Section III. GENERAL MAINTENANCE - TM-10-3930-243-340033

Table 2-1. Troubleshooting-Continued

Probable Cause

Corrective Action

Malfunction

a. Hydraulic pump defective.

a. Repair pump (para 3-57).

18. Truck Steers Hard.

b. Steering cylinder defective.

b. Repair cylinder (para 3-64).

c. Steering valve defective.

c. Repair valve (para 3-59).

a. Sideshift cylinders defective.

a. Repair cylinders (para 3-78).

19. Fork Does Not Shift to Side.

b. Hydraulic pump defective.

b. Repair pump (para 3-71).

c. Control valve defective.

c. Replace valve (para 3-72).

a. Brake shoes defective.

a. Replace shoes (para 3-50).

20. Truck Does Not Stop When

b. Hydraulic

brake

cylinder

b. Replace cylinder (para 3-50).

Brakes Are Applied.

defective.

c. Bleed brake system (TM 10-3930-

c. Air in brake, lines.

243-12).

d. Charge, repair or replace (para 3-

d. Accumulator not charged.

54).

Section III. GENERAL MAINTENANCE

NOTE

2-5 General

Never dry bearings with compressed air. Do not spin

Refer to TM 10-3930-243-12 for analysis of

bearings while they are not lubricated.

operation and for organizational maintenance

instructions.

b. Inspection.

2-6. Wiring Harness

(1) Inspecting cast parts, machined surfaces.

(a) Inspect bores for wear, grooves,

The electrical circuits in the forklift are completed

scratches and dirt. Remove scratches and burrs

by individual wire leads or by leads laced or en-

with crocus cloth. Remove foreign matter. Replace

closed to form a wiring harness. When testing,

parts that are deeply grooved or scratched.

repairing, or replacing the individual wires or

(b) Inspect mounting faces for burrs,

harness refer to the wiring diagrams (figs. 1-1 and

scratches, nicks, and foreign matter. Remove such

1-2).

defects with crocus cloth or a soft stone. If scratches

2-7. Cleaning and Inspection

are deep, replace the defective part.

a. Cleaning. Dirt can cause malfunctions. All

(c) Inspect all machined surfaces for

parts must be clean to permit effective inspection.

damage that could cause oil leakage or other

At assembly, it is very important that no dirt or

malfunction of the part. Rework or replace the

foreign matter enters the transmission or engine.

defective parts.

Even minute particles can cause the malfunction of

(2) Inspecting bushings, thrust washers.

close-fitting parts such as valves.

(a) Inspect bushings for roundness, scores,

(1) Cleaning parts.

burrs, sharp edges, and evidence of overheating.

(a) All metallic parts except bearings should

Remove scores with crocus cloth. Remove burrs

be cleaned thoroughly with volatile mineral spirits,

and sharp edges with a scraper or knife blade. If the

or by the steam cleaning method. Do not use

bushing is out-of-round, deeply scored, or ex-

caustic soda solution for steam cleaning.

cessively worn, replace it, using the proper size

(b) Parts should be dried with compressed

replacement.

air. Steam-cleaned parts should be oiled im-

NOTE

mediately after drying.

If it is necessary to cut out a defective bushing, be

(c) Clean oil passages by working a piece of

careful not to damage the bore into which the bushing

wire back and forth, through the passages and

fits.

flushing them with spirits. Dry the passages with

(b) Inspect thrust washers for distortion,

compressed air.

scores, burrs, and wear. Replace the thrust washer,

(d) Examine parts, especially oil passages,

if it is defective or worn. It is much less expensive to

after cleaning, to make certain they are entirely

replace such parts than to replace converter

clean. Reclean them if necessary.

elements or transmission gearing, which can fail

(2) Cleaning bearings. Bearings that have

due to defective bearings, bushings, or thrust

been in service should be thoroughly washed in

washers.

volatile mineral spirits.

2-3