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GENERAL DISASSEMBLY AND ASSEMBLY INSTRUCTIONS -832450697
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TM-10-3930-660-24-2 Truck Forklift; 6 000 lb. Variable Reach Rough Terrain Manual
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REPAIR INSTRUCTIONS - CONTINUED
TM 10-3930-660-24-2
REPAIR INSTRUCTIONS
1.
General. Any repair procedure peculiar to a specific part or component is covered in the section or paragraph relating to
that item. After repair, clean all parts thoroughly to prevent dirt, metal chips or other foreign material from entering any
working parts.
CAUTION
Repaired items must be thoroughly cleaned to remove metal chips and abrasives to prevent them from enter-
ing working parts of the 6K Forklift.
2.
Casings.
a.
All cracked castings will be replaced.
b.
Only minor repairs to machined surfaces, flanges and gasket mating surfaces are permitted. Remove minor nicks,
burrs and scratches with:
(1)
Fine mill file.
(2)
Crocus cloth dipped in cleaning solvent.
(3)
Lapping across a surface plate.
c.
Remachining of machined surfaces to repair damage, warpage or uneven surfaces is not permitted. Replace cast-
ings.
d.
Repair damaged threaded pipe plug or screw threads with a tap. Repair oversize holes with threaded inserts.
3.
Bearings. Refer to TM 9-214 for repair of bearings.
4.
Studs. Replace all bent and stretched studs. Repair minor thread damage with a thread die. Replace studs having
stripped or damage threads as outlined below:
a.
Remove using a stud remover. Back studs out slowly to avoid heat buildup and seizure that can cause stud to break
off.
b.
If studs break off too short to use a stud remover, use a stud extractor to remove or use "welding method."
CAUTION
Refer to TM 9-237, Welding Instructions, to avoid damage to castings if welding method is used.
c.
Broken studs can be removed by welding bar stock or a nut to stud and removing with wrench.
d.
Install replacement stud slowly to prevent heat buildup and snapping off.
5.
Gears.
a.
Remove gears using pullers.
b.
Only minor repairs to gears are permitted. Remove minor nicks, burrs or scratches on gear teeth with:
(1)
Fine mill file.
(2)
Crocus cloth dipped in cleaning solvent.
c.
If keyways are worn or enlarged, replace gear.

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