Disassembly - TM-10-3930-622-140106

on frame and lift mast assembly from truck.

(1) Reverse procedures in b above.

b. Disassembly.

(2) Bleed air from hoist cylinder (paragraph 6-37

(1) Remove chains (paragraph 6-30).

d).

(2) Remove hoist cylinder (paragraph 6-37).

e. Installation.

(1) Position assembly on bearing bracket on

(3) Lift off load backrest (figure 6-19).

frame. Install angle brackets, washers and cap screws

to secure in position.

(4) Raise inner upright slightly, loosen nut at

bottom of guide rod and unscrew rod from cylinder

(2) Connect hydraulic hose to hoist cylinder

bracket on inner upright. Remove rod, tube, nut, and

fitting.

bushing within crosshead. Remove crosshead.

(3) Connect both tilt cylinders to brackets on

(5) Disassemble crosshead as follows:

outer uprights by installing shafts (figure 6-17), lock

plates, screws and washers.

(a) Remove retaining rings from ends of crosshead

trunnions.

6-40. TEST AFTER INSTALLATION. Operate system

with gradually increasing loads to check for proper

(b) Take off spacers, bearings, and chain rollers.

operation and hydraulic leaks.

(6) Remove screws and washers attaching

6-41.

ELECTRICAL SYSTEM (CHASSIS).

The

cylinder bracket to inner upright and remove cylinder

following paragraphs cover all truck electrical

bracket.

components except those which are included in the

engine assembly. For removal and disassembly of

(7) Remove screws, washers, and carriage bar

electrical assemblies mounted on the engine (starter,

from carriage. Remove forks. Lift carriage out of inner

generator, ignition system) refer to the coverage of the

upright.

engine assembly in this manual.

(8) Remove roller assemblies and shims from

6-42. Repair of the following electrical components is

carriage trunnions.

essentially limited to replacement of the defective

component except where noted. Installation is the

(9) Remove plugs and setscrews, and remove

reverse of removal. Refer to the wiring diagram (figure

inner upright from within outer upright.

6-20) as an aid in tracing circuitry problems in the wiring

harness, as well as diagnosing and isolating any troubles

c. Repair.

encountered in the electrical system.

(1) Thoroughly inspect and examine all parts

prior to assembling the disassembled uprights. Replace

6-43. BATTERY AND CABLES.

any component which shows evidence of excessive

a. Removal.

wear; cracks, fractures or damage. Replace any part

(1) Disconnect ground and starter cables at

when in doubt as to its serviceability.

battery. If necessary use a puller to lift cable terminals

from posts with a vertical pull. Do not twist or pry

(2) Repair damaged threaded items by cleaning

terminals from post.

up threads with a tap or die.

(2) Disconnect ground cable from frame, and

starter cable from starter.

(3) Straighten slightly deformed structural items

(3) Loosen nuts and washers holding strap and

by cold bending.

lift battery clear of truck.

(4) Inspect rollers and bushings for wear and

CAUTION

damage. Check bearings for free rotation. Inspect

Avoid contact with any liquid on the

crosshead for evidence of excessive damage. Replace

battery.

It will probably be

if in doubt of parts serviceability.

electrolyte, which can produce skin

burns and damage clothing if not

(5) Roller bushings must be smooth without

rinsed off quickly with clear water.

pitting, scoring or other defects. Examine carriage for

evidence of excessive wear.

d. Assembly.