TM 10-3930-243-12

D E P A R T M E N T O F T H E A R M Y T E C H N I C A L M A N U A L

TECHNICAL MANUAL

OPERATOR AND ORGANIZATIONAL

MAINTENANCE MANUAL

TRUCK, LIFT, FORK, DIESEL ENGINE,

PNEUMATIC TIRED WHEELS, ROUGH TERRAIN

10,000 LB. CAPACITY, 24 INCH LOAD CENTER

(PETTIBONE - MULLIKEN MODEL RTL10,

ARMY MODEL MHE 199)

FSN 3930-903-0899

(PETTIBONE - MULLIKEN MODEL RTL10-1;

ARMY MODEL MHE 215)

FSN 3930-465-5869

HEADQUARTERS, DEPARTMENT OF THE ARMY

This copy is a repr in t wh ich inc ludes cur rent

p a g e s f r o m C h a n g e s 1 t h r o u g h 6 .

W A R N I N G P A G E

D o n o t s m o k e o r u s e o p e n f l a m e i n t h e a r e a w h e n s e r v i c i n g

h y d r o g e n , a h i g h l y e x p l o s i v e g a s .

t h e b a t t e r i e s . B a t t e r i e s g e n e r a t e

W h e n f i l l i n g t h e f u e l t a n k , a l w a y s p r o v i d e a m e t a l - t o - m e t a l c o n t a c t b e t w e e n c o n t a i n e r a n d f u e l

t a n k .

D o n o t m a k e a n y t e s t s o r a d j u s t m e n t s o r p e r f o r m a n y m a i n t e n a n c e w h i l e t h e t r u c k i s o p e r a t i n g o r

t h e g u a r d s a r e r e m o v e d .

W h e n l i f t i n g t h e t r u c k u s e a s u i t a b l e l i f t i n g d e v i c e o f a t l e s t 3 5 , 0 0 0 p o u n d s c a p a c i t y , a n d d o n o t

a l l o w t h e t r u c k t o s w i n g w h i l e i t i s s u s p e n d e d .

K e e p h a n d s , f l o o r , a n d c o n t r o l s f r e e o f g r e a s e , o i l , o r m u d t o a v o i d p o s s i b l e s e r i o u s i n j u r y .

D o n o t p e r f o r m a n y m a i n t e n a n c e w h i l e t h e t r u c k i s i n o p e r a t i o n .

I f t h e t r u c k i s t o b e t e s t r u n i n a n e n c l o s e d a r e a , t h e e x h a u s t g a s e s m u s t b e p i p e d t o t h e o u t s i d e . T h e

e x h a u s t g a s e s c o n t a i n c a r b o n m o n o x i d e w h i c h c a n b e f a t a l i f i n h a l e d .

D o n o t a t t e m p t t o f i l l t h e f u e l t a n k w h i l e t h e t r u c k i s r u n n i n g .

N e v e r m o v e t h e t r u c k w i t h t h e f o r k s f u l l y r a i s e d . T h e c o r r e c t f o r k h e i g h t i s 1 5 i n c h e s o f f t h e g r o u n d

f o r t r a v e l i n g .

D o n o t r e m o v e t h e r a d i a t o r c a p f r o m a h o t e n g i n e u n t i l e n g i n e h a s b e e n s h u t d o w n f o r

f i v e m i n u t e s t o r e l i e v e p r e s s u r e a n d t o a v o i d b e i n g b u r n e d .

N e v e r l e a v e t h e t r u c k w i t h t h e f o r k s r a i s e d .

A l w a y s s e t t h e h a n d b r a k e w h e n l e a v i n g t h e t r u c k .

W h e n f i l l i n g t h e f u e l t a n k , a l w a y s p r o v i d e a m e t a l - t o - m e t a l c o n t a c t b e t w e e n c o n t a i n e r a n d f u e l

t a n k .

D o n o t c a r r y p a s s e n g e r s .

F a s t e n y o u r s e a t b e l t s .

O p e r a t e i n p r o p e r s p e e d r a n g e . S e l e c t a n o p e r a t i n g s p e e d t h a t i s s a f e f o r t h e p a r t i c u l a r j o b .

Changes in fo rce: C5 and C6

T M 1 0 - 3 9 3 0 - 2 4 3 - 1 2

C 6

C H A N G E H E A D Q U A R T E R S

DEPARTMENT OF THE ARMY

No. 6 Washington D. C., 30 July 1991

O p e r a t o r ’ s a n d 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 M a n u a l

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

ROUGH TERRAIN; 10,000 LB CAPACITY, 24-INCH LOAD CENTER

(PETTIBONE-MULLIKEN MODEL RTL 10)

ARMY MODEL MHE 199

NSN 3930-00-903-0899

(PETTIBONE-MULLIKEN MODEL RTL 10,

WITH ROLL-OVER PROTECTIVE STRUCTURE)

ARMY MODEL MHE 199

NSN 3930-01-052-8997

(PETTIBONE-MULLIKEN MODEL RTL 10-1)

ARMY MODEL MHE 215

NSN 3930-00-465-5869

(PETTIBONE-MULLIKEN MODEL RTL 10-1,

WITH ROLL-OVER PROTECTIVE STRUCTURE)

ARMY MODEL MHE 215

NSN 3930-01-053-4824

TM10-3930-243-12, 3 June 1971, is changed as fol-

l o w s :

Inside front cover: The fol lowing W A R N I N G s h o u l d

be added:

W A R N I N G

If NBC exposure is suspected, all air f i lter media

should be handled by personnel wearing protective

equipment. Consult your unit NBC Officer or NBC

NCO for appropriate handling or disposal instruc-

tions.

N O T E

A decal has been developed that warns of NBC exposure.

It is to be positioned in a noticeable place on or near the

air filter housing. You may order the decal using part

n u m b e r 1 2 2 9 6 6 2 6 , C A G E C 1 9 2 0 7 ; r e f e r e n c e T B

43-0219 for more information.

After new note, add the following W A R N I N G decal as

follows:

I F N B C E X P O S U R E I S S U S P E C T E D A L L

A I R F I L T E R M E D I A W I L L 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 F U L L N B C

P R O T E C T I V E E Q U I P M E N T . S E E O P -

E R A T O R / M A I N T E N A N C E M A N U A L .

7 6 9 0 - 0 1 - 1 1 4 - 3 7 0 2

1

T M 1 0 - 3 9 3 0 - 2 4 3 - 1 2

Page 3-2.. Before Item No. 17 of Table 3-1, “AIR

CLEANER”, add the following WARNING:

WARNING: If NBC exposure is suspected, all air fil-ter media should be handled by personnel wearingprotective equipment. Consult your unit NBC Offi-cer or NBC NCO for appropriate handling or dis-posal instructions.

Page 3-3. Before 2 of Table 3-2, “Engine Misses andLacks Power”, and before paragraph 3-8, “Air CleanerService”, add the following WARNING:

WARNING: If NBC exposure is suspected, all air fil-

By Order of the Secretary of the Army:

Official:

P A T R I C I A P . H I C K E R S O N

B r i g a d i e r G e n e r a l , U n i t e d S t a t e s A r m y

T h e A d j u t a n t G e n e r a l

ter media should be handled by personnel wearingprotective equipment. Consult your unit NBC Offi-cer or NBC NCO for appropriate handling or dis-posal instructions.

Page 4-15. Before paragraph 4-28, “Air Cleaner,Bracket and Hose”, add the following WARNING:

WARNING: If NBC exposure is suspected, all air fil-ter media should be handled by personnel wearingprotective equipment. Consult your unit NBC Offi-cer or NBC NCO for appropriate handling or dis-posal instructions.

GORDON R. SULLIVAN

General, United States Army

Chief of Staff

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

To be distributed accordance with DA Form 12-25-E, Block 2242, Operator, Unit Maint-

enance Requirements for TM10-3930-243-12.

2

Table 2-1. Maintenance and Operating Supplies

(2)

Component Nationalapplication stock number

9150-00-189-6729 (2)

9150-00-191-2772 (2)9150-00-491-7197

9140-00-286-52869140-00-286-52949140-00-286-5283

(3) (4)Quantityrequired

forinitial

Description operation

OIL, LUBRICATION:55 gal. drum as follows:OE/HDO 30 MIL-L- 5 gal.2104OE-10 5 gal.OEA MIL-L-46167 5 gal.

FUEL OIL, DIESEL:Bulk spec VVF-800

TYPE DFl to -25°F 10 gal. (5)TYPE DF2 to -2O’F 10 gal. (5)TYPE DFA to -25°F or .lO gal. (5)below

0501RADIATOR 6850-01-181-7940 ANTIFREEZE: Ethyleneglycol 55 gal. drumMIL-A-46153

30 qt

9150-00-190-0907 Grease: Aircraft, GeneralPurpose, Wide TempRange, MIL-G-81322,35 lb pail

As req

OIL, LUBRICATING:

3 10OESl

22 qt22 qt

9150-00-577-5845 (2)9150-00-257-5443 (2)

OIL, LUBRICATING,GEAR: 55 gal. drum asfollows:GO 90 MIL-L-2105 10 qtGOS 10 qt

OIL, LUBRICATING,GEAR: GO 90 (8) 4 qt (9)GOS 4 qt (9)

OIL, LUBRICATING,GEAR: GO 90 (8) 4 qt (9)GOS 4 qt (9)

OIL, LUBRICATING,(4) OE-10 30 qtOEA 20 qt

OIL, LUBRICATING:55 gal. drum as follows:OE-10 38 gal.OEA 38 gal.

OIL, LUBRICATION (4) As reqOElHDO 30OE-10OEA

9150-00-190-0907 (2)

9150-00-234-5197

GREASE, AUTO-MOTIVE ANDARTILLERY: 35 lb pailGAA

OIL, LUBRICATION:VV-L-751 exposed gear

As req

As req

(1)

OlOl- CRANK-CASE (1)

0306-FUELTANK

0505-FAN HUB(Pulley) Assy

0708-TORQUECONVERTOR

1002-DIFFEREN-TIAL ASSEM-BLY

1003-PLANE-TARY DRIVE

1103-PLANE-TARY DRIVE

1413-TANKRESERVOIR(RTLIO)

2406-HYDRAU-LIC TANK

OIL CANPOINTS

GREASEFITTINGS

CHAINS ANDSPROCKETS

(5)Quantityrequired

for 8hours

operation

(6)

Notes

1) Includes quantityof oil to fill engineoil system asfollows:14-l/2 qt-crank-

casel-112 qt-oil filter

2) See C9100-IL foradditional data andrequisitioning pro-cedure.

3) See current LO forgrade applicationand replenishmentintervals.

4) Use oil as pre-scribed in item 1.

5) Tank capacity.

6) Average fuelconsumption is8.0 gal. per hourof continuousoperation.

7) See TM 10-3930-243-12 for quanti-ties, ambient tem-perature andspecific gravities.

8) Use gear oil as pre-scribed in item 5.

9) Quantities are foreach planetarydrive.

3

Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS - Continued

(1) (2) (3) (4) (5)Tool or TestEquipmentReference Maintenance National/NATO Tool

Code Level Nomenclature Stock Number Number

7 F Shop Equip, Auto Maint: 4910-00-754-0705 SC49 1 O-95CLA3 1Field Maint, Basic(SC 49 1 O-95CL-A3 1)

a F Shop Equip, Fuel and 49 10-00-754-0714 SC491 O-95CLAOlElec Sys, Engine:Field Maint, Basic(SC 49 1 O-95-CL-A0 1)

9 F Tool Kit, Light MachineRepair(SC 5160-90-CL-N26)

5180-00-596-1540 SC51 ao-90CL-N27

10 F Tool Kit, MasterMechanics(SC 51 ao-go-CL-N05)

5180-00-699-5273 SC51 ao-go-CL-NO5

11 F Tool Kit, Body andFender Repair(SC 51 ao-go-CL-N34)

5180-00-754-0643 SC51 ao-90CLN34

12 F Gage, Hydraulic PressureO-3000 psi

H027BM

Section IV. REMARKS

Not Applicable.

Page C-l. Appendix C is superseded as follows:

APPENDIX CBASIC ISSUE ITEMS LIST AND ITEMS TROOP INSTALLED OR AUTHORIZED LIST

Section I. INTRODUCTION

C-l. ScopeThis appendix lists items required by the operator foroperation of the truck.

C-2. GeneralThis basic issue items, troop installed or authorized listis divided into the following sections:

a. Basic Issue Items List-Section II. Not Applica-ble.

b. Items Troop Installed or Authorized List-Section III. A list of items in alphabetical sequence,which at the discretion of the unit commander mayaccompany the truck. These items are NOT SUB-JECT TO TURN IN with the truck when evacuated.

c-3. Explanation of ColumnsThe following provides an explanation of columns inthe tabular list of Basic Issue Items List, Section II,and Items Troop Installed or Authorized List,Section III.

a. Source, Maintenance, and RecoverabilityCode (s) (SMR) .

(1) Source code indicates the source for thelisted item. Source codes are:Code Explanation

P . . . . . . Repair parts, special tools, and test equipment sup-plied from GSAlDSA or Army supply system andauthorized for use at indicated maintenance levels.Repair parts, special tools, and test equipment whichare procured and stocked for insurance purposes be-

31

cause the combat or military essentiality of the enditem dictates that a minimum quantity be available inthe supply system.

(2) Maintenance code indicates the lowestlevel of maintenance authorized to install the listeditem. The maintenance level code is:Code Explanation

C . . . . . . . . . . . . . . . . . . Crew/Operator

(3) Recoverability code indicates whether un-serviceable items should be returned for recovery orsalvage. I tems not coded are nonrecoverable .Recoverability codes are:Code Explanation

R . . . . . Applied to repair parts (assemblies and components),special tools, and test equipment which are consideredeconomically repairable at direct and general supportmaintenance levels.

S . . . . . Repair parts, special tools, test equipment and assem-blies which are economically repairable at DSU and

GSU activities and which normally are furnished bysupply on an exchange basis.

6. National Stock Number. The column indicatesthe national stock number assigned to the item andwill be used for requisitioning purposes.

c. Description. This column indicates the Federalitem name and any additional description of the itemrequired.

d. Unit of Measure (UIM). A 2-character alpha-betic abbreviation indicating the amount or quantity ofthe item upon which the allowances are based (e.g., ft,ea, pr, etc.).

e. Quantity Furnished with Equipment (BIIL). NotApplicable.

f. Quantity Authorized (Items Troop Installed orAuthorized). This column indicates the quantity of theitem authorized to be used with the equipment.

Section II. BASIC ISSUE ITEMS LISTNot Applicable.

Section Ill. ITEMS TROOP INSTALLED OR AUTHORIZED LIST

(1)

SMR

(2) (3) (4) (5)National Unit

Stock of Qt yCode Number Description Meas Auth

7510-00-889-3494 BINDER, Looseleaf EA 1

7520-00-559-9618 CASE, Maintenance and Operation Manuals EA 1

4210-00-889-2221 EXTINGUISHER, Fire EA 1

Page I-l.Change the reference for Air cleaner service to

“paragraph 4-28, page 4-15”.After Air cleaner service, add “Air inlet housing,

paragraph 4-25.1, page 4-12”.After Ammeter, add “Automatic slack adjuster,

paragraph 4-79.1, page 4-48”.Change “Basic issue items” to “Basic issue items list

or items troop installed or authorized list”.After Battery cable, add “Battery charge indicator,

paragraph 4-43.1, page 4-28”.After Daily and weekly preventive maintenance

checks and services, add “Data and instruction plates,paragraph 4-96.1, page 4-61”.

Delete the entry for “Fenders”.Change the reference for Fuel filter service to

“paragraph 4-29, page 4- 16”.

Change “Hydraulic oil reservoir” to “Hydraulic oilreservoir service”.

After Hydraulic reservoir magnet, add “Hydraulicsteering pump, paragraph 4-84.1, page 4-52” and“ Hydraulic tilt cylinder, paragraph 4-91.2,page 4-58”.

Before Maintenance repair parts, add “Main hy-draulic pump, paragraph 4-9 1.1, page 4-58”.Page I-2.

After Transmission and torque converter oil hosesand fittings, add “Transmission assembly pressuretests, paragraph 4-73.1, page 4-44”.

Delete the entry for “Transmission cut of valve(inching) “.

After Wheels, add “Wiring harness, paragraph4-50.1, page 4-38”.

32

Table 2-l. Maintenance and Operating Supplies

(1)

Componentapplication

0101 - CRANKCASE(1)

0306 - FUEL TANK

0501 - RADIATOR

0505 - FAN HUB(Pulley) Assy

0708 - TORQUECONVERTER

1002 - DIFFEREN-TIAL ASSEMBLY

1003 - PLANETARYDRIVE

1103 - PLANETARYDRIVE

1413 - TANK RESER-VOIR (RTLlO)

2406 - HYDRAULICT A N K

OIL CAN POINTS

GREASE FITTINGS

CHAINS ANDSPROCKETS

(2)

Nationalstock number

9150-00-189-6729(2)

9150-00-191-2772(2)

9150-00-491-7197

9140-00-286-5286

9140-00-286-5294

9140-00-286-5283

6850-01-181-7940

9150-00-190-0907

9150-00-577-5845(2)

9150-00-257-5443(2)

9150-00-190-090~(2)

9150-00-234-519~

(3)

Description

3IL, LUBRICATION:55 gal. drum as follows:OE/HDO 30 MIL-L-2104OE-10

3EA MIL-L-46167FUEL OIL, DIESEL:

Bulk spec VVF-800l’YPE DFl to -25°F

TYPE DF2 to -20°F

TYPE DFA to -25°F orbelow

ANTIFREEZE: Ethy-lene glycol 55 gal. drumMIL-A-46153

Grease: Aircraft, GeneralPurpose, Wide TempRange, MIL-G-81322,35 lb pail

OIL LUBRICATING: (4)OE 10OESl

OIL, LUBRICATING,GEAR: 55 gal. drum asfollows:GO90 MIL-L-2105

GOS

OIL, LUBRICATING,GEAR: GO 90 (8)GOS

OIL, LUBRICATING,GEAR: GO 90 (8)GOS

OIL, LUBRICATING,(4) OE-10OEA

OIL, LUBRICATING:55 gal. drum as follows:OE-10OEA

OIL, LUBRICATION (4)OE/HDO 30OE-10OEA

GREASE, AUTO-MOTIVE AND ARTIL-LERY: 35 lb pailGAA

OIL, LUBRICATION:VV-L-751 exposedgear

(4)Quantityrequiredf/initial

operation

5 gal.5 gal.

5 gal.

110 gal.(5)

110 gal.(5)

110 gal.(5)

30 qt

As req

22 qt22 qt

10 qt

10 qt

4 qt (9)4 qt (9)

4 qt (9)4 qt (9)

30 qt20 qt

38 gal38 galAs req

As req

As req

(5)lantitysquired78 hrsmeration

(3)(3)

(3)

(6)

(6)

(6)

(7)

(3)(3)

(3)

(3)

(3)(3)

(3)(3)

(3)(3)

(3)(3)(3)(3)(3)(3)

(3)

(3)

(3)

(6)

Notes

1) Includes quantityof oil to fill engineoil system as fol-lows: 14% qt -crankcase 1% qt -oil filter

2) See C91OOIL foradditional data andrequisitioning proced-ure.

3) See current LO forgrade applicationand replenishmentintervals.

4) Use oil as prescrib-ed in item 1.

5) Tank capacity.6) Average fuel con-

sumption is 8.0 gal.per hour of contin-uous operation.

7) See TM 10-3930-243-12 for quanti-ties, ambient tem-perature and speci-fic gravities.

8) Use gear oil as pre-scribed in item 5.

9) Quantities are foreach planetary drive.

3

“NOTE: CALCIUM CHLORIDE SOLUTION Page B-3, Group no. 02.IS USED ONLY WITH CRANE ATTACH- Valves and Inserts.MENT.” Column (3) H. Change “H” to “F”.Page A-l, paragraph A-5. Column (3) I. Change “H” to “F”.

Change “TM 9-1870-l” to “TM 9-2610-200-20”. Fan assembly.Add the following reference: Column (3) A. add “0”.

TB MED 501.. . . Occupational and Envi- Column (3) I. Change “0” to “F”.ronmental Health: Hearing Conservation Page C-l. Appendix C is superseded as follows:

APPENDIX CBASIC ISSUE ITEMS LIST AND ITEMS TROOP

INSTALLED OR AUTHORIZEDSection I. INTRODUCTION

C-l. ScopeThis appendix lists items required by the operatorfor operation of the truck.

C-2 GeneralThis list is divided into the following sections:

a. Basic Issue Items List - Section II. Notapplicable.

b. Items Troop Installed or Authorized List -Section III. A list of items in alphabetical se-quence, which at the discretion of the unit com-mander may accompany the truck. These itemsare NOT SUBJECT TO TURNIN with the truckwhen evacuated.

C-3. Explanation of ColumnsThe following provides an explanation of columnsin the tabular list of Basic Issue Items List, Sec-tion II, and Items Troop Installed or Authorized,Section III.

a. Source, Maintenance, and RecoverabiltyCode(s) (SMR):

(1) Source code indicates the source for thelisted item. Source codes are:Code ExplanationP . . . . . Repair parts, special tools and test equipment sup-

plied from GSA/DSA or Army supply system andauthorized for use at indicated maintenance le-vels. Repair parts, special Tools, and testequipment which are procured and stocked forinsurance purposes because the combat or mili-tary essentiality of the end item dictates that aminimum quantity be available in the supplysystem.

(2) Maintenance code, indicates the lowest

level of maintenance authorized to install thelisted item. The maintenance level code is:Code ExplanationC . . . . Crew/Operator

(3) Recoverability Code, indicates whetherunserviceable items should be returned for recov-ery or salvage. Items not coded are non-recoverable. Recoverability codes are:Code Explan,ationR Applied to repair parts (assemblies and com-

ponents, special tools, and test equipment whichare considered economically repairable at directand general support maintenance levels.

s . . . . Repair parts, special tools, test equipment, andassemblies which are economically repairable atDSU and GSU activities and which normally arefurnished by supply on an exchange basis.

b. National Stock Number. This column indicatesthe National stock number assigned to the itemand will be used for requisitioning purposes.c. Description. This column indicates the Federalitem name and any additional description of theitem required.d. Unit of Measure (UIM). A 2-character alph-abetic abbreviation indicating the amount orquantity of the item upon which the allowancesare based; e.g., ft, ea, pr, etc.

e . Quantity Furnished With Equipment(BIIL). (Not applicable).

f. Quantity Authorized (Items Troop Installedor Authorized). This column indicates the quan-tity of the item authorized to be used with theequipment.

Section Ill. ITEMS TROOP INSTALLED OR AUTHORIZED LIST

(1)SMRCode

(2) (3) (4) (5)National Description Unit

Stock o f QtyNumber Meas Auth

7510-00-889-3494 BINDER, looseleaf E A 17520-00-559-9618 CASE, Maintenance and Operation Manuals E A 14210-00-889-2221 EXTINGUISHER, Fire E A 1

11

* T M 1 0 - 3 9 3 0 - 2 4 3 - 1 2

i

T E C H N I C A L M A N U A L H E A D Q U A R T E R SDEPARTMENT OF THE ARMY

No. 10-3930-243-12 W A S H I N G T O N, D. C., 3 June 1971

O P E R A T O R A N D 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 M A N U A L

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 ,

P N E U M A T I C T I R E D W H E E L S , R O U G H T E R R A I N

1 0 , 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

( P E T T I B O N E - M U L L I K E N M O D E L R T L 1 0 ,

A R M Y M O D E L M H E 1 9 9 )

FSN 3930-903-0899

( P E T T I B O N E - M U L L I K E N M O D E L R T L 1 0 - 1 ,

A R M Y M O D E L M H E 2 1 5 )

FSN 3930-465-5869

CHAPTERSection

I I .

CHAPTERSection

CHAPTERSection

CHAPTERSection

1.I .

2.I .

I I .I I I .IV.V.

VI.

3.I .

I I .I I I .IV.V.

4.I .

I I .I I I .IV.V.

VI.

I N T R O D U C T I O NGeneral . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O P E R A T I N G I N S T R U C T I O N SService upon receipt of material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Movement to a new worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation under usual conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation under unusual conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Operation of auxiliary material used in conjunction

with the forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

O P E R A T O R ’ S M A I N T E N A N C EBasic issue items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive maintenance checks and services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Maintenance of forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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 SService upon receipt of material . . . . . . . . . . . . . . . . . . . . . . . .Movement to a new worksite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Repair parts, special tools and equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Lubrication instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Preventive maintenance checks and services . . . . . . . . . . . . . . . . . . . . . . . .Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paragraph

1-1, 1-31-4, 1-5

2-1, 2-22-3 - 2-52-6, 2-7

2-8 - 2-112-12- 2-18

2-19, 2-20

3-13-2

3-3, 3-43-5, 3-6

3-7 - 3-11

4-14-2

4-3 - 4-54-6

4-7, 4-84-9, 4-10

Page

1-11-1

2-12-12-12-8

2-21

2-22

3-13-13-13-33-3

4-14-14-14-14-14-4

* T h i s m a n u e l s u p e r s e d e s T M 1 0 - 3 9 3 0 - 2 4 3 - 1 2 , 9 M a y 1 9 6 6 , i n c l u d i n g a l l c h a n g e s .

Page

Section VII.VI I I .

I X .X .

XI .XI I .

X I I I .XIV.XV.

XVI .XVI I .

XVI I I .X I X .X X .

A P P E N D I X A .

B.

REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C.

INDEX

Paragraph

Radio interference suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10A - 4-13Maintenance of forklift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 - 4-17Lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 - 4-21Exhaust system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 - 4-24Fuel system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 - 4-29Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-30 - 4-38Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-39 - 4-50Controls and instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-51 - 4-68Transmission and torque converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-69 - 4-73Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-74 - 4-79Wheels and tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-80, 4-81Steering system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-82 - 4-84Hydraulic lift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-85 - 4-91Hood and body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-92 - 4-96

MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BASIC ISSUE ITEMS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . . .

4-64-64-7

4-104-124-184-254-394-424-454-494-514-544-59

A-1

B-1

C-1

I-1

i i

L I S T O F I L L U S T R A T I O N S

Title PageFigure

N u m b e r

1-1

1-21-31-42-12-12-12-12-12-12-22-22-32-42-52-52-52-52-62-62-62-62-72-82-93-13-23-33-44-1

4-24-34-44-54-64-64-74-84-84-94-104-104-114-124-134-134-144-154-164-174-184-194-204-214-22

4-234-244-254-264-274-284-28

Rough terrain forklift truck, right front, three-quarter view,with shipping dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rough terrain forklift truck, left rear, three-quarter view . . . . . . . . . . . . . . . . . . . . . . . . .Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wiring diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls and instruments (sheet 1 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls and instruments (sheet 2 of 6 ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls and instruments (sheet 3 of 6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls and instruments (sheet 4 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls and instruments (sheet 5 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Controls and instrument (sheet 6 of 6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine starting instructions (sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine starting instructions (sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Forklift stopping instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Improved surface driving instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driving instructions in surf (sheet 1 of 4), . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driving instructions in surf (sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driving instructions in surf (sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driving instructions in sur (sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driving instructions for sand and snow (sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Driving instructions for sand and snow (sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . Driving instructions for sand and snow (sheet 3 of 4). . . . . . . . . . . . . . . . . . . . . . .Driving instructions for sand and snow (sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . .Instructions for picking up load on improved surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Instructions for picking up load on unimproved surface. . . . . . . . . . . . . . . . . . . . . . .Instructions for depositing load. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air cleaner servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel filter servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Ether priming servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Battery servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Radio interference suppression components, location, removal

and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Rocker arm cover, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . .Push rod adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil filter service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Oil filter and bracket, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Crankcase breather, removal and installation (sheet 1 of 2). . . . . . . . . . . . . . . . . . . . . . . . .Crankcase breather, removal and installation (Sheet 2 of 2). . . . . . . . . . . . . . . . . . . . .Oil level dipstick, tube and oil filler cap, removal and installation.. . . . . . . . . . . .Muffler and exhaust pipe, removal and installation (sheet 1 of 2) . . . . . . . . . . . . . . . . .Muffler and exhaust pipe, removal and installation (sheet 2 of 2) . . . . . . . . . . . . . . . . . .Exhaust manifold and flange, removal and instal lat ion . . . . . . . . . . . . . . . . .Fuel tank and lines, removal and installation (sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel tank and lines, removal and installation (sheet 2 of 2). . . . . . . . . . . . .Fuel pump, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Air cleaner, bracket and hose, removal and installation. . . . . . . . . . . . . .Fuel filter, removal and installation (sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fuel filter, removal and installation (sheet 2 of 2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Thermostat housing and thermostat, removal and installation . . . . . . . . . . . . .Water pump and pulley, removal and installation . . . . . . . . . . . . . . . . . . . . .Coolant hoses and fi t t ing, removal and installat ion . . . . . . . . . . . . . . . . .Fan blade, removal and installation. . . . . . . . . . . . . . . . . . . . .Drive belts, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . .Drive belt adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fan guard, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .P u l l e y a n d h u b , r e m o v a l , d i s a s s e m b l y , r e a s s e m b l y , a n d i n s t a l l a t i o n . . . . . .Belt adjusting control, spring and bracket pulley, removal and

installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine generator, on-equipment testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Engine generator and bracket, removal and installation . . . . . . . . . . . . . . . . . . . . . . . .Battery holddown cover, batteries and cables, removal and installation. . . . . . . . . . . . .Receptacle connector, removal and installation . . . . . . . . . . . . . . . . . . . . . . . .Voltage regulator and bracket, removal and installation . . . . . . . . . . . . . . . .Voltage regulator adjustment (sheet 1 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage regulator adjustment (sheet 2 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-41-51-61-72-22-32-42-52-62-72-82-9

2-102-112-122-132-142-152-162-172-182-192-19

2-202-21

3-43-53-63-7

4-64-74-74-84-84-84-9

4-1 04-114-114-124-134-144-154-154-164-174-194-204-204-214-224-234-244-24

4-254-264-274-274-284-284-29

4-30

. . .Ill

FigureN u m b e r

4-284-284-284-294-304-31

4-324-334-344-354-364-364-364-374-384-394-404-41

4-424-424-434-44

4-454-464-474-484-494-504-514-524-534-544-554-564-574-584-594-604-614-62

L I S T O F I L L U S T R A T I O N S - C o n t i n u e d

Title

Voltage regulator adjustment (sheet 3 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage regulator adjustment (sheet 4 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Voltage regulator adjustment (sheet 5 of 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter, on-equipment testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter and solenoid, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Starter magnetic switch and starter pressure switch, removal and

installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Stoplight-taillight, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Blackout lights and headlights, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . .Floodlight, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Horn and buzzer, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Control and instrument, removal and installation (sheet 1 of 3 ). . . . . . . . . . . . . . . . .Control and instrument, removal and installation (sheet 2 of 3 ). : . . . . . . . . . . . . . . . . . . . . . . .Control and instrument, removal and installation (sheet 3 of 3 ). . . . . . . . . . . . . . . . . . . . . . . .Foot controls, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Torque converter f i l ter , removal and installat ion. . . . . . . . . . . . . . . . . . . .Transmission linkage and lever, removal and installation. . . . . . . . . . . . . . . . . . . . .Transmission cut-off valve, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . .Transmission and torque converter oil hoses and fittings, removal

and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Parking brake cable and lever, removal and installation (sheet 1 of 2). . . . . . . . .Parking brake cable and lever, removal and installation (sheet 2 of 2). . . . . . . . . . . . . . . . .Brake hydraulic oil reservoir, removal and installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . .Brake hydraulic oil reservoir filter element and magnet, removal and

installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic brake line, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic brake low pressure switch, removal and installation. . . . . . . . . . . . . . . . . . .Wheel and tire, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Wheel and tire, disassembly and reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Steering wheel, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic lines, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic hose repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic reservoir filter element, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . .Hydraulic reservoir magnet assembly, disassembly and reassembly. . . . . . . . . . . . . . . . . .Hydraulic reservoir, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fork, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fork carriage, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Side shift roller chain, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Overhead guard, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Seat, removal and installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Counterweight and pintle, removal and installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Fenders, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Body panels, removal and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

4-314-324-334-344-35

4-364-374-374-384-384-404-404-414-424-434-434-44

4-444-464-474-47

4-484-484-484-494-504-514-524-534-544-554-564-564-574-584-594-604-604-614-62

i v

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 . G E N E R A L

1 - 1 . S c o p e 1 - 2 . F o r m s a n d R e c o r d s

a. T h e s e i n s t r u c t i o n s a r e p u b l i s h e d f o r t h e u s e o f a . D A f o r m s a n d r e c o r d s u s e d f o r e q u i p m e n tt h e p e r s o n n e l t o w h o m t h e P e t t i b o n e - M u l l i k e n m a i n t e n a n c e w i l l b e o n l y t h o s e p r e s c r i b e d i n T M

F o r k l i f t T r u c k M o d e l R T L 1 0 a n d M o d e l R T L 1 0 - 3 8 - 7 5 0 .

1 i s i s s u e d . T h e y p r o v i d e i n f o r m a t i o n o n t h e b . R e p o r t o f e r r o r s , o m i s s i o n s a n d r e c o m -

o p e r a t i o n a n d 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 o f t h e m e n d a t i o n s f o r i m p r o v i n g t h i s p u b l i c a t i o n b y t h e

e q u i p m e n t . A l s o i n c l u d e d a r e d e s c r i p t i o n s o f t h e i n d i v i d u a l u s e r i s e n c o u r a g e d . R e p o r t s s h o u l d b e

m a i n u n i t s a n d t h e i r f u n c t i o n s i n r e l a t i o n s h i p t o s u b m i t t e d o n D A F o r m 2 0 2 8 ( R e c o m m e n d e d

o t h e r c o m p o n e n t s . C h a n g e s t o P u b l i c a t i o n s ) a n d f o r w a r d e d d i r e c t t o

b . R e f e r t o TM740-90-1 (Administrative C o m m a n d i n g G e n e r a l , U . S . A r m y M o b i l i t y

S t o r a g e o f E q u i p m e n t ) , f o r i n f o r m a t i o n a n d i n - E q u i p m e n t C o m m a n d , A T T N : A M S M E - M P P ,

s t r u c t i o n s p e r t a i n i n g t o o r g a n i z a t i o n a l a d - 4 3 0 0 G o o d f e l l o w B o u l e v a r d , S t . L o u i s , M o . 6 3 1 2 0 .

m i n i s t r a t i v e s t o r a g e . 1 - 3 . E q u i p m e n t S e r v i c e a b i l i t y C r i t i e r i ac. Refer to TM750-244-3 (Procedures for

D e s t r u c t i o n o f E q u i p m e n t t o P r e v e n t E n e m y U s e ) ,Refer to TM10-3900-203-ESC for information

f o r i n f o r m a t i o n a n d i n s t r u c t i o n s o n d e s t r u c t i o n o fo n e q u i p m e n t s e r v i c e a b i l i t y c r i t e r i a .

e q u i p m e n t t o p r e v e n t e n e m y u s e .

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

1 - 4 . D e s c r i p t i o n

T h e P e t t i b o n e - M u l l i k e n R o u g h T e r r a i n F o r k l i f t

T r u c k M o d e l s R T L 1 0 a n d R T L 1 0 - 1 i s c a p a b l e o f

o p e r a t i n g o v e r a l l t y p e s o f t e r r a i n , a n d m a y b e

o p e r a t e d f o r t h r e e t y p e s o f m a t e r i a l h a n d l i n g . T h e

truck may be used as a forkl if t or as a towing truck.

A s a f o r k l i f t t h e t r u c k h a s a r a t e d c a p a c i t y o f

1 0 , 0 0 0 p o u n d s a t a 2 4 i n c h l o a d c e n t e r . A s a

t o w i n g t r u c k , i t h a s a m a x i m u m d r a w b a r p u l l o f

1 9 , 0 0 0 p o u n d s . O v e r a s m o o t h l e v e l s u r f a c e t h e

t ruck can pu l l a l oad 20 t imes i t s d r awba r pu l l . The

t r u c k m a y b e u s e d i n f o r d i n g o p e r a t i o n s w h e n t h e

d e p t h o f t h e s u r f d o e s n o t e x c e e d 5 f e e t t o t h e c r e s t

o f t h e w a v e s . T h e t r u c k i s e q u i p p e d w i t h f r o n t a n d

r e a r a x l e s t e e r i n g w h i c h g i v e s t h e t r u c k a s h o r t e r

t u r n i n g r a d i u s . T h e t r u c k i s a l s o e q u i p p e d w i t h

t w o - w h e e l a n d f o u r - w h e e l d r i v e , e n a b l i n g i t t o

t r a n s v e r s e m u d , s n o w , s a n d , a n d s t e e p g r a d e s w i t h

e q u a l e a s e . T h e b o d y a n d f o r k s o f t h e t r u c k m a y b e

ti l ted r ight or left in relat ion to front axle. The forks

a r e e x t e n d e d b y h y d r a u l i c a l l y o p e r a t e d t e l e s c o p i n g

a r m s w h i c h r e a c h o u t , u p o r d o w n t o h a n d l e l o a d s ,

A h y d r a u l i c c y l i n d e r m o v e s t h e f o r k s r i g h t o r l e f t

f r o m c e n t e r t o l i f t - o f f c e n t e r l o a d s . T h e t r u c k h a s

h y d r a u l i c b r a k e s , h y d r a u l i c - o p e r a t e d p o w e r

s t e e r i n g a n d a t o r q u e c o n v e r t e r . I t i s p o w e r e d b y a

s i x - c y l i n d e r , V - t y p e o v e r h e a d v a l v e , l i q u i d c o o l e d ,

d i e s e l e n g i n e .

1 - 5 . I d e n t i f i c a t i o n a n d T a b u l a t e d D a t a

a . I d e n t i f i c a t i o n . T h e f o r k l i f t h a s t w o i d e n -

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

a n d e n g i n e . T h e y s p e c i f y t h e n o m e n c l a t u r e ,

s h i p p i n g d i m e n s i o n s , m o d e l n u m b e r , a n d e n g i n e

m a n u f a c t u r e r . T h e d a t a f r o m t h e s e p l a t e s c a n b e

f o u n d u n d e r b b e l o w .

b . T a b u l a t e d D a t a .

( 1 ) I d e n t i f i c a t i o n p l a t e s .

( a ) E n g i n e i d e n t i f i c a t i o n p l a t e .

Manufacturer . . . . . . . . . . . . . . D e t r o i t D i e s e l E n g i n eDivision, Detroit ,Michigan, U.S.A.

Model . . . . . . . . . . . . . . . . . . . . . . 5063-5200Max. RPM No Load . . . . . . . . . . . . . . . . 3010

( b ) F o r k l i f t t r u c k i d e n t i f i c a t i o n p l a t e .Stock No.:

Model RTL10 . . . . . . . . . . . . . 3930-903-0899Model RTL10-1 . . . . . . . . . . . 3930-465-5869

Manufacturer. . . . . . . . . . . . . . . . . . . . . . P M C o r p .Model . . . . . . . . . . . . . . . . . . . . . . . RTLl0, RTL10-1Contract No.:

Model RTL10 . . . . . . . . . . . . DA-11-184-AMC-597

DA-23-195-AMC-916Model RTL10-1 . . . . . . . . . . . . DSA-400-69C-5415

1-1

Length . . . . . . . . . . . . . . . . . . . . . . 202 inchesWidth . . . . . . . . . . . . . . . . . . . . . . . 110 inchesHeight . . . . . . . . . . . . . . . . . . . . . . 115 inchesCapacity or pay load . . . . . . . . . 10,000 poundsShipping weight . . . . . . . . . . . . . . 33,500 poundsCubage . . . . . . . . . . . . . . . . . . . . . . l479 cubic feetEngine manufacturer . . . . . . . . . . Detroit DieselSeries . . . . . . . . . . . . . . . . . . . . . . . 6V-53

( 2 ) E n g i n e .

Manufacturer . . . . . . . . . . . . . . . . Detroit Diesel Engine,D i v i s i o n o f G e n e r a l

Motors DivisionNumber of cylinders . . . . . . . . . .6Bore . . . . . . . . . . . . . . . . . . . . . . . . 3.875 inchStroke . . . . . . . . . . . . . . . . . . . . . . . 4.5 inchCompression ratio

(nominal] . . . . . . . . . . . . . . . . . 17 to 1T o t a l d i s p l a c e m e n t -

cubic inches . . . . . . . . . . . . . . . . 318.6Firing order - R / H

rotation . . . . . . . . . . . . . . . . . . . 1L-3R-3L-2R-2L-lRNumber of main bearings . . . . . 4

( 3 ) G e n e r a t o r .

( a ) R T L 1 0 .

Manufacturer . . . . . . . . . . . . . . . . Delco RemyPart no. . . . . . . . . . . . . . . . . . . . . .1117495Volts . . . . . . . . . . . . . . . . . . . . . . . . 24V, DC

( b ) R T L 1 0 - 1 .

Manufacturer . . . . . . . . . . . . . . . . PrestolitePart No . . . . . . . . . . . . . . . . . . . . . GHA804UTVolts . . . . . . . . . . . . . . . . . . . . . . ..24 V, DC

( 4 ) S t a r t e r

Manufacturer . . . . . . . . . . . . . . . . Delco-RemyPart No . . . . . . . . . . . . . . . . . . . . . 1113847Volts . . . . . . . . . . . . . . . . . . . . . . . .24 V, DC

( 5 ) G e n e r a t o r r e g u l a t o r .

Manufacturer . . . . . . . . . . . . . . . . D e l c o - R e m yModel No . . . . . . . . . . . . . . . . . . 111856Rating . . . . . . . . . . . . . . . . . . . . . . 24V, 25 amps, negative

g r o u n d

( 6 ) F u e l f i l t e r s .

( a ) F u e l f i l t e r , p r i m a r y .

Manufacturer . . . . . . . . . . . . . . . . AC Spark PlugPart No . . . . . . . . . . . . . . . . . . . . . . .5577342Element . . . . . . . . . . . . . . . . . . . . . 1595655

( b ) F u e l f i l t e r , s e c o n d a r y ,

Manufacturer . . . . . . . . . . . . . . . . AC Spark PlugPart No . . . . . . . . . . . . . . . . . . . . .5574533Element . . . . . . . . . . . . . . . . . . . . . TP504MS

( 7 ) O i l / f i l t e r .

Manufacturer . . . . . . . . . . . . . . . . AC Spark PlugPart No . . . . . . . . . . . . . . . . . . . . . 5l34392Element . . . . . . . . . . . . . . . . . . . . . MS35802-3

( 8 ) B a t t e r i e s .

Number . . . . . . . . . . . . . . . . . . . . .2Volts . . . . . . . . . . . . . . . . . . . . . . . . 12V, DCUnit Polarity . . . . . . . . . . . . . . . . Negative Ground

( 9 ) A i r c l e a n e r .

Manufacturer . . . . . . . . . . . . . . . . . . . DonaldsonType . . . . . . . . . . . . . . . . . . . . . . . . DryE1ement . . . . . . . . . . . . . . . . . . . . . P10-4986

( 1 0 ) E t h e r p r i m e r ( q u i c k s t a r t ) .

Manufacturer . . . . . . . . . . . . . Turner CorporationReplacement Cylinder No. . . . . LP535

( 1 1 ) F u e l p u m p .

Manufacturer . . . . . . . . . . . . . Detroit DieselPart No . . . . . . . . . . . . . . . . . . . . . 5l347l7

( 1 2 ) G o v e r n o r .

Manufacturer . . . . . . . . . . . . . . . Detroit Diesel MotorsIdle Range . . . . . . . . . . . . . . . . . . 500 to 600Part No . . . . . . . . . . . . . . . . . . . . . 5ll6006

( 1 3 ) H e a d l i g h t s .

( a ) B l a c k o u t , h e a d l i g h t .

Manufacturer . . . . . . . . . . . . . . . . Guide Co.Volts . . . . . . . . . . . . . . . . . . . . . . . 24 V, DCPart No . . . . . . . . . . . . . . . . . . . . . MS5l3l8

( b ) H e a d l i g h t s .

Manufacturer . . . . . . . . . . . . . . . . Hobbs Co.Volts . . . . . . . . . . . . . . . . . . . . . . . 24V, DCPart No . . . . . . . . . . . . . . . . . . . . . M4212

( c ) B l a c k o u t c l e a r a n c e .

Manufacturer . . . . . . . . . . . . . . . . Guide Co.Volts. . . . . . . . . . . . . . . . . . . . . . . 24V, DCPart No . . . . . . . . . . . . . . . . . . . . . MS5l303-2

( 1 4 ) T a i l l i g h t - s t o p l i g h t .

Manufacturer . . . . . . . . . . . . . . . . Do-RayVolts . . . . . . . . . . . . . . . . . . . . . . . 24 V, DCPart No . . . . . . . . . . . . . . . . . . . . . 935ST

( 1 5 ) H o r n .

Manufacturer . . . . . . . . . . . . . . . . SpartanPart No . . . . . . . . . . . . . . . . . . . . .51074

( 1 6 ) F l o o d l i g h t .

Manufacturer . . . . . . . . . . . . . . .. Hobb Co.24 V, DCVolts . . . . . . . . . . . . . . . . . . . . . . .

Part No . . . . . . . . . . . . . . . . . . . .. M4211

( 1 7 ) H y d r a u l i c s t e e r i n g p u m p .

Manufacturer . . . . . . . . . . . . . . . .Part No . . . . . . . . . . . . . . . . . . . . .Rating . . . . . . . . . . . . . . . . . . . . . .

( 1 8 ) H y d r a u l i c s y s t e m

Manufacturer . . . . . . . . . . . . . . . .Part No . . . . . . . . . . . . . . . . . . . . .

Borg -WarnerMHD3-23-EH5-1-R-0130Ghm @ 2800 RPM and

1600 PSI

p u m p , m a i n .

Borg-WarnerM H D 3 & 3 - 2 8 & 1 2 E Z 5 - l

R-01

1-2

Rating . . . . . . . . . . . . . . . 35 & 15RPM and 1600 PSI

( 1 9 ) D u a l l o c k c y l i n d e r p u m p .

Manufacturer . . . . . . . . . . . . . .Part No.. . . . . . . . . . . . . . . . . . .Rating . . . . . . . . . . . . . . . . . . . . . .

( 2 0 ) T r a n s m i s s i o n .

Manufacturer . . . . . . . . . . . . .Part No. . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . .

Borg-WarnerPD 2&2-595ER5-20-L-01616 GPM @ 2800 RPM

and 1600 PSI

Allison Torquematic Drive6777946CRT 3531-1

( 2 1 ) S t e e r i n g c y l i n d e r ( M o d e l R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . Cascade Mfg. Co.Part No.. . . . . . . . . . . . . . . . 4C621479A479AStroke . . . . . . . . . . . . . . . . . . . . 6 7 / 8"Diameter . . . . . . . . . . . . . . . 3 inch

( 2 2 ) S t e e r i n g c y l i n d e r ( M o d e l R T L 1 0 - 1 ) .

Manufacturer. . . . . . . . . . . . . . . . . . . . P M C o r p .Part No. . . . . . . . . . . . . . . . . . . . . . . F10806Stroke . . . . . . . . . . . . . . . . . . . . . 6 13/ 16 inchDiameter . . . . . . . . . . . . . . . . . . . 3 inch

( 2 3 ) L i f t c y l i n d e r ( M o d e l R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . Cascade Mfg. Co.Part No. . . . . . . . . . . . . . . . . 4C621442AStroke . . . . . . . . . . . . . . . . . . . . . 32:¾ in.Diameter . . . . . . . . . . . . . . . . . . . 6 in.

( 2 4 ) L i f t c y l i n d e r ( M o d e l R T L 1 0 - 1 ) .

Manufacturer . . . . . . . . . . . . . . . PM Corp.Part No. . . . . . . . . . . . . . . . . . . F10801.Stroke . . . . . . . . . . . . . . . . . . . . . . 32 ¾ in.Diameter . . . . . . . . . . . . . . . . . . . 6 in.

( 2 5 ) E x t e n s i o n c y l i n d e r ( M o d e l R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . Cascade Mfg. Co.Part No. . . . . . . . . . . . . . . . . . . . 4C621455AStroke . . . . . . . . . . . . . . . . . . . . . . . . 44 5/8Diameter . . . . . . . . . . . . . . . . . 4½ in.

( 2 6 ) E x t e n s i o n c y l i n d e r ( M o d e l

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . PM Corp.Part No. . . . . . . . . . . . . . . . . . . . . . . . F10802Stroke . . . . . . . . . . . . . . . . . . . . . . . . . .44 5/8 in.Diameter . . . . . . . . . . . . . . . . . . . . . . . 4 ½ in.

R T L 1 0 - 1 ) .

( 2 7 ) T i l t c y l i n d e r ( M o d e l R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . Cascade Mfg. Co.Part No. . . . . . . . . . . . . . . . . . . . 4C621371AStroke . . . . . . . . . . . . . . . . . . . . . .33 in.Diameter . . . . . . . . . . . . . . . . . . . 6 ½ in.

( 2 8 ) T i l t c y l i n d e r ( M o d e l R T L 1 0 - 1 ) .

Manufacturer . . . . . . . . . . . . . . . PM Corp.Part No. . . . . . . . . . . . . . . . . . . . . F10804Stroke . . . . . . . . . . . . . . . . . . . . . .33 in.Diameter . . . . . . . . . . . . . . . . . . . . . . . . . 6 ½ in.

( 2 9 ) S l a v e c y l i n d e r ( M o d e l R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . Cascade Mfg. Co.Part No. . . . . . . . . . . . . . . 4C62l386AStroke. . . . . . . . . . . . . . . . . .24 5/8 in . Diameter . . . . . . . . . . . . . . . . . . . 6 ½ in.

( 3 0 ) S l a v e c y l i n d e r ( M o d e l R T L 1 0 - 1 ) .

Manufacturer . . . . . . . . . . . . . PM Corp .Part No. . . . . . . . . . . . . . . . . . . . . . . . . . . F10803Stroke. . . . . . . . . . . . . . . . . . . 24 5/8 inchDiameter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ½ inch

( 3 1 ) S i d e s h i f t c y l i n d e r ( M o d e l R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . . . Cascade Mfg. CO.Part No. . . . . . . . . . . . . . . . . . . . . . . 4C621467AStroke . . . . . . . . . . . . . . . . . . . . . . 34 ½ in.Diameter . . . . . . . . . . . . . . . . . . .4 ½ in.

( 3 2 ) S i d e s h i f t c y l i n d e r ( M o d e l R T L 1 0 - 1 ) .

Manufacturer . . . . . . . . . . . . . . . PM Corp.Part No. . . . . . . . . . . . . . . . . . F10805Stroke . . . . . . . . . . . . . . . . . . . . . 34 ½ inchDiameter . . . . . . . . . . . . . . 4 17 /64 inch

( 3 3 ) O s c i l l a t i o n c y l i n d e r , f r o n t ( M o d e l

R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . Cascade Mfg. Co.Part No . . . . . . . . . . . . . . . . . . . . . . . 4C62l508AStroke. . . . . . . . . . . . . . . . . . . . . . . . . . . 7 3/ 16 in.Diameter . . . . . . . . . . . . . . . . 4 ¾ in.

( 3 4 ) O s c i l l a t i o n c y l i n d e r , f r o n t ( M o d e l

R T L 1 0 - 1 ) .

Manufacturer . . . . . . . . . . . . . . . . PM Corp .Part No. . . . . . . . . . . . . . . . . . . . . F10800Stroke . . . . . . . . . . . . . . . . . . . . . . 7 3 /16 inchDiameter. . . . . . . . . . . . . . . . . . . . . . . . . . 4 49 /64 inch

( 3 5 ) O s c i l l a t i o n c y l i n d e r , r e a r ( M o d e l

R T L 1 0 ) .

Manufacturer . . . . . . . . . . . . . . . . Cascade Mfg. Co.Part No . . . . . . . . . . . . . . . . . . . . . . . 4C621519BStroke. . . . . . . . . . . . . . . . . . . l0 9/16 in.Diameter. . . . . . . . . . . . . . . . . . . . . 4¾ in.

( 3 6 ) C o n t r o l v a l v e s ( M o d e l R T L 1 0 ) .

( a ) L i f t c o n t r o l v a l v e .

Manufacturer . . . . . . . . . . . . . . . Hydreco Mfg. Co.Part No . . . . . . . . . . . . . . . . . . . . . V38DDD28MILType. . . . . . . . . . . . . . . . . . . . . . . 3 spoolRelief valve setting . . . . . . . . . . . . 2000 psi

( b ) O s c i l l a t i n g a n d a i d e s h i f t c o n t r o l v a l v e

( R T L 1 0 ) .

( a ) L i f t c o n t r o l v a l v e .

Manufacturer . . . . . . . . . . . . . . . . Hydrevco Mfg. Co.Part No. . . . . . . . . . . . . . . . . . . . . . V38DDD109MILType . . . . . . . . . . . . . . . . . . . . . . . 3 spoolRelief setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000 psi

( b ) O s c i l l a t i n g a n d s i d e s h i f t c o n t r o l

Manufacturer . . . . . . . . . . . . . . . . Hydreco Mfg. Co.Part No. . . . . . . . . . . . . . . . . . . . . V37DD118MILType . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 spoolRelief setting . . . . . . . . . . . . . 2000 psi

v a l v e .

Manufacturer . . . . . . . . . . . . . . Hydreco Mfg. Co.Part No . . . . . . . . . . . . . . . . V37DD33MILType . . . . . . . . . . . . . . . . . . . . . . . . 2 spoolRelief valve setting . . . . . . . . . . . 2000 psi

( 3 7 ) C o n t r o l v a l v e s ( M o d e l R T L 1 0 - 1 ) .

1-3

Figure 1-1.

( 3 8 ) T i r e s .

Manufacturer. . . . . . . . . . . . . . . Goodyear RubberSpecification. . . . . . . . . . . . . . . ZZT 381Size . . . . . . . . . . . . . . . . . . . . . . . . .20.5-25Pressure . . . . . . . . . . . . . . . . . . . . . 50 psi Front

45 psi RearRating . . . . . . . . . . . . . . . . . . . . . . . l6 ply

( 3 9 ) A d j u s t m e n t s .

Radiator system . . . . . . . . . . . . . . . 30 qt.Wheel hub (planetary

drive) . . . . . . . . . . . . . . . . . . . . . 4 qt. eaDifferentials . . . . . . . . . . . . . . . . . . 10 qt. ea.Pay load . . . . . . . . . . . . . . . . . . . . . 10,000 lb.

( 4 2 ) D i m e n s i o n s a n d w e i g h t .

Length . . . . . . . . . . . . . . . . . . . . . . . 202 in.Width . . . . . . . . . . . . . . . . . . . . . . . . 106 in.

Exhaust valves . . . . . . . . . . . . . . . . (cold) 0.025; (hot) 0.023 Height . . . . . . . . . . . . . . . . . . . . . . . 135 in. (w/overhead guard

Fan belt . . . . . . . . . . . . . . . . . . . . . (deflection) ¾ in. u p )

( 4 0 ) P e r f o r m a n c e .Weight . . . . . . . . . . . . . . . . . . . . . . . . 33,500 lb.

Lifting capacity . . . . . . . . . . . . . . . l0,000 lbs.Drawbar pull . . . . . . . . . . . . . . . . . 19,0001bs.

( 4 3 ) W i r i n g d i a g r a m . S e e f i g u r e 1 - 3 .

( 4 4 ) W i r i n g d i a g r a m . S e e f i g u r e 1 - 4 .

( 4 1 ) C a p a c i t i e s . 1 - 4 6 . D i f f e r e n c e s i n M o d e l s

Fuel tank . . . . . . . . . . . . . . . . . . . . 110 gal.T h i s m a n u a l c o v e r s t h e P e t t i b o n e - M u l l i k e n M o d e l s

Hydraulic tank, main . . . . . . . . . .152 qt. R T L 1 0 a n d R T L 1 0 - l F o r k l i f t T r u c k s . D i f f e r e n c e s

Brake system reservoir . . . . . . . . . 30 qt. (model RTL10) b e t w e e n t h e t w o m o d e l s a r e i n d i c a t e d t h r o u g h o u tTransmission . . . . . . . . . . . . . . . . . 22 qt.Crankcase w/filter . . . . . . . . . . . 20 qt.

t h e m a n u a l b y a p p l i c a b l e m o d e l n u m b e r s .

1-4

Figure 1-2.

1 - 5

Figure 1-3.

1-

6

Figure 1-4.

1-

7

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 . S E R V I C E U P O N

2-1. General

This section contains information on the servicingof the equipment which is the responsibility of theoperator .

2-2 . Inspecting and Servicing the Equipment

a . D e p r e s e r v a t i o n . P r e p a r e t h e u n i t f o r i n -spect ion and operat ion as out l ined on DA Form2258, attached on or near the operator’s controls.

b. Inspection. Make a thorough visual inspectionof the ent ire forkl i f t t ruck for loose or miss ing

mounting hardware , damaged and miss ing parts .Inspect oil lines, fuel lines and hydraulic lines forleaks . Correct a l l de f i c ienc ies or report the con-di t ions to d irect support maintenance .

c. Servicing.

(1) Perform the daily preventive maintenanceservices (para 3-4) .

(2) Lubricate the forklift truck in accordancewith the current lubrication order.

(3) Refer to appendix C and see that the fueltank is filled with the proper grade of fuel.

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

2-3 . Dismantling for Movement

The forks and overhaul guard mayr e d u c e t h e o v e r a l l d i m e n s i o n s o fm o v e m e n t b y carrier. R e f e rorganizat ional maintenance .

2 - 4 . M o v e m e n t

be removed tot h e t r u c k f o rc o n d i t i o n t o

The forklift truck is a completely mobile unit and

S e c t i o n I l l . C O N T R O L S

2-6. General

This sect ion descr ibes the var ious contro ls andinstruments and provides the operator suf f i c ienti n f o r m a t i o n t o i n s u r e p r o p e r o p e r a t i o n o f t h e

forklift truck.

R E C E I P T O F M A T E R I A L

W A R N I N G

W h e n f i l l i n g t h e f u e l tank, always

p r o v i d e a m e t a l - t o - m e t a l c o n t a c t b e -tween the fuel tank and the container.This wil l prevent a spark from being

generated as fuel flows over the metallicsurface.(4) Remove the batteries from the battery box

and fill the cells of the batteries with electrolyte,one-hal f o f an inch above the p lates . Check the

specific gravity of the electrolyte as prescribed in

T M 9 - 6 1 4 0 - 2 0 0 - 1 5 .W A R N I N G

Do not smoke or use an open flame inthe vicinity when servicing the batteries.Batteries generate hydrogen, a highlyexplosive gas .

(5) See that the cooling system contains theproper ant i f reeze mixture in accordance with TB7 5 0 - 6 5 1 .

(6) Check hydraulic reservoir for correct fluid

level in accordance with current lubrication order.

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

can be moved from one worksite to another underi ts own power .

2-5 . Reinstal lation After Movement

A f t e r m o v e m e n t b y c a r r i e r t o a n e w w o r k s i t e ,report condition to organizational maintenance forforks and overhead guard re insta l lat ion .

A N D I N S T R U M E N T S

2-7 . Controls and Instruments

Refer to figure 2-1 for the purpose, normal reading

and locat ion o f a l l contro ls and instruments .

2-1

Figure 2-1.

2-2

Figure 2-1.

2-3

Figure 2-1.

2 - 4

Figure 2-1.

2-5

Figure 2-1.

2-6

Figure 2-1.

2-7

Figure 2-2.

FIG. 2-1

C3 Warning added

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

2-8. General

a. The instructions in this section are publishedfor the information and guidance of the personnelresponsible for the operation of the forklift truck.

b. The operator must know how to perform everyoperat ion o f which the forkl i f t t ruck is capable .This sect ion g ives instruct ions on start ing, s top-

p i n g , a n d c o - o r d i n a t i n g t h e b a s i c m o t i o n s t op e r f o r m t h e t a s k f o r w h i c h t h e e q u i p m e n t i sdesigned. Since nearly every job presents a different

p r o b l e m t h e o p e r a t o r m a y h a v e t o v a r y g i v e nprocedures to fit the individual job.

2-9. Starting

a. Perform the necessary preventive maintenancechecks and services.

C A U T I O NMake sure that the directional controllever (fig. 2-1) is in the neutral positionand that the parking brake lever (fig. 2-1) is in PARK posit ion.

b. Refer to figure 2-2, and start the forklift truckengine .

2-8

Figure 2-2.

FIG. 2-1

2-10. Stopping NOTE

a . N o r m a l S t o p p i n g . Refer to f igure 2-3 for To restart the engine after the emergency stop

stopping instructions. control has been pulled up, push the emergency

b. Emergency Stopping. To stop the engine in anstop control down and manually reset theemergency stop control reset lever, located at the

emergency, pull up on the emergency stop control. rear of blower inlet housing.

2-9

Figure 2-3.

2-11. Operation of Equipment

a. General. The rough terrain forklift truck iscapable of operating over all types of terrain - snow,sand, and steep grades with equal facility.

b. Driving on Improved Surfaces. Refer to figure

2-4 for improved surface driving instructions.c . D r i v i n g o n U n i m p r o v e d S u r f a c e . R e f e r t o

figure 2-5 for driving instructions in surf, and referto figure 2-6 for instructions for driving in snow orsand.

C A U T I O NDo not attempt to cross a slide slope of30° or more with the truck in four wheel

steering, because the truck may turnover.

d. Picking Up Load on Improved Surface. R e f e rto figure 2-7 for instructions for picking up load onimproved sur face .

e . 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 e .Refer to figure 2-8 for instructions for picking upload on unimproved sur face .

f . Depos i t ing Load. Refer to figure 2-9 for in-structions for depositing load.

2-10

Figure 2-4.

FIG. 2-2

2-11

Figure 2-5.

2-12

Figure 2-5.

2 - 1 3

Figure 2-5.

2-14

Figure 2-5.

2-15

Figure 2-6.

2-16

Figure 2-6.

FIG. 2-2

2-17

Figure 2-6.

2-18

Figure 2-6.

FIG. 2-2.1

FIG. 2-1.1

Figure 2-7.

2-19

Figure 2-8.

FIG. 2-3.

2-20

Figure 2-9.

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

2-12. Operation in Extreme Cold (Below 0°F.

(- 18° C.))a. See that antifreeze solution is correct for lowest

t e m p e r a t u r e e x p e c t e d ( T B 7 5 0 - 6 5 1 ) .

b. Inspect cooling system. Correct or report anyleaks .

c. Keep batter ies fu l ly charged. After addingwater to the batteries, run the engine for at least oneh o u r .

d. Keep fuel tank full when not in operation.

e. Drain and service fue l f i l ter (para 3-9) .f . 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

lubr icat ion order .

g. Pull up on ether primer button, engage starterand with the engine turning press the ether button

down. I f combust ion does not occur , repeat thepriming process with the starter engaged.

h. In extremely cold weather, it is desirable to

2-21

give the engine one priming charge before engagingthe starter, Then proceed as in g above.

i. A l l o w e n g i n e t o r e a c h n o r m a l o p e r a t i n gtemperature be fore apply ing load .

2.13. Operation in Extreme Heat

a. Insure radiator filler cap seals properly. Theboiling point of the coolant is raised as the systempressure is increased.

b. Check coolant level frequently. Add coolant asnecessary, Use standard ethylene glycol mixture ass p e c i f i e d i n T B 7 5 0 - 6 5 1 .

c. Remove all obstructions and foreign materialcollected on radiator fins and air passage.

d. Do not overfill fuel tank, Make sure all fuelfilters are clean.

e. Remove engine s ide panels .f. Make sure air cleaner is cleaned and serviced

(para 3-3) .W A R N I N G

Be extremely careful when removingthe radiator filler cap of a hot engine,Release of pressure may cause violentboiling and serious injury to personnel.

2-14. Operation in Dusty or Sandy Area

a. Clean all grease fittings.b . 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

lubr icat ion order .

c. Change engine oil and oil filter frequently.d. Service air filter (para 3-8) often to give the

engine proper air intake.e. Clean and service fuel filter (para 3-9).

2.15. Operation in Salt Water Area

a. Keep all lubricating points wiped clean andwell lubricated,

b. Keep all wiring and ignition terminals free ofcorros ion .

c. Keep forklift truck as clean as possible.d. After operation is complete, wash with fresh

water , Lubricate in accordance with lubr icat ionorder . C h e c k a l l g e a r c a s e s f o r w a t e r c o n -tamination. I f contamination is found (evidenced

by a milky color of lubricant) drain, flush and refill.

2 - 1 6 . O p e r a t i o n U n d e r R a i n y o r H u m i dCondition

a. Keep fuel tank full at all times.b. After operation, wash forklift truck to remove

m u d .

2.17. Operation at High Altitude

a. Keep a constant watch on the coolant level.Add coolant as necessary.

NOTEThe engine will operate with less performance athigh altitudes,

b. During operation keep close watch on engineinstruments .

2-18. Operation in Snow

a . K e e p f u e l t a n k s f u l l a t a l l t i m e s . U s eprecaut ion to keep snow away f rom f i l l er whenservicing fuel tank.

b. Clean all snow from operating controls.c. Clean all snow from steps.

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

C O N J U N C T I O N W I T H T H E F O R K L I F T

2-19. Fire Extinguisher (Dry Chemical Type)

a. Descr ip t ion . The dry chemica l type f i re ex -tinguisher is generally suitable for all types of fires,except fires involved with liquid oxygen generatingequipment .

b. Operation. To operate the fire extinguisher,per form the fo l lowing operat ions :

(1) Remove fire extinguisher from its location.( 2 ) B r e a k s e a l b y p u l l i n g s a f e t y p i n f r o m

handle .

(3) Point horn at base of the fire.(4 ) Depress tr igger for d ischarge and direct

stream of contents at base of the fire.

(5 ) Replace with new cyl inder immediate lyafter use.

2-20. Fire Extinguisher Cylinder Replacementand Maintenance

a. Replacement of Cylinder. To replace with newc y l i n d e r , p e r f o r m t h e f o l l o w i n g o p e r a t i o n s :

(1) Press lever to release pressure from the oldcy l inder .

2-22

( 2 ) L o o s e n s w i v e l

U S E D I N

v a l v e c o u p l i n g n u t a n dremove valve assembly from the used cylinder.

(3 ) Remove instruct ion band from the usedcyl inder .

(4) Place a new cylinder through instructionb a n d .

(5) Replace safety pin in the valve and seal pinwith sealing wire.

(6) Attach valve assembly and tighten swivel

c o u p l i n g n u t o n n e w c y l i n d e r a n d r e p l a c e f i r eextinguisher in mounting bracket.

( 7 ) A d j u s t t h e i n s t r u c t i o n b a n d o n n e wcyl inder to show maintenance and operat ing in-structions.

b. Maintenance . Weigh f i re ext inguisher everythree months and replace the cy l inder i f grossweight has decreased 4 ounces or more. Lubricatethe cylinder neck threads with 1 drop of OE 30 oilbe fore reassembly .

g. (added) c4

C H A P T E R 3O P E R A T O R ’ S 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 . B A S I C

3-1 . Basic Issue Items

Tools, Equipment, and Repair Parts issued with or

I S S U E I T E M S

authorized for theBasic Issue Items

forklift truck are listed in theList , Appendix C.

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

3-2. Detailed Lubrication Information

a. Care o f Lubricants . Keep al l lubr icants insealed containers and stored in a clean, dry place

away from heat. Allow no dirt, dust, or water to mixwith the lubricants at any time. Keep all lubrication

equipment c lean and ready for use .b. Points o f Lubricat ion . F o l l o w t h e d e t a i l e d

l u b r i c a t i o n i n s t r u c t i o n s g i v e n o n t h e c u r r e n tlubrication order. Always apply lubricants specifiedon the current lubrication order.

c. Cleaning. Keep all external parts not requiringl u b r i c a t i o n c l e a n f r o m l u b r i c a n t s . A f t e r e v e r ylubrication operation, remove any excess lubricantsfrom the point of application and-wipe away spilledlubricant .

d. OES Oil.

(1 ) The crankcase o i l l eve l must be checkedfrequent ly , as o i l consumption may increase .

( 2 ) T h e o i l m a y r e q u i r e c h a n g i n g m o r efrequently than usual because contamination byfuel d i lut ion and s ludge formation wi l l increase

under co ld weather operat ion .e . O p e r a t i o n I m m e d i a t e l y A f t e r L u b r i c a t i o n .

O p e r a t e t h e u n i t 5 m i n u t e s i m m e d i a t e l y a f t e rlubrication. Inspect the oil filter and oil lines forevidence of leakage. If the crankcase oil has beenchanged, it will be necessary to operate the enginefor 5 minutes before checking the oil level.

f. Oil Filter. Refer to figure 4-4 and service the oilfilter. The oil filter is located on ‘the right side of theengine n e a r t h e v o l t a g e r e g u l a t o r . R e f e r t olubr icat ion order .

S e c t i o n I l l . P R E V E N T I V E M A I N T E N A N C E C H E C K S A N D S E R V I C E S

3-3. General

T o i n s u r e t h a t t h e f o r k l i f t t r u c k i s r e a d y f o roperat ion a t a l l t i m e s i t m u s t b e i n s p e c t e dsystematically, so that defects may be discoveredand corrected before they result in serious damageand failure. The necessary preventive maintenancechecks and services to be performed are listed andd e s c r i b e d i n p a r a g r a p h 3 - 4 . T h e i t e m n u m b e r si n d i c a t e t h e s e q u e n c e o f m i n i m u m i n s p e c t i o nrequirements. Defects discovered during operationof the unit will be noted for future correction, to be

m a d e a s s o o n a s o p e r a t i o n h a s c e a s e d . S t o po p e r a t i o n i m m e d i a t e l y i f a d e f i c i e n c y i s n o t e dd u r i n g operat ion w h i c h w o u l d d a m a g e thee q u i p m e n t i f o p e r a t i o n were cont inued. A l l

d e f i c i e n c i e s a n d s h o r t c o m i n g s w i l l b e r e c o r d e dtogether with the corrective action taken, on DAF o r m 2 4 0 4 ( E q u i p m e n t I n s p e c t i o n a n d M a i n -tenance Worksheet ) at the ear l iest poss ib le op-

portunity .

3-4. Daily and Weekly Preventive MaintenanceChecks and Services

This paragraph contains an i l lustrated tabulatedl i s t i n g o f p r e v e n t i v e m a i n t e n a n c e c h e c k s a n d

services which are performed by the operator. Theitem numbers are listed consecutively and indicatethe sequence o f minimum requirements . Refer tot a b l e 3 - 1 f o r t h e d a i l y a n d w e e k l y p r e v e n t i v emaintenance checks and serv ices .

3-1

Table 3-1. Preventive Maintenance Checks and Services

B

x

x

x

x

x

x

x

x

D

x

x

x

A

x

w

K

x

x

x

x

x

M

—

e

B – Betara opedtoa A – M& opemttaa M – Btoathty

D – DurtIx Oparatton w - Weakty Q–QuuI=b

Itamtabolaspacted

Lubricate in accord

?uel tank and line

kbrication system

and lines

Batteries

Badiator

Belts

Fuel filter and lines

harting aid

Hydraulic reservoirs

Electrical system

[nstrument and

gages

Air cleaner

Axle, f rent and rear

I’irea

~re extinguisher

Hour-meter

Fork shifter chain

and sprocket

:e with current lubrication order.

Check level. Inspect lines for leaks. Drain

water from primary fuel filter.

Check oil level. Add oil to proper level.

Lubricate in accordance with current

lubrication order. Inspect lines for leaks.

Check electrolyte level. Fill to one-half inch

above the plates with distilled water. In

freezing weather; run engine a minimum of

one hour aftix adding water.

Check coolant level. Correct coolant level as

necewary.

Inspect helte for cuts, breaks and proper

tension.

Inspect fuel filter for dut. Clean fuel filter.

Inspwt fuel lines for leaks.

Replace ether canister as required.

Refer to current lubrication order and service

a8 required.

Check generator, and regulator for proper

operation. Check Iighta for operation.

Check gages during engine operation for

proper operation. Normal readings are:

Coolant temperature 170° to 220e F.

Engine oil pressure (normal) 35 to 50 psi

Engine oil pressure (idle) 8 to 1 S psi

Torque converter temperature-Not over

280° F.

Brake oil pressure (RTL1O) O to 400 psi

Check condition and service air cleaner as

necessary.

Check oil level, as required in accordance

with cum!nt lubrication order.

Perform visual check for proper inflation.

Correct air pressure is 50 psi front, 45 psi

rear (firm terrain and 35 psi front, 30 psi

rear (soft terrain ).

Check for broken seal.

Check for proper operation.

Inspect chain for breaks or cracks in links

Wash chain and sprocket with fresh wate]

after operating in sand or salt water.

( p a r a 2 - 2 )

( p a r a 3 - 2 )

( p a r a 2 - 2 )

( p a r a 2 - 2 )

( p a r a 3 - 9 )

( p a r a 3 - 1 0 )

(para 2-20)

3 - 2

S e c t i o n I V . T R O U B L E S H O O T I N G

3-5. General 3-6 . Troubleshooting

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n T h i s s e c t i o n p r o v i d e s i n f o r m a t i o n u s e f u l i n

troubleshooting of the forklift and its components, diagnosing and correcting unsatisfactory operation

which is the responsibility of the operator. or failure of the forklift truck and its components

(table 3-2) .

T a b l e 3 - 2 . T r o u b l e s h o o t i n g

Malfunction

I. fingine Faifs to Start.

2. Engine Misses and Lacks Power.

3. Toryue Converter Overheats.

.5. Engine Exhaust Smoke Excessive.

6. Batteries Fail tn Maintain Charge.

7. Lights Fail to Operate.

Probable Cause

u. Battery weak.

b. Fuel tank empty.

c. Fuel filter clogged.

d. Low fuel pressure

e. Battery cable loose.

a. Fuel f ifter clogged.

h. Dirty air cleaner.

c. Low fuel pressure.

a. Oil level low.

b. Operating in too high speed range.

Too much oil in crankcase.

Electrolyte level 10W.

Lamps burned out.

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

3-7. General

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n -tenance of the forklift truck which is the respon-

sibility of the operator.

3-8. Air Cleaner Service

NOTEWhen operating in a dusty or sandy area, the airfilter should be serviced daily.Refer to figure 3-1, and service the air cleaner.

NOTEReplace filter after two or three cleanings if in-spection shows element damage. The time in-

Cmrcctive Action

, &q/

a. Service battery ( p a r a 2 - 2 ) . ---”

b. Service fuel tank (para 2-2) with

proper grade of fuel. ( A p p e n d i x

C )

c. Clean fuel filter ( p a r a 3 - 9 ) .

d. Check for loose and leaking fuel

lines. Tighten loose lines ( p a r a 3 -

9 ) .

e. Tighten battery cable ( p a r a 3 - 1 ) .

a. Clean fuel filter ( p a r a 3 - 9 ) .

b. Service air cleaner ( p a r a 3 - 8 ) .

c. Check for loose and leaking fuel

lines. Tighten loose lines ( p a r a 3 -

9 ) .

a. Service transmission in accordance

with current lubrication order

( p a r a 3 - 2 ) .

b. Operate in next lower speed range.

Check level of oil in crankcase ( p a r a

3 - 2 ) .

ljjlAdd electrolyte to battery ( p a r a 2 - 1 ) .

Replace lamps.

O F F O R K L I F T

tervals for replacing the air cleaner element willvary with operating conditions.

C A U T I O N

When using compressed air to blow outt h e f i l t e r , b l o w f r o m t h e i n s i d e o u t ,being careful not to rupture element.Insure O-ring is properly sealed and noleaks exist and that f i lter restrictionindicator reads in the green with enginer u n n i n g . A i r f i l t e r c o n t a m i n a t i o n i n -d i c a t o r i s l o c a t e d a t r i g h t r e a r o foperator’s seat.

3-3

Figure 3-1.

3-9. Fuel Filter Service

Refer to f igure 3 -2 and serv ice the pr imary fue lf i l ter . Wash the metal l ic e lement with c leanings o l v e n t ( F e d P D - 6 8 0 ) . U s e c o m p r e s s e d a i r f o rcleaning by forcing air from the inside out. Replaces e c o n d a r y f u e l f i l t e r e l e m e n t q u a r t e r l y , o r a srequired. Inspect fuel lines for leaks and damage.

3-4

Figure 3-2.

3 - 5

Figure 3.3.

3-10. Ether Primer Servicing

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

3-11. Battery Servicing

Refer to figure 3-4 and service the batteries.

3-6

Figure 3-4.

3-7

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. Service Upon Receipt of Material

Refer to paragraph 2-2 for service upon receipt ofmater ial .

S e c t i o n I l . M O V E M E N T T O A N E W W O R K S I T E

4-2. Movement to a New Worksite

Refer to paragraphs 2-3 thru 2-5 forfor movement to a new works i te .

instructions

P A R T S , S P E C I A L T O O L S A N D E Q U I P M E N T

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 p e r s o n n e l f o r t h e

S e c t i o n I l l . R E P A I R

4-3 . Basic Issue Items

Tools, equipment, and repair parts issued with ormaintenance of this forklift truck.4-5. Maintenance Repair Parts

authorized for the forklift truck are listed in theBasic Issue I tems List , Appendix C. R e p a i r p a r t s a n d e q u i p m e n t a r e l i s t e d a n d

4-4 . Special Tools and Equipment illustrated in the repair parts and special tools list

N o s p e c i a l t o o l s o r e q u i p m e n t a r e r e q u i r e d b ycovering 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 f o r t h i se q u i p m e n t i n T M 1 0 - 3 9 3 0 - 2 4 3 - 3 5 P .

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

4-6. Lubrication Instructions

Refer to paragraph 3-2 for deta i led lubr icat ioninstructions.

S e c t i o n V . P R E V E N T I V E M A I N T E N A N C E C H E C K S A N D S E R V I C E S

4-7. General

T o i n s u r e t h a t t h e f o r k l i f t t r u c k i s r e a d y f o roperat ion a t a l l t i m e s i t m u s t b e i n s p e c t e dsystematically, so that defects may be discoveredand corrected before they result in serious damageand failure. The necessary preventive maintenance

checks and services to be performed are listed andd e s c r i b e d i n p a r a g r a p h 4 - 8 . T h e i t e m n u m b e r si n d i c a t e t h e s e q u e n c e o f m i n i m u m i n s p e c t i o nrequirements. Defects discovered during operationof the unit will be noted for future correction, to bem a d e a s s o o n a s o p e r a t i o n h a s c e a s e d . S t o p

o p e r a t i o n i m m e d i a t e l y i f a d e f i c i e n c y i s n o t e d

d u r i n g operat ion w h i c h w o u l d d a m a g e thee q u i p m e n t i f o p e r a t i o n were c o n t i n u e d . A l ld e f i c i e n c i e s a n d s h o r t c o m i n g s w i l l b e r e c o r d e d ,together with the corrective action taken, on DAF o r m 2 4 0 4 ( E q u i p m e n t I n s p e c t i o n a n d M a i n -tenance Worksheet ) at the ear l iest poss ib le op-portunity .

4 - 8 . M o n t h l y a n d Q u a r t e r l y P r e v e n t i v eMaintenance Checks and Services

a. T h i s p a r a g r a p h c o n t a i n s a n i l l u s t r a t e dtabulated listing of preventive maintenance checks

4-1

a n d s e r v i c e sorganizat ionaland quarterly

w h i c h m u s t b e p e r f o r m e d b y b. The item numbers are listed consecutively andmaintenance personnel at monthly indicate the sequence o f minimum requirements .intervals . A quarter ly interval i s Refer to table 4 -1 for the quarter ly prevent ive

e q u a l t o 3 c a l e n d a r m o n t h s o r 2 5 0 h o u r s o f maintenance checks and serv ices .operation, whichever occurs first.

4 - 2

T a b l e 4 - 1 . P r e v e n t i v e M a i n t e n a n c e C h e c k s a n d S e r v i c e s

1

2

3

4

5

6

7

8

9

10

11

12

13

14

Opw8tar

—

B D A

w M

x

x

x

x

Q

x

x

x

B – Befors Ctpsratton A – After Operation M – Moathly

D — During Operation w – Weekty Q–-b

Ikmtobs Lospected

,ubricate in accordal

Chains and

sprockets

Tires

Fuel System ~ ~

Lubrication system

Belts

Cooling system

Valve adjustment

J&&’” compression

testG’

Electrical system

Hydraulic system

F]re extinguisher

Gages and in

struqents

Hour Meter

Brakes

Transrn ission am

torque converter.

: with current lU rication or er.

Inspect for excessive wear. Check chain

tgnsion. Correct tension is M inch

deflection midway between sprockets

longest span ( 1000 hours).

Inspect for excessive wear, cuts, breaks, and

proper inflation. Correct air pressure is 50

psi front, 45 psi rear ( fiim terrain). 35 psi

front, 30 rear (soft terrain).

Check governor adjustments: 3,1’00 rpm

maximum no load. Check fuel pump

pressure 3 to 7 psi. ~C fuel leaks ( 1000

hours ). lip

Check engine oil level. Add oil to correct

level. Correct lubricant leaks. Lubricate in

accordance with current Lo.

Inspect for excessive wear, cuts, breaks, and

proper tension. Correct tension is V1 inch

deflection midway between pulleys.

Check coolant level. Correct level as

necessary. Check for correct anti-freeze

solution. Clean radiator air passages.

Correct coolant leaks.

Check valve clearance exhaust 0.025 (cold)

and 0.023 (hot). Chqck l-!nmpreaaiml

pressure 385 to 415 psi. Maximum

allowable pressure variation between

cylinders 25 psi (1000 hours).

Check generator and regulator, starter and

lights for proper operation. Check

generator brushes, replace if worn less than

1/2 inch io length ( 1000 hours). Check

battery electrolyte level and specific

gravity. Fill to IA inch above plates. In

freezing weather run engine a minimum of

one hour after adding water. Tighten all

loose connections, replace defective wiring.

Check fluid level. See current LO. Check for

proper operation and correct all leaks.

Inspect for broken seal. Inspect for full

charge by shaking for sound or weighing.

Normal readings are:

Clutch oil pressure —100 to 175 psi

Torque converter temperature—Not over

280° F.

Engine oil pressure —30 to 60 psi

Water temperature gage —1 60° F. to

180° F.

Am meter—In charge area

Brake oil pressure —O to 400 psi (Model

RTL1O)

Inspect for proper operation.

Inspect for proper operation and adjustment.

Brake pedal free travel is % to % inch

( 1000 hours).

Inspect for proper operation and leaks at top

governed rpm. Correct leaks ( 1000 hours).

Note. operational. During operation check

for unusual noise or vibration and proper

operation.

Reference

( p a r a 4 - 9 1 )

(para 4-81)

( p a r a 4 - 2 9 )

( p a r a 4 - 1 8 )

( p a r a 4 - 3 5 )

( p a r a 4 - 3 0 )

( p a r a 4 - 1 7 )

( p a r a 4 - 3 9 )

( p a r a 4 - 8 5 )

( p a r a 4 - 5 9 )

( p a r a 4 - 5 4 )

( p a r a 4 - 2 5 )

( p a r a 4 - 6 9 )

4-3

S e c t i o n V I . T R O U B L E S H O O T I N G

4-9. General probable causes of the trouble. The possible remedy

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n u s e f u l i nrecommended is descr ibed opposi te the probable

diagnosing and correcting unsatisfactory operationcause .

or failure of the forklift truck and its components. 4-10. Troubleshooting

Each trouble symptom stated is followed by a list of Refer to table 4-2 for troubleshooting information.

T a b l e 4 - 2 . T r o u b l e s h o o t i n g

Malfunction

1. Starter Fails to

2. Engine Hard tn

Start.

Crank Engine.

Start or Fails to

3. k;ngine Oil Consumption Ex-

cessive.

4. Engine Overheats.

.3. Engine Has Low or No Oil

Pressure.

6. Kn@e Knocks

Excessive Noise.

or Develops

i. Engine Lacks Pnwer.

8. Engine Stops Suddenly.

9. Engine Misses or

Erratically.

Runs

Probable Cause

ti. Engine starter defective.

b. Starter solenoid defective.

c. Battery cable loose or starter

switch defective.

ii. Fuel fifter clogged.

b. Air intake restricted.

t:. Starter does not crank engine at

proper speed.

d. Oil filter leaks.

b. Worn or broken piston rings.

c. Oil pan or gasket leaking or .

defective.

a. Drive belts loose or broken.

b. Thermostat defective.

c. Water pump defective.

a. Lubrication oil pump defective.

b. Engine oil pressure gage defective.

it. Push rods out of adjustment.

b. Worn or defective rod or main

bearings.

a. Fuel pump defective.

b. Fuel line restricted.

c. Air intake restricted.

d. Fuel filtkrs defective.

a. Fuel tank’ empty.

b. Fuel pump defective

a. Push rods out of adjustment.

b. Fuel line restricted.

c. Fuel pump defective.

d. Injector defective.

c. Fuel filter restricted.

Corrective Action

a. Replace starter ( p a r a 4 - 4 4 ) .

b. ReDbrce solenoid ( p a r a 4 - 4 4 ) ..c. Tighten, repair, or replace battery

cable (para 4 -41) . Replace switch

( p a r a 4 - 5 3 ) .

a.

b.

c.

a.

b.

c.

ii.

b.

c.

a.

Service filter ( p a r a 3 - 9 ) .

Remove restriction from air inlet

pipe or hose.

Replace a defective starter (para 4-

4 4 ) .

Replace a defective oil filter or

gasket ( p a r a 4 - 1 9 ) .

Report this condition to general

support maintenance.

Report this condition to direct

support maintenance.

Adjust or replace drive belts ( p a r a

4 - 3 5 ) .

Replace a defective thermostat

( p a r a 4 - 3 1 ) .

Replace a defective water pump

( p a r a 4 - 3 2 ) .

Report this condition to direct

support maintenance.

Redate a defective engine oilb.

pr&sure gage ( p a r a 4 - 6 0 ) .

a. Adjust the push rods ( p a r a 4 - 1 7 ) .

b. Report this condition to general

support maintenance.

iI. Replace a defective fuel pump

( p a r a 4 - 2 7 ) .

b. Remove restriction from fuel line

or replace line ( p a r a 4 - 2 6 ) .

c. Remove restriction from inlet pipe

or hose (para 4-28).

d. Replace a defective fuel filter

element (para 3-9).

u. Replenish fuel supply.

b. Replace defective fuel pump ( p a r a

4 - 2 7 ) .

a. Adjust the push rods ( p a r a 4 - 1 7 ) .

b. Remove restriction from fuel line

( p a r a 4 - 2 6 ) .

c. Replace a defective fuel pnm p

( p a r a 4 - 2 7 ) .

d. Report this condition to direct

support maintenance.

e. Service fuel filter ( p a r a 3 - 9 ) .

4-4

T a b l e 4 - 2 . T r o u b l e s h o o t i n g - C o n t i n u e d

Malfunction

10. Engine Exhaust Smoke Ex.

ceasive,

11, Batteries Fail to Maintain

Charge.

12, Lights Fafl to Operate.

13, Transmidcm Fails to Shift.

14. Transmission and Torque

Converter Overheat.

1S, Steering Liikage Noisy.

16, Brakes Will Not Work Properly.

17. Hydraulic Cylinders Work

Slowly at Rated Engine Speed.

18. Hydraulic Control Levers Will

Not Operate Properly.

19. Fork Will Not Lift Rated Load or

Creeps Down,

20. Cylinder Chatters When in

Operation.

Probable Cauaa

u,

b.

u.

b.

L’.

u.

b.

(’.

u.

h,

8.

Too much oil in crankcase.

Oil consumption exceaaive.

Electrolyte level low,

Engine generator defective.

Voltage regulator defective.

Lamps burned out.

Light switch defective.

Damaged or defective wiring.

Linkage defective,

Defective transmieaion.

Oil in transmission low.

h, Engine overheating.

Loose drag fink.

a.

b.

c,

d.

u.

b.

c.

u.

b.

Lack of hydraulic fluid (OE 101.

Brake check valve defective.

Leaking or defective lines.

Worn brake Iininga.

Defective lift control valves.

Worn or damaged pump.

Damaged or worn cylinder.

Weak or broken detent spring.

Damaged or defective lever.

ti. Leaking or worn lift cyiindera.

b. Worn or defective control valve.

c. Defective pump.

u. Packing glanda are too tight.

b. Dented cylinder housing.

c. Bent piston rod,

d. Air in hydraulic system.

Corrective Action

11.

b.

Il.

b,

6’,

u.

k

c,

n.

h,

u.

h,

Check level of oil in crankcase.

Inspect oil filter for leaks ( p a r a 4 -1 9 ) .

Fill battery with electrolyte tr

proper level ( p a r a 2 - 2 ) .

Replace generator ( p a r a 4 - 4 0 ) .

Replace regulator ( p a r a 4 - 4 3 ) .

Replace Iempa.

Replace a defective light switch

( p a r a 4 - 5 3 ) .

Repair damaged wires ( f i g s . 1 - 3

a n d 1 - 4 ) .

Replace all defective transmission

linkage ( p a r a 4 - 7 1 ) .

Report this condition to direct

support maintenance.

Refer to A p p e n d i x C and fill the

transmission with the proper

grade of oil.

Check coolant level ( p a r a 2 . 2 ) .

Refer this condition to direct support

maintenance.

a. Check and replenish brake fluid

(L0,10.3930-243 -12).

b. Report this condition to direct

support maintenance,

c. Tighten or rerdace defective lines

( p a r a 4 - 7 8 ) .

d. Report this condition

support maintenance.

u, Report this condition

support maintenance.

b, Report this condition

support maintenance.

c. Report this condition

support maintenance.

n. Report this condition

support maintenance.

b. Report this condition

support maintenance.

u. Report this condition

support maintenance.

b. Report this condition

support maintenance.

c. Report this condition

support maintenance.

u. Report this condition

support maintenance.

b. Report this condition

auppor t main tenance.

c, Report this condition

aurmort maintenance.

to direct

to direct

to direct

to direct

to direct

to direct

to direct.

to direct

to direct

to direct

to direct

to direct

d. W&k the vehicle through several

complete hydraulic functions to

bleed the air out of the hydraulic

system.

4-5

Figure 4-1.

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

4-10A. General Methods Used to Attain ProperSuppression

Essentially, suppression is attained by providing alow resistance path to ground for stray currents.

The methods used includes shielding the ignitiona n d h i g h - f r e q u e n c y w i r e s , g r o u n d i n g t h e f r a m ew i t h b o n d i n g s t r a p s , a n d u s i n g c a p a c i t o r s a n dresistors. F o r g e n e r a l i n f o r m a t i o n o n r a d i o i n -t e r f e r e n c e s u p p r e s s i o n , s e e T M 1 1 - 4 8 3 .

4 - 1 1 . I n t e r f e r e n c e S u p p r e s s i o n C o m p o n e n t s

a . P r i m a r y S u p p r e s s i o n C o m p o n e n t . T h e i n -terference suppression bonding strap is illustratedon f igure 4 -1 .

b . Secondary Suppress ion Components .

(1) T o o t h - t y p e l o c k w a s h e r s .(a) The generator i s mounted on the top

front o f the engine and is grounded by internal -external toothed lockwashers.

(b) The generator regulator is mounted onthe main frame near the left rear end of the engine

and is grounded by internal-external toothed lock-washers and bonding strap.

(2) C a p a c i t o r . T h e i n t e r f e r e n c e s u p p r e s s i o nc a p a c i t o r i s l o c a t e d i n t h e g e n e r a t o r v o l t a g eregulator .

(3) Shie lded cables . The engine generator i se q u i p p e d w i t h a s h i e l d e d c a b l e c o n n e c t i n g t h egenerator and the generator regulator.

4-12. Replacement of Suppression Components

Replace radio inter ference components with newcomponents that are identical. It is essential that agood metal-to-metal contact is achieved to maintainproper radio inter ference suppress ion . To correctfaulty suppress ion, subst i tute new inter ferencesuppress ion c o m p o n e n t s u n t i l t h e f a u l t y c o m -ponents are d iscovered .

a . P r i m a r y S u p p r e s s i o n C o m p o n e n t . R e f e r t ofigure 4-1, and replace the bonding strap.

b . S e c o n d a r y S u p p r e s s i o n C o m p o n e n t s . F o r

replacement of secondary suppression components,refer to the applicable maintenance sections of this

m a n u a l .

4 - 1 3 . T e s t i n g o f R a d i o I n t e r f e r e n c e S u p -pression Components

I f inter ference i s indicated , i so late the cause o f

i n t e r f e r e n c e b y t h e t r i a l - a n d - e r r o r m e t h o d o fr e p l a c i n g e a c h s u p p r e s s i o n c o m p o n e n t i n t u r n ,

u n t i l t h e c a u s e o f i n t e r f e r e n c e i s l o c a t e d a n del iminated.

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

4-14. General Cleaning and Inspection Methods

a. Cleaning .

(1) Clean al l parts in an approved c leaningsolvent , e .g . , Fed P-D-680.

(2) Clean surfaces and install new gaskets asrequired .

(3) When using air use dry low pressure air.b. Inspec t ion .

(1) Inspect all parts visually before installingor re insta l l ing for cracks , wear , rust , corros ion .cuts, breaks and dents,

( 2 ) I n s p e c t a l l e l e c t r i c a l w i r i n g f o rdeterioration of insulation, cuts and bare wires.

(3 ) Inspect a l l hoses for cuts , deter iorat ion ,leaks and loose fittings.

(4) Inspect all lines for dents, cracks and leaks.(5 ) Inspect a l l hardware for damage, rust ,

breaks and damaged threads .

( 6 ) I n s p e c t drive belts for cuts anddeterioration.

4-15 . Engine Assembly

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n -

4-6

Figure 4-2.

Figure 4-3.

tenance of those components and accessories of theengine which is the responsibility of organizational

maintenance .

4 - 1 6 . R o c k e r A r m C o v e r

a. Removal. Refer to figure 4-2 and remove the

rocker arm cover .

4-17 . Push Rod Adjustment

a. Remove the rocker arm cover (para 4 -16) .b. Refer to figure 4-3 and adjust the push rods.c. Install the rocker arm cover.

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

4-18. General f i l ter . Every 100 hours o f operat ion , remove and

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n - discard filter element. Refer to current lubrication

t e n a n c e o f t h e l u b r i c a t i o n s y s t e m w h i c h i s t h e order .

responsib i l i ty o f organizat ional maintenance . b. Removal. Refer to figure 4-5 and remove the

4 - 1 9 . O i l F i l t e roil filter and bracket.

c. Installation. Refer to figure 4-5 and install thea. Service. Refer to figure 4-4 and service the oil oil bracket and filter.

4-7

Figure 4-4.

Figure 4-5.

Figure 4-6.

4-20. Crankcase Breathera. Removal. Refer to figure 4-6 and remove the

crankcase breather .

4 - 8

Figure 4-6.

4-21. Oil Level Dipstick, Tube and Capb. Installation. Refer to figure 4-7 and install the

a. Removal. Refer to figure 4-7 and remove the tube, dipstick and oil filler cap.oil filler cap, dipstick and tube.

4-9

Figure 4-7.

S e c t i o n X . E X H A U S T S Y S T E M

4-22. General 4-23 . Muff ler and Exhaust Pipe

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n - a. Removal. Refer to figure 4-8 and remove thetenance of the exhaust system. These include the muff ler and exhaust p ipe .

muffler, exhaust pipe, exhaust manifold and flange. b. Installation. Refer to figure 4-8 and install themuff ler and exhaust p ipe .

4-10

Figure 4-8.

Figure 4-8.

4-11

Figure 4-9.

4-24. Exhaust Manifold and Flange b. Installation.

a . R e m o v a l . (1) Refer to figure 4-9 and install the exhaust

( 1 ) R e m o v e t h e m u f f l e r a n d e x h a u s t p i p e manifo ld and f lange.

( p a r a 4 - 2 3 ) . (2) Install the muffler and exhaust pipe (para

(2) Refer to figure 4-9 and remove the exhaust 4 - 2 3 ) .

manifo ld and f lange.

S e c t i o n X l . F U E L S Y S T E M

4-25. General 4-26. Fuel Tank and Lines

This sect ion contains information on the main- a. Removal. Refer to figure 4-10 and remove thetenance of those items and components of the fuel fuel lines and tank.s y s t e m w h i c h a r e t h e r e s p o n s i b i l i t y o f b. Installation. Refer to figure 4-10 and reinstallorganizat ional maintenance personnel . the fuel tank.

4-12

Figure 4-10.

4-13

Figure 4-10.

4 - 2 7 . F u e l P u m pb. Installation. Refer to figure 4-11 and reinstall

a. Removal. Refer to figure 4-11 and remove thef u e l p u m p .

the fue l pump.

4-14

Figure 4-12.

Figure 4-11.

4-28. Air Cleaner, Bracket and Hose

a. Removal. Refer to figure 4-12 and remove the b. Installation. Refer to figure 4-12 and install

air cleaner, bracket and hose. the air cleaner, bracket and hose.

4-15

Figure 4-13.

4-29. Fuel Filters

a. Removal. Refer to figure 4-13 and remove thefuel filters.

b. Installation. Refer to figure 4-13 and installthe fuel filter.

4-16

Figure 4-13.

4-17

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

4-30. General

The diesel engine is cooled by circulating the enginecoolant through the radiator , transmiss ion heate x c h a n g e r , c y l i n d e r b l o c k , a n d c y l i n d e r h e a d .

Coolant is drawn from the bottom of the radiatorby the water pump and circulated through the heatexchanger, engine block, and cylinder head. During

warm-up period, when coolant temperture is

b e l o w n o r m a l , t h e c o o l a n t i s r e s t r i c t e d a t t h ethermostat. A bypass tube connected between the

thermostat housing and the water pump providesc i r c u l a t i o n w i t h i n t h e e n g i n e . A s t h e c o o l a n t

t e m p e r a t u r e r i s e s a b o v e 1 6 0 t o 1 7 0 ° F . , t h et h e r m o s t a t v a l v e o p e n s , r e s t r i c t i n g t h e b y p a s s

s y s t e m a n d c o o l a n t i s c i r c u l a t e d t h r o u g h t h eradiator. This section contains information on the

m a i n t e n a n c e o f t h e c o o l i n g s y s t e m c o m p o n e n t sw h i c h i s t h e r e s p o n s i b i l i t y o f o r g a n i z a t i o n a lmaintenance personnel .

4-31 . Thermostat Housing and Thermostat

a . R e m o v a l .

( 1 ) D r a i n t h e c o o l i n g s y s t e m t o b e l o w t h ethermostat housing by opening the drain valve.

( 2 ) R e f e r t o f i g u r e 4 - 1 4 a n d r e m o v e t h ethermostat housing and thermostat .

b. Cleaning and Inspect ion .

(1) Clean thermostat housing seat and gasksurface .

(2) Inspect the thermostat for an accumulationof rust and corrosion.

c . Tes t ing . Check operat ion o f thermostat . I ft h e r m o s t a t r e m a i n s c l o s e d o v e r h e a t i n g o f t h e

engine wi l l result . I f t h e r m o s t a t r e m a i n s o p e n

e n g i n e m a y n o t r e a c h n o r m a l o p e r a t i n g t e m -perature, resulting in i n c o m p l e t e f u e l c o m -

bustion and carbon buildup. To check operation ofthermostat , suspend i t and a thermometer in a

container of water. Do not let the thermometer orthermostat touch the bottom or sides of container.Heat the water, agitate to maintain an even tem-perature. As water is heated the thermostat should

begin to open at 160 to 170°F., and be fully open ata p p r o x i m a t e l y 1 9 0 ° F .

d. Installation.(1 ) Af f ix new gasket to thermostat housing

and seat thermostat in housing so that the spring(or bellows) is down or toward the hot water sidewith unit bolted to cylinder head.

(2) Refer to figure 4-14 and install thermostathousing and hose .

4-18

Figure 4-14.

4-32. Water Pump and Pulley

a . R e m o v a l .

(1 ) Drain the coo lant system.(2) Remove the water pump drive

4 - 3 5 ) .

(2) Inspect the water pump for turning freely.c. Installation.

( 1 ) A f f i x a n e w g a s k e t t o t h e p u m p b o d y .

belts (para Refer to figure 4-15 and install the water pump andpul ley .

(3) Refer to figure 4-15 and remove the water (2) Install the water pump drive belts (para 4-

p u m p a n d p u l l e y . 3 5 ) .

b. Inspec t ion . (3) Fill the coolant system.

(1 ) Inspect water pump housing for cracks .

4-19

Figure 4-15.

Figure 4-16.

4-33. Coolant Hoses and Fittings

a. Removal. Refer to figure 4-16 and remove thecoolant hoses and fittings.

b. Installation. Refer to figure 4-16 and installthe coolant hoses and fittings.

4 - 2 0

Figure 4-17.

4-34. Fan Guard

a. Removal. R e f e rfan guard.

to figure 4-17 and remove the

b. Installation. Refer to figure 4-17 and installthe fan guard in reverse procedure of removal.

4-35. Drive Belts

a. Removal. Refer to figure 4-18 and remove the

drive belts.b. Installation. Refer to figure 4-18 and install

the drive belts.c . Adjustment . Refer to f igure 4-19 and adjust

the drive belts.

NOTEWhen making adjustment for fan drive belts,place the radiator fan control in the OFF positionend with the idler pulley under spring tension.

4-21

Figure 4-18.

FIG. 3-27

4 - 2 2

Figure 4-19.

4 - 3 6 . F a n B l a d e

a . R e m o v a l .

(1) Remove the fan guard (para 4-34).

(2) Refer to figure 4-20 and remove the fan

b l a d e .

b . I n s t a l l a t i o n .(1) Refer to figure 4-20 and install the fan

b l a d e .(2) Install the fan guard (para 4-34).

4-23

Figure 4-20.

Figure 4-21.

4-37 . Pulley and Hub

a. Removal and Disassembly .

(1 ) Remove the fan guard (para 4-34) .(2 ) Remove the fan b lade (para 4-36) .

( 3 ) R e f e r t o f i g u r e 4 - 2 1 a n d r e m o v e a n ddisassemble the pul ley and hub.

b. Reassembly and Instal lat ion .

(1 ) Refer to f igure 4-21 and reassemble andinstall the pulley and hub in the reverse procedureof removal .

(2) Instal l the fan blade (para 4-36) .(3 ) Instal l the fan guard (para 4-34) .

4-24

Figure 4-22.

4 - 3 8 . B e l t A d j u s t i n g C o n t r o l , S p r i n g a n d b. Instal lat ion . Refer to figure 4-22 and install

Bracket Pulley t h e b e l t a d j u s t i n g c o n t r o l , s p r i n g a n d b r a c k e t

a. Removal. Refer to figure 4-22 and remove the pul ley .

belt adjusting control, spring and bracket pulley.

S e c t i o n X I I I . E L E C T R I C A L S Y S T E M

4-39. General

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n -t e n a n c e o f t h e e l e c t r i c a l s y s t e m w h i c h i s t h e

responsib i l i ty o f organizat ional maintenance .W A R N I N G

B e f o r e d i s c o n n e c t i n g a n y e l e c t r i c a lcomponents, make sure battery cablesare disconnected at batteries to preventa serious burn or shock to personnel ordamage to equipment.

4-40. Engine Generator and Bracket

a. On-Equipment Tes t ing .

(1) Refer to figure 4-23, and install a suitableadapter in the generator receptacle.

( 2 ) W h e n a h i g h - c h a r g i n g r a t e w i t h f u l l y -charge batteries is indicated, operate the unit at

half throttle and disconnect the field jumper. If theoutput remains high, the fault is in the generator. Ift h e o u t p u t d r o p s t o z e r o , t h e f a u l t i s i n t h er e g u l a t o r . R e p l a c e a d e f e c t i v e g e n e r a t o r a n d / o rregulator .

( 3 ) W h e n a l o w - o r n o - c h a r g i n g r a t e w i t hpartially or fully discharged batteries is indicated,inspect for loose connections or damaged wiring. Ifn o n e , s t o p t h e e n g i n e a n d d i s c o n n e c t t h e f i e l d

j u m p e r . M o m e n t a r i l y c o n n e c t a j u m p e r w i r eb e t w e e n t h e g e n e r a t o r f i e l d t e r m i n a l a n d t h ep o s i t i v e t e r m i n a l o f b a t t e r i e s t o p o l a r i z e t h egenerator. Reconnect the field jumper and start theengine. If the charging rate does not increase as the

e n g i n e s p e e d i s i n c r e a s e d , s l o w t h e e n g i n e a n dconnect a jumper wire between the armature andf ie ld terminals . I f the charging rate does not in-

4-25

Figure 4-23.

c r e a s e a s t h e e n g i n e s p e e d i s i n c r e a s e d , t h e b. Removal. Refer to figure 4-24 and remove the

generator is faulty. If the rate does increase, the engine generator and bracket .

regulator is faulty. Replace a defective generator c. Installation. Refer to figure 4-24 and install

and / or regulator. the engine generator and bracket.

4-26

Figure 4-24.

Figure 4-25.

4-41. Battery Holddown Cover, Batteries , andCables

a. Removal. Refer to figure 4-25 and remove thebattery ho lddown cover , batter ies , and cables .

b. Installation. Refer to figure 4-25, and installthe battery holddown cover, batteries, and cables.

C A U T I O N

T h i s i s a n e g a t i v e g r o u n d s y s t e m T oreverse polarity will damage the voltager e g u l a t o r . B e s u r e a l l b a t t e r y c o n -nections are clean and tight.

4-27

Figure 4-27.

Figure 4-26.

4-42. Receptacle Connector

a. Removal. Refer to figure 4-26, and remove thereceptac le connector .

b. Installation. Refer to figure 4-26, and installthe receptacle connector.

C A U T I O N

When cables are replaced, insure thatthe positive (+) cable be equipped withthe large battery post connector and thatthe negative ( - ) cable be grounded tot h e e n g i n e . W h e n i n s t a l l i n g t h er e c e p t a c l e , p l a c e t h e p o s i t i v e ( + )

connection up in relation to its mountedposition.

4-43. Voltage Regulator and Bracket

a. On-Equipment Testing. Refer to paragraph 4-4 0 a f o r o n - e q u i p m e n t t e s t i n g o f t h e v o l t a g eregulator .

b. Removal. Refer to figure 4-27, and remove thevoltage regulator and bracket.

c. Installation. Refer to figure 4-27, and installthe voltage regulator and bracket.

d. Adjustment . Refer to figure 4-28, and adjustthe voltage regulator.

4-28

Figure 4-28.

4 - 2 9

Figure 4-28.

4 - 3 0

Figure 4-28.

4 - 3 1

Figure 4-28.

4 - 3 2

Figure 4-28.

4-33

Figure 4-29.

4-44. Starter and Solenoid b. Removal . Refer to f igure 4-30 , and remove

a. On-Equipment Tes t ing . Refer to figure 4-29 the starter and solenoid.

for on-equipment testing of the starter. c. Installation. Refer tothe starter and solenoid.

figure 4-30, and install

4-34

Figure 4-30.

4-45. Starter Magnetic Switch (Model

a. Removal. Refer to figure 4-31 andstarter magnetic switch.

b. Installation. Refer to figure 4-31the starter magnetic switch.

R T L 1 0 - 1 )

remove the

and install

4-35

Figure 4-31.

4-46. Starter Pressure Switch (Model RTL10-1) 4-47. Stoplights-Tail l ights

a. Removal. Refer to figure 4-31 and remove the a . R e m o v a l . Refer to f igure 4-32 and removestarter pressure switch. the stoplights-taillights.

b. Installation. Refer to figure 4-31 and install b. Installation. Refer to figure 4-32 and installthe starter pressure switch.. the stoplight-taillights.

4-36

Figure 4-32.

Figure 4-33.

4.48. Blackout Lights and Headlights

a. Removal. Refer to figure 4-33 and remove theblackout l ights and headl ights .

b. Inst l lat ion . Refer to f igure 4 -33 and instal lthe blackout lights and headlights,

4-37

Figure 4-34.

Figure 4-35.

4-49. Floodlights

a. Removal. Refer to figure 4-34 and remove thef loodl ights .

b. Installation. Refer to figure 4-34 and installthe floodlights.

4-50 . Horn and Buzzer

a. Removal. Refer to figure 4-35 and remove thehorn and buzzer .

b. Installation. Refer to figure 4-35 and installthe horn and buzzer .

4-38

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

4-51. General

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n -tenance of all the controls and instruments of thet r u c k f o r k l i f t w h i c h i s t h e r e s p o n s i b i l i t y o forganizat ional maintenance .

W A R N I N GD i s c o n n e c t b a t t e r y ( ) c a b l e f r o mbattery before disconnecting any wiringunder dash.

4 - 5 2 . A m m e t e r

a. Removal. Refer to figure 4-36 and remove hea m m e t e r .

b. Installation. Refer to figure 4-36, and installthe ammeter .

4-53. Toggle Switches

a. Removal. Refer to figure 4-36 and remove thetoggle switches.

b. Installation. Refer to figure 4-36 and installthe toggle switches.

4 - 5 4 . H o u r m e t e r

a. Removal. Refer to figure 4-36 and remove thehourmeter .

b. Installation. Refer to figure 4-36 and installthe hourmeter.

4-55. Panel Lights

a. Removal. Refer to figure 4-36 and remove thepanel lights.

b. Installation. Refer to figure 4-36, and installthe panel lights.

4-56. Push Switch

a. Removal. Refer to figure 4-36 and remove thepush switch.

b. Installation. Refer to figure 4-36 and installthe push switch.

4-57. Light Switch

a. Removal. Refer to figure 4-36 and remove thelight switch.

b. Installation. Refer to figure 4-36 and installthe light switch.

4-58. Master Switch

a. Removal. Refer to figure 4-36 and remove themaster switch .

b. Installation. Refer to figure 4-36 and installthe master switch.

4-59. Rear Axle Disconnect Indicator Light

a. Removal. Refer to figure 4-36 and remove therear axle disconnect indicator light.

b. Installation. Refer to figure 4-36 and installthe rear axle disconnect indicator light.

4-60. Engine Oil Pressure Gage

a. Removal. Refer to figure 4-36 and remove the

engine oil pressure gage.

b. Installation. Refer to figure 4-36 and installthe engine oil pressure gage.

4 - 6 1 . B r a k e O i l P r e s s u r e G a g e a n d V a l v e

( M o d e l R T L 1 0 )

a. Removal. Refer to figure 4-36 and remove thebrake oil pressure gage and valve.

b. Installation. Refer to figure 4-36 and installthe brake oil pressure gage and valve.

4-62. Engine Coolant Temperature Gage

a. Removal. Refer to figure 4-36 and remove the

engine coo lant temperature gage .b. Instal lat ion . Refer to figure 4-36 and install

the engine coolant temperature gage.

4-63. Torque Converter Temperature Gage

a. Removal. Refer to figure 4-36 and remove thetorque converter temperature gage.

b. Installation. Refer to figure 4-36 and installthe torque converter temperature gage.

4-64. Horn Button

a. Removal. Refer to figure 4-36 and remove thehorn button .

b. Installation. Refer to figure 4-36 and installthe horn button .

4-65. Bank Indicator (RTL10-1)

a. Removal. Refer to figure 4-36 and remove thebank indicator .

b. Installation. Refer to figure 4-36 and install

the bank indicator .

4-66. Clutch Oil Pressure Gage

a. Removal. Refer to figure 4-36 and remove the

clutch oil pressure gage.b. Installation. Refer to figure 4-36 and install

the clutch oil pressure gage.

4-67. Hydraulic Control Levers

a. Removal. Refer to figure 4-36 and remove thehydraulic control levers.

b. Installation. Refer to figure 4-36 and installthe hydraulic control levers.

4-39

Figure 4-36.

Figure 4-36.

4 - 4 0

Figure 4-36.

4 - 6 8 . Foot Controls

a. Removal. Refer tofoot contro ls .

b. Installation. Refer to figure 4-37 and installfigure 4-37 and remove the the foot contro ls .

4-41

Figure 4-37.

S e c t i o n X V . T R A N S M I S S I O N A N D T O R Q U E C O N V E R T E R

4-69. General

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n -tenance of the transmission and torque converter

w h i c h i s t h e r e s p o n s i b i l i t y o f o r g a n i z a t i o n a lmaintenance .

4-70. Torque Converter Filter

a. Removal. Refer to figure 4-38 and remove thetorque converter filter.

NOTEChange filter element at every transmission oilchange. The filter element is a throw away typepaper element.

b. Cleaning and Inspect ion .

( 1 ) C l e a n t h e f i l t e r h e a d w i t h F e d P D - 6 8 0

cleaning solvent and dry thoroughly, Make sure oldg a s k e t m a t e r i a l i s r e m o v e d , i n s t a l l n e w f i l t e re lement and gasket .

(2) Inspect the filter for cracks, breaks, andloose connections. Check the oil for contamination.

c. Installation.

(1) Refer to figure 4 - 3 8 a n d i n s t a l l t h etransmission external filter.

C A U T I O NExcessive torque may damage the stud

i n t h e s u m p . U s e o n l y 7 t o 1 0 f o o t -pounds of torque when tightening coverbolt .

(2 ) Service transmiss ion in accordance withcurrent lubr icat ion order .

4-42

Figure 4-38.

Figure 4-39.

4-71. Transmission Linkage and Levers

a. General. Check all linkage between operator’sc o n t r o l s a n d t r a n s m i s s i o n f r e q u e n t l y . R e m o v ec o n s o l e p a n e l c o v e r ( f i g . 4 - 3 6 ) a n d i n s p e c t t h el inkage for proper lubr icat ion , c leanl iness , wear ,damage and f reedom of operat ion .

(1 ) Range se lector l inkage ( low, med. , h igh) .Make sure operator’s control (fig. 2-1) is positionedto correspond exactly with the detent positions of

range selector valve. If out of adjustment, report todirect support maintenance .

(2 ) Forward and reverse l inkage . Make sureoperator ’ s contro ls ( f ig . 2 -1 ) correspond exact ly

with valve selector detents. If out of adjustment,report to d irect support maintenance .

b. Removal. Refer to figure 4-39 and remove thetransmission linkage and levers.

c. Installation. Refer to figure 4-39 and installthe transmission linkage and levers.

d. Adjustment. Refer to TM10-3930-243-34 foradjustment procedures .

4-43

Figure 4-40.

Figure 4-41.

4-72. Transmission Cut-Off Valve (Inching)

a. Removal .

(1) Remove the driver’s access ladder (fig. 4-6 2 ) .

( 2 ) R e f e r t o f i g u r e 4 - 4 0 a n d r e m o v e t h etransmission cut-off valve.

b. Installation.

(1) Refer to figure 4 - 4 0 a n d i n s t a l l t h etransmission cut-off valve.

(2) Install the driver’s access ladder. (fig. 4-6 2 ) .

4-73. Transmission and Torque Converter OilHoses and Fittings

a. Removal. Refer to figure 4-41 and remove thetransmiss ion and torque converter o i l hoses andfittings, removal and installation.

b. Installation. Refer to figure 4-41 and installthe transmission and torque converter oil hoses andfittings.

4-44

S e c t i o n X V I . B R A K E S

4-74. General

T h i s s e c t i o n c o n t a i n s i n f o r m a t i o n o n t h e m a i n -tenance of the brakes which is the responsibility oforganizat ional maintenance .

C A U T I O NHydraulic f luid (OE 10) only, must be

used in this brake system. Use of regulartype brake f luid wil l result in severe

damage.

4-75. Service Brakes

The serv ice brakes are the expander tube typehydraulically operated. Pressure is supplied by anengine dr iven hydraul ic pump and appl icat ion is

controlled by an applicator valve located under theoperator’s floor plate. The brake system is suppliedwith oil (OE-10) from a hydraulic brake reservoir

( R T L 1 0 ) o r f r o m t h e m a i n h y d r a u l i c r e s e r v o i r( R T L 1 0 - 1 ) . B r a k e a d j u s t m e n t i s a c c o m p l i s h e dautomatical ly by s lack adjusters located in thehydraul ic l ines between the appl icator valve andthe wheel brake assemblies. No provision is madef o r m a n u a l a d j u s t m e n t . I f a n a d j u s t m e n tm a l f u n c t i o n o c c u r s r e p o r t t o d i r e c t s u p p o r tmaintenance .

4.76. Parking Brake Cable and Lever

a . R e m o v a l . Refer to f igure 4-42 and removeparking brake cable and lever .

b. Cleaning and Inspect ion .

(1 ) Clean the parking brake cable and leverwith Fed PD-680 c leaning so lvent .

(2 ) Inspect the cable for broken wires andk i n k s . I n s p e c t h a n d b r a k e l e v e r a n d m o u n t i n gbrackets for cracks , breaks and damaged parts .Replace a l l de fect ive parts .

c. Installation. Refer to figure 4-42 and replace

parking brake cable and lever .d. Adjustment .

(1 ) Release parking brake .(2) Remove handbrake yoke pin and cotter pin

( f i g . 4 - 4 2 A ) .(3) Turn yoke clockwise to tighten brake and

counterc lockwise to l oosen brake .

(4 ) Replace handbrake yoke p in and cotterp i n .

( 5 ) M i n o r a d j u s t m e n t i s a c c o m p l i s h e d b yturning the knurled adjusting knob located at top of

h a n d b r a k e l e v e r . T u r n c l o c k w i s e t o t i g h t e n ;counterc lockwise to loosen .

4-45

Figure 4-42.

4-46

Figure 4-42.

Figure 4-32.

4 - 7 7 . B r a k e H y d r a u l i c O i l R e s e r v o i r ( M o d e lR T L 1 0 )

a. Removal. Refer to figure 4-43 and remove thebrake hydraulic oil reservoir.

b. Installation. Refer to figure 4-43 and installthe brake hydraulic oil reservoir.

c. Filter Element and Magnet. Refer to figure 4-44 and remove the filter element and magnet.

4-47

Figure 4-44.

FIG. 4-52

FIG. 4-53Figure 4-46.

FIG. 4-62

Figure 4-45.

4-78. Hydraulic Brake Lines

a. Removal. Refer to figure 4-45 and remove thehydraulic brake lines.

b. Installation. Refer to figure 4-45 and installthe hydraulic brake lines.

4-79. Hydraulic Brake Low Pressure Switch

a. Removal. Refer to figure 4-46 and remove thehydraul ic brake low pressure switch .

b. Installation. Refer to figure 4-46 and installthe hydraulic brake low pressure switch.

4-48

Figure 4-47.

S e c t i o n X V I I . W H E E L S A N D T I R E S

4-80. General

This sect ion contains information on the main-tenance of the wheels which is the responsibility oforganizat ional maintenance .

4-81. Wheel Flanges, Wheel and Tires

a . R e m o v a l . Refer to f igure 4-47 and removewheel flanges, wheels, and tires.

b . D i s a s s e m b l y . R e f e r t o f i g u r e 4 - 4 8 f o rdisassembly o f wheel assembly .

c . I n s p e c t i o n . I n s p e c t t h e t i r e s f o r c u t s a n ddeterioration. Check lock ring, rim, wheel flanges,w h e e l a n d n u t s f o r c r a c k s , b r e a k s a n d d e n t s .

Replace all defective parts. Refer tofor care and maintenance o f pneumatic t i res .

d . R e a s s e m b l y . R e f e r t o f i g u r e 4 - 4 8 a n dreassemble wheel assembly .

e. Installation. Refer to figure 4-47 and installwheel flanges, wheel and tires.

WARNINGI n s u r e l o c k r i n g i s p r o p e r l y s e a t e dbefore inflating tires. Serious injury topersonnel may result should lock ringsnap out of seat.

4 - 4 9

Figure 4-48.

4-50

Figure 4-49.

S e c t i o n X V I I I . S T E E R I N G S Y S T E M

4-82. General s t e e r i n g s y s t e m t h a t a r e t h e r e s p o n s i b i l i t y o f

The forkl i f t t ruck has both f ront and rear wheelorganizational maintenance.

s teer ing . The f ront and rear wheels are s teered 4-83. Steering Wheel

hydraul ica l ly . The hydraul ic system consists o f a a. Removal. Refer to figure 4-49 and remove theh y d r a u l i c p u m p , s t e e r i n g v a l v e , s e l e c t o r v a l v e , steering wheel.hydraulic cylinders, hoses, and fittings. This section b. Installation. Refer to figure 4-49 and installd e s c r i b e s t h e m a i n t e n a n c e p r o c e d u r e s o f t h e the steering wheel.

4-84. Hydraulic Lines, Hoses and Fittings b. Removal . Refer to figure 4-50 and remove a

a. Inspec t ion . defect ive hydraul ic l ine .

(1) Inspect all hydraulic lines for leaks and c. Repair. Refer to figure 4-51 for hose repair.

d a m a g e . Instal lat ion . Refer to figure 4-50 and replace

(2) Inspect all hoses for cuts and deterioration. hydraul ic l ines .

(3) Replace a defective hydraulic line or hose.

4-51

Figure 4-50.

4-52

Figure 4-51.

4 - 5 3

Figure 4-52.

S e c t i o n X I X . H Y D R A U L I C L I F T S Y S T E M

4-86. Hydraulic Reservoir Filter Element 4-85. General

This section contains information on the main-a. Removal. Refer to figure 4-52 and remove the

hydraulic reservoir filter element.tenance of the hydraulic lift system which is the b. Installation. Refer to figure 4-52 and installresponsibility of organizational maintenance. the hydraulic reservoir filter element.

4-54

Figure 4-53.

FIG. 4-52

4-87. Hydraulic Reservoir Magnet

a. Removal. Refer to figure 4-52 and remove thehydraulic reservoir magnet.

b . D i s a s s e m b l y . R e f e r t o f i g u r e 4 - 5 3 a n d

disassemble and reassemble the hydraulic reservoirmagnet assembly .

c. Installation. Refer to figurethe hydraul i c reservo ir magnet .

4-88. Hydraulic Oil -Reservoir

C A U T I O N

4-52 and instal l

W h e n r e m o v i n g a n y h y d r a u l i c h o s e sand l ines , cap al l openings to preventforeign material from entering system,

causing serious damage to the system.

a. Removal. Refer to figure 4-54 and remove thehydraulic oil reservoir.

b. Installation. Refer to figure 4-54 and installthe hydraulic oil reservoir.

4-55

Figure 4-54.

4 - 8 9 . F o r k s b. Installation. Refer to figure 4-55 and install

a. Removal. Refer to figure 4-55 and remove thethe forks.

forks .

4-56

Figure 4-56.

Figure 4-55.

4-90. Fork Carriage 4-91. Side Shift Roller Chaina. Removal. Refer to figure 4-56 and remove the

fork carriage.a. Removal. Refer to figure 4-57 and remove the

b. Installation. Refer to figure 4-56 and installside shift roller chain.

the fork carriage.b. Installation. Refer to figure 4-57 and install

the side shift roller chain.

4-57

Figure 4-57.

4-5

8

Figure 4-58.

S e c t i o n X X . H O O D A N D B O D Y

4-92. Overhead Guardb. Installation. Refer to figure 4-58 and install

a. Removal. Refer to figure 4-58 and remove the the overhead guard .overhead guard .

4-93. Seat b. Installation. Refer to figure 4-59 and install

a. Removal. Refer to figure 4-59 and remove the the seat.

seat.

4-59

Figure 4-59.

Figure 4-60.

4-94. Counterweight and Pintle

a. Removal. Refer to figure 4-60 and remove thecounterweight and pintle.

b. Installation. Refer to figure 4-60 and installthe counterweight and pintle.

4 - 6 0

Figure 4-62.

4 - 6 2

Figure 4-61.

FIG. 4-33

4-95. Fenders

a. Removal. Refer to figure 4-61 and remove thefenders.

b. Installation. Refer to figure 4-61 and installthe fenders.

4-96. Body Panels

a. Removal. Refer to figure 4-62 and remove thebody panels .

b. Installation. Refer to figure 4-62 and installthe body panels .

4-61

A P P E N D I X A

R E F E R E N C E S

A-1. Fire Protection

T B 5 - 4 2 0 0 - 2 0 0 - 1 0 Hand Portable Fire Ext inguishers Approved forArmy Users

A - 2 . L u b r i c a t i o n

C 9 1 0 0 - I L Identification List for Fuels, Lubricants, Oils and

W a x e s

L O 1 0 - 3 9 3 0 - 2 4 3 - 1 2 Truck, Lift, Fork, Diesel Engine, Pneumatic TiredWheels, Rough Terrain, 10,000 lbs. Capacity, 24I n c h L o a d C e n t e r ( P e t t i b o n e - M u l l i k e n M o d e lR T L 1 0 , A r m y M o d e l M H E 1 9 9 ) F S N 3 9 3 0 -9 0 3 - 0 8 9 9 a n d P e t t i b o n e - M u l l i k e n M o d e lR T L 1 0 - 1 , A r m y M o d e l M H E 2 1 5 , F S N 3 9 3 0 -4 6 5 - 5 8 6 9 , w / E n g i n e , G e n e r a l M o t o r s M o d e l6 V 5 3

A - 3 . P a i n t i n g

T M 9 - 2 1 3

A - 4 . R a d i o S u p p r e s s i o n

T M 1 1 - 4 8 3

A - 5 . M a i n t e n a n c e

T M 9 - 1 8 7 0 - 1T B 7 5 0 - 6 5 1

T M 3 8 - 7 5 0T M 9 - 6 1 4 0 - 2 0 0 - 1 5

T M 1 0 - 3 9 3 0 - 2 4 3 - 2 0 P

A - 6 . S t o r a g e

T M 7 4 0 - 9 0 - 1

A-7. Destruction to Prevent Enemy Use

T M 7 5 0 - 2 4 4 - 3

A-8. Equipment Serviceabil ity Criteria

T M 1 0 - 3 9 0 0 - 2 0 3 - E S C

Paint ing Instruct ions for Fie ld Use

Radio Inter ference Suppress ion

Care and Maintenance o f Pneumatic TiresU s e o f A n t i f r e e z e S o l u t i o n s a n d C l e a n i n g C o m -

ponents in Engine Cool ing SystemsT h e A r m y M a i n t e n a n c e M a n a g e m e n t S y s t e mO p e r a t o r a n d O r g a n i z a t i o n a l , F i e l d a n d D e p o t

Maintenance: Storage Batteries, Lead Acid TypeO r g a n i z a t i o n a l M a i n t e n a n c e R e p a i r P a r t s a n d

S p e c i a l T o o l s L i s t , T r u c k , L i f t , F o r k , D i e s e lE n g i n e , P n e u m a t i c T i r e d W h e e l s , R o u g hT e r r a i n , 1 0 , 0 0 0 l b s . C a p a c i t y , 2 4 I n c h L o a dCenter Pett ibone-Mul l iken Model RTL10, Army

M o d e l M H E 1 9 9 , F S N 3 9 3 0 - 9 0 3 - 0 8 9 9 , a n dP e t t i b o n e - M u l l i k e n M o d e l R T L 1 0 - 1 , A r m yM o d e l M H E 2 1 5 , F S N 3 9 3 0 - 4 6 5 - 5 8 6 9

Administrat ive Storage o f Equipment

P r o c e d u r e s f o r D e s t r u c t i o n o f E q u i p m e n t t o

Prevent Enemy Use

Equipment Serviceabi l i ty Cr i ter ia

A-1 / A-2 blank

A P P E N D I X B

M A I N T E N A N C E A L L O C A T I O N C H A R T

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

B-1. General

a. This section provides a general explanation ofall maintenance and repair functions authorized atvarious maintenance levels.

b. Section II designates overall responsibility fort h e p e r f o r m o f m a i n t e n a n c e f u n c t i o n s o n t h ei d e n t i f i e d e n d i t e m o r c o m p o n e n t . T h e i m -

plementat ion o f the maintenance funct ions uponthe end item or component will be consistent withthe ass igned maintenance funct ions .

c. Sect ion III . Not appl icable .d . S e c t i o n I V c o n t a i n s s u p p l e m e n t a l i n -

structions, explanatory notes and / or illustrationsrequired for a part icular maintenance funct ion .

B-2. Explanation of Columns in Section II

a. G r o u p N u m b e r , C o l u m n ( 1 ) . T h e a s s e m b l yg r o u p i s a n u m e r i c a l g r o u p a s s i g n e d t o e a c h

assembly in a top down breakdown sequence. The

applicable assembly groups are listed on the MACin disassembly sequence beginning with the f irsta s s e m b l y r e m o v e d i n a t o p d o w n d i s a s s e m b l ysequence .

b. Funct ional Group, Column (2) . This co lumncontains a br ie f descr ipt ion o f the components o feach assembly group.

c. M a i n t e n a n c e F u n c t i o n s , C o l u m n ( 3 ) . T h i scolumn lists the various maintenance functions (At h r o u g h K ) . T h e l o w e s t m a i n t e n a n c e c a t e g o r yauthorized to perform these functions are indicatedby a symbol in the appropriate column. The symbol

designations for the various maintenance categoriesare as fo l lows :

C - Operator or crew( ) - Organizational maintenanceF - Direct support maintenanceH - General support maintenanceI ) - Depot maintenance

The maintenance functions are defined as follows:

A - Inspect . To determine serv iceabi l i ty o f anitem by comparing its physical, mechanical,a n d e l e c t r i c a l c h a r a c t e r i s t i c s w i t hestabl ished standards .

B- Test . To ver i fy serviceabi l i ty and to detectelectrical or mechanical failure by use of test

e q u i p m e n t .

C- Service. To clean, to preserve, to charge, andto add fuel, lubricants, cooling agents, and

air . I f i t i s des ired that e lements , such asp a i n t i n g a n d l u b r i c a t i n g , b e d e f i n e dseparately, they may be so listed.

D - Adjust. To rectify to the extent necessary tobr ing into proper operat ing range .

E - Align. To adjust specified variable elements

of an item to bring to optimum performance.

F - Calibrate. To determine the corrections to bemade in the readings of instruments or teste q u i p m e n t u s e d i n p r e c i s e m e a s u r e m e n t .C o n s i s t s o f t h e c o m p a r i s o n o f t w o i n -

struments , o n e o f w h i c h i s a c e r t i f i e dstandard o f known accuracy , to detect and

adjust any discrepancy in the accuracy of thei n s t r u m e n t b e i n g c o m p a r e d w i t h t h e c e r -t i f ied standard.

G - Install. To set up for use in an operational

environment such as an emplacement, site orvehic le .

H - R e p l a c e . T o r e p l a c e u n s e r v i c e a b l e i t e m swith serviceable like items.

I - R e p a i r . T h o s e m a i n t e n a n c e o p e r a t i o n snecessary to restore an item to serviceablec o n d i t i o n t h r o u g h c o r r e c t i o n o f m a t e r i a ldamage or a specific failure. Repair may be

a c c o m p l i s h e d a t e a c h c a t e g o r y o f m a i n -tenance .

J - Overhaul . Normal ly , the h ighest degree o fm a i n t e n a n c e p e r f o r m e d b y t h e A r m y i norder to minimize t ime work in process i sc o n s i s t e n t w i t h q u a l i t y a n d e c o n o m y o foperat ion. I t consists o f that maintenancenecessary to restore, an item to completelys e r v i c e a b l e c o n d i t i o n a s p r e s c r i b e d b ym a i n t e n a n c e s t a n d a r d s i n t e c h n i c a lp u b l i c a t i o n s f o r e a c h i t e m o f e q u i p m e n t .Overhaul normally does not return an itemt o l i k e n e w , z e r o m i l e a g e , o r z e r o h o u r

condit ion .K - R e b u i l d . T h e h i g h e s t d e g r e e o f m a t e r i e l

m a i n t e n a n c e . I t c o n s i s t s o f r e s t o r i n ge q u i p m e n t a s n e a r l y a s p o s s i b l e t o n e wcondit ion i n a c c o r d a n c e w i t h o r i g i n a lmanufactur ing standards . Rebui ld reducesto zero the hours or miles the equipment, orcomponent thereof , has been in use .

d . T o o l s a n d E q u i p m e n t , C o l u m n ( 4 ) . T h i sc o l u m n i s p r o v i d e d f o r r e f e r e n c i n g b y c o d e t h e

B-1

special tools and test equipment (sec. III ) requiredto per form the maintenance funct ions (sec . I I ) .

e . R e m a r k s , C o l u m n ( 5 ) . T h i s c o l u m n i sprovided for referencing by code the remarks (sec.IV) pert inent to the maintenance funct ions .

B-3. Explanation of Columns in Section III (notapplicable)

a. Re ference Code . This co lumn consists o f an u m b e r a n d a l e t t e r s e p a r a t e d b y a d a s h . T h en u m b e r references t h e T & T E r e q u i r e m e n t s

c o l u m n o n t h e M A C . T h e l e t t e r r e p r e s e n t s t h especific maintenance function the item is to be used

with . The let ter i s representat ive o f co lumns At h r o u g h K o n t h e M A C .

b. Maintenance Category . T h i s c o l u m n s h o w sthe lowest level of maintenance authorized to usethe special tool or test equipment.

c. Nomenclature. This column lists the name oridentification of the tool or test equipment.

d . T o o l N u m b e r . T h i s c o l u m n l i s t s t h emanufacturer’s code and part number, or FederalStock Number o f too ls and test equipment .

B-4. Explanation of Columns in Section IV

a. Reference Code. This column consists of twoletters separated by a dash, both o f which are

references to Section II. The first letter referencesc o l u m n ( 5 ) a n d t h e s e c o n d l e t t e r r e f e r e n c e s amaintenance funct ion , co lumn (3) , A through K.

b . R e m a r k s . T h i s c o l u m n l i s t s i n f o r m a t i o np e r t i n e n t t o t h e m a i n t e n a n c e f u n c t i o n b e i n g

performed, as indicated on the MAC, sect ion I I .

B - 2

S e c t i o n I l . M A I N T E N A N C E A L L O C A T I O N C H A R T

0 1

0 2

0 3

0 4

0 5

0 6

0 7

0 8

0 9

1 0

11

1 2

1 3

1 4

(2)FlmcttanalgrouP

ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . .

CYLINDER HEAD . . . . . . . . . . . . . . . . . . . .

Valves and Inserts . . . . . . . . . . . . . . . . . . . . .

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . .

Flywheel Assembly . . . . . . . . . . . . . . . . . .

Connecting Rods, Pistons and

Rod Bearings . . . . . . . . . . . . . . . . . .

Camshaft and Timing Gear

Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker Arm Assembly . . . . . . . . . . . . . . . .

Rocker ,&rn Covers and

Crankcase Breather . . . . . . . . . . . . . . . . .

Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Fifters and Fuel Lines . . . . . . . . . . . .

Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . .

Governor Assembly . . . . . . . . . . . . . . . . . . .

Blower Assembly . . . . . . . . . . . . . . . . . . . . .

Air Inlet Assembly . . . . . . . . . . . . . . . . . . .

Oif Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Pressure Regulator . . . . . . . . . . . . . . . .

Oil Filter and Oil Lines . . . . . . . . . . . . . . .

Oif Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . .

Water Pump, Thermostat and

Water Lines . . . . . . . . . . . . . . . . . . . . . . .

Fan Assembly . . . . . . . . . . . ..’...... . . . . .

Belt s . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust Manifolds . . . . . . . . . . . . . . . . . . .

Generator Assembly . . . . . . . . . . . . . . . . . .

Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Generator Regulator . . . . . . . . . . . . . . . . . . .

Starting Motor and Solenoid . . . . . . . . . . .

RADIATOR ASSEMBLY . . . . . . . . . . . . . . .

MUFFLER AND PIPES . . . . . . . . . . . . . . .

FUEL TANK, LINES AND

FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . .

BATTERIES, STORAGE . . . . . . . . . . . . . . .

LIGHTS

Blackout, Tail; Flood and

Head L~hts . . . . . . . . . . . . . . . . . . . . . . .

HORN AND BUZZER . . . . . . . . . . . . . . .

CONTROLS AND INSTRUMENTS . . . .

RADIO INTERFERENCE

SUPPRESSION . . . . . . . . . . . . . . . . . . . . . .

STARTING AID . . . . . . . . . . . . . . . . . . . . . .

TRANSMISSION ASSEMBLY . . . . . . . . . .

Torque Converter.......,....’.. . . . . . .

Planetaries and Clutches . . . . . . . . . . . . . .

Power Transfer Assembly . . . . . . . . . . . . .

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pressure Regulntor Valve . . . .; . . . . . . . . .

Oil Filter, Transmission . . . . . . . . . . . . . . .

Cut Off Valve (Inching) . . . . . . . . . . . . . .

Transmission Control Linkage . . . . . . . . .

PROPELLER SHAFTS . . . . . . . . . . . . . . . .

FRONT AXLE ASSEMBLY . . . . . . . . . . . .

Differential Assembly with

No Spin Unit . . . . . . . . . . . . . . . . . . . . . .

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S e c t i o n I I . M a i n t e n a n c e A l l o c a t i o n C h a r t

(a)

1 4 ?RONT AXLE ASSEMBLY (COn’t)

15

16

17

18

Axle Shaft Socket and Ball . . . . . ., . . . . . .

Planetary Assembly . . . . . . . . . . . . . . . . . . . . .

Tie Rod Asaembly . . . . . . . . . . . . . . . . . . . .

Steering Cylinder6 . . . . . . . . . . . . . . . . . . . . .

3EAR AXLE ASSEMBLY . . . . . . . . . . . . . .

Differential Assembly with

No Spin Unit . . . . . . . . . . . . . . . . . . . . . .

Axle Shaft Socket and Ball . . . . . . . . . . . . .

Planetary Asaembly . . . . . . . . . . . . . . . .: . . . .

Tie Rod Aseembly . . . . . . . . . . . . . . . . . . . . .

Steering Cylinders . . . . . . . . . . . . . . . . . . . . .

BRAKE SYSTEM

Hand Brake Assembly . . . . . . . . . . . . . . . . .

HydrauHc Brake Assembly . . . . . . . . . . . . .

,Pump, Hydraulic . . . . . . . . . . . . . . . . . . . . . .

Brake Valve . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjuster, Hydraulic . . . . . . . . . . . . . . . . . . . .

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Reservoir, Hydraulic

(Xl, Lines and Fittings . . . . . . . . . . . . . . .

E’HEEL ASSEMBLY . . . . . . . . . . . . . . . . . . .

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ITEERING SYSTEM

Pump, Hydraulic . . . . . . . . . . . . . . . . . . . . . .

Steering Selector Valve . . . . . . . . . . . . . . . . .

Steering Wheel and Horn

Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

,Steering Control Valve . . . . . . . . . . . . . . . . .

Steering Columu . . . . . . . . . . . . . . . . . . . . . .

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering Cylinders. . . . . . . . . . . . . . . . . . . . .

Tie Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drag Link Assembly . . . . . . . . . . . . . . . . . . .

Hydraulic Lines and Fittings . . . . . . . . . . .

;EAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . .

iiYDRAULIC LIFT SYSTEM

Main Hydraulic Pump . . . . . . . . . . . . . . . . .

Hydraukc Control Valve . . . . . . . . . . . . . . .

HydrauHc Control Levers

and Linkage . . . .’ . . . . . . . . . . . . . . . . . . . .

Hydraulic Cylinders

Lift, Sfave, Tilt, Extension,

Oscillation, and Side Shift . . . . . . . . . .

Boom Assembly

Inner and Outer . . . . . . . . . . . . . . . . . . . .

Fork Carriage Assembly . . . . . . . . . . . . . . . .

Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chain, Side Shift . . . . . . . . . . . . . . . . . . . .

Frame, Back Rest . . . . . . . . . . . . . . . . . . .

Reservoir, Hydraulic Oil . . . . . . . . . . . . . . .

Hydraulic Lines and Fittings . . . . . . . . . .

MAINFRAME . . . . . . . . . . . . . . . . . . . . . . . .

Pintle Hook . . . . . . . . . . . . . . . . . . . . . . . . . . .

NRE EXTINGUISHER . . . . . . . . . . . . . . . .

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B - 4

REFERENCECODE

:\— B

B-- K

(> I

1)—(:

K— 1

S e c t i o n I I I . R E M A R K S

REMARKS

Test includes engine operation and compression.

Align, metalize and resize.

I{epbce ring gear.

Replace filter element.

l{cpair by welding.

B-5

A P P E N D I X C

B A S I C I S S U E I T E M S L I S T

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

C - 1 . S c o p e

This appendix l ists i tems which accompany thef o r k l i f t t r u c k o r a r e r e q u i r e d f o r i n s t a l l a t i o n ,

operat ion , or operator ’ s maintenance .

C-2. General

This Basic Issue Items List is d ivided into thefo l lowing sect ions :

a. Basic Issue Items - Section II. A list of itemsw h i c h a c c o m p a n y t h e f o r k l i f t t r u c k a n d a r erequired by the operator / c rew for insta l lat ion ,operat ion , or maintenance .

b. Maintenance and Operating Supplies - SectionIII . A l i s t t i n g o f m a i n t e n a n c e a n d o p e r a t i n g

supplies required for initial operation.

C-3. Explanation of Columns

The following provides an explanation of columnsin the tabular list of Basic Issue Items, Section II.

a . S o u r c e , M a i n t e n a n c e , a n d R e c o v e r a b i l i t yC o d e s ( S M R ) :

(1) Source code, indicates the source for thelisted item. Source codes are:

Code. E x p l a n a t i o n

P R e p a i r p a r t s w h i c h a r e s t o c k e d i n o r s u p p l i e d

f r o m t h e G S A / D S A , o r A r m y s u p p l y s y s t e m

and author ized for use at indicated maintenance

c a t e g o r i e s .

P 2 Repair parts which are procured and s tocked for

i n s u r a n c e p u r p o s e s b e c a u s e t h e c o m b a t o r

mi l i tary essent ia l i ty o f the end i tem dictates that

a m i n i m u m q u a n t i t y b e a v a i l a b l e i n t h e s u p p l y

s y s t e m .

M R e p a i r p a r t s w h i c h a r e n o t p r o c u r e d o r s t o c k e d ,

b u t a r e t o b e m a n u f a c t u r e d i n i n d i c a t e d

m a i n t e n a n c e l e v e l s .

A A s s e m b l i e s w h i c h a r e n o t p r o c u r e d o r s t o c k e d a s

s u c h , b u t a r e m a d e u p o f t w o o r m o r e u n i t s .

S u c h c o m p o n e n t u n i t s c a r r y i n d i v i d u a l s t o c k

n u m b e r s a n d d e s c r i p t i o n s , a r e p r o c u r e d a n d

s t o c k e d s e p a r a t e l y a n d c a n b e a s s e m b l e d t o

f o r m t h e r e q u i r e d a s s e m b l y a t i n d i c a t e d

m a i n t e n a n c e c a t e g o r i e s .

X P a r t s a n d a s s e m b l i e s w h i c h a r e n o t p r o c u r e d o r

s t o c k e d a n d t h e m o r t a l i t y o f w h i c h n o r m a l l y i s

b e l o w t h a t o f t h e a p p l i c a b l e e n d i t e m o r c o m -

p o n e n t . T h e f a i l u r e o f s u c h p a r t o r a s s e m b l y

should resul t in ret i rement o f the end i tem from

t h e s u p p l y s y s t e m .

X l R e p a i r p a r t s w h i c h a r e n o t p r o c u r e d o r s t o c k e d .

The requirement for such i tems wi l l be f i l l ed by

u s e o f t h e n e x t h i g h e r a s s e m b l y o r c o m p o n e n t .

G

S

T

U

C o d e E x p l a n a t i o n

X 2 R e p a r t s w h i c h a r e n o t s t o c k e d . T h e i n d i c a t e d

m a i n t e n a n c e c a t e g o r y r e q u i r i n g s u c h r e p a i r

p a r t s w i l l a t t e m p t t o o b t a i n t h e m t h r o u g h

canniba l izat ion . Where such repair parts are not

o b t a i n a b l e t h r o u g h c a n n i b a l i z a t i o n ,

r e q u i r e m e n t s w i l l b e r e q u i s i t i o n e d , w i t h a c -

c o m p a n y i n g j u s t i f i c a t i o n , t h r o u g h n o r m a l

s u p p l y c h a n n e l s .

M a j o r a s s e m b l i e s t h a t a r e p r o c u r e d w i t h P E M A

f u n d s f o r i n i t i a l i s s u e o n l y a s e x c h a n g e

a s s e m b l i e s a t D S U a n d G S U l e v e l . T h e s e

a s s e m b l i e s w i l l n o t b e s t o c k e d a b o v e G S a n d

D S l e v e l o r r e t u r n e d t o d e p o t s u p p l y l e v e l .

( 2 ) M a i n t e n a n c e c o d e i n d i c a t e s t h e l o w e s tcategory of maintenance authorized to install thel is ted i tem. The maintenance leve l code is :

C o d e E x p l a n a t i o nc O p e r a t o r / c r e w

( 3 ) R e c o v e r a b i l i t y c o d e i n d i c a t e s w h e t h e runserviceable items should be returned for recovery

o r s a l v a g e . I t e m s n o t c o d e d a r e e x p e n d a b l e .Recoverabi l i ty codes are :

C o d e E x p l a n a t i o n

R R e p a i r p a r t s ( a s s e m b l i e s a n d c o m p o n e n t s ) w h i c h

a r e c o n s i d e r e d e c o n o m i c a l l y r e p a r a b l e a t d i r e c t

a n d g e n e r a l s u p p o r t m a i n t e n a n c e l e v e l s . W h e n

the maintenance capabi l i ty to repair these i tems

does not ex is t , they are normal ly d isposed o f at

t h e G S l e v e l . W h e n s u p p l y c o n s i d e r a t i o n s

dictate , some o f these repair parts may be l i s ted

f o r a u t o m a t i c r e t u r n t o s u p p l y f o r d e p o t l e v e l

repair as set forth in AR 710-50 . When so l i s ted ,

they wi l l be rep laced by supply on an exchange

bas i s .

R e p a i r p a r t s a n d a s s e m b l i e s w h i c h a r e

e c o n o m i c a l l y r e p a r a b l e a t D S U a n d G S U a c -

t i v i t i e s a n d w h i c h n o r m a l l y a r e f u r n i s h e d b y

s u p p l y o n a n e x c h a n g e b a s i s . W h e n i t e m s a r e

d e t e r m i n e d b y a G S U t o b e u n e c o n o m i c a l l y

r e p a r a b l e t h e y w i l l b e e v a c u a t e d t o a d e p o t f o r

evaluat ion and analys is be fore f ina l d ispos i t ion .

H i g h d o l l a r v a l u e r e c o v e r a b l e r e p a i r p a r t s w h i c h

are sub ject to spec ia l handl ing and are i ssued on

a n e x c h a n g e b a s i s . S u c h r e p a i r p a r t s n o r m a l l y

a r e r e p a i r e d o r o v e r h a u l e d a t d e p o t m a i n -

t e n a n c e a c t i v i t i e s .

R e p a i r p a r t s s p e c i f i c a l l y s e l e c t e d f o r s a l v a g e b y

r e c l a m a t i o n u n i t s b e c a u s e o f p r e c i o u s m e t a l

con tent , c r i t i ca l mater ia ls , or h igh do l lar va lue

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

C-1

b. Federal Stock Number. This column indicatesthe Federal stock number assigned to the item andwill be used for requisitioning purposes.

c. Description. This column indicates the Federali tem name and any addit ional descr ipt ion o f the

i t e m r e q u i r e d . T h e a b b r e v i a t i o n “ w / e ” , w h e n

used as a part of the nomenclature, indicates theF e d e r a l s t o c k n u m b e r , i n c l u d e s a l l a r m a m e n t ,equipment , accessor ies , and repair parts issued

with the item. A part number or other referencen u m b e r i s f o l l o w e d b y t h e a p p l i c a b l e f i v e - d i g i tF e d e r a l s u p p l y c o d e f o r m a n u f a c t u r e r s i n

parenthesis . Repair parts quant i t ies inc luded inkits, sets, and assemblies are shown in front of therepair part name.

d. Uni t o f Measure (U/M). A t w o - c h a r a c t e ralphabet ic abbreviat ion indicat ing the amount or

quantity of the item upon which the allowances arebased, e.g., ft, ea, pr, etc.

e. Quantity Incorporated in Unit. T h i s c o l u m nindicates the quantity o f the i tem used in theassembly group. A “V” appearing in this column inlieu of a quantity indicates that a definite quantitycannot be indicated (e .g . , shims, spacers , e tc . ) .

f . Q u a n t i t y F u r n i s h e d W i t h E q u i p m e n t . T h i scolumn indicates the quantity of an item furnishedwith the equipment .

g. Illustration. This column is divided as follows:( 1 ) F i g u r e n u m b e r . I n d i c a t e s t h e f i g u r e

number o f the i l lustrat ion in which the i tem iss h o w n .

(2) Item number. Indicates the callout number

used to reference the item in the illustration.

C-4. Explanation of Columns in the TabularList of Maintenance and Operating Supplies -Section III

a . C o m p o n e n t A p p l i c a t i o n . T h i si d e n t i f i e s t h e c o m p o n e n t a p p l i c a t i o n

maintenance or operat ing supply i tem.

b. Federal Stock Number. This co lumn

the Federal stock number assigned to thewill be used for requisitioning purposes.

c. Description. This co lumn indicates the i temname and br ie f descr ipt ion .

d. Quantity Required for Initial Operation. T h i scolumn indicates the quantity of each maintenanceo r o p e r a t i n g s u p p l y i t e m r e q u i r e d f o r i n i t i a loperat ion o f the equipment .

e . Q u a n t i t y R e q u i r e d f o r 8 H o u r s O p e r a t i o n .T h i s c o l u m n i n d i c a t e s t h e e s t i m a t e d q u a n t i t i e srequired for an average 8 hours of operation.

f. Notes. This column indicates informative noteskeyed to data appear ing in a preceding co lumn.

c o l u m no f e a c h

indicatesitem and

C-2

(1)

SMFtCo&

Pc

Pc

PcPc

Pc

S e c t i o n I I . B A S I C I S S U E I T E M S

(2) (3)Description

Fe&raf StOChniunbv

Ref No. & Mfr Cde Usaole on code,

I Group 01 - ACCESSORIES7’520-559-9618

7510-889-3494

4210-889-2221

CASE :-Maintenance and Operational Manuals, Cotton duct,water repellent, mildew resistant, MI L-B-1 1743B

BINDER, LOOSELEAFGroup 02 - PUBLICATIONS

ARMY TECHNICAL MANUAL, TM 10-3930-243-12ARMY LUBRICATION ORDER, LO 10-3930-243.12Group 04 - FIRE EXTINGUISHEREXTINGUISHER ; DRY CHEMICAL

(4)Unit

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1

1

11

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I1lustrati@(A) (B]Fig ItemNo. No.

C-3

Section III.

TM

10-3930-243-12

C-

4

Section III.

C-5

A L P H A B E T I C A L I N D E X

Paragraph Page

AAdjustment, drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35Adjustment, push rod . . . . . . . . . . . . . . . . . .4-17Air cleaner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28Air cleaner service . . . . . . . . . . . . . . . . . . . . . . . . . 3-8Ammeter . . . . . . . . . . . . . . . . . . . . . . . . . 4-52

BBank indicator (RTL10-1) . . . . . . . . .4-65Basic issue items . . . . . . . . . . . . . . . . . . . . . . . 4-3Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . .. .4-41Battery cable . . . . . . . . . . . . . . . . . . . . . . . . . .4-41Battery service . . . . . . . . . . . . . . . . . . . . 3-11Belt adjusting control, spring

and bracket pulley . . . . . . . . . . . . . . . . . . .4-38Belt, drive . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35Blackout lights . . . . . . . . . . . . . . . . . . . . . . . .4-48Body panels . . . . . . . . . . . . . . . . . . . . . . . . . . .4-96Brake hydraulic oil reservoir

(Model RTL10) . . . . . . . . . . . . . . . . . . . . .4-77Brake oil pressure gage and

valve (Model RTL10-1) 4-61

CChain, side shift roller . . . . . . . . . . . . . . . . .4-91Clutch Oil pressure gage . . . . . . . . . . . . . . . .4-66Controls and instruments . . . . . . . . . . . . . 2-7, 4-59Coolant hose and fittings . . . . . . . . . . . . . . .4-33Cooling system . . . . . . . . . . . . . . . . . . . . . . . .4-30Counterweight . . . . . . . . . . . . . . . . . . . . 4-94Crankcase breather . . . . . . . . . . . . . . . . . . . .4-20

DDaily and weekly preventive

maintenance checks and serv ices 3 -4Description . . . . . . . . . . . . . . . . . . . 1-4Detailed lubrication information . . . . . . 3-2Dismantling for movement . . . . . . 2-3Drive belt . . . . . . . . . . . . . . . . . . . . . . . . . . .4-35

EElectrical system . . . . . . . . . . . . . . . . . . . . . .4-39Engine assembly . . . . . . . . . . . . . . . . . 4-15Engine coolant temperature gage . . . . . . . .4-62Engine generator . . . . . . . . . . . . . . . . . . . . . .4-40Engine oil pressure gage . . . . . . . . . . . . . . . . . 4-60Equipment serviceability criteria . . . . . . . . . . . . 1-3Ether primer service . . . . . . . . . . . . . . . . . . .3-10Exhaust manifold and flange . . . . . . . . . . . . . . . 4-24Exhaust pipe . . . . . . . . . . . . . . . . . . . . . . . . .4-23

FFan blade . . . . . . . . . . . . . . . . . . . . . . . . . 4-36Fan guard . . . . . . . . . . . . . . . . . . . . . . . . . . 4-34Fenders . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-95Fire extinguisher . . . . . . . . . . . . . . . . . . . 2-19Floodlight . . . . . . . . . . . . . . . . . . . . . . . . . . 4-49Foot control . . . . . . . . . . . . . . . . . . . . . . . . 4-68Fork carriage . . . . . . . . . . . . . . . . . . . . . . . . . 4-90Forks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-89Forms and records . . . . . . . . . . . . . 1-2Fuel filter . . . . . . . . . . . . . . . . . . . . . . . . . 4-29Fuel filter service . . . . . . . . . . . . . . . 3-9

4-214-7

4-153-3

4-39

4-394-1

4-274-27

3-6

4-254-214-374-61

4-47

4-39

4-574-39

2-1, 4-394-204-184-60

4-8

3-11-13-12-1

4-21

4-254-6

4-394-254-39

1-13-6

4-124-10

4-234-214-612-224-384-414-574-56

1-14-16

3-4

Paragraph

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . .4-27Fuel system . . . . . . . . . . . . . . . . . . . . . . . 4-29Fuel tank and lines . . . . . . . . . . . . . . . . 4-26

GGeneral cleaning and inspection

methods . . . . . . . . . . . . . . . . . . . 4-14Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40

HHeadlights . . . . . . . . . . . . . . . . . . . . . . . 4-48Horn and buzzer . . . . . . . . . . . . . . . . . . . . 4-50Horn button . . . . . . . . . . . . . . . . . . . . . . . 4-64Hourmeter, . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-54Hydraulic brake lines . . . . . . . . . . . . . . . . . . . . 4-78Hydraulic brake low pressure

switch (Model RTL10). . . . . . . . . . . . . . . . . . . . 4-79Hydraulic control levers . . . . . . . . . . . . . . 4-67Hydraulic lift system . . . . . . . . . . . . . . . . . . . . . . 4-85Hydraulic lines, hoses and fittings. . . . . . . . . . . . . . . 4-84Hydraulic oil reservoir. . . . . . . . . . . . . . . . . . . . . . . 4-88Hydraulic reservoir filter element. . . . . . . . . . . . . . . . . . 4-86Hydraulic reservoir magnet. . . . . . . . . . . . . . . . . . . . . 4-87

IIdentification and tabulated data. . . . . . . . . . . . . . . . . . .1 - 5Inspection and servicing equipment. . . . . . . . . . . . . . . 2-2

LLight switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-57Lubrication system . . . . . . . . . . . . . . . . . . 4-18

MMaintenance repair parts. . . . . . . . . . . . . . . . . . . . . 4-5Master switch . . . . . . . . . . . . . . . . . . . . . 4-58Monthly and quarterly preventive

maintenance checks and services. . . . . . . . . . . . . . . . 4 - 8Movement . . . . . . . . . . . . . . . . . . . . . . 2-4Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23

0Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . 4-19Oil level dipstick, tube and cap. . . . . . . . . . . . . . . . . . . . . 4-21Operation at high altitude . . . . . . . . . . . . . . . . . . . . . 2-17Operation in dusty or sandy area. . . . . . . . . . . . . . . . . . . . . . . 2-14Operation in extreme cold. . . . . . . . . . . . . . . . . . . 2-12Operation in extreme heat . . . . . . . . . . . . . . 2-13Operation in salt water . . . . . . . . 2-15Operation in snow . . . . . . . . . . . . . . . . . . . . . . 2-18Operation of equipment . . . . . . . . . . . . . . 2-17Operation under rainy or humid

condition . . . . . . . . . . . . . . . . . . . . . . . . . 2-16Overhead guard . . . . . . . . . . . . . . . . . . . . . 4-92

PPanel lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-55Parking brake cable and lever . . . . . . . . . . . . . . . . . . 4-76Pintle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-94Pulley and hub . . . . . . . . . . . . . . . . 4-37Push rod adjustment . . . . . . . . . . . . . . . . . 4-17Push switch . . . . . . . . . . . . . . . . . . 4-56

Page

4-144-164-12

4 - 64-25

4-3 74-384-394-394-48

4-484-394-544-514-554-544-55

1 - 12 - 1

4-394 - 7

4 - 14-39

4 - 12 - 14-10

4 - 74 - 92-222-222-212-222-222-222-22

2-224-59

4-394-454-604-244 - 74-39

l-1

Paragraph

RRadio interference suppression. . . . . . . . . . . . . . 4-10AReceptacle connector. . . . . . . . . . . . . . . . . . . 4-42Reinstallation after movement. . . . . . . . . . . . . . . . . 2-5Rocker Arm Cover . . . . . . . . . . . . . . . . . . . . 4-16

SScope . . . . . . . . . . . . . . . . .1 - 1Seat. . . . . . . . . . . . . . . . . . . . . . . . .4-93Service brakes . . . . . . . . . . . . . . . . . . . . 4-75Side shift roller chain . . . . . . . . . . . . . . . . . . . . . 4-91Special tools and equipment. . . . . . . . . . . . . . . . . . . 4-4Starter and solenoid . . . . . . . . . . . . . . . 4-44Starter magnetic switch

(Model RTL10-1) . . . . . . . . . . . . . . . . . . . . . 4-45Starter pressure switch

(Model RTL10-1) . . . . . . . . . . . . . . . . . . . . . . . . . 4-46Starting. . . . . . . . . . . . . . . . . . . . . 2-9Steering system . . . . . . . . . . . . . . . . . . . . .4-82Steering wheel . . . . . . . . . . . . . . . . . . . . 4-83Stoplight-Tailight . . . . . . . . . . . . . . . . . . . . . . . . . 4-47Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-10

Page

4 - 64-282 - 14 - 7

1 - 14-594-454-574 - 14-34

4-35

4-362 - 84-514-514-362 - 9

Paragraph Page

TTabulated data . . . . . . . . . . . . . . . . . 1-5Testing of radio interference

suppression components . . . . . . . . . . . . . . . . . 4-13Thermostat and housing . . . . . . . . . . . . . . . . . . . . . . 4-31Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81Toggle switches . . . . . . . . . . . . . . . . . . . . .4-53Tools, equipment, and repair parts . . . . . . . . . . . . . . 3-1Torque converter filter . . . . . . . . . . . . . . . . . . . . . 4-70Torque converter temperature gage . . . . . . . . . . . 4-63Transmission and torque converter

oil hoses and fittings . . . . . . . . . . 4-73Transmission cut of valve (inching) . . . . . . . . . . . . . . 4-72Transmission linkage and lever . . . . . . . . . . 4-71Troubleshooting . . . . . . . . . . . . . . . . . . 3-6, 4-9

VVoltage regulator . . . . . . . . . . . . . . . . . . . 4-43

WWater pump and pulley . . . . . . . . . . . . . 4-32Wheel flanges . . . . . . . . . . . . . . . . . . . . . . 4-81Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-81

1-1

4-184-184-494-39

3-14-424-39

4-444-444-43

3-3, 4-4

4-28

4-194-494-49

I-2

By Order of the Secretary of the Army:

Official :

W. C. WESTMORELAND,General, United States Army,Chief of Staff.

VERNE L. BOWERS,Major General, United States Army,The Adjutant General.

Distribution:

To be distributed in accordance with DA Form 12-25, Section I, (qty rqr blockno. 197) Operator maintenance requirements for Truck, Fork Lift, Gasoline RoughTerrain.

P I N : 0 2 7 7 1 9 - 0 0 0

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