TM-10-3930-660-24-1 Truck Forklift; 6 000 lb Variable Reach Rough Terrain Manual

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TM-10-3930-660-24-1

Unit and Direct Support Maintenance
WARNING SUMMARY
WARNING SUMMARY-CONT.
WARNING SUMMARY-CONT.
WARNING SUMMARY-CONT.
ELECTRICAL SYSTEM MAINTENANCE
HAZARDOUS WASTE DISPOSAL
LIFTING HEAVY PARTS
PRESSURIZED COOLING SYSTEM
LIST OF EFFECTIVE PAGES/WORK PACKAGES
Table of Contents
Table of Contents - Continued
Table of Contents - Continued
Table of Contents - Continued
Table of Contents - Continued
Table of Contents - Continued
Table of Contents - Continued
Table of Contents - Continued
Table of Contents - Continued
Table of Contents - Continued
HOW TO USE THIS MANUAL
CONTENTS OF THIS MANUAL
CHAPTER 1 INTRODUCTORY INFORMATION WITH THEORY OF OPERATION
GENERAL INFORMATION
EQUIPMENT IMPROVEMENT REPORT AND MAINTENANCE DIGEST (EIR MD)
LIST OF ABBREVIATIONS
EQUIPMENT CHARACTERISTICS, CAPABILITIES AND FEATURES
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS
LOCATION AND DESCRIPTION OF MAJOR COMPONENTS - CONTINUED
EQUIPMENT DATA
EQUIPMENT DATA - CONTINUED
SAFETY, CARE AND HANDLING
THEORY OF OPERATION
ENGINE LUBRICATION SYSTEMS
ENGINE COOLING SYSTEM
ELECTRICAL SYSTEM
STEERING AND BRAKE SYSTEMS
HYDRAULIC SYSTEM
HYDRAULIC SYSTEM
CHAPTER 2 TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING INTRODUCTION
PRELIMINARY TROUBLESHOOTING PROCEDURES
TROUBLESHOOTING SYMPTOM INDEX
Malfunction/Symptom Troubleshooting
HYDRAULIC SYSTEM (UNIT)
BRAKING SYSTEM (DS)
Table 1. Charging System Troubleshooting Procedures.
Table 2. Starting System Troubleshooting Procedures.
Table 2. Starting System Troubleshooting Procedures - Continued.
Table 2. Starting System Troubleshooting Procedures - Continued.
Table 3. Gauges and Meters System Troubleshooting Procedures.
Table 3. Gauges and Meters System Troubleshooting Procedures - Continued.
Table 4. Lighting System Troubleshooting Procedures.
Table 4. Lighting System Troubleshooting Procedures - Continued.
Table 4. Lighting System Troubleshooting Procedures - Continued.
Table 5. Battery System Troubleshooting Procedures.
Table 6. Cab Group Troubleshooting Procedures.
Table 6. Cab Group Troubleshooting Procedures - Continued.
Table 7. MLRS Attachment Group Troubleshooting Procedures.
Table 7. MLRS Attachment Group Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 8. Engine System (Unit) Troubleshooting Procedures - Continued.
Table 9. Cooling System Troubleshooting Procedures.
Table 9. Cooling System Troubleshooting Procedures - Continued.
Table 10. Transmission Troubleshooting Procedures.
Table 10. Transmission Troubleshooting Procedures - Continued.
Table 10. Transmission Troubleshooting Procedures - Continued.
Table 11. Axles and Differential Troubleshooting Procedures.
Table 12. Braking System (Unit) Troubleshooting Procedures.
Table 12. Braking System (Unit) Troubleshooting Procedures - Continued.
Table 12. Braking System (Unit) Troubleshooting Procedures - Continued.
Table 12. Braking System (Unit) Troubleshooting Procedures - Continued.
Table 13. Hydraulic System (Unit) Troubleshooting Procedures.
Table 14. Engine System (DS) Troubleshooting Procedures.
Table 16. Steering System Troubleshooting Procedures.
Table 16. Steering System Troubleshooting Procedures - Continued.
Table 17. Braking System Troubleshooting Procedures.
Table 17. Braking System Troubleshooting Procedures - Continued.
Table 18. Hydraulic System Troubleshooting Procedures.
Table 18. Hydraulic System Troubleshooting Procedures - Continued.
STE/ICE VEHICLE SYSTEM DIAGNOSTIC CHECK
STE/ICE-R VEHICLE SYSTEM DIAGNOSTIC CHECK - CONTINUED
STE/ICE-R VEHICLE SYSTEM DIAGNOSTIC CHECK - CONTINUED
VEHICLE DIAGNOSTIC CONNECTOR ASSEMBLY (DCA)
STE/ICE-R GO-CHAIN TESTS
STE/ICE GO-CHAIN TESTING SEQUENCE
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
STE/ICE-R GO-CHAIN TESTS - CONTINUED
TRANSMISSION CLUTCH PRESSURE
TRANSMISSION CONVERTER CHARGE
TRANSMISSION CONVERTER CHARGE-CONT.
TRANSMISSION BRAKE CUTOFF
TRANSMISSION BRAKE CUTOFF VALVE
FUEL RETURN LINE
FUEL RETURN LINE-CONT.
STE/ICE-R NO-GO-CHAIN TESTS
STE/ICE-R NO-GO-CHAIN TESTS - CONTINUED
STE/ICE-R NO-GO-CHAIN TESTS - CONTINUED
FUEL SYSTEM TESTS
FUEL SYSTEM TESTS-CONT.
FUEL SYSTEM TESTS-CONT.
ALTERNATOR TESTS
ALTERNATOR TESTS-CONT.
STARTER CIRCUIT
STARTER CIRCUIT
STARTER CIRCUIT -CONT.
STARTER CIRCUIT -CONT.
BATTERY TESTS
BATTERY TESTS-CONT.
BATTERY TESTS-CONT.
STARTER TESTS
STARTER TESTS-CONT.
ENGINE TESTS
ENGINE TESTS-CONT.
STARTER CURRENT TEST
6K FORKLIFT TEST CARD
FORKLIFT VEHICLE TEST CARD
STE/ICE-R VEHICLE SYSTEM DIAGNOSTIC CHECK
Table 1. STE/ICE-R Kit.
Table 1. STE/ICE-R Kit - Continued.
Table 2. Transducer Kit
Table 2. Transducer Kit - Continued.
STE/ICE-R TESTING PROCEDURES
VEHICLE DIAGNOSTIC CONNECTOR ASSEMBLY (DCA)
CHAPTER 3 UNIT MAINTENANCE
SERVICE UPON RECEIPT
PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) INTRODUCTION
GENERAL LUBRICATION PROCEDURES
GENERAL PMCS PROCEDURES
GENERAL PMCS PROCEDURES - CONTINUED
GENERAL PMCS PROCEDURES - CONTINUED
Table 1. CHART A -- ENGINE AND OIL CAN POINTS
Table 3. CHART C -- HYDRAULIC RESERVOIR
Table 5. CHART E -- ANTIFREEZE
GENERAL PMCS PROCEDURES - CONTINUED
VIEW A - CARRIAGE TILT CYLINDER PINS
VIEW C - AXLE CARRIER PIN FITTING
VIEW E - TIE ROD ENDS
VIEW G - BRAKE PEDAL AND TRANSMISSION DISCONNECT PEDAL COUNTER SHAFT
VIEW I - REAR PROPELLER SHAFT SLIP JOINT AND U-JOINT
VIEW K - TRANSMISSION INPUT SHAFT BEARING, SLIP JOINT AND U-JOINT
VIEW M - BOOM EXTEND CHAIN SHEAVE
VIEW O - BOOM PIVOT PINS
VIEW Q - TRANSMISSION OIL FILTER
VIEW S - TRANSMISSION
VIEW U - PLANETARY HUBS
VIEW W - FRAME TILT CYLINDER PINS
VIEW Y - MLRS ATTACHMENT PIVOT PINS
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
Table 1. Unit Preventive Maintenance Checks and Services (PMCS) for 6K Forklift - Continued.
ENGINE ASSEMBLY SERVICE
ENGINE ASSEMBLY SERVICE - CONTINUED
CYLINDER HEAD SERVICE
ADJUSTMENT
ADJUSTMENT - CONTINUED
ROCKER LEVER COVERS REPLACEMENT
ROCKER LEVER COVERS REPLACEMENT - CONTINUED
ENGINE OIL LEVEL GAUGE REPLACEMENT
ENGINE OIL FILLER NECK REPLACEMENT
ENGINE OIL SAMPLING VALVE REPLACEMENT
EXHAUST MANIFOLD REPLACEMENT
REMOVAL
INTAKE MANIFOLD COVER REPLACEMENT
FUEL SHUTOFF SOLENOID TESTING (152 HP)
TESTING
FUEL SHUTOFF SOLENOID TESTING (165 HP)
ELECTRICAL TESTING OF SHUTOFF SOLENOID
ELECTRICAL TESTING OF SHUT-OFF SOLENOID - CONTINUED
FUEL TRANSFER PUMP MAINTENANCE (152 HP)
REMOVAL
TESTING
FUEL TRANSFER PUMP MAINTENANCE (165 HP)
TESTING FUEL TRANSFER PUMP PRESSURE AND FLOW
REMOVAL
REMOVAL
AIR CLEANER ASSEMBLY MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
DISASSEMBLY
ASSEMBLY
INSTALLATION
INSTALLATION
INSTALLATION - CONTINUED
AIR CLEANER INTAKE CAP REPLACEMENT
TURBOCHARGER ASSEMBLY REPLACEMENT (152 HP)
TURBOCHARGER ASSEMBLY REPLACEMENT (165 HP)
REMOVAL
INSTALLATION
TURBOCHARGER AIR LINES REPLACEMENT (152 HP)
REMOVAL
INSTALLATION
TURBOCHARGER AIR HOSES AND TUBES REPLACEMENT (165 HP)
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
TURBOCHARGER OIL LINES REPLACEMENT (152 HP)
INSTALLATION
TURBOCHARGER OIL HOSES AND TUBES REPLACEMENT (165 HP)
REMOVAL
FUEL/HYDRAULIC TANK SERVICE
SERVICE BY DRAINING AND FILLING TANK WITH FUEL
FUEL STRAINER ASSEMBLY MAINTENANCE
SERVICE
HIGH PRESSURE FUEL LINES REPLACEMENT (152 HP)
REMOVAL
INSTALLATION
HIGH PRESSURE FUEL HOSES AND TUBES REPLACEMENT (165 HP)
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
FUEL DRAIN LINES AND MANIFOLD REPLACEMENT (152 HP)
REMOVAL
INSTALLATION
FUEL DRAIN TUBES AND MANIFOLD REPLACEMENT (165 HP)
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
FUEL SUPPLY LINES REPLACEMENT (152 HP)
REMOVAL
INSTALLATION
FUEL SUPPLY HOSES AND TUBES REPLACEMENT (165 HP)
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
FUEL/WATER SEPARATOR REPLACEMENT (152 HP)
REMOVAL
INSTALLATION - CONTINUED
FUEL/WATER SEPARATOR REPLACEMENT (165 HP)
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
FUEL FILTER AND HEAD MAINTENANCE (152 HP)
SERVICE
SERVICE
INSTALLATION
FUEL FILTER AND HEAD MAINTENANCE (165 HP)
SERVICE
SERVICE - CONTINUED
REMOVAL
REMOVAL - CONTINUED
ETHER START HOSE AND ATOMIZER REPLACEMENT
REMOVAL
ETHER START CARTRIDGE REPLACEMENT
REMOVAL
ETHER START THERMOSTAT REPLACEMENT
REMOVAL
OETHER START CARTRIDGE MOUNTING BRACKET REPLACEMENT
ACCELERATOR CABLE MAINTENANCE (152 HP)
REMOVAL
ADJUSTMENT
ADJUSTMENT
ACCELERATOR CABLE MAINTENANCE (165 HP)
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
ADJUSTMENT
ACCELERATOR PEDAL ASSEMBLY MAINTENANCE
DISASSEMBLY
ASSEMBLY
MUFFLER AND TAILPIPE REPLACEMENT
INSTALLATION
EXHAUST PIPE REPLACEMENT
RADIATOR MAINTENANCE
SERVICE
SERVICE - CONTINUED
REMOVAL
REMOVAL - CONTINUED
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
PRESSURE TESTING COOLING SYSTEM
COOLANT OVERFLOW TANK REPLACEMENT
INSTALLATION
THERMOSTAT AND WATER OUTLET REPLACEMENT
REMOVAL
INSTALLATION
RADIATOR HOSES MAINTENANCE
INSTALLATION
WATER INLET MAINTENANCE
WATER PUMP REPLACEMENT
ENGINE COOLING FAN REPLACEMENT
REMOVAL
INSTALLATION
ENGINE COOLING FAN GUARDS REPLACEMENT
INSTALLATION
DRIVE BELT AND TENSIONER REPLACEMENT
INSTALLATION
ALTERNATOR AND ALTERNATOR PULLEY REPLACEMENT (152 HP)
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
ALTERNATOR AND ALTERNATOR PULLEY REPLACEMENT (165 HP)
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
STARTING MOTOR REPLACEMENT (152 HP)
REMOVAL
INSTALLATION
STARTING MOTOR REPLACEMENT (165 HP)
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
NEUTRAL SAFETY SWITCH MAINTENANCE
REMOVAL
INSTRUMENT PANELS REPLACEMENT
REMOVAL
INSTALLATION
GAUGES REPLACEMENT
REMOVAL
TOGGLE AND PUSHBUTTON SWITCHES REPLACEMENT
REMOVAL
INSTALLATION
HOURMETER REPLACEMENT
INSTALLATION
CIRCUIT BREAKERS REPLACEMENT
REMOVAL
INSTALLATION
STARTER SWITCH REPLACEMENT
REMOVAL
ENGINE OIL PRESSURE SWITCH MAINTENANCE (152 HP)
ENGINE OIL PRESSURE SWITCH MAINTENANCE (165 HP)
ENGINE WATER TEMPERATURE SWITCH REPLACEMENT
TRANSMISSION TEMPERATURE SWITCH REPLACEMENT
BRAKE HYDRAULIC PRESSURE SWITCH MAINTENANCE
REMOVAL
JOYSTICK HARNESS ASSEMBLY MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
TESTING
FORK AUTO LEVELER CIRCUIT BOARD MAINTENANCE
TESTING
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
FORK AUTO LEVELER SWITCH MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION
ADJUSTMENT
STARTER RELAY MAINTENANCE
REMOVAL
INSTALLATION
TESTING
EMERGENCY STEERING PUMP RELAY (PUMP-MOUNTED) MAINTENANCE
REMOVAL
TESTING
CONSOLE-MOUNTED RELAYS MAINTENANCE
REMOVAL
INSTALLATION
TESTING
TURN SIGNAL FLASHER REPLACEMENT
REMOVAL
BOOM ELECTRICAL JUNCTION BOX ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
STE/ICE-R RESISTOR ASSEMBLY REPLACEMENT
STE/ICE-R FUEL PRESSURE SENDER REPLACEMENT
STE/ICE-R FUEL FILTER DIFFERENTIAL PRESSURE SWITCH REPLACEMENT
REMOVAL
STE/ICE-R PULSE TACHOMETER AND DRIVE ASSEMBLY REPLACEMENT
REMOVAL
STE/ICE-R SHUNT REPLACEMENT
REMOVAL
INSTALLATION
HYDRAULIC BYPASS SWITCH MAINTENANCE
REMOVAL
INSTALLATION
TESTING
TESTING - CONTINUED
WARNING LIGHTS REPLACEMENT
REMOVAL
TURN SIGNAL SWITCH REPLACEMENT
INSTALLATION
BLACKOUT/SERVICE LIGHT SWITCH REPLACEMENT
INSTALLATION
FLOODLIGHTS AND SPOTLIGHTS MAINTENANCE
OFLOODLIGHTS AND SPOTLIGHTS MAINTENANCE - CONTINUED
REMOVAL OF CAB SPOTLIGHTS
INSTALLATION OF CAB SPOTLIGHTS - CONTINUED
BULB REPLACEMENT OF FLOODLIGHTS
BULB REPLACEMENT OF CAB SPOTLIGHTS
BLACKOUT HEADLIGHT MAINTENANCE
BULB REPLACEMENT
FRONT AND REAR COMPOSITE LIGHTS MAINTENANCE
REMOVAL
BULB REPLACEMENT
REAR TURN SIGNAL LIGHTS REPLACEMENT
REMOVAL
BULB REPLACEMENT
ENGINE OIL PRESSURE SENDER MAINTENANCE
REMOVAL
INSTALLATION
WATER TEMPERATURE SENDER REPLACEMENT
TRANSMISSION TEMPERATURE SENDER REPLACEMENT
FUEL LEVEL SENDER MAINTENANCE
CLEANING
BACK-UP ALARM REPLACEMENT
BACK-UP ALARM SWITCH MAINTENANCE
REMOVAL
ADJUSTMENT
HORN REPLACEMENT
BATTERIES MAINTENANCE
SERVICE
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
TESTING
BATTERY CABLES AND TERMINALS MAINTENANCE
SERVICE
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
BATTERY BOX AND COVER REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
CAB WIRING HARNESSES MAINTENANCE
REPAIR
INSTALLATION
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
MAIN WIRING HARNESS MAINTENANCE
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
BOOM ELECTRICAL CABLE MAINTENANCE
REPAIR
STE/ICE-R WIRING HARNESS MAINTENANCE
REMOVAL
INSTALLATION
SLAVE RECEPTACLE REPLACEMENT
REMOVAL
TRANSMISSION SHIFTER MAINTENANCE
REMOVAL
ADJUSTMENT
TRANSMISSION CABLE ASSEMBLY REPLACEMENT
INSTALLATION
TRANSMISSION DISCONNECT AND BRAKE PEDALS MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
ADJUSTMENT OF TRANSMISSION DISCONNECT PEDAL LINKAGE
ADJUSTMENT OF BRAKE PEDAL LINKAGE
TRANSMISSION DISCONNECT MASTER CYLINDER ASSEMBLY REPLACEMENT
REMOVAL
INSTALLATION
TRANSMISSION ASSEMBLY MAINTENANCE
SERVICE BY DRAINING AND FILLING TRANSMISSION WITH OIL
TRANSMISSION DRIVESHAFT ASSEMBLY MAINTENANCE
REMOVAL
ASSEMBLY
TRANSMISSION OIL FILTER HEAD ASSEMBLY REPLACEMENT
REMOVAL
TRANSMISSION OIL SAMPLING VALVE REPLACEMENT
TRANSMISSION CONTROL VALVE LINKAGE REPLACEMENT
INSTALLATION
TRANSMISSION BREATHER REPLACEMENT
PROPELLER SHAFTS, FRONT AND REAR DIFFERENTIAL MAINTENANCE
REMOVAL
DISASSEMBLY
ASSEMBLY
INSTALLATION
AXLE ASSEMBLIES SERVICE
SERVICE
PLANETARY WHEEL ENDS SERVICE
PARKING BRAKE ASSEMBLY REPLACEMENT
REMOVAL
INSTALLATION
PARKING BRAKE LEVER AND CABLE MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
ADJUSTMENT OF PARKING BRAKE CABLE
ADJUSTMENT OF PARKING BRAKE CABLE
BLEEDING BRAKE SYSTEM
BLEEDING
BRAKE SHOES MAINTENANCE
REMOVAL
INSPECTION
BRAKE CONTROL VALVE MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
ADJUSTMENT OF ACCUMULATOR CHARGING PRESSURE
BRAKE HYDRAULIC ACCUMULATOR MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
TESTING
BRAKE SYSTEM HOSES, LINES AND FITTINGS MAINTENANCE
REMOVAL
WHEEL ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
TIRES REPLACEMENT
DEMOUNTING
DEMOUNTING - CONTINUED
DEMOUNTING - CONTINUED
MOUNTING
MOUNTING - CONTINUED
STEERING WHEEL REPLACEMENT
STEERING COLUMN REPLACEMENT
INSTALLATION
TIE ROD ADJUSTMENT
ADJUSTMENT
ADJUSTMENT - CONTINUED
EMERGENCY STEERING PUMP REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
STEERING HOSES, LINES AND FITTINGS REPLACEMENT
REMOVAL
INSTALLATION
STEERING CYLINDERS REPLACEMENT
REMOVAL
INSTALLATION
STEERING CYLINDER BALL JOINT END CAP ASSEMBLIES REPLACEMENT
STEERING CONTROL VALVE REPLACEMENT
REMOVAL
STEERING SELECT VALVE MAINTENANCE
REMOVAL
DISASSEMBLY
COUNTERWEIGHT REPLACEMENT
REMOVAL
INSTALLATION
PINTLE HOOK MAINTENANCE
ASSEMBLY
ENGINE COVERS REPLACEMENT
REMOVAL
RADIATOR COVERS REPLACEMENT
ENGINE DOOR PANELS REPLACEMENT
REMOVAL
TRANSMISSION COVER REPLACEMENT
CAB DOORS MAINTENANCE
REMOVAL
REMOVAL
REPAIR
FIRE EXTINGUISHER BRACKET REPLACEMENT
TOOL BOX DOOR LATCH REPLACEMENT
CAB FLOOR MAT REPLACEMENT
FENDERS REPLACEMENT
REMOVAL
INSTALLATION
FENDER BRACES REPLACEMENT
INSTALLATION
CAB WINDSHIELD AND WINDOWS REPLACEMENT
INSTALLATION
CAB SKYLIGHT GUARD AND WINDOW REPLACEMENT
REMOVAL
INSTALLATION
CAB REAR WINDOW REPLACEMENT
INSTALLATION
SEAT MAINTENANCE
REMOVAL
CLEANING
SEAT BELTS REPLACEMENT
ACCESSORIES STORAGE BOX REPLACEMENT
FRONT WINDSHIELD WIPER ASSEMBLY MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
DISASSEMBLY
INSTALLATION
INSTALLATION - CONTINUED
REAR WINDSHIELD WIPER ASSEMBLY REPLACEMENT
INSTALLATION
WINDSHIELD WASHER ASSEMBLY MAINTENANCE
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
MIRROR REPLACEMENT
REMOVAL AND INSTALLATION OF MIRROR ASSEMBLY
REMOVAL AND INSTALLATION OF MIRROR FACE
CAB DEFROSTER FANS REPLACEMENT
REMOVAL
CAB HEATER REPLACEMENT
REMOVAL
HEATER TEMPERATURE CONTROL VALVE AND CABLE REPLACEMENT
REMOVAL
HEATER HOSES, LINES AND FITTINGS REPLACEMENT
REMOVAL
INSTALLATION
DATA PLATES REPLACEMENT
HYDRAULIC SYSTEM MAINTENANCE
PURGING AIR FROM PISTON PUMP AND TANDEM GEAR PUMP
PURGING AIR FROM PISTON PUMP AND TANDEM GEAR PUMP - CONTINUED
PURGING AIR FROM PISTON PUMP AND TANDEM GEAR PUMP - CONTINUED
TANDEM GEAR PUMP REPLACEMENT
REMOVAL
INSTALLATION
PISTON PUMP REPLACEMENT
REMOVAL
REMOVAL
INSTALLATION
INSTALLATION
INSTALLATION - CONTINUED
MAIN CONTROL VALVE MAINTENANCE
REMOVAL
INSTALLATION
ADJUSTMENT OF MAIN RELIEF VALVE
ADJUSTMENT OF MAIN RELIEF VALVE - CONTINUED
ADJUSTMENT OF BOOM EXTEND RELIEF VALVE - CONTINUED
ADJUSTMENT OF BOOM HOIST RELIEF VALVE
ADJUSTMENT OF BOOM LOWER RELIEF VALVE
MLRS ATTACHMENT CONTROL VALVE ASSEMBLY REPLACEMENT
REMOVAL
REMOVAL
INSTALLATION
PRIORITY VALVE REPLACEMENT
REMOVAL
INSTALLATION
RELIEF VALVE, FRAME TILT/BRAKES REPLACEMENT
REMOVAL
TESTING AND ADJUSTMENT
SHUTTLE VALVE REPLACEMENT
REMOVAL
INSTALLATION
FRAME TILT VALVE REPLACEMENT
REMOVAL
REMOVAL
HYDRAULIC JOYSTICK CONTROL VALVE REPLACEMENT
REMOVAL
INSTALLATION
BOOM CYLINDER FLOW CONTROL VALVE REPLACEMENT
REMOVAL
INSTALLATION
FRAME TILT CYLINDER REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
CARRIAGE TILT CYLINDER REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
MLRS ATTACHMENT CYLINDER REPLACEMENT
REMOVAL
INSTALLATION
INSTALLATION - CONTINUED
FORKS REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
FORK BUSHINGS REPLACEMENT
INSTALLATION
MLRS ATTACHMENT REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
BOOM PIVOT PINS SERVICE
BOOM WEAR PADS INSPECTION
INSPECTION
INSPECTION
BOOM HOSE PULLEY REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
INSTALLATION - CONTINUED
BOOM CHAIN PULLEYS REPLACEMENT
REMOVAL OF RETRACT CHAIN PULLEY
INSTALLATION OF RETRACT CHAIN PULLEY
REMOVAL OF EXTEND CHAIN PULLEY
REMOVAL OF EXTEND CHAIN PULLEY - CONTINUED
BOOM EXTEND AND RETRACT CHAINS SERVICE
INSPECTION AND ADJUSTMENT
BOOM HYDRAULIC HOSES AND ELECTRICAL CABLE TENSION MAINTENANCE
CHECKING AND ADJUSTING
CHECKING AND ADJUSTING - CONTINUED
HYDRAULIC HOSES, LINES AND FITTINGS REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
REMOVAL - CONTINUED
INSPECTION
HYDRAULIC TUBING REPLACEMENT
REMOVAL
HYDRAULIC OIL SAMPLING VALVE REPLACEMENT
HYDRAULIC OIL STRAINERS MAINTENANCE
SERVICE
HYDRAULIC OIL FILTER REPLACEMENT
REMOVAL
FORK SIDESHIFT CYLINDERS REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
BOOM HOIST CYLINDERS REPLACEMENT
REMOVAL
REMOVAL - CONTINUED
INSTALLATION
HYDRAULIC OIL SIGHT GAUGES REPLACEMENT
AIR CLEANER RESTRICTION INDICATOR REPLACEMENT
PREPARATION FOR SHORT-TERM STORAGE
INTRODUCTION
INTRODUCTION
INTRODUCTION
INTRODUCTION
INTRODUCTION
CHAPTER 7 SUPPORTING INFORMATION
PUBLICATION INDEXES
TECHNICAL MANUALS
THE ARMY MAINTENANCE SYSTEM MAC
EXPLANATION OF COLUMNS IN THE MAC, TABLE 1
EXPLANATION OF COLUMNS IN THE TOOLS AND TEST EQUIPMENT REQUIREMENTS, TABLE 2
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Table 1. MAC for the 6K Forklift
Table 1. MAC for the 6K Forklift - Continued
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 1. MAC for the 6K Forklift - Continued.
Table 2. Tools and Test Equipment Requirements for The 6K Forklift.
Table 2. Tools and Test Equipment Requirements for The 6K Forklift - Continued.
Table 2. Tools and Test Equipment Requirements for The 6K Forklift - Continued.
Table 3. Remarks for the 6K Forklift.
EXPENDABLE AND DURABLE ITEMS LIST
Table 1. Expendable and Durable Items List-cont.
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
Table 1. Expendable and Durable Items List - Continued.
TOOL IDENTIFICATION LIST
Table 1. Tool Identification List for the 6K Forklift.
Table 1. Tool Identification List for the 6K Forklift - Continued.
Table 1. Tool Identification List for the 6K Forklift - Continued.
ILLUSTRATED LIST OF MANUFACTURED ITEMS
Main Wiring Harness.
MAIN WIRING HARNESS - CONTINUED
Table 1. Wire List.
Table 1. Wire List - Continued.
Table 1. Wire List - Continued.
Table 1. Wire List - Continued.
Table 1. Wire List - Continued.
CAB WIRING HARNESS
CAB WIRING HARNESS - CONTINUED
CAB WIRING HARNESS - CONTINUED
CAB WIRING HARNESS - CONTINUED
CAB WIRING HARNESS - CONTINUED
Table 2. Wire List
Table 2. Wire List - Continued.
Table 2. Wire List - Continued.
Table 2. Wire List - Continued.
Table 2. Wire List - Continued.
Table 2. Wire List - Continued.
Table 2. Wire List - Continued.
Table 2. Wire List - Continued.
STE/ICE-R WIRING HARNESS
Table 3. Wire List
Table 3. Wire List - Continued.
Table 3. Wire List - Continued.
Electric Joystick.
Table 4. Wire List
Boom Electrical Cable
Tandem Gear Pump Seal Removal Tool
Tandem Gear Pump Drive Gear Installation Tool
Differential Resistance Tool.
Planetary Hub Drag Tool
Planetary Hub Drag Tool-CONT.
YOKE
TRANSMISSION ALIGNMENT BARS
Bearing Removal/Installation Tool
HYDRAULIC PISTON PUMP
Shaft Seal Driver
Valve Block Bearing Race Removal Tool
Valve Block Bearing Race Removal Tool-C0NT.
Valve Block Bearing Race Installation Tool.
6000M EPA ENGINE RETROFIT INSTALLATION INSTRUCTIONS
ENGINE OIL PRESSURE SENDER REPLACEMENT (new engine)
ENGINE OIL PRESSURE SWITCH REPLACEMENT (new engine)
STE/ICE FUEL PRESSURE SENDER AND STE/ICE FUEL FILTER DIFFERENTIAL PRESSURE SWITCH REPLACEMENT
STE/ICE FUEL PRESSURE SENDER AND STE/ICE FUEL FILTER DIFFERENTIAL PRESSURE SWITCH REPLACEMENT
FUEL DRAIN TUBE REPLACEMENT
AIR CLEANER REPLACEMENT/REPAIR
ENGINE WATER TEMPERATURE SWITCH REPLACEMENT (new engine)
FUEL TRANSFER PUMP REPLACEMENT (new engine)
TURBOCHARGER AIR HOSE AND TUBES REPLACEMENT (new engine)
ACCELERATOR BRACKET AND CABLE REPLACEMENT (new engine)
EPA ENGINE STARTER REPLACEMENT (new engine is not supplied with a starter)
EPA ENGINE HARNESS RETROFIT REPLACEMENT (new engine)
ETHER START ATOMIZER REPLACEMENT (new engine)
ELECTRICAL SCHEMATIC
INDEX
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
INDEX - Continued
THE METRIC SYSTEM AND EQUIVALENTS
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TM-10-3930-660-24-1
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RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
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REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOG/SUPPLY MANUALS
RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
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REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOG/SUPPLY MANUALS
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REPAIR PARTS AND SPECIAL TOOL LISTS AND SUPPLY CATALOG/SUPPLY MANUALS
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RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
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RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
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RECOMMENDED CHANGES TO PUBLICATIONS AND BLANK FORMS
Distribution
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