TM-10-3930-243-34 Truck Lift Fork Diesel Engine Pneumatic Tired Wheels Rough Terrain 10 000 lb. Capacity 24 Inch Load Center Manual

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TM-10-3930-243-34

TECHNICAL MANUAL
WARNING PAGE
Direct Support and General Support Maintenance Manual
Transmission Cut-Off Valve (Inching)
Figure 3-139.1. Hydraulic reservoir, removal and installation.
Figure 3-158.1. Fenders, removal and installation.
Distribution
Direct Support and General Support Maintenance Manual
Fan Hub (Pulley) Assembly
Fan Hub (Pulley) Assembly - continued
Figure 3-146. Hydraulic left Cylinder, disassembly and reassembly (Sheet 1 of 2)
Distribution
DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
List of Illustrations
List of Illustrations - continued
List of Illustrations - continued
List of Illustrations - continued
Chapter 1. INTRODUCTION
Tabulated Data
Tabulated Data - continued
Tabulated Data - continued
Figure 1-2. Schematic wiring diagram, Model RTL10-1
Hydraulic Piping Diagram
Figure 1-5. Hydraulic steering system diagram
Table 1-1. Repair and Replacement Standards
Table 1-1. Repair and Replacement Standards - continued
Table 1-1. Repair and Replacement Standards - continued
Chapter 2. DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS
Table 2-1. Troubleshooting
Section III. GENERAL MAINTENANCE
Section IV. REMOVAL AND INSTALLATION OF MAJOR COMPONENTS AND AUXILIARIE
Figure 2-2. Torque convertor, transmission and transfer assembly, removal and installation.
Figure 2-3. Mast column assembly, removal and installation.
Figure 2-4. Axle assembly, removal and installation.
Chapter 3. REPAIR OF FORKLIFT
Figure 3-2. Oilpump and crankshaft pulley, removal and installation.
Oil Cooler
Figure 3-4. oil cooler, removal and installation.
Figure 3-5. Oil cooler, disassembly and reassembly.
Figure 3-6. Air inlet housing blower assembly, removal and installation.
Figure 3-7. Air inlet housing, disassembly and reassembly
Engine Blower Assembly
Engine Blower Assembly - continued
Figure 3-8. Engine blower assembly and governor housing, removal and installation.
Figure 3-9. Blower drive support, removal and installation.
Figure 3-10. Blower assembly, disassembly and reassembly
Key to figure 3-10.
Blower Drive Support
Figure 3-11. Blower drive support, disassembly and reassembly
Limiting Speed Mechanical Governor
Adjust Maximum No-Load Engine Speed.
Figure 3-18. Governor assembly, removal and installation
Figure 3-13. Limiting speed governor, disassembly end reassembly (sheet 1 of 2).
Figure 3-13. Limiting speed governor, disassembly end reassembly (sheet 2 of 2).
Figure 3-14. Governor spring assembly, disassembly and reassembly.
Figure 3-15. Water pump, disassembly and reassembly.
Reassembly
Figure 3-16. Engine generator, disassembly and reassembly (sheet 1 of 2)
Key to figure 3-16
Engine generator, disassembly and reassembly (sheet 2 of 2)
KEY to figure 3-16 (sheet 2 of 2)
Starting Motor
Figure 3-17. starting motor, disassembly and reassembly (sheet 2 of 2).
Section II. FUEL SYSTEM
Fuel Injector Control Lever and Tube Assembly
Figure 3-18. Fuel injector control lever and tube assembly, removal and installation.
Fuel Injector (Crown Valve)
Figure 3-21. Defective fuel injector plungers.
Figure 3-22. Fuel injector in testing and popping fixture, installation.
High pressure test.
Figure 3-23. Fuel injector high pressure test.
Figure 3-24. Fuel injector follower stop pin removal.
Figure 3-25. Injector rack, gear, spray tip and valve assembly components, removal and installation.
Figure 3-27. Injector follower, spring and plunger, removal and installation
Figure 3-28. Reaming fuel injector spray tip.
Figure 3-29. Cleaning fuel tip orifices.
Figure 3-30. Cleaning fuel injector nut spray tip seat.
Figure 3-31. Fuel injector sealing surfaces which may require lapping.
Figure 3-32. Checking fuel injector spray tip concentricity.
Rocker Arms and Push Rods
Figure 3-33. Rocker arm and push rod, removal and installation
Figure 3-34. Rocker arm and push rod, disassembly and reassembly.
Figure 3-36. Cam roller wear and clearance diagram.
Figure 3-37. Fuel pump, disassembly and reassembly.
Section III. CYLINDER HEAD, VALVES, FLYWHEEL, AND FLYWHEEL HOUSING
Figure 3-39. Cylinder head and valve assembly, disassembly and reassembly.
Figure 3-40. Minimum distance between top and bottom faces of cylinder head.
Install Cylinder Head.
Install Cylinder Head - continued
Figure 3-42. Removing exhaust valve spring.
Figure 3-43. Valves and injector operating mechanism.
Inspect Exhaust Valve Spring.
Figure 3-44. Relationship between exhaust valve, insert and cylinder head.
Figure 3-45. Checking relative concentricity of exhaust valve seat insert with relation to valve guide.
Flywheel
Figure 3-46. Flywheel and flywheel housing, removal and installation.
Inspection.
Section IV. OIL PAN, OIL PUMP SCREEN, INLET PIPE, CONNECTING ROD, PISTON AND OIL PRESSURE REGULATOR
Figure 3-49. Oil pump screen and inlet pipe, disassembly and reassembly.
Figure 3-50. Piston and connecting rod assembly, removal and installation.
Figure 3-51. Piston and connecting rod, disassembly and reassembly.
Figure 3-52. Piston pin bushing, removal and installation.
Figure 3-53. Piston pin retainer, installation.
Cleaning and Inspection.
Figure 3-57. Comparison of used pistons.
Figure 3-58. Reaming bushing in piston.
Figure 3-59. Measuring piston-to-liner clearance.
Figure 3-60. Measuring piston ring gap with feeler gage.
Figure 3-61. Measuring piston ring side clearance.
Figure 3-63. Cylinder liner mounted in block.
Figure 3-64. Cylinder liner removal.
Figure 3-65. Cylinder liner measurement diagram.
Figure 3-66. Checking bore of cylinder liner.
Figure 3-67. Checking distance of line flange below top face of cylinder block.
Figure 3-68. Installing piston and connecting rod assembly in ring compressor and cylinder liner.
Figure 3-69. Installing piston, connecting rod and liner assembly in cylinder block.
Section V. CAMSHAFT, CRANKSHAFT AND BEARINGS
Camshaft and Bearings
Figure 3-72. Camshft gear retainer, removal and installation
Figure 3-73. Removing or installing nut on camshaft.
Figure 3-74. Camshaft pulley removal.
Figure 3-75. Thrust washer retaining bolts, removal and installation.
Disassemble Camshaft.
Figure 3-77. Camshaft gear removal.
Figure 3-78. Camshaft, disassembly and reassembly.
Figure 3-79. Camshaft gear installation
Figure 3-80. Idler gear, removal and installation.
Figure 3-81. Idler gear assembly, disassembly and reassembly.
Figure 3-82. Installing idler gear hub.
Figure 3-84. Upper and lower main bearing shells, bearing caps, and rear main bearing thrust washers.
Inspection.
Figure 3-86. Rear main bearing thrust washer and mounting.
Crankshaft
Figure 3-88. Crankshaft, disassembly and reassembly.
Figure 3-89. Ridging of crankshaft.
Figure 3-90. Critical crankshaft loading zones.
Figure 3-91. Crankshaft fatigue cracks.
Installation.
Section VI. CYLINDER BLOCK AND RADIATOR
Cleaning, Inspection, and Repair.
Radiator Assembly
Figure 3-94. Radiator, removal and installation.
Figure 3-95. Transmission, cross-section view.
Figure 3-96. Transmission disassembly (sheet 1 of 15).
Figure 3-96. Transmission disassembly (sheet 2 of 15).
Figure 3-96. Transmission disassembly (sheet 3 of 15).
Figure 3-96. Transmission disassembly (sheet 4 of 15).
Figure 3-96. Transmission disassembly (sheet 5 of 15).
Figure 3-96. Transmission disassembly (sheet 6 of 15).
Figure 3-96. Transmission disassembly (sheet 7 of 15)
Figure 3-96. Transmission disassembly (sheet 8 of 15)
Figure 3-96. Transmission disassembly (sheet 9 of 15)
Figure 3-96. Transmission disassembly (sheet 10 of 15)
Figure 3-96. Transmission disassembly (sheet 11 of 15)
Figure 3-96. Transmission disassembly (sheet 12 of 15)
Figure 3-96. Transmission disassembly (sheet 13 of 15)
Figure 3-96. Transmission disassembly (sheet 14 of 15)
Figure 3-96. Transmission disassembly (sheet 15 of 15)
Figure 3-97. Transmission reassembly (sheet 1 of 15).
Figure 3-97. Transmission reassembly (sheet 2 of 15).
Figure 3-97. Transmission reassembly (sheet 3 of 15).
Figure 3-97. Transmission reassembly (sheet 4 of 15).
Figure 3-97. Transmission reassembly (sheet 5 of 15).
Figure 3-97. Transmission reassembly (sheet 6 of 15).
Figure 3-97. Transmission reassembly (sheet 7 of 15).
Figure 3-97. Transmission reassembly (sheet 8 of 15).
Figure 3-97. Transmission reassembly (sheet 9 of 15).
Figure 3-97. Transmission reassembly (sheet 10 of 15).
Figure 3-97. Transmission reassembly (sheet 11 of 15).
Figure 3-97. Transmission reassembly (sheet 12 of 15).
Figure 3-97. Transmission reassembly (sheet 13 of 15).
Figure 3-97. Transmission reassembly (sheet 14 of 15).
Figure 3-97. Transmission reassembly (sheet 15 of 15).
Figure 3-98. Transmission torque valves.
Converter Stall Test
Transmission Control Valve
Figure 3-100. Transmission control valve, disassembly and reassembly.
Section VIII. PROPELLER SHAFTS
Front Propeller Shaft
Section IX. FRONT AND REAR AXLE ASSEMBLIES
Figure 3-105. Axle assembly, removal and installation.
Figure 3-106. Axle assembly, disassembly and reassembly (sheet 1 of 6).
Figure 3-106. Axle assembly, Disassembly and reassembly (sheet 2 of 6).
Figure 3-106. Axle assembly, disassembly and reassembly (sheet 3 of 6).
Figure 3-106. Axle assembly, disassembly and reassembly (sheet 4 of 6).
Figure 3-106. Axle assembly, disassembly and reassembly (sheet 5 of 6).
Figure 3-106. Axle assembly, disassembly and reassembly (sheet 6 of 6).
Figure 3-107. Correct tooth contact patterns.
Section X. Hydraulic Brake System
Reassembly
Figure 3-108. Brake assembly, disassembly and reassembly.
Lock Steering and Hydraulic Brake Pump
Figure 3-110. Lock steering and hydraulic brake pump, disassembly and reassembly.
Brake Valve
Test Procedure.
Figure 3-111. Brake valve, removal and installation.
Figure 3-112. Brake valve, disassembly and reassembly
Figure 3-113. Automatic slack adjuster, removal and installation.
Figure 3-114. Automatic slack adjuster, disassembly and reassembly.
Figure Figure 3-116. Hydraulic brake and steering system accumulator, disassembly and reassembly.
Figure 3-117. Hydraulic brake reservoir, disassembly and reassembly.
Section XI. STEERING SYSTEM
Figure 3-119. Hydraulic steering pump, disassembly and reassembly (sheet 1 of 2).
Figure 3-119. Hydraulic steering pump, disassembly and reassembly (sheet 2 of 2).
Steering Selector Valve
Figure 3-121. Steering selector valve, disassembly and reassembly (sheet 1 of 2)
Figure 3-121. Steering selector valve, disassembly and reassembly (sheet 2 of 2).
Steering Control Valve
Figure 3-122. Steering control valve, removal and installation.
Figure 3-123. Steering control valve, disassembly and reassembly'
Steering Column
Figure 3-125. Steering column, disassembly and reassembly.
Figure 3-126. Tie rod assembly, removal and installation.
Figure 3-127. Tie rod assembly, disassembly and reassembly.
Drag Link
Figure 3-129. Drag link assembly, disassembly and reassembly.
Steering Cylinder
Figure 3-130. Hydraulic steering cylinder, removal and installation.
Figure 3-131. Hydraulic steering cylinder, disassembly and reassembly (sheet 1 of 2).
Figure 3-131. Hydraulic steering cylinder, disassembly and reassembly (sheet 2 of 2).
Figure 3-132. Two wheel steering lock cylinder, removal and installation.
Figure 3-133. Two wheel steering lock cylinder, disassembly and reassembly.
Figure 3-134. Four wheel steering lock cylinder, removal and installation.
Figure 3-135. Fourwheel steering lock cylinder, disassembly and reassembly.
Crab Lock Cylinders (Model RTL10)
Figure 3-137. Crab lock cylinder. disassembly and reassembly.
Figure 3-138. Hydraulic steering manifold, removal and installation.
Figure 3-139. Hydraulic steering manifold, disassembly and reassembly.
Hydraulic Reservoir
Figure 3-140. Hydraulic reservoir, disassembly and reassembly.
Section XII. HYDRAULIC LIFT SYSTEM
Figure 3-141. Main hydraulic pump, removal and installation
Figure 3-142. Main hydrsaulic pump, disassembly and reassembly.
Lift System Main Control Valve
Figure 3-143. Main control valves, removal and installation.
Figure 3-144. Main control valves, disassembly and reassembly (sheet 1 of 4).
Figure 3-144. Main control valves, disassembly and reassembly (sheet 2 of 4).
Figure 3-144. Main control valves, disassembly and reassembly (sheet 3 of 4).
Figure 3-144. Main control valves, disassembly and reassembly (sheet 4 of 4).
Figure 3-145. Hydraulic lift cylinder, removal and installation.
Figure 3-146. Hydraulic lift cylinder, disassembly and reassembly (sheet 1 of 2).
Figure 3-146. Hydraulic lift cylinder, disassembly and reassembly (sheet 2 of 2).
Slave Cylinder
Figure 3-147. Hydraulic slave cylinder, removal and installation.
Figure 3-148. Hydraulic slave cylinder, disassembly and reassembly (sheet 1 of 2).
Figure 3-148. Hydraulic slave cylinder, disassembly and reassembly (sheet 2 of 2).
Figure 3-149. Hydraulic tilt cylinder, removal and installation.
Figure 3-150. Hydraulic tilt cylinder, disassembly and reassembly (sheet 1 of 2).
Figure 3-150. Hydraulic tilt cylinder, disassembly and reassembly (sheet 2 of 2).
Hydraulic Extension Cylinder
Figure 3-152. Extension cylinder, assembly and reassembly (sheet 1 of 2).
Figure 3-152. Extension cylinder, assembly and reassembly (sheet 2 of 2).
Oscillation Hydraulic Cylinder
Figure 3-154. Oscillation cylinder, disassembly and reassembly (sheet 1 of 2).
Figure 3-154. Oscillation cylinder, disassembly and reassembly (sheet 2 of 2).
Figure 3-155. Oscillating cylinder check valve, removal and installation (sheet 1 of 2).
Figure 3-155. Oscillating cylinder check valve, removal and installation (sheet 2 of 2).
Side Shift Hydraulic Cylinder
Figure 3-157. Side shift cylinder, disassembly and reassembly (sheet 1 of 2).
Figure 3-157. Side shift cylinder, disassembly and reassembly (sheet 2 of 2).
Section XIII. BOOM ASSEMBLY, INSTRUMENT PANEL AND FRAME
Frame, Hood and Panels
Figure 3-159. Frame, hood and panels, disassembly and reassembly (sheet 2 of 2).
Appendix A. REFERENCES
ALPHABETICAL INDEX
ALPHABETICAL INDEX - continued
Figure 1-1. Schematic wiring diagram (Model RTL10).
Figure 1-3. Hydraulic piping diagram (Model RTL10).
Figure 1-4. Hydraulic piping diagram (Model RTL10-1).
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TM-10-3930-243-34
Distribution
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