is t e d .

B - B e f o r e D - D u r i n g A - A f t e r W - W e e k l y

In te rva l I t em To Be Inspec ted

I t e m P r o c e d u r e : C h e ck fo r a n d h a v e r e p a i r e d , fi lle d , o r E q u i p m e n t is n o t R e a d y

No. B D A W a d j us t e d a s ne e de d . Availab le If:

21 RADIATOR

WARNING

Pressurized cooling system. Remove cap

slowly and only when engine is cool or pain-

fud burns could resu lt.

Visually check coolant level and ensure that coolant Radiator obviously low or

is 1-1/2 to 2 inches below neck. empty. Refer to instrument

checks.

22 FUEL SYSTEM

CAUTION

In freezing weather , drain wat er from pr i-mary falter after operation or damage to

equipment could result.

Drain water and contaminants from primary falter.

Frozen water in fuel system could cause damage to

equipment.

Sect ion I I I . TROUBLESHOOTING

3-5. G e n e r a l actions. If a malfunction is not listed or is no

a . T h i s s e c t i o n c o n t a i n s t r o u b l e s h o o t i n g

inform at ion for locating a nd correcting most of the

operating troubles which may develop in the rough

terrain forklift truck. Each malfunction for an

individual component, unit, or system is followed by

a list of tests or in spections wh ich will help you t o

determine corrective actions to take. You should

perform the tests or inspections and corrective

actions in the order listed.

b. This manu al cannot list all malfunctions t hat

may occur, nor all tests or inspections and corrective

corrected by listed corrective actions, notify you

supervisor.

c. Table 3-2 lists the common malfunctions whic

you m ay find du ring th e operat ion or m aintena nce

the rough terr ain forklift tru ck or its component

You should perform the tests or inspections and th

corrective actions in the order listed.

NOTE

Before you u se th is table, be sure you ha ve

performed all applicable operating checks.

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Table 3-2. O p e r a t o r / C r e w T r o u b l e s h o o t i n g

MalfunctionTest or inspection

Corrective action

1. ENGINE FAILS TO STARTStep 1. Check for hose, corroded or damaged battery cables and connection. Clean corroded cables. Tighten loose connections

Step

Step

Step

and report damaged cables to organizational maintenance.2. Check to be sure that engine shut-off is pushed down and that lever at the governor housing is in the start position.Adjust cable as necessary.3. Check to be sure the emergency stop is in operating position at the engine blower.Reset if required.

If NBC exposure is suspected, all air filter media should be handledby personnel wearing protective equipment. Consult your unit NBCOfficer or NBC NCO for appropriate handling or disposal procedures.

4. Check for air cleaner intake restrictions.Correct as necessary.5. Check for empty fuel tank.Fill as required.

Step

2. ENGINE OPERATES ERRATICALLYStep 1. Check for clogged air cleaner.

Have air cleaner serviced.Step 2. Check for condensation and fuel contamination.Drain condensation from fuel filters before engine. Report evidence of fuel contamination to organizational main-tenance.

Step 3. Notify supervisor and organiazational/direct support maintenance to check governor gap.3. ENGINE LACKS POWER

Step 1. Check for clogged air cleaner.Have air cleaner serviced.

Step 2. Check fuel fiiters for contamination.Drain condensation from fuel filters before starting engine. Report evidence of fuel contamination to organizational main-tenance.

Step 3. Notify supervisor and organizational/direct support maintenance to check fuel rack and govenor operation.4. ENGINE OVERHEATS

Step 1. Check radiator for low level of coolant.Allow engine to cool and fill with coolant.

Step 2. Check fan belt for looseness.

Report a hose or damaged fan belt to organizational maintenance.Step 3. Check radiator for free airflow.Clean radiator fins if required.

5. ENGINE EXHAUST SMOKE EXCESSIVEStep 1. Check for clogged air cleaner.

Have air cleaner serviced.6. ENGINE OIL CONSUMPTION EXCESSIVE

Step 1. Inspect engine compartment for oil leaks.Do not continue operation if oil leak is likely to reduce engine off below a safe operating level. Report leaks to organisationalmaintenance.

7. STEERING ERRATICStep 1. Check for rear steering cross-shaft binding in tube.

Do not continue operation if the erratic stearing constitutes a threat to personnel or may result in equipment damage. Reportto organizational maintenance.

Step 2. Check for low level of hydraulic fluid.Report low hydraulic fluid level to organizational maintenance.

8. BATTERY FAILS TO MAINTAIN CHARGEStep 1. Check for low level of electrolyte.

Fill battery with distilled water.Step 2. Visually inspect battery for damage such as loose terminal posts or warped internal plates.

Report unserviceable batteries to organizational maintenance.

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Section IV. OPERATOR/CREW MAINTENANCE PROCEDURES

3-6. Engine Ai r Cleaner Inspec t ion

WARNINGIf NBC exposure is suspected, all air filter m e-

dia should be handled by personnel wearing

protective equipment. Consult your u nit NBCOfficer or NBC NCO for a ppr opriate h an dlingor disposal procedures.

Loosen the clamp and remove the cup. Remove the

element and inspect it for excessive accumulation of

dirt. Remove the cup dust trap and inspect for

excess ive accumulat ion of dus t . Repor t to

organizational maintenance for Servicing.

3-7. E t h e r P r i m e r

Refer to figure 3-2 and service the ether primer.

Figu re 3-2. E th er p r imer serv ic in g ,

3-8. B a t t e r y

Visually inspect batteries for damage, such as loose above the plates. Replace vent cap. Inspect cables

electr olyte. The electr olyte sh ould be one-half inch

terminal posts or warped internal plates. Remove and battery holddown hardware for corrosion.

battery cell vent caps (fig. 3-3) and check the level of

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Figur e 3-4 E x h a u s t m a n i f o l d a n d f l a n g e .

Fi gu r e 3 - 3.Bat tery.

3-9. F u e l T a n k

a. In spection. Inspect the fuel tank for dents and

leaks.

b. S ervice. Fill fuel tank with diesel fuel ac-

cording to table 33.

Ta ble 3-3. Fuel Use According to Temp erture

Temperature range Fuel

+20 F. and warmer VVF-800 Type DF2

25 F. and warmer VVF-800 Type DF1

25 F. an d colder VVF-800 Type DFA

3-11. E x h a u s t M a n i fo ld a n d F l a n g e

Inspect exhaust manifold and flange for cracks,

nicks, and dama ged parts. Refer to figure 3-4.

3-12. M u f f l e r a n d E x h a u s t P i p e

Inspect muffler an d exhau st pipe for cracks, dents,

and rus t .

3-13. L i g h t s

a . Inspect ion. V i s u a l l y i n s p e c t h e a d l i g h t s ,

blackout lights, stop/taillights, and marker lights

for operation.b. Adjustment. Headlights and blackout lights

may be adjusted to meet lighting requirements, as

these requirements change with various jobs.

3-10. C o o la n t H o s e s a n d F i t t i n g s

Inspect hoses and fittings for cracks and damage.

Inspect hoses for deterioration and cuts.

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C H A P T E R 4

O R G A N I Z A T I O N A L M A I N T E N A N C E I N S T R U C T I O N S

S e c t i o n I . S E R V I C E U P O N R E C E I P T O F M A T E R I A L

4-1. I n s p e c t i n g Ne w E q u i p m e n t

a. Assure that the required tools, repair parts,

and other items troop installed or authorized are

included with the equipment.

b. Inspect the diesel engine and mounted com-

ponents for damaged or missing items.

c. Inspect wiring, fuel and oil lines, radiator

hoses, fuel and hydraulic oil tanks, hydraulic system

piping, gages, instruments, and lights for missing,

loose, broken, or damaged parts.

d. Inspect drain plugs, breat hers, filter caps, and

drain cocks for improper installation and damage.e. Inspect air and hydraulic hoses and lines and

elect r ica l leads for cuts , breaks , or s igns of

deterioration.

f. Correct deficiencies falling within the limits of

organizational maintenance.

4-2. S e r v i c in g E q u i p m e n t

a. Perform daily preventive maintenance as in-

dicat ed in ta ble 3-1.

WARNING

Avoid contact with electrolyte. If elec-

trolyte comes in contact with eyes, flush

thoroughly and immediately with coldwater. Do not rub eyes. All parts of the

S e c t i o n I I . M O V E M E N T

CAUTION

Height of equipment should be con-

sidered when shipping. The installation of

the roll over protective structure (ROPS)

adds t o the height which m aybe damaged

by low overpasses, bridges, and other

s tructures .

4-3. P r e p a r a t i o n F o r M o ve m e n ta. Local Movement. The forklift truck does not

requ ire special treat ment for local relocat ion a s it is

capable of moving short distances under its own

power.

b. Shipment.

(1) Disassembly. Remove side shift roller cha in,

cylinder, a nd fork s. Refer t o para graph 4-75.

(2) Roll Over Protective Structure (ROPS).

body touched by electrolyte should be

washed with cold water immediately. For

contact with fabrics, neutral ize elec-

trolyte using baking soda or household

am monia in a ddition to wash ing with cold

w a t e r .

b. Remove vent fill caps on the batteries and fill

each cell with dist illed wat er t o a level one ha lf inch

above the tops of the plate separators.

c. Replace vent caps.

d. Apply a light coating of nonmetallic grease or

petroleum jelly to the bat tery posts. Install batt ery

cables. Tighten and cable terminals securely.

e. Wipe the tops of the batteries and battery

holddown hardware with a cloth moistened with

baking soda or ammonia solution to remove any

spilled acid. Wipe dry with a clean cloth.

f. Insure that, all drain valves on the engine and

radiator are closed. Fill the radiator with clean

water to a level 1 inches below the neck of the

radiator.

NOTE

When operating in temperatures below

freezing, use antifreeze in quanti t ies

indicated in ta ble 2-1.g. Install and secure ra diator cap.

T O A N E W W O R K S I T E

(a) Depending on the mode of shipment,

height requirements, route, etc., it maybe nece ssary

to remove ROPS prior to shippin g.

(b) Refer to paragraph 4-68 and remove

ROPS.

(3)Mode of Sh ipm ent. Either railroad flat car orlow-boy trailer can be used to transport the forklift

truck over long distances. Secure the forklift truck

to the traiIer or flat car and cover as required.

4-4. As s e m b ly A ft e r M o v e m e n t

a. Refer to paragraph 4-74 and install side shift

roller chain, cylinder, and forks.

b. If ROPS was removed prior to shipping, refer

t o p a r a g r a p h 4 - 6 8 a n d i n s t a l l R O P S a f t e r

movement.

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Section III. REPAIR PARTS, SPECIAL TOOLS AND EQUIPMENT

4-5. T o o ls a n d E q u i p m e n t

There are no special tools and equipment authorized

for maintenance of this equipment.

Section IV. ORGANIZATIONAL

4 -6 Ma i n t e n a n c e R e p a i r P a r t s .

Repair parts and equipment are listed and illustrated

in TM 10-3930-242-20P.

PREVENTIVE MAINTENANCE

C H E C K S A N D S E R V I C E S ( P M C S )

4-7. G e n e r a l

To make sure that your vehicle is ready for operation

at all times, inspect it systematically so you can dis-

cover any defects and have them corrected before

they result in serious damage or failure. The table on

the next few pages contains your organizational

PMCS. The item num bers indicate the sequence of

minimum inspection requirements. If youre operat-ing the vehicle and notice something wrong which

could damage the equipment if you continue opera-

tion, stop operation immediately.

Record all deficiencies and shortcomings, along with

th e corr ective action ta ken, on DA Form 2404. The

Item Number Column is the source for the numbers

used on the TM Number Column on DA Form

2404.

4-8. O r g a n i z a t i o n a l P r e v e n t i v e M a i n t e n a n c e

Che c ks a nd Se rv ic e s

a. The item n umbers of the ta ble indicate the se-

quence of the PMCS. Perform at the intervals shown

below.

(1) Do your (Q) PREVENTIVE MAINTE-

NANCE quarterly (every three months).

(2) Do your (A) PREVENTIVE MAINTE-

NANCE an nu ally (once every year).

b. If something doesnt work, tr oubleshoot it a c-

cording to the instructions in this manual or notify

your supervisor.

c. Always do your prevent ive mainten an ce in th e

sam e order so it gets t o be a ha bit. Once youve had

some practice, you will spot anything wrong in a

hurry.

d. If anyt hing looks wr ong an d you cant fix it,

write it down on your DA Form 2404. If you find

something seriously wrong, report it to direct support

as soon as possible.

Dry cleaning solvent, P-D-680, is toxic and

flammable. Wear protective goggles and

gloves, and use only in a well-ventilated area.

Avoid allowing solvent to contact skin, eyes,

an d cloth es, and dont brea th e vapors. Do

not use near open flame or excessive heat. If

you become dizzy while using cleaning sol-

vent, get fresh air immediately and get

medical aid. If solvent comes in contact with

skin or clothing, wash with water. If solvent

gets in your eyes, flush eyes with water and

get medical aid immediat ely. Flash point of

solvent is 100-138F (38-59C).

(1) Keep it clean. Dirt, grease, oil, and debris

only get in the way and may cover up a serious prob-

lem. Clean as you work and as needed. Use dry

clean ing solvent (P-D-680) to clean met al su rfaces,

Use soap a nd wat er when you clean ru bber or plastic

mater ia l .(2) Bolts, nuts, and screws. Check that they

ar e not loose, missing, bent, or br oken. You cant tr y

th em a ll with a tool, of course, but look for chipped

paint, bare metal, or rust around bolt heads. Tighten

an y bolt, nu t, or screw th at you find loose.

(3) Welds. Look for loose or chipped paint,

rust, or gaps where parts are welded together. If you

find a bad weld, report it to direct support.

(4) Electric wires and connectors. Look for

cracked or broken insu lation, bare wires, an d loose

or broken connectors. Tighten loose connections and

ma ke sur e th e wires are in good condit ion.

(5) Hoses an d fluid lines. Look for wear, dam-

age, and leaks. Make sur e clamps an d fittings ar e

tight. Wet spots show leaks, but a stain around a fit-

ting or connector can also mean a leak. If leakage

comes from a loose fittin g or conn ector, t ighten th e

fitt ing or conn ector. If somethin g is broken or worn

out, either correct it or report it to direct su pport.

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e. It is n ecessarv for vou t o know how fluid leaks Leakage Definitions for Operator/ Crew PMCS

affect the status of your equipment. The following Class I Seepage of fluid (as indicated by wetnes s ordiscoloration) not great enough to form

are definitions of the types/classes of leakage you drops.need to know to be able to determine the status of Class II Leaka ge of fluid great enough to form drops,

your equipment. Learn and be familiar with t hem, but not enough to cause drops to drip from the

and REMEMBER item being checked/inspected.

when in d oubt, notify your su- Class III Leaka ge of fluid great en ough to form dropspervisor. that fall from the item being checked/in-

spected.

Tab l e 4 -1 . O r gan i z a t i ona l Pr e v e n t i v e M a i n t e nanc e Ch e c k s an d Se r v i c es

Q Q u a r t e r l y A -A n n u a l l y

I t e mNo .

1

2

3

In te rva l

Q A

I tem To Be Inspec ted

Pr oc edur e : Che c k fo r a nd ha ve r e pa i re d , fi ll ed , o r a d j us t e d a s n e e de d .

NOTE

Perform operator/crew PMCS before or in conjunction with organizational

PMCS if:

a. There is a delay between the daily operation of the equipment and the

o r g a n i z a t i o n a l P M C S .

b. Regular operator is not assisting/participating.

BATTERI ES

a .

b.

WARNING

Do not smoke or allow any flame or spa rk in t he vicinity wh ile checking or

filling battery. The battery generates hydrogen, a highly explosive gas.

CAUTION

In cold weather operations, charge battery immediately after adding water to

combine the water with battery electrolyte to prevent freezing. Be careful not

to overfill when servicing batteries.

Test ba tt ery to deter mine cell condition. (Ref TM 9-6140-200-14)

Clean battery top and terminals. Ensure that all connections are tight. (Ref

TM 9-6140-200-14)

TIRE S AND WHEE LS

a .

b.

c.

WARNING

Ensure that lockring is properly seated before inflating tire. Serious injury or

death to personnel ma y result sh ould lockring snap out of seat.

Check tire air pressure (45 psi front, 35 psi rear).

Check tires for cut s, wear, an d deter iora tion. (Ref TM 9-2610-200-24)

Check locking rim, wheel flanges, wheel, and nuts for cracks, breaks, and dents.Replace all defective parts.

BELTS

Check for excessive wear, da ma ge, and proper t ension (1/2 inch t o 3/4 inch deflec-

tion with a bout 10 lbs app lied force midway between th e pulleys) (par a 4-28).

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Tab l e 4 -1 . O r gan i z a t i ona l Pr e v en t i v e M a i n t e na nc e Che c k s and Se r v i c es -Con t i nue d

Q Q u a r t e r l y A-An n u a l ly

In te rva l

I tem I tem To Be Inspec ted

No. Q A Pr oc e dure : Che c k fo r a nd ha ve r e pa i re d , fi ll ed , o r a d j us t e d a s n e e de d .

4 AIR CLEANER

WARNING

Low pressure air used for cleaning purposes will not exceed 30 psi. Effec-

tive chip guarding and personnel protective equipment (goggles/shield,

gloves, et c.) will be used .

If NBC exposure is su spected, all air filter media will be ha ndled by per-

sonnel wearing full NBC protective equipment.

Clean air cleaner filter with low pressure air by blowing from the inside out

(para 4-20). Reset contamination indicator.

5 FUE L SYSTEM

a. Clean primary fuel filter (para 4-22).

b. Replace secondary fuel filter (para 4-22).

6 CRANKCASE BRE ATHER

Clean cran kcase breat her (para 4-13).

7 SERVI CE BRAKES

Check for linin g wear (para 4-59).

8 HOSE S, L INES, AND FITTIN GS

Inspect a ll hoses, lines, and fittin gs for dama ge or leak s (para 4-77).

9 P ARKING BRAKE

Check par king brake for pr oper adjustm ent (para 4-60 an d 4-61).

10 FRAME AND CARRIAGE

Check frame, forks, and carriages for damage, cracks, or bends.

11 RADIATOR

WARNING

Pressurized cooling system. Remove cap slowly and only when radiator is

cool or serious bur ns could resu lt.

Check coolan t condit ion in a ccordan ce with TB 750-651 a nd inspect cooling systemfor excessive rust or corrosion. Drain, clean, and refill the cooling system if required

(para 4-25 and 4-26).

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Section V. TROUBLESHOOTING4-9. G e n e r a l actions to be taken. Perform the tests/inspections

This section contains troubleshooting information and corrective actions in the order listed.

for locating and correcting most of the malfunctions 4-10. L i m i t a t i o nwhich may occur in the 6,000 pound rough terrain

forklift truck, Army Models MHE 200, MHE 202,This manual cannot list all malfunctions that may

and MHE 222. Each malfunction for an individualoccur, nor all tests or inspections and corrective

component, unit, or system is followed by a list ofactions. Notify your supervisor when malfunctions

tests or inspections. The tests and inspections willoccur that are not covered in troubleshooting table

help to determine probable causes and corrective4-2.

Table 4-2. Organizational Troubleshooting


Corrective action

1. ENGINE WILL NOT CRANKStep 1. Inspect battery connections for poor contact. Clean contact surfaces of battery connections and reinstall serviceable

cables. Replace cables that are damaged beyond repair,Step 2. Using a hydrometer, test the specific gravity of the electrolyte. A reading of 1.220 or lower indicates that the battery

is less than half charged. If electrolyte is too low to test, add distilled water and charge batteries for one hour beforechecking hydrometer readings.

If battery does not accept charge, replace (para 4-34).Step 3. Inspect starter for defective wiring.

Replace starter (para 4-37).WARNING

If NBC exposure is suspected, all air filter media should be ha ndledby personnel wearing protective equipment. Consult your unit NBCofficer or NBC NCO) for appropriate handling or disposal procedures.

2. ENGINE CRANKS, BUT FAILS TO STARTStep 1. heck to be sure engine stru t off is pushed down and tha t cable is actuating th e governor contr ol.Step 2. Check to be sure emergency shut-off is in start position.Step 3. Check the fuel tank for fuel and fuel fil ters for contamination.

Refuel an d/or r eplace filters a s n ecessary (para 4-22).Step 4. Inspect air cleaner for obstruction.

Clean if required (para 4-20).

3. ENGINE OPERATES ERRATICALLYStep 1. Check to be sur e fuel filters a re n ot obstru cting flow.

Clean if required (para 4-22).

Step 2. Check air cleaner for restriction.Clean if required (para 4-201.

Step 3. Notify supervisor and direct support to check governor and fuel rack.

4. ENGINE LACKS POWERStep 1. Inspect throttle linkage for damage, excessive wear, and limited movement.

Adjust serviceable linkage. Replace damaged or excessively worn linkage.Step 2. Inspect air cleaner for damage or obstruction.

Replace dama ged air cleaner or faulty air cleaner h oses (para 4-20).Step 3. Notify supervisor and direct support maintenance to check governor and fuel rack.

5. ENGINE OVERHEATSStep 1. Check radiator fins for free air flow.

Clean if required.Step 2. Inspect for loose, damaged, or broken fan belts.

Adjust loose fan belts. Replace unserviceable belts (para 4-28).Step 3. Inspect for poor coolant circulation.

Replace faulty hoses, clamps (para 4-26) and thermostats (para 4-24).Check water pump and replace if faulty (para 4-25).

6. EXCESSIVE LUBRICATING OIL CONSUMPTIONStep 1. Inspect engine compartment for evidence of oil leakage.

Replace defective or worn hoses, tubing, fittings, and gaskets.

7. TRANSMISSION AN TORQUE CONVERTER OVERHEATSStep 1. Inspect for low transmission oil level.

Service transmission IAW LO 10-3930-242-12-1.Step 2. Check for loss of oil due to defective hose assemblies.

Replace hose assemblies (para 4-77).

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Table 4-2. Organizational Troubleshooting-Continued


Corrective action

Step 3. Inspect for clogged or damaged filter.Clean or replace filter as necessary (para 4-54).

Step 4. Check gear range being used by operator.May have to use lower gear range for specific operating condition.

8. CONVERTER STALL SPEED LOWStep 1. Inspect throttle linkage for proper adjustment.

Adjust linkage for full governor travel.Step 2. Notify supervisor and direct support to check governor and fuel rack.

9. STEERING ERRATICStep 1. Inspect s teering cross-sha ft for binding in the tube. Lubricate cross-shaft and all steering linka ge IAW LO

10-3930-242-12-2.

10. BATTERIES FAIL TO MAINTAIN CHARGEStep 1. Inspt battery for shorted plates or loose terminal posts.

Replace shorted orunserviceable batteries (para 4-34).

11. BRAKES WILL NOT APPLYStep 1. Inspect for hydraulic leaks in t he brake system.

Replace defective hoses, lines, fittings, and seal (para 4-77).Step 2. Inspect for air in hydraulic system.

Bleed hydraulic brake system (para 4-59b).

12. BRAKES DRAG, RUN HOT, OR DO NOT RELEASE PROPERLYStep 1. Inspect for air in h ydraulic actuating system.

Bleed service brakes (para 4-59b).Step 2. Inspect for clogged or restricted hydraulic tank filter (para 4-76). Replace clogged or dam aged filter IAW LO

10-3930-242-12-2.

13. LOW HYDRAULIC SYSTEM PRESSUREStep 1. Check for clogged hydraulic filter (para 4-76).

Replace if required IAW LO 10-3930-242-12-2.Step 2. Inspect for leaks at cylinder gland packing.

Tighten packing nuts. If leakage continues, report to direct support maintenance.

S e c t i o n V I . M A I N T E N A N C E O F L U B R I C A T I O N S YS T E M

WARNING

Drycleaning solvent, P-D-680, used to



open flame or excessive heat. Flash point

of solvent is 138 F.

4-11. G e n e r a l

This section contains information for organizational

maintenance of the lubrication system. Main-

tenance includes oil filter, crankcase breather, and

dipstick.

4-12. O i l F i l t e r

a. Removal. Refer to figure 4-1 and remove the oil

filter.

b. Cleanin g and Inspection.

(1) Refer to figure 4-2 and service the oil filter.

Remove center stud and disassemble f i l ter as

shown.

(2) Make sure the gasket surfaces are clean.

Clean with drycleaning solvent (item 1, App F) and

dry thoroughly.

(3) Inspect flange and block for nicks and

cracks. Remove sma ll nicks with emery cloth .

c. Installation. Use a new gasket. Refer to figure

4-1 and in sta ll oil filter.CAUTION

Check for oil leaks while engine is run-ning. Oi l leaks could cause ser ious

damage to the engine.

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Figure 4-1. Oil filter, removal and installation.

Figure 4-2. Oil filter service.

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4-13. C r a n k c a s e B r e a t h e r

a . Removal. Refer to figure 4-3 and remove the

crankcase breather.

b. Cleaning and Inspection.WARNING

Compressed air used for cleaning pur-

poses will not exceed 30 psi. Use only

with effective chip guarding and personal

protective equipment (goggles/shield,gloves, etc.)

(1) Wash the inside of the crankcase breather

with drycleaning solvent (item 1, App F). Dry with

compressed air.

(2) Inspect the crankcase breather for cracks

and bends.

c. lnstallation. Refer to figure 4-3 and instal l the

crankcase breather.

TM10-3930-242-12

4-14. Oi l Level Dipst ick

a. Refer t o figure 4-4 for removal and installation,

of th e oil level dispst ick.

b. Check, clean, and repair as required.

4-15. O i l F i ll e r P i p e a n d C a p

a . Removal. Refer to figure 4-4 and remove the

filler cap.

b. Cleaning and Inspection.(1) Clean the oil f i l ler pipe and cap with

drycleaning solvent ( i tem 1, App F) a n d d r y

thoroughly.

(2) Inspect the cap seal for deterioration.

Replace a defective or damaged seal. Inspect the

filler pipe an d cap for cra cks an d da ma ge. Replace a

defective pipe or cap.

c.Installation. Refer to figure 4-4 and instal l the

oil filler cap.

Figu re 4-3. Crank case brea ther , removal and insta l la t ion .

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Figu re 4-4. O i l l ev e l d i p s t ic k a nd o i l fi l l er p i pe an d c ap , r em ov a l and i n s t a l l a t i on .

Sect ion VII . MAINTENANCE OF EXHAUST SYSTEM

WARNINGDrycleaning solvent, P-D-680, used to



open flame or excessive heat. Flash point

of solvent is 138 F.

4-16. G e n e r a l

This section contains information for organizational

maint enan ce of components of the exhau st system.

This includes the muffler and exhaust pipe.

4-17. M u f fl e r a n d E x h a u s t P i p e

a. Removal. Refer to figure 4-5 and remove the

muffler and exhaust pipe.

b. Inspection. Check muffler and exhaust pipe for

leaks, cracks, dents, and holes. Replace a defective

muffler.

c.Installation. Refer to figure 4-5 and instal l the

muffler and exhaust pipe.

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Figur e 4-5. M u f f l e r a n d e x h a u s t p i p e , r em o v a l a n d i n s t a l l a t i on .

Sect ion VIII . MAINTENANCE OF FUEL SYSTEM

WARNING

Drycleaning solvent, P-D-680 USed to


personnel and property. Do not u se near

open flame or excessive hea t. Fla sh pointof solvent is 138 F.

4-18. G e n e r a l

This section cont ains inform at ion for organ izational

maintenance of the fuel system. This includes the

fuel pump, air cleaner and hose, and fuel filter.

4-19. F u e l P u m p

a . Removal Refer to figure 4-6 and remove the

fuel pump.

b. Cleanin g and Inspection.

(1) Clean the fuel pump with drycleaningsolvent (item 1, App F ), and dry th oroughly.

(2) Inspect the fuel pump for cracks, breaks, or

other dam age. Replace if defective.

c. Installation.

(1) Affix a new gasket to the body of the pump

an d locate the pump drive coupling over the squar e

end of the fuel pump drive shaft.

(2) Refer to figure 4-6 and install the fuelp u m p .

Figure 4-6. Fuel pump, removal and installation.

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4-20. Eng ine A i r C leane r

WARNING

I f N B C ex p o s u r e i s s u s p ec t e d , a l l a i ra f t e r m e d i a s h o u l d b e h a n d l e d b y

p e r s o n n e l w e a r i n g p r o t e c t iv e e q u i p -

m ent . C onsu l t your un i t N B C or

N B C N C O fo r appropr i a t e hand l ing

o r d i s p o s a l p r o c e d u r e s .

a. Service. Refer to figure 4-7 for servicing

the air cleaner.

b. General. Service the primary filter when

th e air cleaner r estr iction indicat or is red.

(2) Cleaning

(a) The primary fi l ter element can be

cleaned by reverse flushing, compressed air, or

washing in water. Compressed air is recom-

mended when the element is to be reused imme-

diately. An element that has been washed in

water should be dried th oroughly before reuse.

Water is th e best cleaning agent a nd sh ould be

used when soot or oil has plugged the element.

The filter element should be replaced after six

cleanings or annually. The safety filter element

must be replaced at every third primary element

service.

WARNING

C o m p r e s s e d a i r u s e d f o r c l e a n i n g

pu rp ose w i l l no t exceed 30 ps i . U se

on ly w i th e f f ec t ive gua rd ing and

p e r s o n a l p r o t e c t iv e e q u i p m e n t g o g-

gles /sh ie ld , g loves , e tc ) .

NOTE

The safety filter element should not be

cleaned and reused.

(b) When using compressed air, direct the

air from inside the element to the outside, being

careful not to rupture the element. Insure O-ring

is properly seated and no leaks exist, Insure that

the filter restriction indicator indicates in the

green while engine is running.

(c) When u sing water to clean t he element ,

soak the element for at least 15 minutes in a de-

tergent an d water solution. Rinse with a h ose un-

til water runs clean. The maximum allowablewater pressure is 40 psi.

(d) Allow the element to dry thoroughly be-

fore using. Do not use compressed air or light

bulbs to dry a wet element.

(3) Inspection.

(a) Inspect the filter element by placing a

bright light inside and rotating the element

slowly. If any rupture or holes are discovered, re-

place element.

(b) inspect the air cleaner body, inlet stack,

and rain cap for damage. Replace defective parts.

(4) Installation.(a) Refer to paragraph 4-7 and install the air

cleaner elements.

(b) Reset th e rest riction indicator t o green.

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Figure 4-7 . A i r c l e a n e r s er v i c i n g .

NOTE: AFTER SERVICE, REINSTALL FILTER ELEMENTS,REI NSTALL CUP AND HOOK LATCH

4-21. Ai r C leaner Assemblya Removal. Refer to figure 4-8 and remove the

air cleaner a ssembly.

b. Cleaning and Inspection

(1) Flush the air cleaner body with water or

compressed.

(2) Clean all tubes and make sure they are open.

use a fiber brush to clean tubes.

(3) Empty the dust cap and clean the air cleaner

stack.

(4) Inspect hoses for damage and defective

connections.

(5) Replace all defective or worn parts.c. Assembly and Installation. Refer to figure 4-8

and assemble and install the air cleaner assembly.

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CAUTION

Be sure hose and hose connections are

leak-proof. Insure that the air cleaner

cover is properly secured. Unfiltered air

can cause serious dam age to the en gine.

TM10-3930-242-1

Figur e 4-8 A ir c lea n er a ssemb ly , r emo va l a n d in s ta l la t io n .TA072396

4-22. F u e l F i l t e r s (1) Refer to figure 4-10 and service the fuel

a. General. Change the secondary filter every 250 filters.

hours of operation and service the primary filter (2) Inspect hoses for deterioration and cuts.

every 50 hours. Inspect the body and head for cracks and breaks.

b. Removal. Refer to figure 4-9 and remove the

Replace defective parts.

primary and secondary fuel filters. d.Installation. Refer to figure 4-9 and instal l the

c. Cleaning and Inspectionprimary and secondary fuel filters. Use new gaskets

and be sur e the m ount ing surfaces are clean.

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Figure 4-9. F u e l f i l t e r s , r em o va l a n d in s ta l la t io n .

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TA031848Figure 4-10. Fuel f i l t er serv i ce .

S e c t i o n I X . M A I N T E N A N C E O F C O O L I N G S Y S T E M

WARNING is drawn from the bottom of the radiator by the

Drycleaning solvent, P-D-680, used to water pump. During the warm-up period, whenclean parts is potentially dangerous to coolant temperature is below normal, the coolant ispersonnel and property. Do not use near restricted by the thermostat. A bypass tube con-open flam e or excessive heat . Flash point netted between the thermostat housing and theof solvent is 138F. water

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TM 10- 3930-242-12