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• TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
• WARNING
• TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
• TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
• TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
• TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
• TECHNICAL MANUAL ORGANIZATIONAL, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL
• WARNING
• WARNING
• WARNING
• TABLE OF CONTENTS
• TABLE OF CONTENTS-cont.
• HOW TO USE THIS MANUAL
• HOW TO USE THIS MANUAL (cont)
• MHE 237 Forklift Trucks
• CHAPTER 1 INTRODUCTION
• COMMON TOOLS AND EQUIPMENT
• Section II. EQUIPMENT DESCRIPTION AND DATA
• DATA, INSPECTION AND WARRANTY PLATES
• DATA, INSPECTION AND WARRANTY PLATES (cont)
• EQUIPMENT DATA
• Section III. PRINCIPLES OF OPERATION
• FUEL SYSTEM
• ELECTRICAL SYSTEM
• Instrument Panel Switches and Gage Lights.
• TRANSMISSION AND DRIVE SHAFTS
• AXLES AND WHEELS
• HYDRAULIC LIFT SYSTEM
• HYDRAULIC LIFT SYSTEM (cont)
• CHAPTER 2 ORGANIZATIONAL MAINTENANCE PROCEDURES
• SERVICING NEW EQUIPMENT
• Section II. (ORGANIZATIONAL) PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)
• ORGANIZATIONAL PREVENTIVE MAINTENANCE CHECKS AND SERVICES
• ORGANIZATIONAL Preventive Maintenance CHECKS AND SERVlCES
• Section III. TROUBLESHOOTING INDEX
• Section III. TROUBLESHOOTING INDEX (cont)
• Section III. TROUBLESHOOTING INDEX (cont)
• Section III. TROUBLESHOOTING INDEX (cont)
• S e c t i o n IV. ENGINE, FUEL, EXHAUST, AND COOLING SYSTEMS AND GAGES  MAINTENANCE
• ENGINE TROUBLESHOOTING
• ENGINE TROUBLESHOOTING (cont)
• ENGINE HARD TO START OR WILL NOT START
• ENGINE HARD TO START OR WILL NOT START
• ENGINE TROUBLESHOOTING
• ENGINE MISFIRES
• ENGINE STALLS FREQUENTLY OR DOES NOT DEVELOP FULL POWER
• ENGINE STALLS FREQUENTLY OR DOES NOT DEVELOP FULL POWER (cont)
• ENGINE STALLS FREQUENTLY OR DOES NOT DEVELOP FULL POWER (cont)
• ENGINE CRANKS BUT DOES NOT START WHEN QUICK START IS ACTIVATED
• LOW ENGINE OIL PRESSURE
• FUEL SYSTEM TROUBLESHOOTING
• EXCESSIVE FUEL USAGE
• COOLING SYSTEM TROUBLESHOOTING
• ENGINE DOES NOT REACH OPERATING TEMPERATURE
• COOLING SYSTEM TROUBLESHOOTING (cont)
• GAGES TROUBLESHOOTING
• ENGINE MAINTENANCE
• Draining and Refilling Engine Crankcase
• Oil Filter
• Intake Manifold
• Intake Manifold
• Intake Manifold (cont)
• Intake Manifold (cont)
• Exhaust Manifold
• Exhaust Manifold (cont).
• Exhaust Manifold (cont).
• Exhaust Manifold (cont).
• FUEL SYSTEM MAINTENANCE
• Electric Fuel Pump and Lines
• Electric Fuel Pump and Lines (cont).
• Electric Fuel Pump and Lines (cont).
• Electric Fuel Pump and Lines (cont).
• Aircleaner.
• Air Cleaner (cont).
• Air Cleaner (cont).
• Air Cleaner (cont).
• Fuel Tank, Lines and Fittings
• Fuel Tank, Lines and Fttings (cont),
• Fuel Tank, Lines and Fittings (cont).
• Fuel Tank, Lines and Fittings (cont).
• Fuel Tank, Lines and Fittings (cont).
• Fuel Tank, Lines and Fittings (cont).
• In-Line Fuel Filter
• Fuel Filter Assembly
• Fuel Filter Assembly (cont).
• Fuel Filter Assembly (cont).
• Fuel Strainer.
• Fuel Strainer (cont)
• Fuel Strainer (cont).
• Quick Start Kit.
• Quick Start Kit (cont).
• Quick Start Kit (cont).
• Quick Start Kit (cont).
• Accelerator//Throttle Control
• Accelerator/Throttle Control (cont).
• Accelerator/Throttle Control (cont).
• Accelerator/Throttle Control (cont).
• Accelerator/Throttle Control (cont).
• SPARK ARRESTING MUFFLER AND EXHAUST PIPE MAINTENANCE
• SPARK ARRESTING MUFFLER AND EXHAUST PIPE MAINTENANCE (cont)
• SPARK ARRESTING MUFFLER AND EXHAUST PIPE MAINTENANCE (cont)
• SPARK ARRESTING MUFFLER AND EXHAUST PIPE MAINTENANCE (cont)
• SPARK ARRESTING MUFFLER AND EXHAUST PIPE MAINTENANCE (cont)
• COOLING SYSTEM MAINTENANCE
• Radiator Servicing
• Radiator Servicing (cont)
• Hoses
• Hoses (cont)
• Radiator and Shroud
• Radiator and Shroud (cont).
• Radiator and Shroud (cont).
• Radiator and Shroud (cont).
• Radiator and Shroud (cont).
• Thermostat and Housing.
• Thermostat and Housing (cont)
• Thermostat and Housing (cont)
• Water Pump Assembly
• Water Pump Assembly (cont)
• Water Pump Assembly (cont).
• Fan and Belt
• Fan and Belt (cont)
• Fan and Belt (cont).
• Gage Bulb Replacement
• Gages Replacement
• Gages Replacement (cont)
• Section V. ELECTRICAL SYSTEM MAINTENANCE
• BATTERY SYSTEM TROUBLESHOOTING
• ALL ELECTRICAL SYSTEMS ARE WEAK
• STARTER CRANKS TOO SLOWLY
• STARTER FAILS TO CRANK
• STARTER CRANKS CONTINUOUSLY
• CHARGING SYSTEM TROUBLESHOOTING
• HORN AND BACK-UP ALARM SYSTEM TROUBLESHOOTING
• BACK-UP ALARM DOES NOT SOUND
• LIGHT SYSTEMS TROUBLESHOOTING
• FRONT BLACK OUT LIGHT INOPERATIVE
• SERVICE TAIL LIGHTS INOPERATIVE
• SERVICE STOP LIGHTS INOPERATIVE
• REAR FLOOD LIGHTS INOPERATIVE
• INSTRUMENT PANEL TROUBLESHOOTING
• WARNING LIGHTS INOPERATIVE
• ALTERNATOR MAINTENANCE
• REMOVAL
• CLEANING
• INSTALLATION/REPLACEMENT
• TESTING
• STARTING SYSTEM MAINTENANCE
• Starter
• Starter (cont).
• Starter (cont).
• Starter (cont).
• Starter Relay and 25 AMP Circuit Breaker.
• Starter Relay and-25 AMP Circuit Breaker (cont).
• Starter Relay and-25 AMP Circuit Breaker (cont).
• INSTRUMENT PANEL MAINTENANCE
• Flood Light Switches and Circuit Breakers
• Flood Light Switches and Circuit Breakers (cont).
• START Switch and VEHICLE LIGHTS Switch.
• START Switch and VEHICLE LIGHTS Switch (cont).
• START Switch and VEHICLE LIGHTS Switch (cont).
• Ignition Switch and Circuit Breaker
• Ignition Switch and Circuit Breaker (cont).
• Lockout Relay
• Lockout Relay
• Warning Lights and Diodes
• Warning Lights and Diodes (cont).
• AUXILIARY PANEL MAINTENANCE
• Slave Receptacle
• Slave Receptacle (cont).
• Hourmeter
• Hourmeter (cont).
• LIGHT SYSTEMS MAINTENANCE
• Flood Lights
• Flood Lights (cont).
• Front Blackout Light.
• Front Blackout Light (cont).
• Front Blackout Light (cont).
• Rear. Blackout Lights
• Rear Blackout Lights (cont).
• Rear Blackout Lights (cont).
• Rear Blackout Lights (cont).
• Stop and Tail tight.
• Stop and Tail Light (cont).
• Stop and Tail Light (cont).
• SENDING UNITS AND SWITCHES MAINTENANCE
• Fuel Gage Sending Unit
• Fuel Gage Sending Unit (cont).
• Neutral Start and Back-up Alarm Switches.
• Neutral Start and Back-up Alarm Switches (cont).
• Engine and Transmission Temperature Switches.
• Engine and Transmission Temperature Switches (cont).
• Engine and Transmission Temperature Switches (cont).
• Engine and Transmission Temperature Switches (cont).
• Engine and Transmission Temperature Switches (cont).
• Engine Oil Pressure Switch and Sending Unit
• Engine Oil Pressure Switch and Sending Unit (cont)
• Engine Oil Pressure Switch and Sending Unit (cont).
• Stop Light and Hydraulic Fiber Switches
• Stop Light and Hydraulic Filter Snitches (cont).
• Stop Light and Hydraulic Filter Snitches (cont).
• Stop Light and Hydraulic Filter Snitches (cont).
• Stop Light and Hydraulic Filter Snitches (cont).
• HORN AND BACK-UP ALARM MAINTENANCE
• Horn
• Horn Switch.
• Horn Switch (cont).
• Back-up Alarm
• Back-up Alarm (cont).
• BATTERY SYSTEM MAINTENANCE
• Battery Cover
• Battery Cover (cont).
• Battery Cables and Batteries.
• Battery Cables and Batteries (cont).
• Battery Cables and Batteries (cont).
• WIRING HARNESS MAINTENANCE
• Front Wiring Harness
• Front Wiring Harness (cont).
• Front Wiring Harness (cont).
• Rear Wiring Harness.
• Rear Wiring Harness (cont).
• Rear Wiring Harness (cont).
• Section VI. POWER TRAIN MAINTENANCE
• TRANSMISSION TROUBLESHOOTING
• TRANSMISSION TROUBLESHOOTING (cont)
• LOSS OF DRIVE IN ALL RANGES
• LESS OF DRIVE IN ALL RANGES (cont)
• LOSS OF POWER
• CONTINUOUS AXLE OR WHEEL NOISE
• TRANSMISSION MAINTENANCE
• Transmission Servicing and Inspection
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Servicing and Inspection (cont).
• Transmission Linkage Controls.
• Transmission Linkage Controls (cont)
• Transmission Linkage Controls (cont).
• Transmission Linkage Controls (cont).
• Transmission Linkage Controls (cont).
• Transmission Linkage Controls (cont).
• Transmission Linkage Controls (cont).
• Transmission Linkage Controls (cont).
• Transmission Linkage Controls (cont).
• Axle Disconnect Lever.
• Axle Disconnect Lever (cont).
• Axle Disconnect Lever (cont).
• Dipstick Tube Assembly
• Dipstick Tube Assembly (cont).
• Dipstick Tube Assembly (cont).
• Control Valve. This task covers inspection of the control valve
• Transmission Hoses, Lines and Fittings
• Transmission Hoses, Lines and Fittings (cont).
• Transmission Hoses, Lines and Fittings (cont).
• Transmission Oil Cooler
• Transmission Oil Cooler (cont)
• AXLES AND DRIVE SHAFT ASSEMBLIES MAINTENANCE
• Front Drive Shaft Assembly and Support Bearing
• Front Drive Shaft Assembly and Support Bearing
• Front Drive Shaft Assembly and Support Bearing (cont).
• Center Drive Shaft Assembly
• Center Drive Shaft Assembly (cont)
• Center Drive Shaft Assembly (cont)
• Center Drive Shaft Assembly (cont).
• Center Drive Shaft Assembly (cont).
• Rear Drive Shaft Assembly.
• Rear Drive Shaft Assembly (cont)
• Rear Drive Shaft Assembly (cont).
• Rear Drive Shaft Assembly (cont).
• Front and Rear Axle Assemblies
• Front and Rear Axle Assemblies (cont).
• Axle Breathers
• Axle Breathers (cont).
• Axle Breathers (cont).
• Front and Rear Axle Shafts and Bearings
• Front and Rear Axle Shafts and Bearings (cont)
• Front and Rear Axle Shafts and Bearings (cont).
• Front and Rear Axle Shafts and Bearings (cont).
• Front and Rear Axle Shafts and Bearings (cont).
• Front and Rear Axle Shafts and Bearings (cont).
• Front and Rear Axle Shafts and Bearings (cont).
• Section VII. BRAKE SYSTEM MAINTENANCE
• TROUBLESHOOTING SYMPTOM INDEX
• BRAKE SYSTEM TROUBLESHOOTING
• SERVICE BRAKES SPONGY
• SERVICE BRAKES GRAB
• SERVICE BRAKES SQUEAK
• SERVICE BRAKES OVERHEAT
• EXCESSIVE SERVICE BRAKE PEDAL TRAVEL
• EXCESSIVE SERVICE BRAKE PEDAL TRAVEL (cont)
• EXCESSIVE SERVICE BRAKE PEDAL EFFORT REQUIRED (cont)
• SERVICE BRAKES GROAN AT END OF STOP
• SCRAPING NOISE FROM SERVICE BRAKES WHEN APPLIED
• PARKING BRAKE MAINTENANCE
• Parking Brake Linkage
• Parking Brake Linkage (cont).
• Parking Brake Linkage (cont).
• Parking Brake Linkage (cont).
• Parking Brake Assembly.
• Parking Brake Assembly (cont).
• Parking Brake Assembly (cont).
• Parking Brake Assembly (cont).
• Parking Brake Assembly (cont).
• Parking Brake Assembly (cont).
• SERVICE BRAKE MAINTENANCE
• Service Brake Assembly
• Service Brake Assembly (cont).
• Service Brake Assembly (cont).
• Service Brake Assembly (cont).
• Service Brake Assembly (cont).
• BLANK PAGE
• Service Brake Assembly (cont).
• Service Brake Assembly (cont).
• Service Brake Assembly (cont).
• Brake Hoses, Lines and Fittings.
• Brake Hoses, Lines, and Fittings
• Brake Hoses, Lines, and Fittings (cont).
• Brake Hoses, Lines, and Fittings (cont).
• Brake Hoses, Lines, and Fittings (cont).
• Hydraulie Brake Valve
• Hydraulie Brake Valve (cont).
• BLANK PAGE
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Hydraulic Brake Valve (cont).
• Declutch Valve.
• Declutch Valve (cont).
• Declutch Valve (cont)
• Declutch Valve (cont).
• Declutch Valve (cont).
• Brake Pedal and Declutch Pedal.
• Brake Pedal and Declutch Pedal (cont).
• Brake Pedal and Declutch Pedal (cont).
• Brake Pedal and Declutch Pedal (cont).
• Section VIII. WHEELS AND STEERING MAINTENANCE
• WHEELS AND TIRES TROUBLESHOOTING
• STEERING SYSTEM TROUBLESHOOTING
• STEERING SYSTEM TROUBLESHOOTING (cont)
• STEERING WHEEL TURNS HARD OR VEHICLE TURNS TOO SLOW
• EFFORT TO TURN IN ONE DIRECTION IS MORE THAN REQUIRED IN OTHER DIRECTION
• WHEELS AND TIRES MAINTENANCE
• WHEELS AND TIRES MAINTENANCE (cont)
• WHEELS AND TIRES MAINTENANCE (cont)
• Hydraulic Pump.
• Hydraulic Pump (cont)
• Hydraulic Pump (cont)
• Hoses, Lines and Fittings
• Hoses, Lines and Fittings (cont)
• Hoses, Lines and Fittings (cont).
• Hoses, Lines and Fittings (cont)
• Steering Gear to Steering Cylinder Assemblies
• Steering Gear to Steering Cylinder Assemblies (cont).
• Steering Gear to Steering Cylinder Assemblies (cont).
• Steering Gear to Steering Cylinder Assemblies (cont).
• Steering Gear to Steering Cylinder Assemblies (cont).
• Hydraulic Pump to Steering Gear
• Hydraulic Pump to Steering Gear (cont)
• Hydraulic Pump to Steering Gear (cont)
• Hydraulic Pump to Steering Gear (cont)
• Hydraulic Pump to Steering Gear (cont)
• Hydraulic Pump to Steering Gear (cont)
• Hydraulic Pump to Steering Gear (cont)
• Hydraulic Pump to Steering Gear (cont)
• Steering Cylinder Assembly
• Steering Cylinder Assembly (cont)
• Steering Cylinder Assembly (cont).
• Steering Cylinder Assembly (cont).
• Section IX. BODY, CAB AND ROLL OVER PROTECTIVE STRUCTURE MAINTENANCE
• FRAME AND TOWING ATTACHMENTS TROUBLESHOOTING
• BODY. CAB AND HOOD TROUBLESHOOTING
• FRAME AND TOWING ATTACHMENTS MAINTENANCE
• Roll Over Protective Structure
• Roll Over Protective Structure (cont).
• Chassis Stop Bumper
• Chassis Stop Bumper
• Tow Bar, Tow Chains and Pintle Hook
• Tow Bar, Tow Chains and Pintle Hook (cont)
• Tow Bar, Tow Chains and Pintle Hook (cont)
• BODY, CAB AND HOOD MAINTENANCE
• Grille
• Grille (cont).
• Grille (cont).
• Fenders
• Fenders (cot).
• Fenders (cot).
• Side Panels.
• Side Panels (cont).
• Side Panels (cont).
• Top Hood.
• Top Hood (cont).
• Hood Panels and Hood Support Plates.
• Hood Panels and Hood Support Plates (cont).
• Hood Panels and Hood Support Plates (cont).
• Front Cover Panel.
• Front Cover Panel (cont).
• Front Cover Panel (cont).
• Operator's Seat.
• Operator's Seat (cont).
• Operator's Seat (cont).
• Noise Baffle Mat
• Noise Baffle Mat (cont).
• Chassis Floor Plate and Guard.
• Chassis floor Plate and Guard (cont).
• Chassis floor Plate and Guard (cont).
• Section X. HYDRAULIC LIFT SYSTEM MAINTENANCE
• HYDRAULIC LIFT SYSTEM TROUBLESHOOTING
• UNABLE TO LIFT, TILT, SHIFT OR ROTATE LOAD
• LIFT, TILT, SHIFT, OR ROTATE TOO SLOW
• HYDRAULIC LIFT SYSTEM MAINTENANCE
• Operational Test (cont)q
• Operational Test (cont).
• Control Levers and Linkages.
• Control Levers and Linkages (cont).
• Control Levers and Linkages (cont).
• Control Levers and Linkages (cont).
• LiftingForks.
• Lifting Forks (cont)
• Lift Chains and Pulleys.
• Lift Chains and Pulleys (cont).
• Lift Chains and Pulleys (cont).
• Lift Chains and Pulleys (cont).
• Lift Chains and Pulleys (cont).
• Lift Chains and Pulleys (cont).
• Lift Chains and Pulleys (cont).
• Lift Chains and Pulleys (cont).
• Lift Chains and Pulleys (cont).
• Sideshift Chains and Pulleys.
• Sideshift Chains and Pulleys (cont).
• Sideshift Chains and Pulleys (cont).
• Sideshift Chains and Pulleys (cont).
• Sideshift Chains and Pulleys (cont).
• Hoses, Lines and Fittings.
• Hoses, Lines and Fittings (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Hydraulic Oil Filter Assembly to Control Valve to Mast Assembly (cont).
• Mast Assembly
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Mast Assembly (cont).
• Hydraulic Reservoir.
• Hydraulic Reservoir (cont)
• Draining, Cleaning, and Refilling
• Hydraulic Oil Filter Assembly
• Hydraulic Oil Filter Assembly (cont).
• Hydraulic Oil Filter Assembly (cont).
• Hydraulic Oil Filter Assembly (cont).
• Strainer
• Strainer (cont).
• Strainer (cont).
• Air Breather
• Removal and Installation
• Removal and Installation (cont).
• Removal and Installation (cont).
• Removal and Installation (cont).
• CHAPTER 3 DIRECT SUPPORT MAINTENANCE PROCEDURES
• TROUBLESHOOTING SYMPTOM INDEX
• ENGINE STARTS BUT WILL NOT RUN
• ENGINE STALLS FREQUENTLY OR DOES NOT DEVELOP FULL POWER
• ENGINE COMPRESSION TEST
• FUEL SYSTEM TROUBLESHOOTING
• ENGINE HARD TO START
• ENGINE HARD TO START (cont)
• ENGINE HARD TO START (cont)
• ENGINE STARTS AND STOPS
• ERRATIC ENGINE OPERATION (SURGE, MISFIRING, POOR GOVERNOR REGULATION)
• ERRATIC ENGINE OPERATION (SURGE, MISFIRING, POOR GOVERNOR REGULATION) (cont)
• ERRATIC ENGINE OPERATION (SURGE, MISFIRING, POOR GOVERNOR REGULATION) (cont)
• ENGINE IDLES IMPERFECTLY
• ENGINE IDLES IMPERFECTLY (cont)
• ENGINE DOES NOT DEVELOP FULL POWER OR SPEED
• ENGINE DOES NOT DEVELOP FULL POWER OR SPEED (cont)
• ENGINE SMOKES BLACK
• ENGINE SMOKES BLUE OR WHITE
• FUEL DELIVERED FROM TRANSFER PUMP BUT NOT TO FUEL INJECTORS
• FUEL DELIVERED FROM TRANSFER PUMP BUT NOT TO FUEL INJECTORS (cent)
• FUEL REACHING FUEL INJECTORS BUT ENGINE WILL NOT START
• FUEL REACHING FUEL INJECTORS BUT ENGINE WILL NOT START (cont)
• ENGINE MAINTENANCE
• Engine Tune-up
• Locating Top Dead Center
• Locating Top Dead Center (cont).
• Locating Top Dead Center (cont).
• Valve Tappet Clearance Adjustment.
• Valve Tappet Clearance Adjustment (cont).
• Valve Tappet Clearance Adjustment (cont).
• Fuel Injection Pump Adjustments
• Fuel Injection Pump Adjustments (cont).
• Fuel Injection Pump Adjustments (cont).
• Fuel Injection Pump Adjustments (cont).
• Fuel Injection Pump Adjustments (cont).
• Fuel Injection Pump Adjustments (cont).
• Engine Mount
• Engine Mount (cont).
• Engine Mount (cont).
• Engine Mount (cont).
• Power Pack.
• Power Pack (cont)
• Power Pack (cont).
• Power Pack (cont).
• Separation of Engine and Transmission
• Separation of Engine and Transmission (cont).
• Separation of Engine and Transmission (cont).
• Cylinder Block.
• Tachometer Drive
• Tachometer Drive (cont).
• Tachometer Drive (cont).
• Cylinder Head
• Cylinder Head (cont).
• Cylinder Head (cont).
• Cylinder Head (cont).
• Flywheel Housing
• Flywheel Housing (cont)
• Rocker Arm Cover
• Rocker Arm Cover (cont).
• Rocker Arm Cover (cont).
• Rocker Arm Assembly.
• Rocker Arm Assembly (cont)
• Rocker Arm Assembly (cont)
• Rocker Arm Assembly (cont)
• Rocker Arm Assembly (cont)
• Rocker Arm Assembly (cont)
• Oil Part
• Oil Pan (cont).
• Oil Pan (cont).
• FUEL SYSTEM MAINTENANCE
• Fuel Injection Lines and Fittings
• Fuel Injection Lines and Fittings (cont).
• Fuel Injection Lines and Fittings (cont).
• Fuel Injection Lines and Fittings (cont).
• Fuel Injector
• Fuel Injector (cont)
• Fuel Injector (cont).
• Fuel Injection Pump
• Fuel Injection Pump (cont).
• Fuel Injection Pump (cont).
• Fuel Injection Pump (cont).
• Fuel Injection Pump (cont).
• Fuel Injection Pump (cont).
• Fuel Injection Pump (cont).
• RADIATOR AND SHROUD MAINTENANCE
• RADIATOR AND SHROUD MAINTENANCE (cont)
• Section II. ELECTRICAL SYSTEM MAINTENANCE
• ALTERNATOR TROUBLESHOOTING
• IMPROPER OUTPUT CURRENT
• STARTER AND SOLENOID TROUBLESHOOTING
• STARTER FAILS TO CRANK
• ONE ELECTRICAL CIRCUIT INOPERATIVE
• ALTERNATOR REPAIR
• ALTERNATOR REPAIR (cont)
• ALTERNATOR REPAIR (cont)
• ALTERNATOR REPAIR (cont)
• ALTERNATOR REPAIR (cont)
• ALTERNATOR REPAIR (cont)
• ALTERNATOR REPAIR (cont)
• ALTERNATOR REPAIR (cont)
• STARTER AND SOLENOID REPAIR
• STARTER AND SOLENOID REPAIR (cont)
• STARTER AND SOLENOID REPAIR (cont)
• DISASSEMBLY
• DISASSEMBLY (cont)
• INSPECTION
• TESTING
• TESTING (cont)
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• ASSEMBLY
• INSTRUMENT PANEL REPLACEMENT
• INSTRUMENT PANEL REPLACEMENT (cont)
• REMOVAL
• WIRING HARNESS REPLACEMENT
• Front Wiring Harness
• Front Wiring Harness (cont).
• Rear Wiring Harness.
• Rear Wiring Harness (cont).
• Rear Wiring Harness (cont).
• Section III. POWER TRAIN MAINTENANCE
• LOSS OF DRIVE IN ALL RANGES
• AXLES AND DIFFERENTIAL CARRIER ASSEMBLIES TROUBLESHOOTING
• TRANSMISSION MAINTENANCE
• Transmission Pressure Check
• Transmission Pressure Check (cont).
• Transmission Pressure Check (cont).
• Transmission Mounts
• Transmission Mounts (cont).
• Transmission Mounts (cont).
• Transmission Removal.
• Contol Valve and Modulation Valve Assemblies
• Charging Pump Assembly.
• Charging Pump Assembly (cont)
• Transmission Oil Cooler
• AXLES AND DIFFERENTIAL CARRIER ASSEMBLIES MAINTENANCE
• Front Axle Assembly
• Rear Axle Assembly
• Rear Axle Assembly (cont)
• Front Axle Differential Carrier Assembly
• Front Axle Differential Carrier Assembly (cont)
• Front Axle Differential Carrier Assembly (cont).
• Front Axle Differential Carrier Assembly (cont).
• Front Axle Differential Carrier Assembly (cont).
• Rear Axle Differential Carrier Assembly.
• Rear Axle Differential Carrier Assembly (cont).
• Rear Axle Differential Carrier Assembly (cont).
• Rear Axle Differential Carrier Assembly (cont).
• Rear Axle Differential Carrier Assembly (cont).
• Section IV. STEERING SYSTEM MAINTENANCE
• HYDRAULIC PUMP TROUBLESHOOTING
• STEERING COLUMN AND CYLINDER TROUBLESHOOTING
• STEERING WHEEL TURNS HARD IN BOTH DIRECTIONS
• Steering Wheel and Column
• Steering Wheel and Column (cont).
• Steering Wheel and Column (cont).
• Steering Wheel and Column (cont).
• Steering Wheel and Column (cont).
• Steering Gear.
• Steering Gear (cont)
• Steering Gear (cont).
• Steering Gear (cont).
• Steering Gear (cont).
• Steering Gear (cont).
• Steering Gear (cont).
• Steering Gear (cont).
• Steering Gear (cont).
• Steering Gear (cont).
• Steering Gear (cont).
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• INSTALLATION/REPLACEMENT
• Hydraulic Pump Repair.
• Hydraulic Pump Repair (cont).
• Hydraulic Pump Repair (cont)
• CLEANING
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• Steering Cylinder Assembly Repair
• Steering Cylinder Assembly Repair (cont).
• Steering Cylinder Assembly Repair (cont).
• Steering Cylinder Assembly Repair (cont).
• Steering Cylinder Assembly Repair (cont).
• Section V. CHASSIS MAINTENANCE
• SEPARATION OF FRONT AND REAR CHASSIS
• REMOVAL
• CLEANING
• Section VI. HYDRAULIC LIFT SYSTEM MAINTENANCE
• HYDRAULIC LIFT SYSTEM TROUBLESHOOTING
• UNABLE TO LIFT A LOAD (ALL OTHER FUNCTIONS NORMAL)
• LOAD DRIFTS DOWN
• UNABLE TO SIDESHIFT LOAD (ALL OTHER FUNCTIONS NORMAL) (cont)
• SIDESHIFT CYLINDER ASSEMBLY OPERATION SLUGGISH
• UNABLE TO TILT LOAD (ALL OTHER FUNCTIONS NORMAL)
• TILT CYLINDER ASSEMBLIES OPERATION SLUGGISH
• UNABLE TO ROTATE LOAD (ALL OTHER FUNCTIONS NORMAL)
• ROTATION OPERATION SLUGGISH
• HYDRAULIC LIFT SYSTEM MAINTENANCE
• Conntrol Valve
• Conntrol Valve (cont).
• Conntrol Valve (cont).
• Conntrol Valve (cont).
• Conntrol Valve (cont).
• ROTATE, SIDESHIFT, AND TILT VALVE SECTIONS DISASSEMBLY
• ROTATE, SIDESHIFT, AND TILT VALVE SECTIONS DISASSEMBLY (cont)
• LIFT VALVE SECTION DISASSEMBLY
• CLEANING
• LEFT COVER PLATE REASSEMBLY
• LIFT VALVE SECTION REASSEMBLY
• FINAL REASSEMBLY
• INSTALLATION/REPLACEMENT
• Tilt Cylinder Assemblies.
• Tilt Cylinder Assemblies-CONT.
• Tilt Cylinder Assemblies (cont).
• Tilt Cylinder Assemblies (cont).
• Tilt Cylinder Assemblies (cont).
• Tilt Cylinder Assemblies (cont).
• Tilt Cylinder Assemblies (cont).
• Sideshift Cylinder Assembly.
• Sideshift Cylinder Assembly (cont).
• REMOVAL
• DISASSEMBLY
• INSPECTION/REPAIR
• TESTING
• INSTALLATION/REPLACEMENT
• Rotation Cylinder Assembly.
• Rotation Cylinder Assembly (cont
• Rotation Cylinder Assembly (cont).
• Rotation Cylinder Assembly (cont).
• INSPECTION/REPAIR
• REASSEMBLY
• INSTALLATION/REPLACEMENT
• Lift Cylinder Assembly
• Lift Cylinder Assembly (cont).
• Lift Cylinder Assembly (cont).
• REMOVAL
• DISASSEMBLY
• Lift Cylinder Assembly (cont)
• DISASSEMBLY
• DISASSEMBLY (cont)
• INSPECTION/REPAIR
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• INSTALLATION/REPLACEMENT
• INSTALLATION/REPLACEMENT
• MAST ASSEMBLY MAINTENANCE
• Carriage Assembly
• CLEANING
• Side Shifter Frame and Rotation Bearing
• Side Shifter Frame and Rotation Bearing (cont).
• REMOVAL
• REMOVAL (cont)
• CLEANING
• INSTALLATION/REPLACEMENT
• INSTALLATION/REPLACEMENT (cont)
• INSTALLATION/REPLACEMENT (cont)
• Inner and Outer Mast
• Inner and Outer Mast.
• Inner and Outer Mast (cont)
• INSPECTION/REPAIR
• INSTALLATION/REPLACEMENT
• CHAPTER 4 GENERAL SUPPORT MAINTENANCE PROCEDURES
• ENGINE MAINTENANCE
• Cylinder Block Assembly
• Cylinder Block Assembly (cont).
• CLEANING
• INSPECTION
• REASSEMBLY
• REASSEMBLY
• Cylinder Head and Valves.
• Cylinder Head and Valves (cont).
• CLEANING
• INSPECTION AND REPAIR
• INSPECTION AND REPAIR (cont)
• INSPECTION AND REPAIR (cont)
• INSPECTION AND REPAIR (cont)
• VALVES AND VALVE SEAT REFACING
• VALVES AND VALVE SEAT REFACING (cont)
• VALVES AND VALVE SEAT REFACING (cont)
• INSTALLATION
• Crankshaft Oil Seal Retainer Assembly.
• Crankshaft Oil Seal Retainer Assembly (cont).
• CLEANING
• INSTALLATION (cont)
• INSTALLATION (cont)
• Crankshaft and Main Bearings
• Crankshaft and Main Bearings (cont).
• REMOVAL
• CLEANING
• INSPECTION
• INSPECTION (cont)
• INSPECTION (cont)
• INSPECTION (cont)
• INSPECTION (cont)
• INSTALLATION
• INSTALLATION (cont)
• INSTALLATION (cont)
• Flywheel and Flywheel Housing
• Flywheel and Flywheel Housing (cont).
• Flywheel and Flywheel Housing (cont).
• INSTALLATION
• Pistons and Connecting Rods
• Pistons and Connecting Rods (cont).
• REMOVAL
• DISASSEMBLY
• CLEANING
• INSPECTION
• INSPECTION (cont)
• INSPECTION (cont)
• REASSEMBLY
• INSTALLATION
• INSTALLATION (cont)
• Camshaft and Bearings.
• REMOVAL
• DISASSEMBLY
• INSPECTION AND REPAIR
• INSPECTION AND REPAIR (cont)
• INSPECTION AND REPAIR (cont)
• REASSEMBLY
• INSTALLATION
• INSTALLATION (cont)
• Timing Gear Cover
• Timing Gear Cover (cont).
• REMOVAL
• CLEANING
• INSTALLATION
• INSTALLATION (cont)
• INSTALLATION (cont)
• INSTALLATION (cont)
• Oil Pump
• Oil Pump (cont).
• CLEANING
• INSPECTION
• REASSEMBLY
• INSTALLATION
• Fuel Injector
• Fuel Injector (cont).
• TESTING
• TESTING (cont)
• TESTING (cont)
• TESTING (cont)
• DISASSEMBLY
• CLEANING AND INSPECTION
• CLEANING AND INSPECTION (cont)
• RECONDITIONING/OVERHAUL
• REASSEMBLY
• ADJUSTMENTS
• ADJUSTMENTS (cont)
• ADJUSTMENTS (cont)
• Fuel injection Pump
• Fuel Injection Pump (cont).
• Fuel Injection Pump (cont).
• DISASSEMBLY
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• INSPECTION
• INSPECTION (cont)
• INSPECTION (cont)
• INSPECTION (cont)
• INSPECTION (cont)
• INSPECTION (cont)
• INSPECTION (cont)
• INSPECTION (cont)
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• TESTING
• TESTING (cont)
• TESTING (cont)
• TESTING (cont)
• Section Il. POWER TRAIN MAINTENANCE
• TRANSMISSION MAINTENANCE
• Torque Converter Group
• Torque Converter Group (cont).
• DISASSEMBLY
• DISASSEMBLY
• DISASSEMBLY
• DISASSEMBLY
• DISASSEMBLY
• DISASSEMBLY
• CLEANING
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• Converter Housing
• Converter Housing
• DISASSEMBLY
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• CLEANING
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• Transmission Rear Cover
• REMOVAL
• REMOVAL (cont)
• CLEANING
• INSTALLATION
• INSTALLATION (cont)
• INSTALLATION (cont)
• Gear and Clutch Group
• Gear and Clutch Group (cont).
• DISASSEMBLY
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• CLEANING
• CLEANING (cont)
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• Transmission Housing
• Transnrission Housing (cont)
• DISASSEMBLY
• CLEANING
• REASSEMBLY
• REASSEMBLY (cont)
• Reverse and Second Clutch Assembly
• Reverse and Second Clutch Assembly.
• DISASSEMBLY
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• DISASSEMBLY (cont)
• CLEANING
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• Low Clutch Assembly
• Low Clutch Assembly (cont).
• DISASSEMBLY
• DISASSEMBLY (cont)
• CLEANING
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• REASSEMBLY (cont)
• Third Clutch Assembly.
• DISASSEMBLY
• DISASSEMBLY (cont)
• CLEANING
• REASSEMBLY
• REASSEMBLY (cont)
• Foruurd Clutch Assembly
• DISASSEMBLY
• DISASSEMBLY (cont)
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• Control Valve Assembly
• Control Valve Assembly (cont).
• DISASSEMBLY
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• Modulation Valve Assembly
• DISASSEMBLY
• INSPECTION
• AXLE MAINTENANCE
• Differential Carrier
• DISASSEMBLY
• DISASSEMBLY (cont)
• INSPECTION
• REASSEMBLY
• REASSEMBLY (cont)
• ADJUSTMENTS
• ADJUSTMENTS (cont)
• ADJUSTMENTS (cont)
• Differential Case and Gear Assembly
• DISASSEMBLY
• CLEANING
• INSPECTION
• Section III. CHASSIS MAINTENANCE
• REAR AXLE TRUNNION
• CLEANING
• APPENDIX A REFERENCES
• OTHER PUBLICATIONS
• APPENDIX B MAINTENANCE ALLOCATION CHART
• COLUMN ENTRIES USED IN THE MAC
• Section II. MAINTENANCE ALLOCATION CHART
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• Section II. MAINTENANCE ALLOCATION CHART (cont)
• SECTION III.  TOOL AND TEST EQUIPMENT REQUIREMENTS
• Section III. TOOL AND TEST EQUIPMENT REQUIREMENTS (cont)
• APPENDIX D EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
• SECTION II EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST
• APPENDIX E TORQUE LIMITS
• Table E-2. Torque Limits for Wet Fasteners
• APPENDIX F ELECTRICAL AND HYDRAULIC DIAGRAMS
• ELECTRICAL SYMBOLS
• Figure F-1. Logic Tree Troubleshooting Technique.
• Figure F-2. Electrical SymboIs (Sheet 1 of 2).
• Figure F-2. Electrical Symbols (Sheet 2 of 2).
• Figure F-3. Hydraulic Diagram (Oil Flow with Controls in Neutral Position).
• Figure F-4. Hydraulic Diagram (Oil Flow with Controls Activated).
• Figure F-5. Electrical Diagram
• GLOSSARY
• ABBREVIATIONS (cont)
• ABBREVIATIONS (cont)
• APPENDIX H ILLUSTRATED LIST OF MANUFACTURED ITEMS
• ALPHABETICAL INDEX
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• ALPHABETICAL INDEX (cont)
• THE METRIC SYSTEM AND EQUIVALENT
• Distribution
• TM-10-3930-638-24-P
• BLANK PAGE
• Distribution
• BLANK PAGE
• REASSEMBLY (cont)
• BLANK PAGE
• REVERSE OF DA FORM 2O28-2
• DISTRIBUTION
• REVERSE OF DA FORM 2O28-2
• BLANK PAGE
• REVERSE OF DA FORM 2O28-2
• Distribution
• RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
• BLANK PAGE
• BLANK PAGE
• BLANK PAGE
• REVERSE OF DA FORM 2O28-2
• RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
• BLANK PAGE
• BLANK PAGE
• RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
• BLANK PAGE
• BLANK PAGE
• RECOMMENDED CHANGES TO EQUIPMENT TECHNICAL PUBLICATIONS
• Distribution
• BLANK PAGE
• Distribution
• BLANK PAGE
• BLANK PAGE