TM 10-3930-609-12 MANUAL

DEPARTMENT OF THE ARMY TECHNICAL

OPERATOR AND ORGANIZATIONAL

MAINTENANCE MANUAL

TRUCK, FORK, LIFT, ELECTRIC, SOLID RUBBER TIRES,

2,000 LBS CAPACITY, 144 IN. LIFT,
BAKER MODEL FTD-020-EE-SS, ARMY MODEL MHE-204,
FSN 3930-935-7864

HEADQUARTERS, DEPARTMENT OF THE ARMY

MAY 1969
 SAFETY PRECAUTIONS
BEFORE OPERATION
When servicing battery, do not smoke or use flame in the vicinity. Batteries generate hydrogen,
a highly explosive gas.
Avoid contact with the battery electrolyte. If the solution comes in contact with the skin, rinse
the area immediately with clean water to avoid skin burns.
Check equipment logbook for record of proper servicing and maintenance.
Check the operating area to be sure it is clear of personnel and obstructions.

DURING OPERATION
Be alert for other workers to be sure they are not in the way of the load or the moving truck.
Be sure there is sufficient clearance overhead and on each side of the truck.
Always travel with the mast tilted back and with forks raised just high enough to clear any un-
even floor conditions.
Avoid sudden starting and stopping of the truck. Reduce speed when making a turn.
Face in the direction of travel.
Know the rated capacity of the truck and do not overload it. Never pick up a load until certain
it can be carried safely.
Make sure the load is steady before lifting it and keep the load against the carriage backrest.
When transporting bulky loads, travel in reverse. Always descend ramps in reverse when carry-
ing a load.
When unloading a heavy elevated load, position the load directly over the unloading spot, as low
as possible, before tilting the mast forward.
Be very careful when high-tiering.
Do not butt loads with the forks or with the rear of the truck.
Report any evidence of faulty truck performance.

AFTER OPERATION
Make sure forks are lowered to the ground and handbrake is engaged firmly.
If truck is parked on an incline, block at least two wheels in the event of handbrake failure.
 Changes in force: C1, C2, and C3

TM 10-3930-609-12
C3
CHANGE HEADQUARTERS
No. 3 DEPARTMENT OF THE ARMY
Washington D.C., 22 March 1991

Operator’s and Organizational Maintenance Manual

TRUCK, FORK LIFT, ELECTRIC, SOLID RUBBER TIRES,
2,000-LB CAPACITY, 144-INCH LIFT,
BAKER MODEL FTD-020-EE-SS,
ARMY MODEL MHE-204,
NSN 3930-00-935-7864

TM 10-3930-609-12, 21 May 1969, is changed as follows:

Page 1-1. mand, ATTN: AMSTA-MP, Warren, MI
Paragraph 1-1. Change “Federal Stock Number 48397-5000. We’ll send you a reply.
3930-935-7864” to “National Stock Number Page 2-1.
3930-00-935-7864”. Paragraph 2-3b(2). Change “TM 38-750” to
Paragraph 1-2 is superseded as follows: “DA Pam 738-750”.
1-2. Maintenance Forms, Records, and Reports Paragraph 2-4e. Change “TM 10-1690A” to
“TM 10-6140-200-14”.
Maintenance forms, records, and reports which are to
be used by maintenance personnel at all maintenance Page 2-6, paragraph 2-23. Change “TB 5-4200-
levels are listed in and prescribed by DA Pam 200-10” to “TB 5-4200-200-100”.
738-750. Page 3-3, Table 3-1. Add Item number: 17; Interval:
Paragraph 1-3 is superseded as follows: Monthly; Item to be inspected: Seat, overhead guard,
1-3. Reporting Errors and Recommending and access covers; Procedure: Check for damage to
Improvements seat, overhead guard, and all access covers. Tighten
any loose component.
You can help improve this manual. If you find any
Page 3-17. Paragraph 3-31.1 is added after paragraph
mistakes or if you know of a way to improve the
3-31.
procedures, please let us know. Mail your letter or DA
Form 2028 (Recommended Changes to Publications 3-31.1. Wheel Cylinders
and Blank Forms) direct to: Commander, U.S. Army a. Removal.
Tank-Automotive Command, ATTN: AMSTA-MB, (1) Remove brakeshoes (para 3-30c).
Warren, MI 48397-5000. A reply will be furnished to (2) Disconnect both brake tubing from adapt-
you. ers on wheel cylinder. Use care to prevent kinking or
Paragraph 1-3.1 is added after paragraph 1-3. denting tubing, and to avoid entrance of foreign mat-
1-3.1. Reporting Equipment Improvement ter.
Recommendations (EIRs) (3) Remove bolts and washers that secure
wheel cylinders to backing plates. Remove wheel cyl-
If your fork lift needs improvement, let us know. Send
inders.
us an EIR. You, the user, are the only one who can tell
b. Installation. Reverse procedure in a above.
us what you don’t like about your equipment. Let us
know why you don’t like the design. Tell us why a Page 3-23. Paragraphs 3-47 through 3-49 are re-
procedure is hard to perform. Put it on an SF 368 scinded.
(Quality Deficiency Report). Mail it to us at: Page 3-24. Paragraph 3-50 and figure 3-16 are re-
Commander, U.S. Army Tank-Automotive Com- scinded.

1
Page 3-25. Paragraph 3-52 is superseded as follows: b. Repair. Repair by replacing knob, lever, or
3-52. Directional Control Switch Lever mounting hardware.
a. Removal. If knob is damaged, unscrew and re- c. Installation. Reverse procedure in a above.
move from lever. To remove lever, remove screw and Page A-1. Appendix A is superseded as follows:
lockwasher.

APPENDIX A
REFERENCES

A-1. Fire Protection

TB 5-4200-200-100 Hand Portable Fire Extinguishers Approved for Army Users
A-2. Lubrication
LO 10-3930-609-12 Lubrication Order

A-3. Painting
TM 43-0139 Painting Instructions for Field Use

A-4. Radio Interference Suppression

FM 11-65 High Frequency Radio Communications
A-5. Maintenance
DA Pam 738-750 The Army Maintenance Management System (TAMMS)
TM 9-6140-200-14 Operator’s, Organizational, Direct Support and General Support Maintenance
Manual for Lead-Acid Storage Batteries
TM 10-6140-200-14 Installation, Use, Maintenance, and Repair of Industrial Motive Power Storage
Batteries for Materials Handling Equipment
TM 10-3930-609-20P Organizational Maintenance Repair Parts and Special Tools Lists
A-6. Shipment and Storage
TB 740-93-2 Preservation of USAMEC Mechanical Equipment for Shipment and Storage
TM 740-90-1 Administrative Storage of Equipment
TM 38-230 Packaging of Material: Preservation

MIL-STD-129 Marking for Shipment and Storage

Page C-1. Appendix C is superseded as follows:

APPENDIX C
MAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION
C-1. General b. The Maintenance Allocation Chart (MAC) in
a. This section provides a general explanation of all Section II designates overall authority and responsibil-
maintenance and repair functions authorized at the ity for the performance of maintenance functions on
various maintenance levels. the identified end item or component. The application

2
of the maintenance functions to the end item or com- cific damage, fault, malfunction, or failure in a part,
ponent will be consistent with the capacities and subassembly, module (component or assembly), end
capabilities of the designated maintenance levels. item, or system.
c. Section III lists the tools and test equipment j. Overhaul. That maintenance effort (service/ac-
(both special tools and common tool sets) required for tion) prescribed to restore an item to a completely
each maintenance function as referenced from Sec- serviceable/operational condition as required by
tion II. maintenance standards in appropriate technical publi-
d. Section IV contains supplemental instructions cations (i.e., DMWR). Overhaul is normally the
and explanatory notes for a particular maintenance highest degree of maintenance performed by the
function. Army. Overhaul does not normally return an item to
like new condition.
C-2. Maintenance Functions
k. Rebuild. Consists of those services/actions nec-
Maintenance functions will be limited to and defined essary for the restoration of unserviceable equipment
as follows: to a like new condition in accordance with original
manufacturing standards. Rebuild is the highest de-
a. Inspect. To determine the serviceability of an
gree of materiel maintenance applied to Army
item by comparing its physical, mechanical, and/or equipment. The rebuild operation includes the act of
electrical characteristics with established standards returning to zero those age measurements (hours/
through examination (e.g., by sight, sound, or feel). miles, etc.) considered in classifying Army
b. Test. To verify serviceability by measuring the equipment/components.
mechanical, pneumatic, hydraulic, or electrical char-
acteristics of an item and comparing those C-3. Explanation of Columns in the MAC,
characteristics with prescribed standards. Section II
c. Service. Operations required periodically to a. Column 1, Group Number. Column 1 lists func-
keep an item in proper operating condition, i.e., to tional group code numbers, the purpose of which is to
clean (includes decontaminate, when required), to identify maintenance significant components, assem-
preserve, to drain, to paint, or to replenish fuel, lubri- blies, subassemblies, and modules with the next higher
cants, chemical fluids, or gases. assembly. End item group number shall be “00.”
d. Adjust. To maintain or regulate, within pre- b. Column 2, ComponentlAssembly. Column 2
scribed limits, by bringing into proper or exact contains the names of components, assemblies, subas-
position, or by setting the operating characteristics to semblies. and modules for which maintenance is
specified parameters. authorized.
e. Aline. To adjust specified variable elements of c. Column 3, Maintenance Function. Column 3
an item to bring about optimum or desired perform- lists the functions to be performed on the item listed in
ance. Column 2. (For a detailed explanation of these func-
f. Calibrate. To determine and cause corrections tions, see paragraph C-2.)
to be made or to be adjusted on instruments or test, d. Column 4, Maintenance Level. Column 4 speci-
measuring, and diagnostic equipments used in preci- fies, by the listing of a work time figure in the
sion measurement. Consists of comparisons of two appropriate subcolumn(s), the level of maintenance
instruments, one of which is a certified standard of authorized to perform the function listed in Column 3.
known accuracy, to detect and adjust any discrepancy This figure represents the active time required to per-
in the accuracy of the instrument being compared. form that maintenance function at the indicated level
g. Remove/Install. To remove and install the same of maintenance. If the number or complexity of the
item when required to perform service or other main- tasks within the listed maintenance function vary at
tenance functions. Install may be the act of different maintenance levels, appropriate work time
emplacing, seating, or fixing into position a spare, re- figures will be shown for each level. The work time
pair part, or module (component or assembly) in a figure represents the average time required to restore
manner to allow the proper functioning of an equip- an item (assembly, subassembly, component, module,
ment or system. end item, or system) to a serviceable condition under
h. Replace. To remove an unserviceable item and typical field operating conditions. This time includes
install a serviceable counterpart in its place. “Re- preparation time (including any necessary disassem-
place” is authorized by the MAC and is shown as the bly/assembly time), troubleshooting/ fault location
third position of the SMR code. time, and quality assurance/quality control time in ad-
i. Repair. The application of maintenance serv- dition to the time required to perform the specific
ices, including fault location/troubleshooting, tasks identified for the maintenance functions author-
removal/installation, and disassembly/assembly proce- ized in the Maintenance Allocation Chart. The
dures, and maintenance actions to identify troubles symbol designations for the various maintenance lev-
and restore serviceability to an item by correcting spe- els are as follows:

3
 C ......... Operator or Crew correlates with a code used in the MAC, Section II,
O ........... Organizational Maintenance Column 5.
F ............ Direct Support Maintenance b. Column 2, Maintenance Level. The lowest level
H ........... General Support Maintenance of maintenance authorized to use the tool or test
equipment.
D ........... Depot Maintenance c. Column 3, Nomenclature. Name or identifica-
e. Column 5, Tools and Equipment. Column 5 tion of the tool or test equipment.
specifies, by code, those common tool sets (not indi- d. Column 4, National/NATO Stock Number. The
vidual tools) and special tools, TMDE, and support National or NATO Stock Number of the tool or test
equipment required to perform the designated func- equipment.
tion. e. Column 5, Tool Number. The manufacturer’s
f. Column 6, Remarks. This column shall, when part number.
applicable, contain a letter code, in alphabetic order,
which shall be keyed to the remarks contained in Sec- C-5. Explanation of Columns in Remarks,
tion IV. Section IV
C-4. Explanation of Columns in Tool and Test a. Column 1, Reference Code. The code recorded
in Column 6, Section II.
Equipment Requirements, Section III
b. Column 2, Remarks. This column lists informa-
a. Column I, Tool or Test Equipment Reference tion pertinent to the maintenance function being
Code. The tool and test equipment reference code performed as indicated in the MAC, Section II.

Section II. MAINTENANCE ALLOCATION CHART

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remark
06 ELECTRICAL SYSTEM
0606 Seat Switch Inspect 0.1
Adjust 1.0
Replace 1.5
0609 Lights
Lamps Inspect 0.1
Replace 0.4
Stoplight, Taillight, Inspect 0.1
Headlight Replace 0.4
Repair 0.2
0611 Horn
Button, Horn Replace 0.2
Repair 0.4
Horn Assembly Test 0.1
Replace 0.4
Contact Assembly Inspect 0.2
Replace 1.0
Repair 0.4

4
 Section II. MAINTENANCE ALLOCATION CHART - Continued

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remarks
0612 Batteries, Storage Inspect 0.2
Test 0.4
Service 0.4
Replace 0.4
Repair 8.0

Receptacle, Charging Inspect 0.1

Replace 0.5

10 FRONT AXLE
1000 Front Axle Assembly Inspect 0.1
Service 0.4
Replace 4.0
Repair 8.0
Overhaul 8.0

1003 Final Drive

Input Case Assembly Replace 6.0
Repair 3.0

11 REAR AXLE
1100 Rear Axle Assembly Inspect 0.2
Adjust 1.0
Replace 4.0
Repair 4.0

Bearing, Bell Crank Inspect 2.0

Replace 2.5
Bell Crank Inspect 2.0
Replace 2.0
1102 Differential Inspect 1.0
Service 0.4
Replace 4.0
Repair 8.0

12 BRAKES
1201 Hand Brakes
Brake Shoe Assembly, Inspect 1.0
Motor Adjust 1.4
Replace 2.0
Repair 1.0

5
 Section II. MAINTENANCE ALLOCATION CHART - Continued

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remarks
1201 Hand Brakes (Con’t)
Cable, Hand Brake Inspect 0.1
Adjust 0.5
Replace 0.5
Control, Linkage Adjust 0.5
Replace 0.5
Drum, Brake Replace 2.0
Lever, Hand Brake Inspect 0.1
Replace 0.4
1202 Service Brakes
Brake Shoe Assembly Inspect 0.5
Adjust 0.8
Replace 1.0
Repair 1.0
1204 Hydraulic Brake System
Master Cylinder Inspect 0.1
Service 0.3
Replace 1.0
Tube Assembly, Metal Inspect 0.5
Replace 0.5
Wheel, Cylinder Inspect 1.0
Replace 1.0
1206 Mechanical Brake Sys-
tem
Pedal, Brake Replace 0.4

13 WHEELS
1311 Wheel Assembly
Bearings and Seals, Inspect 0.5
Rear Wheels Service 0.8
Adjust 0.5
Replace 0.8
Wheel Assembly, Inspect 0.2
Steering Axle Align 0.6
Replace 0.3
Repair 1.0

6
 Section II. MAINTENANCE ALLOCATION CHART - Continued

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remarks
1311 Wheel Assembly (Con‘t)
Wheel, Solid Rubber,
Drive Axle Replace 1.5
1313 Tires Inspect 0.1
Replace 1.0

14 STEERING
1401 Mechanical Steering
Gear Assembly
Drag Link Inspect 0.2
Service 0.3
Adjust 0.5
Replace 1.0
Rod Assembly, Tie Service 0.3
Adjust 0.4
Replace 1.0
Repair 1.0
Steering Gear Assembly Service 0.4
Adjust 0.8
Replace 2.0
Repair 4.0
Wheel, Steering Replace 0.4

18 BODY, CAB AND HOOD

1801 Body, Cab and Hood
Assemblies
Covers and Doors Inspect 0.1
Replace 0.1
Overhead Guard Inspect 0.5
Replace 0.5
1806 Upholstery Seats Inspect 0.1
Replace 0.4
Repair 0.5

7
 Section II. MAINTENANCE ALLOCATION CHART - Continued

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remarks
22 BODY CHASSIS AND
ACCESSORY ITEMS
2210 Data Plates and
Instruction Holders Replace 0.2

24 HYDRAULIC AND FLUID

SYSTEMS
2401 Pump and Motor
Pump, Rotary, Power Inspect 1.0
Driven, Hydraulic Replace 1.0
Repair 2.5
Motor, Direct Current, Inspect 2.0
Hydraulic Pump Test 1.0
Replace 2.0
Repair 3.0
Overhaul 4.0
2402 Control Valves
Valve, Directional Inspect 0.8
Control Test 1.0
Replace 0.8
Repair 2.0
2403 Hydraulic Controls
Bracket, Valve Lever Replace 0.5
Levers, Control Replace 0.4
2404 Tilt Cylinders Inspect 0.1
Test 0.2
Replace 0.5
Repair 1.5
2405 Mast Column
Chain Assembly Inspect 0.2
Service 0.2
Adjust 0.4
Replace 0.5
Cross Head Replace 1.5

8
 Section II. MAINTENANCE ALLOCATION CHART - Continued

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remarks
2405 Mast Column (Con’t)
Cylinder Assembly, Inspect 0.1
Hoist Actuating Replace 1.5
Repair 1.5
Forks Replace 0.2
Roller, Carriage Replace 1.5
Upright Assembly Inspect 0.1
Service 0.3
Replace 2.0
Repair 4.0
Lift Carriage Replace 4.5
Repair 1.0
2406 Filters, Lines and fit-
tings
Hydraulic Oil Filter Replace 0.2
Repair 0.5
Filter Element Replace 0.2
Hose Assemblies, Inspect 0.1
Rubber Replace 0.4
Repair 0.4
Valve, Bypass Replace 0.6
2408 Liquid Tanks
Tank, Oil Inspect 0.1
Service 0.1
Replace 0.8
Repair 1.5

40 ELECTRIC MOTORS
AND GENERATORS

4000 Motor Generator and Ro-

tating Exciter Assemblies
Motor Assembly, Travel Inspect 4.0
Test 1.5
Replace 4.0
Repair 8.0
Overhaul 8.0

9
 Section II. MAINTENANCE ALLOCATION CHART - Continued

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remarks
4009 Control Panels, Housing
Cubicles
Electrical Wiring Inspect 1.2
Test 1.0
Replace 2.0
Dash Panel,
Instrumentation Replace 0.4
4010 Master or Auxiliary Con-
trol Assembly
Control Panel Replace 0.5
Repair 1.0
Potentiometer Inspect 1.0
Replace 0.4
Control, Accelerator Inspect 1.0
Replace 0.8
Repair 2.0
Switch, Sensitive Replace 1.2
SCR Panel Replace 1.0
Repair 4.0
Fuse, Cartridge inspect 0.1
Replace 0.2
Fuse Holder Replace 0.4
Link, Fuse Replace 0.8
4011 Circuit Breakers, Cut-
outs, Fuse and Fuse
Holders
Switch, Battery
Disconnect Replace 1.0
4012 Switches
Lever, Switch Inspect 0.1
Adjust 0.2
Replace 0.2
Repair 0.5
Switch, Directional Inspect 0.8
Control Replace 0.5
Repair 0.8

10
 Section II. MAINTENANCE ALLOCATION CHART - Continued

(1) (2) (3) (4) (5) (6)

Maintenance Level
Group Maintenance Tools and
Number Component/Assembly Function C O F H D Equipment Remarks
4015 Relay or Assembly
Relays, Armature Inspect 0.4
Test 0.5
Replace 0.5
Contacts, Relay Inspect 0.4
Replace 0.4
Relay, Thermal Inspect 0.4
Test 0.4
Replace 0.4
Repair 1.0
4019 Radio interference
Suppression Replace 1.0

Section Ill. TOOL AND TEST EQUIPMENT REQUIREMENTS

Not Applicable.
Section IV. REMARKS
Not Applicable.

Page I-1. Before Reporting of equipment manual improve-

Change “Directional control switch” to "Directional ments, add “Reporting equipment improvement
control switch lever”. recommendations, paragraph 1-3.1, page 1-1”.
Change “Maintenance forms and records” to Change “Reporting of equipment manual improve-
“Maintenance forms, records, and reports”. ments” to “Reporting errors and recommending
Page I-2. improvements”.
Delete the entry for “Motor brush replacement”. After Wheel alinement measurement, add “Wheel
Delete the entry for “Relay contact replacement”. cylinder, paragraph 3-31.1, page 3-17”.
Delete the entry for “Relay interlock switch replace-
ment”.

11
 By Order of the Secretary of the Army:
CARL E. VUONO
General, United States Army
Chief of Staff
Official:

PATRICIA P. HICKERSON
Colonel, United States Army
The Adjutant General

Distribution:
To be distributed in accordance with DAForm 12-25-E, block 2116, Operator and Unit
maintenance requirements for TM 10-3930-609-12.

12 :: U.S. GOVERNMENT PRINTING OFFICE 1991 — 543-025 40028

PIN: 028289-003
 TM 10-3930-609-12
C 2

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
No. 2 WASHINGTON, DC, 7 February 1980

Operator and Organizational

Maintenance Manual

TRUCK, FORK LIFT, ELECTRIC, SOLID RUBBER TIRES, 2000 LBS CAPACITY, 144 IN LIFT,
BAKER MODEL FTD-020-EE-SS, ARMY MODEL MHE-204, NSN 3930-00-935-7864.

TM 10-3930-609-12, 21 May 1969, is changes as follows.

Page 3-2, paragraph 3-6. Add the following before paragraph 3-6.

WARNING
Insure that static electricity discharge straps are installed on the forklift truck and are
in good condition. Failure to use the straps could result in the generation of a spark
which could ignite explosives or flammables.

By Order of the Secretary of the Army:

E. C. MEYER
General, United States Army
Official: Chief of Staff

J. C. PENNINGTON
Major General, United States Army
The Adjutant General

Distribution:
To be distributed in accordance with DA Form 12-25A, Organizational maintenance requirements for
Warehouse Equipment.

*U.S. GOVERNMENT PRINTING OFFICE: 1980-665-119/178

 TM 10-3930-609-12
C1

CHANGE HEADQUARTERS
DEPARTMENT OF THE ARMY
No. 1 WASHINGTON, D.C., 30 March 1972

Operator and Organizational

Maintenance Manual

TRUCK, FORK, LIFT, ELECTRIC, SOLID RUBBER TIRES,

2000 LBS CAPACITY, 144 IN. LIFT,
BAKER MODEL FTD-O20-EE-SS, ARMY MODEL MHE-204
FSN 3930-935-7864

TM 10-3930-609-12 21 May 1969, is changed c. Maintenance and Operating Supplies. For a

as folIows: listing of maintenance and operating supplies
Page 2-1. Paragraph 2-3c is added as fol-
lows: required for initial operation, refer to table 2-1.

1
 C1, TM 10-3930-609-12
Table 2-1 Maintenance and Operating Supplies

(1) (2) (3) (4) (5) (6)

Component Federal Description Quantity Quantity Notes
application stock No. required required
F/initial F/8 hrs
operation operation

BRAKE MASTER BRAKE FLUID, AUTO- (1) See C9100-IL for

CYLINDER MOTIVE: gal can as additional data and req-
follows uisitioning procedure.
9150-231-9071(1) HB 1 pt (2) (2) See current LO for
grade, application and
replenishment intervals.
DIFFERENTIAL LUBRICATING OIL,
DRIVE AXLE GEAR: 5 gaI drum
as follows:
9150-577-5844(1) GO-90 1 qt (2)
9150-257-5440(1) GOS 20 qt (2)
HYDRAULIC OIL, LUBRICATING :
SYSTEM 5 gaI pails as follows:
9150-265-9428(1) OE-10 1 qt (2)
9150-242-7603(1) OES 20 qts (2)
LUBRICATION GREASE, AUTOMO-
FITTINGS TIVE AND ARTIL-
LERY: 1 lb can as
follows:
9150-190-0904(1) GAA 1 lb (2)

2
 C1, TM 10-1930-609-12
Page B-1. Appendix B is superseded as follows:

APPENDIX B

BASIC ISSUE ITEMS LIST AND ITEMS

TROOP INSTALLED OR AUTHORIZED

Section 1. INTRODUCTION

B-1. Stop. (3) Recoverability code, indicates whether

unserviceable items should be returned for re-
This appendix lists items required by the opera- covery or salvage. Items not coded are nonre-
tor for operation of the fork lift truck. coverable. Recoverability codes are:
B-2. General Code Explanation
This list is divided into the following sections: R----Applied to repair parts (assemblies and compo-
a. Basic Issue Items List-Section, II. Not ap- nents), special tools and test equipment which
plicable. are considered economically reparable at direct
b. Items Troop Installed or Authorized List- and general support maintenance levels.
S----Repair parts. special tools. test equipment and
Section III. A list of items in alphabetical se- assemblies which are economically reparable at
quence, which at the discretion of the unit com- DSU and GSU activities and which normally
mander may accompany the fork lift truck. These are furnished by supply on an exchange basin.
items are NOT subject to turn-in with the truck b. Federal Stock Number. This column indi-
when evacuated. cates the Federal stock number assigned to the
B-3. Explanation of Columns. item and will be used for requisitioning purposes.
The following provides an explanation of columns c. Description. This column indicates the Fed-
in the tabular list of Basic Issue Items List, Sec- eral item name and any additional description
tion II, and Items Troop Installed or Authorized, of the item required.
Section III. d. Unit of Measure (C/M). A 2 character al-
a. Source. Maintenance, and Recoverability phabetic abbreviation indicating the amount or
Code(r) (SMR): quantity of the item upon which the allowances
(1) Source code. indicates the source for are based, e.g.. ft, ea, pr. etc.
the listed item. Source codes are: e. Quantity Furnished with Equipment (BIIL
Code Explanation only). This column indicates the quantity of an
P---- Repair parts, special tools and test equipment item furnished with the equipment.
supplied from GSA/DSA or Army supply sys- f. Quantity Authorized (Items Troop Installed
tem and authorized for use at indicated main- or Authorized Only). This column indicates the
tenance Ievels.
P2---- Repair parts, special tools and test equipment
quantity of the item authorized to be used with
which are procured and stocked for insurance the equipment.
purposes because the combat or miIitary essen- g. Illustration (BIIL Only). This column is di-
tiality of the end item dictates that a minimum vided as follows:
quantity be availabIe in the supply system.
(1) Figure Number. Indicates the figure
(2) Maintenance code, indicates the lowest number of the illustration in which the item is
level of maintenance authorized to install the shown.
listed item. The maintenance level code is: (2) Item Number. Indicates the callout
Code Explanation number used to reference the item in the illustra-
C__Crew/Operator tion.

3
C1, TM 10-3930-609-12

Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST

(1) (2) (3) (4) (5)

Smr Federal Stock Description Unit Qty Auth
code No. Ref No. & Mfr Usable of
Code on code Meas
7510-889-3494 BINDER, Looseleaf ea 1
7520-559-9618 CASE, Maintenance and Operating Manuals ea 1
4210-889-2222 EXTINGUISHER, Fire. 2 1/2 lb. Fed. Spec. O-E95 ea 1

4
 C1, TM 10-3930-609-12

By Order of the Secretary of the Army:

W.C. WESTMORELAND,
General, United States Army,
Official: Chief of Staff.

VERNE L. BOWERS,
Major General, United States Army,
The Adjutant General.

Distribution:

To be distribution in accordance with DA Form 12-25A (qty rqr block No. 891) Organizational Maintenance re-
quirements for Warehouse.

GPO 887-578

5
 TM 10-3930-609-12

TECHNICAL MANUAL HEADQUARTERS,

DEPARTMENT OF THE ARMY
No. 10-3930-609-12 W ASHINGTON , D. C., 21 May 1969

OPERATOR AND ORGANIZATIONAL MAlNTENANCE MANUAL

TRUCK, FORK, LIFT, ELECTRIC, SOLID RUBBER TIRES,

2,000 LBS CAPACITY, 144 IN. LIFT, BAKER MODEL
FTD-020-EE-SS, ARMY MODEL MHE-204,
FSN 3930-935-7864

Paragraph Page
C HAPTER 1. INTRODUCTION
Section I. General ---------------------------------------------------------------------------------------- 1-1 1-1
II. Desription and data ---------------------------------------------------------------------------- 1-5 1-1
CHAPTER 2. INSTALLATION AND OPERATING INSTRUCTIONS
Section I. Service upon receipt of truck --------------------------------------------------------------------------- 2-1 2-1
II. Movement to a new worksite ------------------------------------------------------------------------------2-6 2-2
III. Controls end instruments ------------------------------------------------------------------------------------ 2-8 2-2
IV. Operation under usual conditions ----------------------------------------------------------------------- 2-11 2-4
V. Operation under unusual conditions ----------------------------------------------------------------------------- 2-16 2-6
VI. Operation of auxiliary materiel used in conjunction with the equipment ---------------------- 2-21 2-6
C HAPTER 3. OPERATOR AND ORGANIZATIONAL MAINTENANCE
INSTRUCTIONS
Section I. Operator and organizational maintenance repair parts,
tools and equipment ----------------------------------------------------------------------- 3-1 3-1
II. Lubrication -------------------------------------------------------------------------------------------- 3-4 3-1
III. Preventive maintenance service ------------------------------------------------------------------------- 3-6 3-2
I V . Operator's maintenance ----------------------------------------------------------------------------------- 3-8 3-4
V. Troubleshooting -------------------------------------------------------------------------------------------------- 3-10 3-4
Field expedient repairs ----------------------------------------------------------------------------- 3-11 3-8
VII. Seat, overhead guard and access covers ----------------------------------------------------------- 3-14 3-8
VIII. Load backrest, forks and upright assembly ----------------------------------------------------- 3-22 3-12
IX. Brake system ------------------------------------------------------------------------------------------ 3-26 3-13
X. Electrical system --------------------------------------------------------------------------------- 3-33 3-18
XI. Hydraulic system ------------------------------------------------------------------------------------ 3-57 3-27
XII. Steering system ------------------------------------------------------------------------------------------ 3-64 3-31
XIII. D r i v e a x l e s --------------------------------------------------------------------------------------------------- 3-71 3-33
C HAPTER 4. SHIPMENT, ADMINISTRATIVE STORAGE, AND DEMOLITION
TO PREVENT ENEMY USE
Section I. Shipment end Administrative Storage -------------------------------------------------------------------- 4-1 4-1
II. Demolition of material to prevent enemy use ------------------------------------------------------ 4-3 4-1
APPENDIX A. REFERENCES ---------------------------------------------------------------------------------------------------------------- A-1 A-1
B. BASIC ISSUE ITEMS --------------------------------------------------------------------------------------- B-1 B-1
C. MAINTENANCE ALLOCATION CHART ---------------------------------------------------------- C-1 C-1
INDEX -------------------------------------------------------------------------------------------------------------- I-1

1
 TM 10-3930-609-12

CHAPTER 1
INTRODUCTION

Section I. GENERAL

1-1. Scope 1-3. Report of Equipment Manual

These instructions are published for the use of Improvements
personnel responsible for the operation and or- Report of errors, omissions, and recommenda-
ganizational maintenance of Truck, Fork, Lift, tions for improving this publication by the in-
Electric, Solid Rubber Tires, 2,000 Pound Capa-
city, Baker Model FTD-020-EE-SS, Army dividual user is encouraged. Reports should be
Model MHE-204, Federal Stock No. 3930-935- submitted on DA Form 2028 (Recommended
7864. Changes to DA Publications) and forwarded di-
1-2. Maintenance Forms and Records rect to the Commanding General, U.S. Army
The DA forms and records used for equipment Mobility Equipment Command, ATTN: AMS-
maintenance will be only these prescribed in TM ME-MPP, 4300 Goodfellow Boulevard, St.
38-750. Louis, MO. 63120.

Section II. DESCRIPTION AND DATA

1-4. Description reduction gearing, to a bevel ring gear and

pinion in the axle, through the axle drive shafts
a. General. Army Model MHE-204 (Baker
and wheels.
Model-FTD-020-EE-SS, type EE, spark en-
closed) is a nonntactical fork-Lift truck designed d. Control System. The travel motor power
for warehouse operation. This truck (fig. 1 and and vehicle speed and direction are regulated by
2) can be used to load, transport, unload, and a system which includes relays, an electronic
stack loads weighing as much as 2,000 pounds SCR control system, an accelerating master switch
at a load center of 24 inches. (The load center and directional switch providing stepless speeds
is measured from the heel of the forks.) The forward or reverse. A foot accelerator operates
truck is designed to lift loads to a height of 144 the accelerating master switch to control the
inches. speed of the truck.
b. Truck. Power for travel and lifting is by a e. Steering System. The steering system in-
36-volt battery. The travel system includes cludes a recirculating ball type steering gear
motor, motor controls, and power axle assembly mounted at front of truck, connected by a drag-
to provide stepless speeds forward and reverse. link to the steering bellcrank, tie rods, and steer-
The lifting system includes an electric motor, ing knuckles, mounted on the trailing axle.
pump, controls, reservoir, lift and tilt cylinders,
mast assembly, and forks. Hydraulic service f. Brake System. The brake system consists of
brakes, and both hand and automatic parking a mechanical parking brake and a hydraulic foot
brake. The mechanical brake operates on a drum
brakes are used.
on the travel motor armature shaft. This brake
c. Power Axle and Motor Assembly. The is applied either by a handle on the steering
power train consists of the travel motor, cou- column, or automatically through spring action
pling; power axle with differential, axle shafts, as the driver rises from the seat. The hydraulic
and wheels. Power is transmitted direct from the brake is a conventional automotive type system,
travel motor through an adapter incorporating effective only on the front (drive) wheels.

1-1
TM 10-3930-609-12

Figure 1-1. Truck, three-quarter front view, with shipping dimensions.

g. Mast Assembly. The mast assembly con- base of the outer upright assembly, is secured
sists of five main assemblies as follows: to the inner upright assembly. The inner up-
(1) Outer upright assembly. The outer up right assembly is raised or lowered by action of
right assembly is a welded one-piece assembly the hoist cylinder.
that is mounted on the frame assembly and in- (3) Intermediate upright assembly. The in-
closes the hoist cylinder, intermediate upright termediate upright assembly positioned between
assembly and inner upright assembly. the inner and outer uprights provides additional
(2) Inner upright assembly. The inner up mast rigidity and an overall lower truck profile
right assembly is a welded one-piece assembly while permitting a lift height of 145 1/2 inches.
that is mounted within the intermediate upright As the inner upright approaches its extended
assembly. The hoist cylinder, mounted in the height, the intermediate upright starts to raise
1-2
 TM 10-3930-609-12

Figure 1-2. Truck, three-quarter rear view.

until it reaches its full extended height at which are attached to the chain anchors secured to the
time the carriage is at its maximum lift height outer upright base. The chain is reeved over the
of 145 1/2 inches. crosshead, under the outer channel rollers, over
(4) Crosshead assembly. The crosshead as- the inner channel rollers and connected to the
sembly is mounted over the hoist cylinder. Chains rear at the carriage. As the cylinder rises, the
1-3
TM 10-3930-609-12
crosshead assembly rises, tightening the chains n. Directional Switch. The directional switch
and raising the lift carriage assembly. selects “forward” or “reverse” operation of the
(5) Lift carriage assembly. The lift carriage travel motor. This switch is a three-position,
assembly rides on four rollers within the inner manually operated, two-circuit pilot device. The
upright assembly, which in turn slides up and direction switch is located on the steering gear
down inside of the intermediate upright chan- post.
nets. Two forks are mounted on the front of the o. Relays and SCR Control System. The relays
lift carriage assembly for handling of loads. make and break the circuits in response to re-
h. Lift Hydraulic System. The hydraulic sys- lated manual and automatic controls. The SCR
tem consists of a reservoir, pump, control valve, control system provides close stepless control
hoist and tilt cylinder, and hydraulic hoses. The over the truck travel system with protection
hoist cylinder raises the lift carriage and forks by against over-current or overvoltage. These relays
hydraulic pressure supplied by the pump. Grav- are mounted at the rear of the truck.
ity lowers the lift carriage. p. Travel Motor. The travel motor, under the
i. Lift Cylinder. A compound lift is used on operator’s floor plate, is a series wound, direct
this vehicle. The lift carriage rises to the top of current electric motor. Connected to the power
the outer upright before the inner and inter- axle, it drives the truck forward or backward.
mediate uprights together with the lift carriage q. Hydraulic Pump Motor. The pump motor
move upward. This is achieved by a dual hy- for the upright hydraulic system is controlled by
draulic hoist cylinder assembly with two pistons a switch which closes the pump motor relay. The
working in sequence. switch is operated by either the lift control, or
j. Tilt Cylinders. The tilt cylinders are double- the tilt control, starting the motor when either
acting. The uprights are tilted in and out by hy- lever is moved about onequarter of its travel
draulic pressure to the tilt cylinders. toward lift or tilt position. The switch is opened
k. Electrical System. The electrical system is a when the lever is returned to neutral position.
two-wire, ungrounded type. The battery is con- The pump motor is a series wound, direct current
nected into the circuit by means of a removable motor.
connector. The charging connection is also made r. Hourmeter. The hourmeter is the only in-
through this connector. The weight of the op- strument used on this truck. This meter auto-
erator in the driver’s seat closes the circuit to the matically records the number of hours truck has
accelerating switch by an interlock switch. Travel been in operation.
control is through the accelerating switch, with
circuit made and broken by relay. A panic switch 1-5. Identification and Tabulated Data
mounted on the dash panel opens and closes the a. Identification. The truck has three major
travel circuit. The direction of travel is selected identification plates.
by the directional switch lever on the steering (1) Travel motor identification plate. Lo-
gear post. The stop and taillight is inclosed in cated on the travel motor housing. Specifies the
a guard on the rear of the truck. The headlight, manufacturer, type and serial number.
mounted on the right side of the hoist upright, (2) Pump motor identification plate. Lo-
is controlled by a toggle switch on the instru- cated on the pump motor housing. Specifies the
ment housing. manufacturer, type and serial number.
1. Battery. The 36-volt battery (Government-
furnished equipment) used will weigh approxi- (3) Manufacturers idetification plate. Lo-
mately 1,600 pounds. The inside of the truck bat- cated on the right front of the truck, it speci-
tery compartment is 26 13/16 inches long, fies nomenclature, type tires, capacity, manu-
32 7/8 inches wide, and 23 3/8 inches high. facturer, serial number, model number, registra-
m. Accelerator Master Assembly. The accele- tion number, contract number or order number,
rator master assembly contains three sensitive service weight, wheel loading (no load on
switches, operated in sequence by cams. The forks), wheel loading (rated load on forks), and
cams are actuated by the accelerator pedal. The center of gravity.
switches energize relays which through the SCR b. Tabulated Data.
control system govern the speed of the travel ( 1) Capacities.
motor. A potentiometer governs signal strength
Differential _ _ _ _ _ _ _ _ _ _ _ 2 pt (pint)
and thereby power output of the SCR travel Hydraulic system_ _ _ _ _ _ _ _ 5 gal (gallon)
motor control circuit. The accelerating switch is Brake system _ _ _ _ _ _ _ _ _ _ 1 pt
located under the floor plate. Steering gear _ _ _ _ _ _ _ _ _ _ 1 pt
1-4
 TM 10-3930-609-12

(2) Overall dimensions and weight. Stroke _ _ _ _ _ _ _ _ _ _ 3.250 in.

Clued length (mounting 13.531 in.
Ground clearance (at mast 3 in. (inch) centers).
center). Lift cylinder
Height (overall): Manufacturer _ _ _ _ _ _ _ Baker
With uprights extended 164 3/4 in. Part number_ _ _ _ _ _ _ _ A9025GV25
(less back rest). Extended length _ _ _ _ _ _ 109.250 in.
With uprights retracted Compressed length_______ 43.375 in.
(with overhead guard) _ 83 in. Primary stroke ________ 35.625 in.
(less overhead guard)_ _ 68 in. Secondary stroke _ _ _ _ _ 36.250 in.
Length: Hydraulic system filter
Overall_ _ _ _ _ _ _ _ _ _ _ 106 in. Manufacturer _ _ _ _ _ _ _ Marvel Engineering
Forks _ _ _ _ _ _ _ _ _ _ _ 36 in. Part number (element)_____ 529206-1106
weight w/battery_______ 5,626 lb (pound) Rating _ _ _ _ _ _ _ _ _ _ 10 micron
Weight w/o battery_ _ _ _ 4,026 lb Regulator valve (lift
Width _ _ _ _ _ _ _ _ _ _ _ _ 35 1/2 in cylinder).
Wheel land (empty) : Manufacturer _ _ _ _ _ _ _ Waterman Hydraulic
Drive _ _ _ _ _ _ _ _ _ _ _ 2,740 lb Part number _ _ _ _ _ _ _ _ 1461T10-1
Steer_ _ _ _ _ _ _ _ _ _ _ 2,886 lb
Shipping dimensions_ _ _ _ _ Refer fig. 1-1 (5) Brake system.
(3) Performances. Master cylinder
Manufacturer _ _ _ _ _ _ _ Wagner Electric
Aisle width (minimum) Part number _ _ _ _ _ _ _ FE 2796
(carrying 48 in cube) : Wheel cylinder
Intersecting __________ 69 in. Manufacturer _ _ _ _ _ _ _ _ _ Rockwell Standard
Right angle stacking_ _ _ _ _ 128 in. Part number _ _ _ _ _ _ _ A1-3761B28
Gradeability (maximum 15 percent
load). (6) Steering gear.
Hoist speed (empty)_ _ _ _ _ 55.5 ft/minute
Hoist speed (maximum 36.6 ft/minute Steering gear
load). Manufacturer _ _ _ _ _ _ Saginaw Steering
Lift height (maximum)_ _ _ _ _ 145 1/4 in. Part number _ _ _ _ _ _ _ 7804220
Lad capacity (maximum)_ _ _ 2,000 lb Travel
Maximum speed (empty) : Left hand (2.72 turns of 46º
Forward _ _ _ _ _ _ _ _ _ _ _ _ 5.8 mph steering wheel).
Reverse _ _ _ _ _ _ _ _ _ _ _ _ 5.8 mph Right hand (2.72 turns 46°
Maximum speed (loaded) : of steering wheel).
Forward ____________ 5.6 mph Gear ratio_ _ _ _ _ _ _ _ _ _ 21.3:1
Reverse _ _ _ _ _ _ _ _ _ _ _ _ 5.6 mph
(7) Electrical system.
Tilt limitation:
Backward _ _ _ _ _ _ _ _ _ _ 1 0 ° Hydraulic system pump
Forward _ _ _ _ _ _ _ _ _ _ _ _ 3 ° motor.
Turning radius (no load) : Manufacturer _ _ _ _ _ Baker
Inside_ _ _ _ _ _ _ _ _ _ _ _ _ 6 7/8 in. Part number_ _ _ _ _ _ 9044H6
Outside_ _ _ _ _ _ _ _ _ _ _ _ 64in. Bating (36 volts) _ _ _ _ _ 1.8 HP at 3,920 rpm (revo-
(4) Hydraulic system. lutions per minute)
Current draw (no load)_ _ _ _ 90 amp (amperes)
Hydraulic fluid capacity_ _ _ _ _ 5 gal Current draw (with load) _ 150 amp
Type of fluid _ _ _ _ _ _ _ _ _ Oil, Engine OE-10 MIL- Travel motor
L-210H Manufacturer _ _ _ _ _ _ _ _ Baker
Pressure relief setting_______ 1,400 psi (pound per square Part number _ _ _ _ _ _ _ _ 9044AW1
inch) Bating (36 volts) _ _ _ _ _ _ 2.0 hp at 2,100 rpm
Hydraulic lift and tilt pump shaft rotation_ _ _ _ _ _ _ Clockwise and counterclock-
Manufacturer _ _ _ _ _ _ _ _ Tyrone wise
Part number _ _ _ _ _ _ _ _ GPA1-30A-DY Current draw (no load)_ _ _ _ 55/110 amp
Capacity_ _ _ _ _ _ _ _ _ _ _ 3.40 gpm at 1,200 rpm and Current draw (with load) _ 65/115 amp
1,000 psi Stall test_ _ _ _ _ _ _ _ _ 82 ft-lb (foot pounds)
Splined shaft rotation _ _ _ _ Counterclockwise Hydraulic pump relay
Directional control valve Manufacturer _ _ _ _ _ _ _ GeneraI Electric
Manufacturer _ _ _ _ _ _ _ _ Parker Hydraulics Part number _ _ _ _ _ _ _ _ 1C2800M120A412
Part number _ _ _ _ _ _ _ _ _ VDP11PD5 Accelerating relay
Tape_ _ _ _ _ _ _ _ _ _ _ _ _ 2 spool Manufacturer _ _ _ _ _ _ _ General Electric
Tilt cylinders Part number _ _ _ _ _ _ _ _ 1C2800M250A006B
Manufacturer _ _ _ _ _ _ _ _ Baker Master switch relay
Part number _ _ _ _ _ _ _ _ 9025JY and 9025JY6 Manufacturer _ _ _ _ _ _ _ General Electric
Bore_ _ _ _ _ _ _ _ _ _ _ _ _ 3 in. Part number _ _ _ _ _ _ _ 1C2800M120A414

1-5
TM 10-3930-609-12
Reversing relay Number:
Manufacturer _ _ _ _ _ _ _ General Electric Drive_ _ _ _ _ _ _ _ _ _ 2
Part number_ _ _ _ _ _ _ _ _ 1C2800M254C006B Steer _ _ _ _ _ _ _ _ _ 2
Directional control switch
Manufacturer _ _ _ _ _ _ _ _ Baker Size:
Part number _ _ _ _ _ _ 177MHW1 D r i v e _ _ _ _ _ _ _ _ _ _ 16 1/4 x 5 x 11 1/4
Type_ _ _ _ _ _ _ _ _ _ _ _ Double pole double throw- S t e e r _ _ _ _ _ _ _ _ _ _ _ 13 x 4 1/2 x 8
3 position--center off
Accelerator switch (10) Nut and bolt torque data. The follow-
Manufacturer _ _ _ _ _ _ _ General Electric ing lists bolt and nut torque specifications recom-
Part number_ _ _ _ _ _ 1C3012BH742AF01 mended for applications where specific torque
Fuses requirements are not stated.
Type_ _ _ _ _ _ _ _ _ _ _ Cartridge
Rating Comm.
1 required_ _ _ _ _ _ 140 amp 125 v (volts) Grade Low-Carb.
Bolt SAE-2 SAE-5 SAE-7 SAE-8
1 required_ _ _ _ _ _ _ 225 amp 125 v
5 required _ _ _ _ _ _ _ 14 amp 125 v Head
Headlight Marking
Manufacturer _ _ _ _ _ _ Baker
Part number_ _ _ _ _ _ _ 424MBD1 Bolt or Nut Size In.-Lbs
Lamp_ _ _ _ _ _ _ _ _ General Electric 60W 4-40 8
PAR46, sealed beam 6-32 12
Stop Light-Taillight 8-32 20
Manufacturer _ _ _ _ _ Baker 10-24 25
Part number _ _ _ _ _ _ 424 MCY1 10-32 30
Lamp_ _ _ _ _ _ _ _ _ _ General Electric 1054,36 v 12-24 35
incandescent
Hourmeter Ft-Lbs Ft-Lbs Ft-Lbs Ft-Lbs
Manufacturer _ _ _ _ _ _ Hamilton 1/4-20 4 7 9 11
Part number_ _ _ _ _ _ _ 572-36/48DCNB 1/4-28 5 9 11 13
Maximum reading _ _ _ _ _ 9,999.9 hr (hour(r)) 6/16-18 9 15 19 23
Reading increment_ _ _ _ _ 0.1 hr 5/16-24 10 17 21 26
Battery (Government-fur- 3/8-16 15 27 35 42
nished equipment). 3/8-24 18 33 42 50
Voltage_ _ _ _ _ _ _ _ _ _ 36 v 7/16-14 25 45 60 70
Type_ _ _ _ _ _ _ _ _ _ _ _ Lead-acid o rnickel-iron 7/16-20 30 55 70 80
Part number_ _ _ _ _ _ _ _ MS 15367 Battery, Storage 1/2-13 40 75 90 105
for Electric Powered 1/2-20 46 85 105 120
Industrial Trucks and 9/16-12 60 110 135 150
Tractors 9/16-18 65 120 150 165
(8) Chassis. 5/8-11 80 140 170 200
5/8-18 90 155 200 230
Drive axle 3/4-10 125 240 300 350
Manufacturer _ _ _ _ _ _ _ Rockwell Standard 3/4-16 140 275 350 400
Part number_ _ _ _ _ _ _ _ TA260FHX32 7/8-9 175 375 500 575
Type_ _ _ _ _ _ _ _ _ _ Single-reduction, ring and 7/8-14 200 400 550 625
pinion 1-8 250 575 750 850
Overall reduction (in- 20.300:1 1-12 275 650 825 950
cluding adapters).
Bevel gear reduction_ _ _ _ 5-1/6:1 (11) Wiring diagram and schematic. Refer
Width (hub to hub)_ _ _ _ _ _ 32.000 in. to figure 1-3 for the wiring diagram and figure
Pinion gear backlash_ _ _ _ 0.004 to 0.012 in.
Brake_ _ _ _ _ _ _ _ _ _ _ Hydraulic drum type 1-4 for the wiring schematic.
Differential
Manufacturer _ _ _ _ _ _ _ _ Rockwell Standard 1-6. Difference in Models
Part number_ _ _ _ _ _ _ _ _ _ A3-3835L350-5-1/6:1
Type_ _ _ _ _ _ _ _ _ _ _ _ Conventional This manual covers the Baker Model FTD-020-
EE-SS fork lift truck (Army Model MHE-204).
(9) Tires. No known differences exist for the model cov-
Type_ _ _ _ _ _ _ _ _ _ Solid rubber ered by this equipment publication.

1-6
 TM 10-3930-609-12

Figure 1-3. Wiring diagram.

1-7
TM 10-3930-609-12

Figure 1-4. Wiring schematic.

1-8
 TM 10-3930-609-12

CHAPTER 2

INSTALLATION AND OPERATING INSTRUCTIONS

Section I. SERVICE UPON RECEIPT OF TRUCK

2-1. General (2) The deficiencies and shortcomings

noted, and the corrective action taken will be re-
When a new truck is received by an organization, ported on the appropriate forms prescribed and
it must be serviced as described in paragraphs explained in TM 33-750.
2-2 and 2-3 by organizational maintenance per-
sonnel. 2-4. Installation of Separately Packed
Components
2-2. Removal of Preservatives
a. Fire Extinguisher. Remove separately pack-
a. Remove tape, paper, or other packing. Use ed fire extinguisher and install in bracket at
extreme care when unpacking and installing front of truck. Be certain bracket clamp locks
separately packaged components. properly to secure fire extinguisher in position.
b. Remove with SD (solvent, drycleaning) b. Directional Control Switch Knob. Screw di-
preservative compound from exposed metal sur- rectional control switch knob onto lever of di-
faces. Because this compound is not a lubricant, rectional control switch secured to steering gear
take special care to see that it is completely re- column.
moved from all wearing surfaces. c. Headlight.
c. Fill drive axle, hydraulic tank and master (1) Secure headlight to left side of outer
cylinder with proper lubricant as indicated in upright with two screws, nuts and lockwashers.
lubrication order (fig. 3-1). (2) Remove headlight guard, bezel and
d. Refer to paragraph 2-4e. for battery instal- sealed beam light.
lation. (3) Insert conduit through rear of headlight
shell and connect conduit leads securely to head-
2-3. Inspecting and Servicing the light terminals.
Equipment (4) Install sealed beam light, bezel and
a. Inspecting. headlight guard using the same hardware that
(1) Inspect the packing list for missing was removed.
components. d. Forks. Pull up ring catch on fork, position
(2) Inspect exterior surfaces for broken or fork in desired location on carriage and release
dented parts, and for damaged painted surfaces. ring catch to lock fork on carriage. Repeat to in-
(3) Inspect visible wiring and hydraulic stall other fork.
lines for cuts, breaks, or other damage.
(4) Inspect the lift chain and carriage as- e. Battery. The battery is a Government fur-
sembly for damage. nished, 36 volt storage type, shipped dry and
(5) Inspect the controls and instruments separately from the equipment. The electrolyte is
for breaks, cracks, bends, or other defects. also packed in a separate container. Fill the bat-
b. Servicing. tery with electrolyte to the level 3/8 inch above
the plates and connect the battery to a charge
(1) The organization mechanic will per- until it is fully charged, Service in accordance
form the services and tests that are listed and with TM 10-1690A. To install battery, proceed
described in paragraph 3-7. The services per- as follows:
formed at this time will begin the cycle of re-
gularly scheduled preventive maintenance serv- (1) Open battery compartment top and side
ices. doors. Latch top door to overhead guard.
2-1
TM 10-3930-609-12
(2) Using a hoist rated at more than hoist. Tighten battery clamp screws to prevent
2,000 pound capacity, lift battery by hooks in- battery movement.
serted through lifting eyes at each side of bat- (4) Connect battery leads securely at bat-
tery. Use a spreader bar as wide as the battery tery receptacles and close battery compartment
between the lifting hooks to avoid an inward doors.
pull on the battery case. 2-5. lnstallation of Setting Up
Warning: Avoid contact with the bat- Instructions
tery electrolyte. If the solution comes in con- The truck is shipped as a completed unit except
tact with the skin, rinse the area immediately for the separately packed components (para 2-
with clean water to avoid skin burns. Do not 4). After the separately packed components are
smoke or use an open flame in the vicinity installed, the preservatives removed (para 2-2)
when servicing batteries as they generate hy- and the inspection and servicing preformed
drogen, an explosive gas. (para 2-3) the truck may be entered into service.
No other installation or setting up procedures
(3) Position battery between battery are required other than operator orientation and
clamps in battery compartment and remove training.

Section II. MOVEMENT TO A NEW WORKSITE

2-6. Local Worksite 2-7. Distant Worksite

When the new worksite is near, the fork lift When the fork lift truck must be moved to a
truck may be operated under its own power if distant worksite, it may be loaded onto a truck,
the area is relatively level. If the ground is trailer, or other carrier and secured with block-
ing, strapping, cables and the like. Disconnect
rough, sandy, or muddy, the fork lift may be the battery cable connector before transporting
loaded into a truck, trailer, or other carrier to the fork lift truck. The only reinstallation after
be moved. No dismantling of the truck is re- movement required is the connection of the bat-
quired for movement to a local worksite. tery cable connector with its mating receptacle.

Section Ill. CONTROLS AND INSTRUMENTS

2-8. General c. Parking Brake Lever. The parking brake
This section describes, locates, illustrates, and lever is located to the right of the operator’s seat
in front of the cowl. Pull up on the lever to
furnishes the operator, crew, or organizational
apply the brake and hold the truck in a station-
maintenance personnel sufficient information ary position. Twist the lever clockwise and move
about the various controls and instruments to downward to release brake.
insure proper operation of the Baker FTD-
020-EE-SS (Army Model MHE-204) Fork d. Steering Handwheel. The steering hand-
Lift Truck. wheel controls the direction of travel of the
truck. Turn the handwheel to the right (clock-
2-9. Controls wise) to move the truck to the right; turn the
a. Operator’s Seat. As the operator places handwheel to the left (counterclockwise) to
his weight on the operator’s seat (fig. 2-1), a move the truck to the left.
switch is closed which activates the travel e. Accelerator Pedal. The accelerator pedal is
motor circuit. Simultaneously, the travel motor located on the floor plate, convenient to the op-
brake is released. As the driver removes his erator’s right foot. Depression of the accelerator
weight from the seat, the motor brake is en- pedal either rapidly or slowly will cause the
gaged and the travel motor circuit is opened. truck to move in the direction selected at the
b. Horn Button. The horn button is located speed and acceleration desired by the operator.
in the center of the steering handwheel. De- Release the pressure on the pedal to slow the
press the button to sound horn. speed of the truck.
2-2
 TM 10-3930-609-12

Figure 2-1. Controls and Instruments.

f. Light Switch. The light switch is located on lever. Move the tilt control lever forward to tilt
the left side of the instrument panel. Push the the forks forward. Move the lever backward to
light switch up to turn on the headlight and tail- tilt the forks backward.
light. Push the light switch down to turn off the j. Direction Control Lever. The direction con-
headlight and taillight. trol lever is located on the right side of the
g. Panic Button. The panic button is located steering column. This lever provides three posi-
to the right of the light switch. Push in the tion control of the truck; forward, off, and re-
panic switch to open the power circuit. Pull out verse. Move the lever forward for forward
the panic switch to close the power circuit. travel, move the lever to the center position for
h. Lift Control Lever. The lift control lever is off, and move the lever backward for reverse
located on the cowl to the right of the opera- travel. Leave the lever in the off position when
tor’s seat. Move the lever to the rear to lift the the truck is parked. Mechanical linkages attached
forks. Move the lever forward to lower the to the operator’s seat will automatically return
forks. the lever to the off position when the operator
i. Tilt Control Lever. The tilt control lever is rises from the seat. The directional control lever
located directly to the right of the lift control may be used for either forward or reverse
2-3
TM 10-3930-609-12
torque braking. Move the direction control lever Move the adjuster lever toward the seat and
in the opposite position you are traveling. The move the seat forward or backward as desired.
truck will come to almost a complete stop before Release the adjuster lever when seat is in posi-
going in the opposite direction. Depress the ac- tion.
celerator pedal if more severe torque braking is
required. 2-10. Instruments
k. Brake Pedal. The brake pedal is located on The hourmeter is the only instrument used on
the floor immediatley to the right of the steering this truck. It is located on the instrument panel
column. Depress the brake pedal to stop the to the right of the panic switch. This meter op-
truck and simultaneously illuminate the stop- erates only when the truck is in motion. The
light. figure (extreme right center) records 10th of an
l. Seat Adjuster. The seat adjuster is located hour. The small indicator (upper right) visibly
on the lower left side of the operator’s seat. turns when the meter is recording.

Section IV. OPERATION UNDER USUAL CONDITIONS

2-11. General tained. If the truck fails to move, report this to

the proper authority.
a. The instructions in this section are pub-
lished for the information and guidance of per- b. Stopping.
sonnel responsible for operation of the fork lift (1) Remove foot from the accelerator
truck. pedal.
b. The operator must know how to perform (2) Apply gradual pressure on the brake
every operation of which the fork lift truck is pedal to bring the truck to a safe smooth stop.
capable. This section gives instructions on start- Avoid sudden stops.
ing and stopping the fork lift truck, operation (3) Apply the parking brake. Move the di-
of the fork lift truck, and on coordinating the rection control lever to the center-off position.
basic motions to perform the specific tasks for (4) Move the tilt control lever forward to
which the equipment is designed. Since nearly bring the mast to the vertical position.
every job presents a different problem, the op- (5) Move the lift control lever forward and
erator may have to vary given procedures to fit lower the forks to the g-round.
the individual job. (6) As the operator removes his weight
from the seat, the travel motor brake is applied
2-12. Driving the Truck and the seat switch is opened, thereby cutting
a. Starting. off current to the travel motor. The direction
(1) Perform the preventive maintenance control lever is also automatically returned to
checks and services required by paragraph 3-7. the center off position.
(2) Mount truck and take position in op- (7) Every 8 hours or after a day’s work
erator’s seat. with the truck, the operator must have the bat-
(3) Check that panic button is pulled out tery charged over night for efficient operation of
(toward operator). the fork lift truck the following day.
(4) Depress brake pedal with right foot, c. Emergency Stopping. The mechanical brake
and simultaneously release parking brake lever is automatically applied when the operator’s
with right hand. weight is removed from the seat. The power cir-
(5) Move the lift control lever gradually to cuit is automatically opened whenever the op-
the rear to raise the forks to normal traveling erator depresses the panic switch mounted on the
position (8 to 10 inches above working surface). instrument panel. Either above procedure will
(6) Move the tilt control lever backward permit emergency stopping of the truck.
and tilt the forks backward.
(7) Move the direction control lever from 2-13. Picking Up the Load
the center-off position to forward or reverse a. Approach the load squarely with forks
position, depending on desired direction. spaced to divide load evenly and halt the truck.
(8) Place foot on the accelerator pedal and Move the tilt control lever forward and bring
gradually depress the accelerator pedal until
the mast assembly to the vertical position. Raise
truck begins to travel. Continue to depress the or lower the forks to the proper height to pick
accelerator pedal until safe operating speed is at- up the load.
2-4
 TM 10-3930-609-12

b. Move the truck forward until the forks are (2) Drive the truck forward until the load
positioned under the load. Make certain the is above its resting place.
forks are fully inserted in the pallet or under (3) Pull up on the parking brake lever to
the load. apply the parking brake.
c. Apply the parking brake to prevent the
truck from shifting position during the lifting (4) Move the direction control lever to the
operation. center-off position. Move the tilt control lever
d. Move the direction control lever to the forward and tilt the forks forward until the load
center-off position. is aligned with the tier.
e. Move the lift control lever to the rear and (5) Move the lift control lever forward and
raise the load approximately 12 inches above carefully lower the load into position on the tier.
ground level. Release the lift control lever.
Continue to lower the forks until they can be
Move the tilt control lever backward to tilt the
easily withdrawn from the pallet.
forks backward. Release the tilt control lever.
(6) Move the direction control lever to the
2-14. Moving Load reverse position. Release the parking brake
a. Move the direction control lever from the lever, and slowly back the truck away from the
center-off position to the proper position for the tiered stack until the forks are clear.
desired direction of travel. (7) Move the lift control lever forward to
b. Release the parking brake lever, depress lower the forks into normal traveling position
the accelerator pedal, and move the load to the (8 to 10 inches above surface).
desired location.
b. Depositing the Load in a Storage Area.
Caution: Accelerate only as needed to over-
(1) Carefully drive up to the position at
come truck gravity, release brake pedal, then
continue to accelerate. Do not accelerate to the which the load is to be deposited. Depress the
extent that the drive motor must overcome brake pedal to halt the truck.
brakes. This is not only detrimental to the drive (2) Apply the parking brake, and move the
motor, but also increases brake lining wear. direction control lever to the center-off position.
Warning: The operator must be alert at, all
(3) Move the tilt control lever forward and
times while operating the fork lift truck. Fail-
bring the mast assembly to the vertical position.
ure to observe this warning can result in serious
injury or death to the operator or other person- (4) Move the lift control lever forward
nel. and carefully lower the load to the ground. Con-
tinue to lower the forks until they can be easily
2-15. Dopositing the Load withdrawn from under the load.
a. Depositing the Load on a Tiered Stack. (5) Place the direction control lever in the
(1) Move the lift control lever to the rear reverse position. Release the parking brake lever,
until the load reaches the desired height above and slowly back the truck away from the de-
the tier. posited load.

Section V. OPERATION UNDER UNUSUAL CONDITIONS

2-16. Operation in Extreme Cold (Below d. Lubricate as specified in the current lubri-
0° F.) cation order.
a. See that hydraulic reservoir is filled to e. Be extremely careful when handling hoses,
proper level. (Refer to current lubrication lines, or wiring to avoid breakage.
order.) Inspect for leaks at all accessible lines, f. Wipe exposed areas dry with a clean cloth.
hoses and fittings. 2-17. Operation in Extreme Heat
b. Inspect brakes for proper operation. a. Make certain that hydraulic reservoir is
c. Keep battery fully charged, if battery indi- filled to proper level.
cator shows low charge or is low on electrolyte, b. Inspect lines, and fittings for breaks, or
report this condition to proper authority. leaks.

2-5
TM 10-3930-609-12
c. Inspect battery for low electrolyte level. d. Cleaning. Wipe dust and dirt from all ex-
ternal areas regularly.
2-18. Operation in Dusty or Sandy Areas
2-19. Operation Under Rainy or Humid
a. Protection. Shield the fork lift truck from Conditions
dust and sand as much as possible when not in If unit is outside and not operating, protect it
use. Take advantage of natural barriers which with a canvas or other waterproof covering. Re-
offer protection from dust and sand. move cover during dry periods. Keep hydraulic
b. Hydraulic System. Check air filter fre- reservoir full to avoid condensation. Wipe excess
moisture from external surfaces.
quently for clogged condition. Wipe dust and
dirt from filter area before removing from res- 2-20. Operation in Salt-Water Areas
ervoir. Wipe dust and dirt from cylinders fre- a. General. Wash the unit frequently with
quently as sand and dust is an abrasive and can clean, fresh water. Do not contaminate hydraulic
damage the lift cylinders. system or damage electrical components.
b. Protection. Coat exposed metal surfaces
c. Lubrication. Clean all lubrication points with rust-proofing material. Remove rust im-
thoroughly before applying lubricants. mediately and apply paint or oil as applicable.

Section VI. OPERATION OF AUXILIARY MATERIAL USED

IN CONJUNCTION WITH THE EQUIPMENT

2-21. Fire Extinguisher (Dry Chemical Type) b. Hold the extinguisher upright, aim the
nozzle at the base of the fire and raise the op-
The dry chemical type fire extinguisher is ef- erating lever.
fective in areas where ambient temperature is c. Direct the discharge at the base of the fire
-25°F. and above. If winterized (pressurized with a side-to-side sweeping motion.
with nitrogen), the fire extinguisher may be
used in temperatures below -25°F. The fire ex- 2-23. Maintenance
tinguisher is a 2 1/2 pound, stored pressure, Weigh the fire extinguisher every 6 months. Re-
lever-operated extinguisher. place the extinguisher if the weight is less than
4 1/2 pounds, or the pressure is below 1,25
2-22. Operating the Extinguisher (fig. 2-1) pounds. The dry chemical type fire extinguisher
will be serviced at installation level through Re-
a. Disconnect the clamp that secures the ex- pair and Utilities facilities, with the filling agent
tinguisher to its mounting bracket, swing the supplied by local procurement through Troop
clamp open, and remove the extinguisher. Supply Channels. Refer to TB 5-4200-200-10.

2-6
 TM 10-3930-609-12

CHAPTER 3

OPERATOR AND ORGANIZATIONAL MAINTENANCE

INSTRUCTIONS

Section I. OPERATOR AND ORGANIZATIONAL MAINTENANCE

REPAIR PARTS, TOOLS AND EQUIPMENT

3-1. Special Tools and Equipment for the fork lift truck are listed in Appendix B.
No special tools or equipment are required by
the operator or organizational maintenance per- 3-3. Organizational Maintenance Repair
sonnel for the maintenance of the fork lift truck. Ports
3-2. Basic Issue Tools and Equipment Organizational maintenance repair parts are
Tools and repair parts issued with or authorized listed and illustrated in TM 10-3930-609-20P.

Section II. LUBRICATION

3-4. General lubrication Information proved cleaning solvent. Remove all excess
lubricant after lubrication.
a. This section contains lubrication instruc- (3) Drain plug and breather. Keep the
tions which are supplemental to, and not specifi- area clean around the drain plug, and hydrau-
cally covered in the lubrication order. lic reservoir breather. Remove the drain plug
b. For current lubrication order, refer to LO only when necessary to remove hydraulic oil.
10-3930-609-12. (4) Bearings. Clean and lubricate un-
Figure 3-1. Not used. sealed bearings ( (a) and (b) below).
(a) Wash all of the old lubricant out of
3-5. Detailed lubrication Information the hearings with volatile mineral spirits or
a. Care of Lubricants and Lubrication Equip- drycleaning solvent and dry the parts
ment. Keep all lubricants in closed containers thoroughly.
and store in a clean, dry area away from heat. Caution: Bearings must not be spun
Do not allow dirt, dust, water, or other foreign dried with compressed air.
matter to come in contact with the lubricants at (b) Pack the bearings by hand or with
any time. Keep all lubrication equipment clean a mechanical packer, introducing the lubricant
and ready for use. carefuIly between the balls and rollers. Do not
smear grease only on the outside of the bear-
b. Cleaning. ings and expect it to work in. Great care must
(1) General. Keep the fork lift truck clean be exercised to insure that dirt, grit, lint, or
by wiping it regularly with a cloth dampened other contaminants are not introduced into the
lightly in an approved cleaning solvent and dry bearings. If the bearings are not to be installed
thoroughly. Clean lubrication points and area immediately after repacking, wrap them in
around hydraulic reservoir fill before lubrication. clean oilproof paper to protect them from con-
(2) Grease fittings. Wipe grease fittings taminants.
with a clean, dry cloth before lubrication. Re- c. Usual Conditions. Service intervals specified
move old or hardened lubricants with an ap- on the lubrication order are for normal opera-
3-1
TM 10-3930-609-12
tion and where moderate temperature, humidity, are prescribed in the “Key” in accordance with
and atmospheric conditions prevail. three temperature ranges; above +32°F., +40° to
d. Unusual Conditions. Reduce service intervals -10°F., and from 0° to -65°F. Change the grade
specified on the lubrication order, i.e., lubricate of lubricants whenever weather forecast data in-
more frequently, to compensate for abnormal or dicate that air temperatures will be consistently
extreme conditions, such as high or low tempera- in the next higher or lower temperature range or
tures, continued operation in sand or dust, or when sluggish operation caused by lubricant
exposure to moisture or salt water environment. thickening occurs. No change in grade will be
Any one of these operations or conditions may made when a temporary rise in temperature is
cause contamination and quickly destroy the pro- encountered.
tective qualities of the lubricants. Intervals may f. Maintaining Proper Lubricant Levels. Lu-
be extended during inactive periods commensur- bricant levels must be observed closely and
ate with adequate preservation. necessary steps taken to replenish in order to
e. Changing Grade of Lubricants. Lubricants maintain proper levels at all times.

Section III. PREVENTIVE MAINTENANCE SERVICES

3-6. General the equipment if operation were continued. AU

deficiencies and shortcomings will be recorded,
To insure that the fork lift truck is ready for together with the corrective action taken, on DA
operation at all times, it must be inspected sys- Form 2404 at the earliest possible opportunity.
tematically, so that defects may be discovered
and corrected before they result in serious dam- 3-7. Preventive Maintenance Checks and
age or failure. The necessary Preventive Main- Servicer
tenance Checks and Services to be performed are a. General. This paragraph contains tabulated
listed and described in paragraph 3-7. The item listing of preventive maintenance checks and
numbers indicate the sequence of minimum in- services which must be performed by the op-
spection requirements. Defects discovered during erator and/or Organizational Maintenance per-
operation of the unit shall be noted for future sonnel. The item numbers are listed consecutive-
correction, to be made as soon as operation has ly and indicate the sequence of minimum re-
ceased. Stop operation immediately if deficiency quirements. Refer to Table 3-1 for the preven-
is noted during operation which would damage tive maintenance checks and services.

Table 3-1. Preventive Maintenance Checks and Services

Interval B--Before operation A--After operation M--Monthly

D--During operation W-- Weekly Q--Quaterly
Operator Org.
Daily

B D A W M Q Item to be inspected Procedure Reference

Lubricate in accordance with

the Lubrication Order.
1 X X X X Headlight and tail- Check operation. Replace de- Para 3-42
light fective lamp.
2 X X X Tires Check for cuts. Remove em-
bedded foreign material.
3 X X X X laster cylinder Check for leaks and loose
connections. Fill as required
to within 1/4-inch of top.
4 X X X Hydraulic oil tank Check fluid level. Fill as re- Para 3-60
quired. Replace dirty air
cleaner element.
5 X X X Battery Remove corrosion. Add elec-
trolyte as required.
6 X X Brake pedal Check for strong pressure
when brake pedal is applied.
Check for exercise
travel.

3-2
 TM 10-3930-609-12

Interval B--Before operation A--After operation M--Monthly

D--During operation W--Weekly Q--Quaterly
Operator Org.

Daily
B D A W M Q Item to be inspected Procedure Reference

7 X X Horn Check operation. Replace if Para 3-44 & 3-45

defective.
8 X X Controls and instru- Chock for proper operation.
ment Controls should operate
freely with no binding.
9 X X X General Check for unusual noise, vi-
bration or any other indica-
tion signifying trouble.
10 X X X Fire extinguisher Cheek for proper charge.
11 X X X X X Tilt cylindera Check for leaks and loose con-
nections. Mast will tilt
evenly when properly
adjusted.
12 X X X Lift chains Check for cracked, broken or
excessively worn links.
13 X X Hoist cylinder Check for leaks and loose con-
nection.
14 X X X X Handbrake lever Check for proper operation.
15 X X X X Power axle Check for lubricant leakage.
16 X X X X X Steering gear Check for lubricant leakage.
Check for proper operation.

b. Intervals. Each truck will be inspected by cessively worn, not leaking, and adequately lu-
its assigned operator, each day it is operated. bricated apply to most items in the preventive-
This service is divided into three parts. maintenance and inspection procedures. Any or
(1) Before-operation service. This is a brief all of these checks that are pertinent to any item
service to ascertain that the truck is ready for (including supporting, attaching, or connecting
operation; it is mainly a check to see if condi- members) will be performed automatically as
tions affecting the truck’s readiness have changed general procedures, in addition to any specific
since the last after-operation service. procedures given.
(2) During-operation service. This service (a) Inspection for good condition is usu-
consists of detecting unsatisfactory performances. ally visual inspection to determine if the unit is
While driving or operating, the driver should safe or serviceable. Good condition is explained
be alert for any unusual noises or odors, steer- further as meaning: not bent or twisted, not
ing irregularities, or any other indication of mal- chafed or burned, not broken or cracked, not
function of any part of the truck. Every time the bare or frayed, not dented or collapsed, not tom
operator picks up or deposits a load, applies the or cut, not deteriorated.
brakes, accelerates or turns the truck, it should (b) Inspection of a unit to see if it is cor-
be considered a test and any unusual or unsatis- rectly assembled is usually a visual inspection to
factory performance noted. see if the unit is in its normal position in the
(3) After-operation service. This is the truck and if all its parts are present and in their
basic daily service for all trucks. It consists of correct relative positions.
correcting, so far as possible, any operating de- (c) Inspection of a unit to see if it is
ficiencies, so that the truck is prepared to be op- secure is usually a visual, hand-feel, pry-bar,
erated again, upon a moment’s notice, should wrench, or screwdriver inspection for looseness
the situation so require. in the unit. This inspection will include any
c. General Procedures for AU Services and brackets, lockwashers, locknuts, locking wires,
Inspections. and cotter pins as well as any connecting tubes,
(1) The general procedures ((2) below) hoses, or wires.
apply to all inspections and are just as important (d) Excessively worn is understood to
as the specific procedures. mean worn beyond serviceable limits, or likely to
(2) Inspections to see if items are in good fail if replaced before the next scheduled inspec-
condition, correctly assembled, secure, not ex- tion. Excessive wear of mating parts or linkage
3-3
TM 10-3930-609-12
connections is usually evidenced by too much compound, protective grease, etc.; prepare parts
play (lash or lost motion). It includes illegibili- as required (oil seals, etc.); and for those parts
ty as applied to markings and data plates, and requiring lubrication, apply the lubricant pre-
printed matter. scribed in the lubrication order.
d. General Cleaning. Any special cleaning in- e. General Precautions in Cleaning.
structions required for specific mechanism or (1) Dry-cleaning solvent and volatile min-
parts are contained in the pertinent section. Gen- eral spirits are inflammable and should not be
eral cleaning instructions are shown in (1) used near an open flame. Fire extinguishers
through (4) below. should he provided when these materials are
(1) Use dry-cleaning solvent or volatile used. Use only in well ventilated places.
mineral spirits to clean or wash grease or oil
from all parts of the truck. (2) These cleaners evaporate quickly and
(2) A solution of one part grease-cleaning have a drying effect on the skin. If used without
compound to four parts of dry-cleaning solvent gloves, they may cause cracks in the skin and,
or volatile mineral spirits may be used for dis- in the case of some individuals, a mild irritation
solving grease and oil from chassis, mast and or inflammation.
other parts. Use cold water to rinse off any solu- (3) Avoid getting petroleum products, such
tion which remains after cleaning. as dry-cleaning solvent, volatile mineral spirits,
(3) After the parts are cleaned, rinse and engine fuels, or lubricants on rubber parts as
dry them thoroughly. Apply a light grade of oil
they will deteriorate the rubber.
to all polished metal surfaces to prevent rusting.
(4) Before installing new parts, remove any (4) The use of diesel fuel oil, gasoline, or
preservative materials, such as rust-preventive benzene (benzol) for cleaning is prohibited.

Section IV. OPERATOR’S MAINTENANCE

3-8. General tions and services outlined in the preventive

maintenance checks and services (table 3-1) and
Instructions in this section are published for the the general services outlined in paragraph 3-7 c
information and guidance of the operator to through 3-7 e. Refer to the applicable refer-
maintain the fork lift truck.
enced paragraphs for the corrective action re-
3-9. Operator’s Maintenance quired and the performance of the specific main-
Operator maintenance is limited to the inspec- tenance service.

Section V. TROUBLESHOOTING

3-10. General ponents. Malfunctions which may occur are

listed in table 3-2. Each malfunction stated is
This section provides information useful in di- followed by a list of probable causes of the
agnosing and correcting unsatisfactory operation trouble. The corrective action recommended is
or failure of the fork lift truck and its com- described opposite the probable cause.
Table 3-2. Troublerhooting

Malfunction Probable cause Corrective action

1. Truck will not start or develop a. Dead battery. a. Charge or replace (para 3-46).
full power. b. Fusetron blown. b. Replace (para 3-51).
c. Defective battery plug or receptacle. c. Replace plug or receptacle (para 3-
51).
d. Contacts dirty, worn, or broken in d. Clean or replace contacts (para
relay. 3-49).
e. Dirt in relay causing mechanical re- e. Clean relay throroughly.
striction. f. Replace accelerator master assembly
f. Snap switches malfunctioning in (para 3-56).
accelerator master assembly.

3-4
 TM 10-3930-609-12

Malfunction Probable cause Corrective action

g. Seat switch not working. g. Adjust or replace switch (para 3-54).
h. Open circuit due to loose connections h. Clean and secure connections firmly
in accelerator master assembly. (para 3-56).
i. Mechanical binding in accelerator i. Replace accelerator master assembly
master assembly. (para 3-56).
j. Other causes. j. Refer other causes to direct and gen-
eral support maintenance personnel.

2. All speeds not obtainable. a. Object lodged in relay. a. Remove object.

b. Dirty contacts on relay. b. Replace contacts (para 349).
c. Switches in accelerator master assem- c. Replace accelerator master assembly.
bly malfunctioning. (para 3-56).
d. Sticking or binding of accelerator d. Replace accelerator master assembly
any part of stroke. (para 3-56).
e. Other causes. e. Refer other causes to direct and gen-
eral support maintenance personnel.
3. overheating. a. Dirty relay contacts. a. Replace contacts (para 3-49).
b. Vehicle operating in low speed for b. No technical remedy. Advise opera-
prolonged periods. tor to avoid practice if possible.
c. Other causes. c. Refer other causes to direct and gen-
eral support maintenance personnel.

4. Improper plugging control and a. Dirt in relay or directional switch. a. Clean unit thoroughly.
timing through all speeds. b. Dirty contact in relay. b. Clean or replace contacts (para 3-49).
c. Other causes. c. Refer other causes to direct and gen-
eral support maintenance person-
nel.
5. Brakes dragging. a. Improper brake adjustment. a. Adjust brakes (para 3-30a).
b. Plugged master cylinder compensat- b. Open wheel cylinder bleeder fitting.
ing port. If brakes release when fluid es
capes, replace master cylinder
(para 3-31).
e. Seat brake improperly adjusted. c. Adjust so that brake does not drag
when seat is down and is firmly
applied when seat is up (para 3-
29b).
d. Mineral oil in brake system. d. Bleed brake system (para 3-30b).
e. Brake return spring weak or broken e. Replace brake system return spring
(para 3-30c).
f. Other causes. f. Refer other causes to direct and gen-
eral support maintenance person-
nel.
6. Brake pedal goes to floor. a. W orn lining. a. Install new lined brake shoes (para
3-30d).
b. Air in system. b. Bleed system (para 3-30b).
c. Fluid low in master cylinder. c. Replenish fluid and chock for leaks.
d. Pedal improperly adjusted. d. Adjust brake pedal (para 3-30a).
e. Broken brake line. e. Replace brake line.
f. other causes. f. Refer other causes to direct and gen-
eral support maintenance person-
nel.
7. Brake pedal under pressure a. Leaks in hydraulic brake system. a. Locate and eliminate leaks.
gradually goes to floor plate. b. Scored master cylinder barrel or b. Replace master cylinder (para 3-41).
defective cup.
c. other causes. c. Refer other causes to direct and gen-
eral support maintenance person-
nel.
8. Brake pedal has springy or rub- a. Air in system. a. Bleed system (para 3-30b).
bery action. b. Other causes. b. Refer other causes to direct and gen-
eral support maintenance person-
nel.

3-5
TM 10-3930-609-12
Malfuction Probable cause Corrective action

9. Weak braking action. a. Oil on linings. a Replace brakeshoes (para 3-30c).

b. Incorrect lining. b. Replace brakeshoes (para 3-30c).
c. Improper brake adjustment. c. Adjust brakes (para 3-30a).
d. Other causes. d. Refer other causes to direct and
general support maintenance
personnel.

10. Harsh braking action. a. Brake lining grease or oil soaked. a. Replace brakeshoes (para 3-30c).
b. Brake backing plate loose. b. Refer to direct support.
c. Other causes. e. Refer other causes to direct and gen-
eral support maintenance person-
nel.

11. Brake releases slowly. a. Hydraulic fluid congealed. a. Drain, flush, and replace with
proper brake fluid (para 3-30b).
b. Retraction of brakeshoes restricted b. Clean. adjust or replace as necessary
by weak return springs or dirt. (para 3-30b).
c. Dirt in master cylinder. c. Replace master cylinder (para 3-31).
d. Other causes. d. Refer other cause to direct and gen-
eral support maintenance person-
nel.

12. Truck pulls to one aide. a. Brake lining grease or oil soaked. a. Replace brakeshoes (para 3-30b).
b. Brake line closed b. Replace brake line.
c. Other causes. c. Refer other causes to direct and
general support maintenance per-
sonnel.
13. Steering difficult or wandering. a. Steering gear adjustment too slack. a. Readjust steering gear (para 3-66).
b. Other causes. b. Refer other causes to direct and
general support maintenance per-
sonnel.
14. Lift carriage will not lift load. a. Lift chains broken. a. Replace lift chains (pan 3-24).
b. Oil leaks in hoses. b. Inspect fittings and couplings
Tighten or replace as required.
c. Fusetron blown. c. Replace (para 3-51).
d. Hydraulic fluid low. d. Fill reservoir to prescribed level.
e. Other causes. e. Refer to direct and general support
maintenance personnel.
15. Load creeps down from raised a. Oil leak in lines. a. Tighten fittings.
position. b. Leaky control valve b. Tighten connections.
c. Other causes. c. Refer other cause to direct and gen-
eral support maintenance person-
nel.
16. Hoisting speed erratic a. Air in system. a. Bleed air from system by operation
b. Low level in reservoir. b. Fill reservoir to prescribed
c. Other causes. level.
c. Refer other causes to direct and
general support maintenance per-
sonnel.
17. Control valve plungers will not a. Refer malfunction to direct and
return to neutral. general support maintenance
personnel.
18. Forks uneven when load is lifted. a. Lift chains out of adjustment a. Adjust so chain raises forks evenly
(para 3-24a).
19. No motion of hydraulic unit a. Oil supply in tank too low. a. Fill reservoir to prescribed level.
when first started up. b. Oil viscosity too heavy. b. Change to oil specified
c. Air leak in pump inlet line. c. Tighten hose connection.
d. Restricted pump inlet hose. d. Repair or replace (para 3-62).
e. Truck overloaded e. Reduce load.
f. Failure at switch. f. Replace control lever switch (para
3-53).
g. Other causes. g. Refer other causes to direct and gen-
eral support maintenance personnel.
3-6
 TM 10-3930-609-12

Malfunction Probable cause Corrective action

20. Loss of motion during operation. a. Loss of oil supply due to broken a. Replace hose (para 3-62).
pump inlet, outlet or cylinder con-
necting hoses or tank return hose
b. Other causes. b. Refer other causes to direct and
general support maintenance per-
sonnel.

21. Slow motion a. Failure in hydraulic hoses. a. Replace hoses (para 3-62).
b. Aerated oil supply (foam in tank). b. Change oil.
c. Oil too thin. c. See LO 10-3930-609-12 for proper
grade.
d. Oil supply too low. d. Fill reservoir (LO 10-3930-609-12).
e. Cylinder misalinement. e. Correct chain adjustment (para 3-
24a).
f. Mechanical obstruction of moving f. Remove obstruction.
parts.
g. Other causes. g. Refer other causes to direct and
general support maintenance per-
sonnel.
22. Jerky motion. a. Air in system. a. Bleed hydraulic system by
operation.
b. Other causes. b. Refer other causes to direct and
general support maintenance
personnel.
23. Speed or operation slow down a. Improper oil used in system. a. See LO 10-3930-609-12 for proper
after usage. grade.
b. Dirt or foreign matter in system. b. Drain, flush out system, replace
with new oil.
c. Other causes. c. Refer other causes to direct and
general support maintenance per-
sonnel.
24. Noisy operation. a. Air in hydraulic system. a. Bleed system by operation.
b. Insufficient oil supply. b. Fill reservoir (LO 10-3930-609-12).
c. Air leak in pump intake line. c. Tighten hose.
d. Vibration of pump lines. d. Secure lines.
e. Other causes. e. Refer other causes to direct and
general support maintenance per-
sonnel.
25. Oil heats up rapidly. a. Bump slippage, oil too thin. a. See LO 10-3930-609-12.
b. Operating pressure is close to relief b. Check operation of truck.
valve pressure setting.
c. Dirty oil. c. Change oil (LO 10-3930-609-12).
d. Other causes. d. Refer other causes to direct and
general support maintenance
personnel.
26. Hoist cylinder packing leaks. Refer malfunction to direct and general
support maintenance personnel.
27. Hoist or tilt cylinder lowers or a. Wrong packing. a Replace tilt cylinder (para, 3-59a).
tilts while truck stands idle. b. Worn or soored seals, packing or b. Replace tilt cylinder (para 3-59a).
cylinders.
c. Failure in hydraulic hose. c. Cheek, tighten or replace hose.
d. other causes. d. Refer other causes to direct and
general support maintenance per-
sonnel.
28. Reservoir flows over. a. Excess oil in reservoir. a. Check oil level with forks in lowered
position and tilted back.
b. Refer other causes to direct and
general support maintenance per-
sonnel.
a. Replace tilt cylinders (para 3-59).

3-7
TM 10-3930-609-12

Malfunction Probable cause Corrective action

b. Hydraulic fluid low. b. Replenish hydraulic fluid

c. Other causes. c. Refer other causes to direct and
general support maintenance per-
sonnel.

Section VI. FIELD EXPEDIENT REPAIRS

3-11. General 3-12. Truck Will Not Start

Organizational troubles may occur while the Trouble Expedient Remedy
Seat switch, battery recep- Short circuit switch leads
fork lift truck is operating in the field where tacle switch or panic to by-pass defective switch
supplies and repair parts are not available and switch malfunctioning short across fuseholder
normal corrective action cannot be performed. fuse blown. contacts.
When this condition exists, the following ex-
3-13. Hydraulic Brakes Fail
pedient repairs may be used in emergencies, Trouble Expedient Remedy
upon the decision of the unit commander. Equip- Air in system, low fluid Use parking brake in con-
ment so repaired must be removed from opera- level. broken brake line junction with directional
or pedal improperly ad- control to slow, stop and
tion as soon as possible and properly repaired justed. otherwise control truck
before being placed in operation again. speed.

Section VII. SEAT, OVERHEAD GUARD AND ACCESS COVERS

3-14. General (3) Turn seat adjuster knob counterclock-

wise to release from guide rail. Spring will fall
The seat is mounted on a spring type mounting free.
so when the seat is depressed the travel motor (4) Do not disassemble guide rails.
brake is released. The overhead guard provided
c. Repair. Repair slightly damaged (tom) up-
for operator protection is constructed of a heavy
holstery material in accordance with good com-
tubular frame and is mounted at each frame side mercial practice, by sewing or application of an
on the front and rear. The battery compartment adhesive patch. If wear or damage is extensive,
is housed with a cover and two side panels which replace backrest or seat cushion.
are retained by the cover. The floorboard is d. Assembly. Reverse procedure in b above.
mounted to the frame and supports the accelera- e. Installation. Reverse procedure in a above.
tor and also serves as a foot rest. The control
panel cover is mounted with eight screws and Adjust seat position as desired for operator con-
serves as a protective cover for the contractor venience.
panel. The fuse panel cover is secured to the con- 3-16. Overhead Guard
trol panel cover with six screws, providing ready a. Removal.
access to the fuses. The instrument panel and
(1) Remove two screws (fig. 3-3), nuts
cowl houses the various controls and instruments
used in the operation of the fork lift truck. and lockwashers securing overhead guard at rear
of truck.
3-15. Seat Assembly (2) Remove three screws, nuts and flat-
a. Removal. Tilt seat forward, remove two washers securing overhead guard to each side of
cowl.
screws (fig. 3-2). nuts and washers securing
seat to brake actuating bar and remove seat as- (3) Using suitable hoisting equipment., re-
sembly from truck. move overhead guard from truck.
b. Installation. Reverse procedure in a above.
b. Disassembly.
(1) Remove four wood screws securing seat 3-17. Battery Compartment Covers
backrest to frame and remove backrest. a. Removal.
(2) Reaching under seat cushion, remove (1) Tilt seat assembly full forward and
four nuts and washers securing seat cushion to fully raise battery compartment top cover (fig.
frame studs and remove seat cushion. 3-3) releasing battery compartment side covers.

3-8
 TM 10-3930-609-12

Figure 3-2. Seat assembly.

(2) Open side covers and lower top cover. 3-18. Floor Plate
(3) Use a small diameter drift pin and
drive top and side cover hinge pins out to re- a. Removal.
(1) Disengage accelerator pedal from ac-
lease covers and remove covers from truck.
celerator rod by pulling pedal upward.
b. Installation. Reverse procedure in a above. (2) Remove four screws and flatwashers
Oscillate door while mating hinges to facilitate securing floorplate (fig. 3-3) to frame and re-
installation of hinge pins. move floorplate from truck.
3-9
TM 10-3930-609-12

Figure 3-3. Overhead guard and access covers.

b. Installation. Reverse procedure in a above. b. Installation. Reverse procedure in a above.

3-19. Control Panel Cover Replace cover mounting gasket if it is damaged
a. Removal. Remove eight screws and lock- to prevent dust, dirt and other contaminants
washers (fig. 3-3) securing control panel cover
to truck and remove from truck. from entering control panel compartment.

3-10
 TM 10-3930-609-12

3-20. Fuse Access Cover 3-21. Valve Cover

a. Removal. Remove six screws and lockwash- a. Removal. Remove six screws and lockwash-
ers (fig. 3-3) securing fuse access cover to con- ers (fig. 3-4) securing valve cover frame and re-
trol panel cover and remove fuse access cover move valve cover from truck.
from truck.
b. Installation. Reverse procedure in a above. b. Installation. Reverse procedure in a above.

Figure 3-4. Value cover, load backrest, forks and upright assembly.

3-11
TM 10-3930-609-12

Section VIII. LOAD BACKREST, FORKS AND UPRIGHT ASSEMBLY

3-22. Load Backrest (fig. 3-4) (4) Remove chain assembly from truck by
reeving over rollers.
a. Removal. Hoist load backrest to disengage (5) Repeat steps (1) through (4) for re-
from carriage and remove from truck. maining chain assembly.
b. InstaIlation. Reverse procedure in a above.
c. Repair. Repair is limited to replacing dam-
aged links.
3-23. Forks (fig. 3-4) (1) With chain removed from truck, use a
a. Removal. Fully lower carriage, pull up on chain breaking tool and remove damaged link or
ring catch to release fork lock and disengage links from chain. Failure of one link may dam-
fork from carriage. Repeat with other fork. age adjacent links. Remove all damaged links.
b. Installation. Reverse procedure in a above (2) Install replacement link and rivet pin
positioning forks in desired locations on carri- end to secure side plates of chain.
age. Note. Plates of end links are secured by cotter-
pins. Do not rivet or peen these pins.
3-24. Chain Assemblies
d. Installation.
a. Adjustment. Lift chain adjustment is pro- (1) Insert link in end of chain and into
vided at the base of the outer channel. Lower brackets on carriage assembly. Secure link with
carriage (fig. 3-5) until hoist cylinder bottoms. cotterpins in ends.
Remove slack from chains, adjusting the chain
adjusting nuts until chains are taut. (2) Reeve chains over rollers as shown in
figure 3-5.
Caution: Be certain load is shared equally (3) Secure chain to chain anchor with cot-
by both chains, otherwise first chain to begin terpin through link ends.
lifting will cock crosshead and cause rapid wear (4) Secure chain anchors to base of outer
and damage to hoist cylinder. upright with adjustment nuts and adjust chain
b. Removal. tension (para 3-24a).
(1) Lower carriage until hoist cylinder bot-
toms. 3-25. Upright Assembly
(2) Remove bottom adjusting nuts securing Organizational maintenance of the upright as-
chain anchor to outer upright. sembly is performed in accordance with the lu-
(3) Remove cotterpin and bottom chain brication indicated in the lubrication order (LO
link from rear of carriage. 10-3930-609-12).

3-12
 TM 10-3930-609-12

ME 3930-609-12/3-5

Figure 3-5. Triple lift upright assembly.

Section IX. BRAKE SYSTEM

3-26. General seat or pulling up on the handbrake lever to
apply the travel motor brake. The hydraulic
This section contains organizational maintenance service brake system is also included in this sec-
instructions for the mechanical parking brake tion. Depressing the brake pedal applies the
system which is applied by raising the operator’s drive axle hydraulic brakes.

3-13
TM 10-3930-609-12
3-27. Handbrake Lever orientation, and to facilitate removal and instal-
lation that may be performed in conjunction
a. Removal. with the organizational maintenance services.
(1) Fully release handbrake lever (fig. 3- b. Seat Brake Adjustment.
6) and remove screws, nuts and washers securing (1) Two adjustments are provided to main-
handbrake lever to forward angle. tain the motor brake at required efficiency. The
(2) Remove screw, nut and lockwasher brake shoe adjusting nut (on brake actuating
securing handbrake lever to control cable and clevis) provides the basic adjustment on which
pull handbrake lever out of truck. the seat actuation adjustment depends.
b. Installation. Reverse procedure in a above, (2) Remove truck cowl and valve cover
adjusting handbrake cable (para 3-28c) after in- (para 3-21) and floor plate (para 3-18). With
stallation. truck seat occupied and handbrake released,
check with leaf or round feeler gage for brake
3-28. Handbrake Cable and Control shoe lining-to-drum clearance of 0.010 inch to
linkage 0.020 inch.
a. Removal. (3) If required, tighten brake shoe adjust-
(1) Disengage handbrake lever from con- ing nut to set clearance between these values.
trol cable (para 3-27a (2)). Do not overtighten, so brake will not drag.
(2) Unscrew nut securing control cable in (4) With loaded truck held on 15o incline
clevis and remove spring. by foot brake application, raise from operator's
(3) Pull cable from clevis and remove out- seat and release foot brake. If truck rolls, stop
side clevis nut. with foot brake and continue to (5) below.
(4) Remove nut securing control cable out- (5) Tighten spring adjusting nut not over
er covering to travel motor mounting bracket two turns, and repeat (4) above to test results.
and pull control cable off truck. Repeat until spring application of motor brake
b. Installation. Reverse procedure in a above, holds loaded truck on 15o incline.
adjusting handbrake cable (para 3-28c) after in- c. Brake Rod Adjustment.
stallation. (1) Adjust spring tension raising seat to
c. Adjustment. suit operator, by turning large nut above spring.
(1) Check seat brake adjustment (para 3- (2) Adjust position of motor switch sup-
29b). port strip with seat bottomed by operator's
(2) Fully release handbrake lever and fully weight, so motor switch is definitely actuated.
depress operator’s seat.
(3) Rack off outside clevis nut and press 3-30. Service Brake
control cable into clevis. Run outside clevis nut
a. Brake Adjustment. The service brakes are
up to clevis.
(4) Tighten inside clevis nut to prevent self-adjusting to take up play due to lining wear.
spring from free movement but not enough to Refer to paragraph 3-31b(4) for pedal adjust-
compress spring. ment.
b. Bleeding Service Brake System. The hy-
(5) Sit in operator’s seat and engage hand-
brake to be certain travel motor brake fully en- draulic brake system must at times be bled to
gages expel air in the system. The need is generally
(6) If brakes do not fully engage, repeat indicated by springy or spongy brake pedal
steps (2) through (5) above pressing control action. Unless special brake bleeding equipment
cable further into clevis. Reverse this procedure is available, two men are required to bleed the
if brakes engage with no application of hand- system, one to maintain a constant supply of
brake lever. fluid in the master cylinder and to pump the
brake pedal, the other to perform the bleeding
operation.
3-29. Seat Brake and Control Linkage (1) Remove floor plate (para 3-18). Re-
a. General. The parts shown in figure 3-7 move filler plug from master cylinder and fill
comprise the footbrake and seat brake linkage. with hydraulic brake fluid.
With the exception of the brake master cylinder, (2) Clean bleeder screws at each wheel cy-
these parts and linkages are not subject to re- linder (fig. 3-8). Remove small screws from
pair other than replacement of individual dam- bore of bleeder screws. Attach one end of bleed-
aged parts. The parts are illustrated for general er hose to bleeder screw and place other end of
3-14
 TM 10-3930-609-12

ME 3930-609-12/3-6
Figure 3-6. Handbrake lever, cable and control linkage.
hose in clean container partially filled with hy- (4) Maintain fluid level in master cylinder
draulic brake fluid. Be sure end of hose is sub- and continue to operate brake pedal until fluid
merged in the hydraulic fluid. flows in a steady solid stream without air bub-
(3) Turn bleeder screw counterclockwise bles. Close bleeder screw by turning it clock-
three-quarters of a turn. Apply steady pressure wise. Remove bleeder hose, and replace small
to brake pedal. Hydraulic fluid containing air screw in bleeder screw.
bubbles should be forced through bleeder hose (5) Repeat bleeding procedure at other
into container. wheel, replenishing brake fluid in master cy-
3-15
TM 10-3930-609-12

ME 3930-609-12/3-7
Figure 3-7. Foot brake and seat brake linkage.
linder before each wheel cylinder is bled. Re- tially of tapping self-adjuster levers toward cen-
place filler plug in master cylinder. ter of axle.
Caution: Hydraulic brake fluid bled from (3) Install front wheels (para 3-72) and
the brake system must not be reused. operate brake pedal several times to adjust
brakes.
c. Brakeshoe Removal.
(1) Remove drive axle wheel (para 3-72). 3-31. Master Cylinder
(2) With brake spring pliers, remove a. Removal.
brakeshoe return spring (fig. 3-9) and retainer (1) Remove floor plate (para 3-18).
spring. Carefully remove brakeshoes, and install (2) Remove hollow bolt (fig. 3-7) and
brake clamps on wheel cylinder to prevent brakeline fitting from front of master cylinder.
pistons being pushed out of cylinder by residual Take precautions to keep dirt from entering
pressure in brake lines. brakeline.
d. Brakeshoe Installation. (3) Remove nuts, lockwashers, and screws
(1) Reverse procedure in c(2) above. attaching master cylinder to truck, and remove
(2) Temporarily adjust shoes inward as far master cylinder. Pushrod will remain connected
as they will go. This procedure consists essen- to brakeshaft and need not be removed.
3-16
 TM 10-3930-609-12

Figure 3-8. Bleeding Brakes.

b. Installation. 3-32. Brake Pedal

(1) Reverse procedures in a above. a. Removal.
(1) Remove floor plate (para 3-18) from
(2) Fill cylinder with brake fluid (LO 10- truck.
3930-609-12). (2) Remove cotterpin and clevis pin (fig.
(3) Bleed brake hydraulic system (para 3- 3-7) from pushrod. Disconnect spring from
30b). brake pedal.
(3) Remove screw, nut, and lockwasher at-
(4) Loosen jamnut on pushrod, and adjust taching brake pedal and remove pedal from
length of pushrod by turning adjustment to give truck. Lift free of truck.
1/4 inch to 5/8 inch free travel of pedal before b. Installation and Adjustment. Reverse pro-
brake application begins. Tighten jamnut to cedures in a above and check for proper pedal
secure adjustment. adjustment (para 3-31b(4)).

3-17
TM 10-3930-609-12

ME 3930-609-12/3-9

Figure 3-9. Service brake assembly, exploded view.

Section X. ELECTRICAL SYSTEM

3-33. General 3-35. Light Switch

The electrical system consists of a battery, head- a. Removal.
light, stop and taillight, resistors, SCR control (1) Remove nut at top of light switch (fig.
panel with magnetic relays, drive motor, pump 2-1) and lower switch out bottom of instrument
motor and various switches for the operation and panel.
safety of the fork lift truck. The battery charge (2) Disconnect, tape, and tag leads from
receptacle is a quick disconnect type so the bat- switch.
tery can be disconnected from the circuit and re- b. Installation. Reverse procedures in a above.
charged without being removed from the truck.
3-36. Panic Switch
3-34. Hourmeter a. Removal.
a. Removal. (1) Pull button off panic switch (fig. 2-1),
(1) Disconnect two leads at hourmeter (fig. unscrew knurled retaining nut at top of switch
2-1) from under instrument panel, tape ends, and lower switch out bottom of instrument
and tag leads for identification. panel.
(2) Remove two nuts holding hourmeter to (2) Disconnect, tape, and tag leads from
instrument panel and lift hourmeter off panel. switch.
b. Installation. Reverse procedures in a above. b. Installation. Reverse procedures in a above.

3-18
 TM 10-3930-609-12
3-37. Battery Connector Receptacle are connected to “B” terminals. If not, connect
them correctly before proceeding.
a. Removal.
(1) Release battery connector (fig. 3-10) (3) Connect a voltmeter lead to each “A”
and pull connector free from receptacle. terminal, and operate switch button by hand. If
(2) Remove four screws and lockwashers meter reads system voltage with button free, and
securing receptacle to vehicle. zero voltage with button pressed, switch is op-
(3) Remove control panel cover (para 3- erative. Test at “B” terminals for opposite re-
19). sults.
(4) Remove nuts, lockwashers and insula- (4) With voltmeter still connected as in
tors securing plus (+) and minus (-) leads at (3) above, operate pedal manually. If operation
bottom of control panel. of pedal does not give same results, switch posi-
(5) Remove clamps securing leads to bot- tion must be adjusted so brake application closes
tom of vehicle and withdraw battery connector switch at “A” terminals and opens switch at “B”
receptacle with leads attached. terminals, reversing this on releasing brake
b. Installation. Reverse procedures in a above pedal.
being certain to properly secure leads with re-
moved cable clamps to bottom of truck. b. Adjustment. Disconnect leads and loosen
switch attaching nuts. Adjust switch position
3-38. Stoplight Switch orientation so switch lights stoplight before
braking action begins, and light goes out before
Before replacing switch, check that it is truly de- pedal reaches top of travel. Tighten nuts.
fective, and not merely in need of adjustment,
c. Removal.
and that leads are correctly installed as in a fol-
lowing. (1) Remove floor plate (para 3-18).
(2) Remove switch attaching screws, nuts
a. Inspection and Test. and lockwashers and leads, and remove switch
(1) Remove floor plate (para 3-18). from bracket.
(2) Inspect that wires labeled (35) and
(86-1) at switch (fig. 3-7) are connected to ter- d. Installation. Reverse procedures in c above
minals marked “A” and wires (70) and (94) and adjust switch (b above).

3-39. Battery Connector Receptacle Switch

a. Removal.
(1) Raise battery connector handle.
(2) Unscrew switch extension (fig. 3-10)
from switch.
(3) Remove nut and lockwasher securing
switch to bracket and pull switch free.
(4) Disconnect, tape and tag leads from
switch.
b. Installation. Reverse procedures in a above.

3-40. Headlight
a. Removal.
(1) Remove clamps (fig. 3-11) holding
conduit to outer upright.
(2) Disconnect two wires at terminals at
bottom end of conduit.
(3) Remove two screws, nuts and washers
attaching light to upright and remove light and
conduit as an assembly.
b. Repair. Repair of headlight is confined to
replacing the sealed beam lamp (para 3-42).
Figure 3-10. Battery connector receptacle and switch. c. Installation. Reverse procedures in a above.
3-19
TM 10-3930-609-12
(3) Disconnect stop and taillight connector.
(4) Remove nut and washer holding light
to truck and remove light and guard.
b. Repair. Remove lens attaching screws and
lens, and install new bulb. Replace lens attach-
ing screws and lens.
c. Installation. Reverse procedures shown in a
above.

3-42. Lamps
a. Headlight Lamp Replacement.
(1) Remove bezel from headlight.
(2) Withdraw sealed beam unit from head-
light sheel and disconnect two wires from lamp.
b. Installation. Reverse procedures in a above.
c. Stop and Taillight Lamp Replacement. See
paragraph 3-41 b.

3-43. Taillight Resistor (fig. 3-13)

a. Removal.
(1) Remove control panel cover (para 3-
19).
Figure 3-11. Headlight. (2) Disconnect wires numbered (13A-5),
(19) and (35) from resistor, located at top right.
3-41. Stop and Taillight Remove two mounting screws and remove resis-
tor.
a. Removal.
b. Test. Test resistor with ohmmeter across
(1) Remove two screws, and washers (fig. terminals for 40 ohms resistance, plus or minus
3-12) attaching guard to truck. Lift guard.
20 percent.
(2) Remove control panel cover (para 3-
19). c. Installation. Reverse procedures in a above.

Figure 3-12. Stop and taillight.

3-20
 TM 10-3930-609-12

ME 3930-609-12/3-13
Figure 3-13. Control panel.

3-44. Horn 3-45. Horn Button

a. Removal. a. Removal. Remove four screws (fig. 3-15)
and lift off cover, button, separator, insulator,
(1) Remove truck floor plate (para 3-18). contact, spring and contact.
(2) Disconnect wires (fig. 3-14) from horn. b. Installation. Reverse procedures in a above.
(3) Remove screws and washers holding 3-46. Battery Maintenance
horn to adapter and remove horn. a. Checking Specific Gravity. The specific
b. Installation. Reverse procedures in a above. gravity of the electrolyte at 77oF, with electro-
3-21
TM 10-3930-609-12

ME 3930-609-12/3-15

Figure 3-15. Horn button.

(1) Put battery on charge again at the

finish rate, so cells gas for thorough mixing of
electrolyte.
Note. Never make a gravity adjustment on a cell
which does not gas freely on charge.
(2) Draw off electrolyte down to splash
cover from low reading cells. Slowly pour elec-
trolyte of 1.300 to 1.350 specific gravity in cell
to high lever (1/4 inch below filler neck).
Caution: Never use acid or higher speci-
fic gravity than 1.350.
ME 3930-609-12/3-14 (3) Wait twenty minutes for added electro-
lyte to become thoroughly mixed by gassing
Figure 3-14. Horn. charge and then read specific gravities. If the
gravity of any cell is still below normal repeat
steps (1) through (3). Repeat as many times as
lyte at normal level and cells fully charged necessary.
should be 1.265 to 1.285. This specific gravity (4) Continue charging battery for one hour
is correct when the battery is delivered and will at the finishing rate, after gravity has been ad-
not require adjusting during the lift of the bat- justed.
tery unless electrolyte is actually lost out of the (5) If the corrected specific gravity of any
battery. cell is higher than normal (1.285) proceed as
b. Adjusting Specific Gravity. Acid or electro- follows:
lyte should never be added to a cell without first (6) As the battery charges, withdraw from
being sure that charging will not restore the the cell a small amount of electrolyte and re-
gravity. Give the battery a thorough equalizing place with water. Repeat at 20 minute intervals,
charge (para 3-46e). Charge should be con- if necessary, until a 1.285 specific gravity reading
tinued until specific gravity when tested every is obtained.
hour for three hours shows no further rise at c. Adding Water to Battery. Add only dis-
any cell. If, after charge, gravity is still below tilled water or chemically analyzed and approved
normal proceed as follows: water from public drinking source. The proper
3-22
 TM 10-3930-609-12
level of electrolyte is 1/4 inch from bottom of commercial practice in their repair. Refer to the
filler neck. wiring diagram (fig. 1-3) and conduct a syste-
matic inspection using an ohmmeter to isolate
Caution: Do not use water which has passed the trouble. Remedy the trouble by splicing
through a water softener. This water is chemic- leads where required and applying electrical tape
ally destructive to a lead-acid battery. It is not to prevent short circuits from occurring. Refer to
equivalent to distilled water. direct support maintenance for replacement of a
(1) Add water slowly. Water should be complete wiring harness or repair to wiring en-
added before charging to insure prompt mixing cased in flexible metal conduit.
with the electrolyte.
(2) In sub-freezing temperatues battery 3-48. Motor Brush Replacement
must be put on finish charge for one hour after
Motor brush replacement (fig. 3-16) for the
water has been added. travel motor or hydraulic pump motor is the
d. Cleaning the Battery. The entire battery
same.
and battery compartment should be kept clean
a. Removal.
and dry. If the electrolyte has been spilled or
(1) Remove screw, nut and lockwasher
corrosion has formed on the battery proceed as securing brush covers to motor housing and re-
follows: move brush covers.
(1) Add one pound of bicarbonate of soda
(2) Remove screw and lockwasher securing
to one gallon of warm water. Pour solution over
brush leads.
corrosion or spilled electrolyte. (3) Pull back on brush spring sufficiently
(2) When foaming action stops rinse off to release brush and pull brush out of brush
the entire battery with clear water. holder.
Caution: Vent plugs must be installed in (4) Repeat steps (1) through (3) for re-
cells to prevent soda solution from getting into moval of remaining brushes.
the cells. Do not use steam or very hot water to b. Inspection. Compare length of used brush
clean battery. with length of a new brush from stock. Replace
any brush worn to half (or less) the length of
e. Charging the Battery. Batteries normally
new brush, as given below.
discharged more than one third of their capacity
c. Installation.
daily should be recharged daily. Other batteries (1) Install new brushes in brush holders
in use should be charged at least once a week. with short side of brush toward spring side of
Do not charge batteries more often than neces- holder, so brush friction surface contour mates
sary to reduce gassing and water loss. Plan on re-
with surface of armature commutator. If brush
charge time, for a completely discharged battery,
edge meets commutator, reverse brush in hold-
of about eight hours, proportionally less for
er. Fasten brush leads to holder with removed
partially discharged batteries. Charge as follows:
screws and lockwashers.
(1) Disconnect battery leads at battery con-
nector receptacle and connect charger to battery (2) Hook brush springs over brushes and
half of connector. check pressure exerted on brush with brush
(2) Using procedure appropriate to the spring pull scale. Pressure should be 26 ounces
to 32 ounces at time scale lifts spring from brush
charger being used, adjusted initial charging
rate for a fully discharged battery of 130 to 160 on either motor.
(3) Install brush covers and secure in posi-
amperes. tion on motor housing with removed screw, nut
(3) At end of charging time disconnect
charger and observe cell vent; caps for signs of and lockwasher.
excessive gassing. This is usually indicated by 3-49. Relay Contact Replacement
electrolyte around the fill hole of the cell.
Relay contact maintenance is restricted to those
f. Removal. Reverse the procedures outlined
relays having contacts visible for inspection, and
in paragraph 2-4e.
replaceable without removing the relays. Main-
g. Installation. Refer to paragraph 2-4e. tenance requiring more than contact or interlock
switch replacement, shall be performed by direct
3-47. Wiring Harness support maintenance personnel. Contacts require
Repair of the wiring harness is limited to iso- replacement when the silver has worn down to
lating shorted and open circuits and using good the steel support.

3-23
TM 10-3930-609-12

ME 3930-609-12/3-16

Figure 3-16. Motor brush replacement.

a. Removal. 3-50. Relay Interlock Switch Replacement
(1) Remove control panel cover (para 3-
19). a. Removal.
(2) Remove nuts (fig. 3-13) holding con-
tacts which are to be removed. Remove contacts (1) Remove control panel cover (para 3-
from relay. 19).
b. Installation. Put new contacts in position
and install nuts. No special check or adjustment (2) Disconnect leads from interlock switch
is needed after installation. (fig. 3-13).
3-24
 TM 10-3930-609-12
(3) Remove the screws, flatwashers and 3-55. Thermal Relay
lockwashers securing the interlock switch to its Each motor is protected by a thermal relay, ex-
bracket and remove the switch. ternally mounted on the motor housing adjacent
b. Installation. Reverse the procedures in a to the motor leads, which will open the motor
above. circuit if overheating occurs. When temperature
sensed by the relay drops to a safe operating
3-51. Fuse and Fusetron Replacement value, the relay will automatically close.
a. Removal. a. Removal.
(1) Remove fuse access cover (para 3-20).
(2) Loosen screws (fig. 3-13) securing (1) Remove screw, lockwasher and clamp
fusetron to fuse panel and slide fusetron off fuse which fastens relay to motor and lift relay from
panel. motor.
(3) Pull fuses straight off fuse panel. (2) Scrap sealing compound from relay ter-
b. Installation. Reverse applicable procedures minals. Unsolder leads at terminals.
in a above to replace fusetrons and fuses. b. Installation. Reverse procedures in a above,
soldering leads to terminals with rosin flux and
3-52. Directional Control Switch solder. Avoid unnecessary heating of the relay
while soldering. Coat terminals after soldering
Maintenance of the directional control switch with silicone rubber sealing compound.
(fig. 2-1) consists of replacing internal switches.
The switch need not be removed. c. Test.
a. Removal. (1) Test electrical continuity of relay be-
(1) Remove cover attaching screws and tween terminals with an ohmmeter or test light.
washers, or remove cover. Test at room temperature.
(1) Disconnect and tag leads from switch (2) If controlled temperature is available,
terminals. test opening temperature of relay. It should open
(3) Remove switch attaching screws and on rising temperature at 224oF, plus or minus
nuts, and remove switch. 4 o.
b. Installation. Reverse procedure in a above.
3-56. Accelerator Master Assembly
3-53. Pump Motor Switch a. Removal.
a. Removal. (1) Remove floor plate from truck (para
(1) Remove valve cover (para 3-21).
(2) Disconnect and tag leads at switch (fig. 3-18).
(2) Disconnect linkage and spring from op-
3-17), loosen jamnut, and screw switch out of
erating lever (fig. 3-18), remove cover screws,
switch bracket. and remove cover.
b. Installation. Reverse procedures in a above, (3) Disconnect and carefully tag leads in-
turning switch in switch bracket to point where
side housing at switch terminal screws. Care-
switch is actuated when either the tilt or hoist fully tag leads inside housing at switch terminal
lever is operated.
screws. Carefully draw leads out through conduit
fitting. Do not remove identification labels from
3-54. Seat Switch leads.
a. Removal. (4) Remove screws and lockwashers hold-
(1) Remove valve cover (para 3-21). ing mounting bracket to truck and remove as-
(2) Disconnect and tag leads at switch (fig. sembly.
3-17).
(3) Remove switch attaching screws, nuts b. Repair. The following procedure does not
and lockwashers securing switch to bracket and require removal of the assembly.
remove switch. (1) Remove cover screws and cover.
(2) Disconnect leads at switch to be re-
b. Installation. Reverse procedures in a above,
placed, remove switch holddown screws, and re-
adjusting switch position up or down as required
so that it is just actuated as the operator’s seat move switch.
is fully lowered. Loosen bracket screws to posi- (3) Install new switch by reversing pro-
tion bracket with attached switch for proper actu- cedures in (1) to (3) above.
ation and then tighten bracket screws. c. Installation. Reverse procedures in a above.
3-25
 TM 10-3930-609-12

Figure 3-17. Seat switch and pump motor switch.

3-26
 TM 10-3930-609-12

Figure 3-18. Accelerator master assembly.

Section Xl. HYDRAULIC SYSTEM

3-57. General (8) Remove screws, nuts and lockwashers

securing bracket and switch actuator hinge; re-
The hydraulic system (fig. 3-19) consists of a
move bracket and switch actuator hinge.
pump and drive motor, control valves, hoist and
b. Installation. Reverse procedure in a above,
tilt cylinders, filters, hoses and lines for the op-
adjusting position of sleeves on connecting rods
eration of the tilt and lift functions of the fork
until control valve actuation is proper, then
lift truck. This section provides information use-
secure with setscrews.
ful in the repair of the hydraulic system. When
ever hydraulic components are disconnected or
removed, operate the tilt and hoist control valves 3-59. Tilt Cylinders
several times after installation to purge air from a. Removal.
the hydraulic system. (1) Remove truck floor plate (para 3-18).
(2) Tag and disconnect hoses (fig. 3-21)
3-58. Control Valve levers and Linkage from tilt cylinders. Cap hoses and plug ports in
a. Removal. cylinders to exclude dirt.
( 1) Remove valve cover plate (para 3-21). (3) Support mast so it will not suddenly
(2) Remove retaining rings (fig. 3-20) tilt on removal of tilt cylinders.
securing connecting rods to hoist and tilt levers.
Warning: If not supported the mast will
(3) Pull out cotterpin securing rod in
bracket and pull out rod to release hoist and fall forward when the tilt cylinders are discon-
tilt levers. nected.
(4) Remove screws and lockwashers secur- (4) Remove screws attaching shafts to
ing bracket to truck and remove bracket. brackets on truck frame and on uprights.
(5) Remove cotterpins and clevis pins (5) Pull or drive shafts from cylinder ends.
securing clevis and connecting rods to control Be careful not to let cylinder fall as shafts are
valve. If valve actuation is proper, note position removed.
of sleeves and connecting rod clevises before dis-
b. Installation.
assembling them from the connecting rods.
(6) Compress spring, turn disc to release (1) Position tilt cylinder (back end) in U
pin and remove disc, spring and pin from shaped bracket on truck frame.
bracket. (2) Aline bracket holes and cylinder end
(7) Remove screws securing spacer clips; hole. Insert shaft through bracket and cylinder
remove spacer clips. end hole. Secure shaft with screw.

3-27
TM 10-3930-609-12

ME 3930-609-12/3-19

Figure 3-19. Hoist and tilt hydraulic system.

(3) Remove plugs from ports and caps (2) Unscrew and discard air cleaner and
from hoses and connect hydraulic hoses to cylin- gasket (fig. 3-21) from hydraulic tank.
ders. b. Installation. Reverse procedures in a above.
(4) Check hydraulic fluid level in reservoir.
(5) After installation, operate tilt control 3-61. Filter Cartridges
lever several times to purge air from cylinders.
Check cylinders and hose fittings for leakage Two filters are used in the hydraulic system; one
while operating. in suction line adjacent to pump, the other in
(6) Retract both tilt pistons fully. With return line from control valve, at left rear of hy-
mast tilted 10o to rear of vertical and pistons draulic tank.
retracted fully, repeat step b above. Secure front a. Return Filter Cartridge Replacement.
end of tilt cylinders to upright brackets with (1) Turn cartridge (fig. 3-22) from filter
shafts and attaching screws. cover by hand.
(2) Install new cartridge by reversing pro-
3-60. Air Cleaner cedure in ( 1) above.
b. Suction Filter Element Replacement.
a. Removal. (1) Unscrew filter housing (fig. 3-22)
(1) Remove truck floor plate (para 3-18). from head and discard housing seal.
3-28
 TM 10-3930-609-12

Figure 3-20. Control Levers and linkage.

(2) Remove and discard filter element and fective parts and replacement with new hydraulic
element seal. lines and fittings. Visually inspect hydraulic
(3) Install new filter element and seals by lines and fittings during operation for signs of
reversing procedures (1) and (2) above. hydraulic fluid leakage or restrictions signified
by operational malfunction. Tag hydraulic lines
3-62. Hydraulic Lines and Fittings as they are disconnected to facilitate installation
Organizational maintenance of the hydraulic and cap hoses or plug parts, as required, to ex-
lines and fittings is limited to removal of de- clude dirt or other contamination.

3-29
TM 10-3930-609-12

Figure 3-21. Tilt cylinders, hoses and air cleaner

3-63. Hoist Regulating Valve bottom of hoist regulating valve mounted just
a. Removal. above base of hoist cylinder. Cap hose to exclude
dirt.
(1) Fully lower lift carriage. (3) Unscrew hoist regulating valve with at-
(2) While working from front of truck tached fittings from hoist cylinder and move
through hole in lift carriage, unscrew hose from fittings. Discard O ring packings.
3-30
 TM 10-3930-609-12
b. Installation. Reverse procedures in a above
using new O ring packing. Operate hoist control
valve several times to purge air and check for
hydraulic fluid leakage at fittings. Tighten as re-
quired.

Figure 3-22. Suction filter.

Section VII. STEERING SYSTEM

3-64. General (2) Loosen jamnut and turn lash adjuster

with screwdriver until steering wheel passes
The steering system consists of the steering through center of travel with 14 to 18 ounces
wheel, steering gear assembly, steering axle pull on the rim. Tighten jamnut, recheck adjust-
with wheels and tie rods, and the draglink. ment and then install draglink.
3-65. Steering Wheel b. Steering Linkage Adjustment.
(1) With steering wheel halfway between
a. Removal. extreme right and extreme left turn, assemble
(1) Remove horn button (para 3-45).
pitman arm to steering gear as shown in figure
(2) Remove steering wheel nut (fig. 3-15)
3-23.
and using a suitable puller, remove steering (2) With trailing axle wheels in straight
wheel from steering gear column.
ahead position, adjust draglink to proper length
b. Installation. Reverse procedures in a above by loosening clamps and turning draglink tubing
orienting steering wheel on steering gear column until tie rod end at front of draglink will enter
so that keyway properly mates with key before
hole in pitman arm freely, with pitman arm ver-
securing steering wheel with nut.
tical.
3-66. Steering Gear (3) Tighten draglink clamps.
Organizational maintenance of the steering gear
is limited to lash adjustment and steering link- 3-67. Wheel Alinement Measurement
age adjustment. Refer all other maintenance to Determine if wheel alinement adjustment is
direct support maintenance. needed as follows:
a. Lash Adjustment. a. With rear axle level front to rear, and
(1) Remove nut (fig. 3-23) holding drag- wheels in straight ahead position, measure inside
link to pitman arm, and disconnect draglink. span between tiers at hub height at front of
Note. If necessary, use puller, but do not dam- axle.
age threads, or place strain on pitman arm. b. Repeat a above at rear of axle.
3-31
TM 10-3930-609-12

ME 3930-609-12/3-23

Figure 3-23. Steering adjustment.

c. If measurements obtained in a and b above (3) Draw wheel from steering axle spindle.
differ by 1/16 inch, adjust as below until wheels Because of manufacturing tolerances the cone
are parallel to within 1/16 inch as measured in and rollers of the inboard bearing may remain
a and b above. with spindle. If so, it can easily be removed.
Avoid damaging oil seal, if possible, when re-
3-68. Wheel Alinement Adjustment moving wheel.
a. Loosen (but do not remove) screws and b. Installation. Reverse procedures in a above,
nuts from all tie rod end clamps (fig. 3-24). tightening wheel nut snug, then backing it off
b. Turn each tie rod an equal number of turns not more than 1/6 turn, and install cotterpin.
in the direction necessary to change toe-in as re-
quired. 3-70. Rear Wheel Bearings
Note. Each tie rod has right hand threads at one a. Removal.
end, left hand threads at the other, so adjustment can ( 1) Remove rear wheels (para 3-69a).
be made to change effective length without dismounting (2) Pull bearings from bore of wheel. A
tie rod. slip hammer bearing puller may be used to pull
c. When adjustment has been completed, bearings from wheel if they stick in bore.
tighten tie rod clamp screws and nuts and re- (3) Remove retaining rings which position
check wheel alinement measurement (para 3- bearings.
67). b. Service.
(1) Clean bearings with SD and dry
3-69. Rear Wheels thoroughly.
a. Removal. (2) Inspect cups and rollers for wear or
failure. Inspect cone and roller assemblies for
(1) Lower forks fully and tilt mast back. roughness when rotated.
Raise rear of truck until wheels clear floor. (3) If bearings are serviceable, repack with
(2) Remove hub cap (fig. 3-25), and re- grease in accordance with LO 10-3930-609-12,
move cotterpin, nut, and washer from bore of using a bearing packing device, if available.
wheel. c. Installation. Reverse procedures in a above.

3-32
 TM 10-3930-609-12

ME 3930-609-12/3-24

Figure 3-24. Wheel alinement adjustment.

ME 3930-609-12/3-25

Figure 3-25. Rear wheel and bearings.

Section XIII. DRIVE AXLE

3-71. General 3-72. Drive Axle Wheels
This section contains instructions for replace- a. Removal.
ment of the drive axle wheels. Refer service (1) Jack up front wheels as follows:
other than this to direct support maintenance. (a) Tilt mast to extreme back position.

3-33
TM 10-3930-609-12
(b) Place block directly under mast at (3) Remove wheel.
lift cylinder. Note. If brake lining drags on wheel, interfering
(c) Tilt mast forward until wheels are with removal, slack off adjusment of brake self-adjust-
clear. ers by vigorously wiggling wheel to force brakeshoes
inward.
(2) Remove six screws holding wheel to
truck. b. Installation. Reverse procedures in a above.

3-34
 TM 10-3930-609-12

CHAPTER 4
SHIPMENT, ADMINISTRATIVE STORAGE, AND DEMOLITION
TO PREVENT ENEMY USE

Section I. SHIPMENT AND ADMINISTRATIVE STORAGE

4-1. Preparation of Equipment for Shipment d. Packing. Pack the disassembled compo-
nents, basic issue items, and publications in a
a. General. Instructions for preparation of the suitable container, and secure to the Fork Lift
Fork Lift Truck for domestic shipment are pro- Truck. Refer to TM 38-230 for guidance in se-
vided in this paragraph. Preservation and pack- lection, fabrication and packing of the container.
aging shall be accomplished in a sequence that e. Marking. Mark in accordance with MIL-
will not require the operation of previously pre- STD-129.
served component. f. Loading. Load, block, and tie-down the
b. Inspeciton. Examine the Fork Lift Truck
Fork Lift Truck in accordance with carrier rules
for any unusual condition such as damage, rust- and regulations.
ing, accumulation of water and /or missing com-
ponents. Make a complete inspection of the
Fork Lift Truck as outlined in the Preventive 4-2. Administrative Storage
Maintenance checks and services, paragraph 3-7. Preparation, care, and removal of equipment in
c. Preservation. Clean, paint, preserve and administrative storage will be in accordance with
weather-proof in accordance with applicable re- the applicable requirements of TM 740-90-1
quirements of TM 740-90-1. (Administrative Storage of Equipment).

Section II. DEMOLITION OF MATERIAL TO PREVENT ENEMY USE

4-3. General (2) Battery.
When capture or abandonment of the fork lift (3) Hydraulic motor and traveling motor.
truck to an enemy is imminent, the responsible Note. The above steps are minimum requirements
unit commander must make the decision either to for this method.
destroy the equipment or to render it inopera- (4) Steering Column.
tive. Based on this decision, orders are issued (5) Hydraulic pump.
which cover the desired extent of destruction.
Whatever method of demolition is employed, it (6) Mast.
is essential to destroy the same vital parts of all b. Demolition by Misuse. Pour sand in the
fork lift trucks and all corresponding repair oil reservoir and operate the fork lift until
parts. failure occurs.

4-4 Demolition to Render the Fork Lift 4-5. Demolition by Explosives or Weapons
Truck Inoperative Fire
a. Demolition by Mechanical Means. Use a. Explosives. Place as many of the following
sledge hammers. crowbars, axes, picks, or any charges as the situation permits and detonate
other heavy tools which may be available to them simultaneously with detonating cord and a
destroy the following: suitable detonator.
(1) Contactors. (1) One 1/2-lb. charge on lift cylinder.

4-1
TM 10-3930-609-12
(2) One 1/2-lb. charge inside of each drive Saturate this packing with gasoline, oil, or diesel
wheel. fuel and ignite.
(3) One 1/2-lb. charge inside of each steer- b. Submersion. Totally submerge the fork lift
ing wheel. truck in a body of water to provide water dam-
Note. The above are minimum requirements for age and concealment. Salt water will damage
this method. metal parts more than fresh water.
(4) One 1/2-lb. charge inside of control
panel. 4-7. Training
(5) One 1/2-lb. charge on hydraulic oil All operators should receive thorough training
pump and motor. in the destruction of the fork lift truck. Refer to
(6) One 1/2-lb. charge on the differential. FM 5-25. Simulated destruction, using all of the
(7) Two 1/2-lb. charges on traveling motor. methods listed above, should be included in the
(8) Two 1/2-lb. charges inside of battery operator training program. It must be empha-
compartment. sized in training, that demolition operations are
usually necessitated by critical situations when
b. Weapons Fire. Fire on the fork lift truck
time available for carrying out destruction is
with the heaviest practical weapons available.
limited. For this reason, it is necessary that op-
erators be thoroughly familiar with all methods
4-6. Other Demolition Methods of destruction of equipment, and be able to
a. Burning. Pack rags, clothing, or canvas, carry out demolition instructions without refer-
under, around, and inside the fork lift truck. ence to this or any other manual.

4-2
 TM 10-3930-609-12

APPENDIX A
REFERENCES

A-1. Fire Protection

TB 5-4200-200-10 Hand Portable Fire Extinguishers Approved for Army Users

A-2. Lubrication
C9100IL Fuels, Lubricants, Oils and Waxes
LO 10-3930-609-12 Lubrication Order

A-3. Painting
TM 9-213 Painting Instructions for Field Use

A-4. Radio Suppression

TM 11-483 Radio Interference Suppression

A-5. Maintenance
TM 38-750 Army Equipment Procedures
TM 9-6140-200-15 Operation and Organizational Field and Depot Maintenance
TM 10-3930-609-20P Organizational Maintenance Repair Parts & Special Tools List Manual

A-6. Shipment and Storage

TB 740-93-2 Preservation of USAMEC Mechanical Equipment for Shipment and Stor-
age
TM 740-90-1 Administrative Storage of Equipment

A-1
 TM 10-3930-609-12

APPENDIX B
BASIC ISSUE ITEMS LIST

Section I. INTRODUCTION
Code Explanation
B-1. Scope
bled by units at indicated maintenance cate-
This appendix lists items which accompany the gories.
fork lift truck or are required for installation, X Applied to parts and assemblies which are
operation, or operator's maintenance. not procured or stocked, the mortality of
which is normally below that of the appli-
cable end item, and the failure of which
B-2. General should result in retirement of the end item
This Basic Issue Items List is divided into the from the supply system.
X1 Applied to repair parts which are not pro-
following sections: cured or stocked, the requirement for which
a. Basic Issue Items-Section II. A list of will be supplied by use of the next higher
items which accompany the fork lift truck or are assembly or components.
required for the installation, operation, or op- X2 Applied to repair parts which are not stocked.
erator’s maintenance. The indicated maintenance category requir-
ing such repair parts will attempt to obtain
b. Maintenance and Operating Supplies-Sec- them through cannibalization; if not ob-
tion III. A listing of maintenance and operating tainable through cannibalization, such re-
supplies required for initial operation. pair parts will be requisitioned with sup-
porting justification through normal supply
channels.
B-3. Explanation of Columns C Applied to repair parts authorized for local
The following provides an explanation of col- procurements. If not obtainable from local
umns in the tabular list of Basic Issue Items, procurement, such repair parts will be req-
uisitioned through normal supply channels
Section II. with a supporting statement of nonavaila-
a. Source, Maintenance, and Recoverability bility from local procurement.
Codes (SMR), Column (1). G Applied to major assemblies that are procured
with PEMA (Procurement Equipment Mis-
Note. Common hardware items known to be readily sile Army) funds for initial issue only to
available in Army supply will be assigned Maintenance be used as exchange assemblies at DSU and
Codes only. Source Codes, Recoverability Codes, and GSU level or returned to depot supply
Quantity Authorized will not be assigned to this cate- level.
gory of items.
(1) Source Code, indicates the selection (2) Maintenance Code, indicates the lowest
status and source for the listed item. Source category of maintenance authorized to install the
codes are: listed item. The maintenance level code is:
Code Explanation Code Explanation
P Applied to repair parts which are stocked in C -- Operator/crew
or supplied from GSA/DSA or Army sup- O -- Organizational maintenance
ply system, and authorized for use at indi- (3) Recoverability Code, indicates whether
cated maintenance categories. unserviceable items should be returned for re-
M Applied to repair parts which are not pro-
cured or stocked but are to be manufactured covery or salvage. Items not coded are expend-
at indicated maintenance categories. able.
A Applied to assemblies which are not - procured Recoverability codes are:
or stocked as such, but made up of two or
more units, each of which carry individu- Code Explanation
al stock numbers and descriptions and are R Applied to repair parts and assemblies which
procured and stocked and can he assem- are economically repairable at DSU and

B-1
TM 10-3930-609-12
Code Explanation thorized the operator/crew to have on hand or
GSU activities and are normally furnished to obtain as required. As required items are in-
by supply on an exchange basis. dicated with an asterisk.
T Applied to high dollar value recoverable re- i. Illustration, Column (9). This column is
pair parts which are subject to special han-
dling and are issued on an exchange basis. divided as follows:
Such repair parts are normally repaired or (1) Figure Number, Column (9)(a). Indi-
overhauled at depot maintenance activities. cates the figure number of the illustration in
U Applied to repair parts specifically selected which the item is shown.
for salvage by reclamation units because of (2) Item Number, Column (9)(b). Indi-
precious metal content, critical materials, cates the callout number used to reference the
high dollar value reusable casings and
castings. item in the illustration.
b. Federal Stock Number, Column (2). This B-4. Explanation of Columns in the
column indicates the Federal stock number for Tabular list of Maintenance and
the item. Operating Supplies-Section III
c. Description, Column (3). This column indi-
cates the Federal item name and any additional a. Component Application, Column (1). This
description of the item required. A part num- column identifies the component application of
ber or other reference number follows the appli- each maintenance or operating supply item.
cable five-digit Federal supply code for manu- b. Federal Stock Number, Column (2). This
facturers in parentheses. Repair parts quantities column indicates the Federal stock number for
included in kits, sets, and assemblies are shown the item and will be used for requisitioning
in front of the repair part name. purposes.
d. Unit of Issue, Column (4). This column c. Description, Column (3). This column in-
indicates the unit used as a basis for issue, e.g., dicates the item and brief description.
ea, pr, ft, yd, etc. d. Quantity Required for Initial Operation,
e. Quantity Incorporated in Unit rack, Col- Column, (4). This column indicates the quan-
umn (5). This column indicates the actual tity of each maintenance or operating supply
quantity contained in the unit pack. item required for initial operation of the
f. Quantity Incorporated in Unit, Column (6). equipment.
This column indicates the quantity of the item e. Quantity Required for 8 Hours Operation,
used in the functional group. Column (5). This column indicates the esti-
g. Quantity Furnished with Equipment, Col- mated quantities required for an average eight
umn (7). This column indicates the quantity of hours of operation.
an item furnished with the equipment. f. Notes, Column (6). This column indicates
h. Quantity Authorized, Column (8). This informative notes keyed to data appearing in a
column indicates the quantity of an item au- preceding column.

Section II. BASIC ISSUE ITEMS

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Description Qty Qty Illustration
Unit inc Qty
SMR in inc furn (a) (b)
Federal stock Ref No & Mfr Usable of unit in with Qty Fig Item
code number Code on Code issue pack unit epuip auth No. No.
P10 7520-559-9618 Case, maintenance and opera-
tional manuals ea 1 1 1 1
X20 4210-889-2221 Extinguisher, fire ea 1 1 1 1
X20 Fork Assembly (05416) ea 2 2 2 2
A700FD3
X20 Headlight Assembly
(05415) 424MBL2 ea 1 1 1 1
X20 Knob, Directional Control
(81487) 9203W7 ea 1 1 1 1
REPAIR PARTS
None authorized for operator
maintenance.

B-2
 TM 10-3930-609-12

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Qty Illustration
Description Unit Inc Qty Qty
in inc furn (a) (b)
SMR Federal stock Ref No & Mfr Useable of unit in with Qty Fig Item
code number Code on Code issue pack unit epuip auth No. No.
SPECIAL TOOLS
None authorized for operator
maintenance.
RECORDS
EQUIPMENT LOG BOOK
7510-889-3494 Consisting of the following DA
Forms:
2408, 2408-1, 2408-2, 2408-3,
2408-5, 2408-6, 2408-7, 2408-
8, 2408-10, and 2408-11.

Section III. MAINTENANCE AND OPERATING SUPPLIES

(1) (2) (3) (4) (6) (6)

Quantity Quantity
Component FederaI Description required required Notes
application stock number f/initial f/8 hrs
operation operation

BRAKE MASTER BRAKE FLUID, AUTOMOTIVE (1) See C9100-IL for addi-
CYLINDER gal can as follows: tional data an requisition-
ing procedure.
9150-231-9071 HB 1 pt (2) (2) See current LO for
(1) grade, application and
replenishment intervals.
DIFFERENTIAL LUBRICATING OIL, GEAR:
DRIVE AXLE 5 gal drum as follows:
9150-577-5844 GO-90 1 qt (2)
(1)
9150-257-5440 GOS 20 qt (2)
(1)
HYDRAULIC OIL, LUBRICATING: 5
SYSTEM gal pails as follows:
9150-265-9428 (1) OE-10 1 qt (2)
9150-242-7603 (1) OES 20 qts (2)
LUBRICATION GREASE, AUTOMOTIVE AND
FITTINGS ARTILLERY: 1 lb can as
follows:
9150-190-0904 GAA lb (2)
(1)

B-3
 TM 10-3930-609-12

APPENDIX C
MAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION
C-1. General The maintenance functions are defined as fol-
lows:
a. This section provides a general explanation A Inspect: To determine serviceability of an item by
of all maintenance and repair functions au- comparing its physical, mechanical, and electrical
thorized at various maintenance levels. an item to bring to optimum performance.
b. Section II designates overall responsibility B Test: To verify serviceability and to detect elec-
for the performance of maintenance functions on trical or mechanical failure by use of test equip-
ment
the identified end item or component. The im- C Service: To clean, to preserve, to charge, to paint,
plementation of the maintenance functions upon and to add fuel, lubricants, cooling agents, and
the end item or component will be consistent air.
with the assigned maintenance functions. D Adjust: To rectify to the extent necessary to
c. Section III lists the special tools and test bring into proper operating range.
equipment required for each maintenance func- E Aline: To adjust specified variable elements of
an item to bring to optimum performance.
tion as referenced from Section II. F Calibrate: To determine the corrections to be
d. Section IV contains supplemental instruc- made in the readings of instruments or test equip-
ment used in precise measurement. Consists of the
tions, explanatory notes and/or illustrations re- comparisions of two instruments, one of which is
quired for a particular maintenance function. a certified standard of known accuracy, to detect
and adjust any discrepancy in the accuracy of the
C-2. Explanation of Columns in Section II instrument being compared with the certified
standard.
a. Group Number, Column (1). The function- G Install: To set up for use in an operational en-
al group is a numerical group set up on a vironment such as an emplacement, site, or ve-
functional basis. The applicable functional hicle
H Replace: To replace unserviceable items with serv-
grouping indexes (obtained from TB 750-93-1, iceable assemblies, subassemblies, or parts.
Functional Grouping Codes) are listed on the I Repair: To restore an item to serviceable condition.
MAC (Maintenance Allocation Chart) in the ap- This includes, but is not limited to, inspection,
propriate numerical sequence. These indexes are cleaning, preserving, adjusting, replacing, weld-
normally set up in accordance with their function ing, riveting, and strengthening.
J Overhaul: To restore an item to a completely serv-
and proximity to each other. iceable condition as prescribed by maintenance
serviceability standards using the Inspect and Re-
b. Functional Group, Column (2). This col- pair Only as Necessary (IROAN) technique.
umn contains a brief description of the compo- K Rebuild: To restore an item to a standard as near-
nents of each functional group. ly as possible to original or new condition in ap-
pearance, performance, and life expectancy. This
c. Maintenance Functions, Column (3). This is accomplished through complete disassembly of
column lists the various maintenance functions the item, inspection of all parts or components,
(A through K) and indicates the lowest main- repair or replacement of worn or unserviceable
tenance category authorized to perform these elements (items) using original manufacturing
tolerances and specifications, and subsequent re-
functions. The symbol designations for the vari- assembly of the item.
ous maintenance categories are as follows:
d. Tools and Equipment, Column (4). This
C Operator or crew column is provided for referencing by code the
O Organizational maintenance special tools and test equipment, (sec. III), re-
F Direct support maintenance quired to perform the maintenance functions
H General support maintenance
D Depot maintenance (sec. II).
C-1
TM 10-3930-609-12
e. Remarks, Column (5). This column is pro- c. Nomenclature. This column lists the name
vided for referencing by code the remarks (sec. or identification of the tool or test equipment.
IV) pertinent to the maintenance functions. d. Tool Number. This column lists the manu-
facturer’s code and part number, or Federal
C-3. Explanation of Columns in Section Ill stock number of tools and test equipment.
a. Reference Code. This column consists of a
number and a letter separated by a dash. The C-4. Explanation of Columns in Section IV
number references the T&TE requirements col- a. Reference Code. This column consists of
umn on the MAC. The letter represents the two letters separated by a dash, both of which
specific maintenance function the item is to be are reference to Section II. The first letter refer-
used with. The letter is representative of col- ences column 5 and the second letter references
umns A through K on the MAC. a maintenance function, column 3, A through K.
b. Maintenance Category. This column shows b. Remarks. This column lists information
the lowest level of maintenance authorized to pertinent to the maintenance function being per-
use the special tool or test equipment. formed, as indicated on the MAC, Section II.

Section II. MAINTENANCE ALLOCATION CHART

Maintenance functions Note reference

A B C D E F G H I J K L M
Component assembly
nomenclature Tools
and Remarks
equipment
06 ELECTRICAL SYSTEM
0607 Instrument panel
Hour meter---------------------- O -- -- -- -- -- -- O
Switch, light -------------------------- O O -- -- - - -- -- O
0608 Miscellaneous items
Receptacle battery ------------------------- -- -- -- -- -- -- -- O
Switch, stoplight -------------------- O -- -- -- -- -- -- O
0609 Lights
Lamps ---------------------------- O -- -- -- -- -- O
Lights -------------------------------- O -- -- -- -- -- -- O
Resistors, lights------------------ -- O -- -- -- -- -- O
0611 Horn
Button, horn ---------------------------- -- -- -- -- -- -- O O -- - - -- A
Horn assembly ------------------- -- O -- -- -- -- -- O
0612 Batteries
Battery, storage--------------------------- O O O -- -- -- -- O
Cables, battery---------------------------- -- -- -- -- -- -- O
0613 Hull or chassis wiring harness
Harness, wiring --------------------- O -- -- -- -- -- -- F O
19 FRONT AXLE
1000 Front axle assembly
Axle assembly, driving -------------- O -- O -- -- -- -- F F H
1002 Differential
Differential assembly----------------- F -- O -- -- -- -- F F H
11 REAR AXLE
1100 Rear axle assembly
Axle assembly, steering ------------- O -- -- O -- -- -- F F
1104 Steering
Arm, steering ------------------------ O -- -- F -- -- -- F
Axle, steering ----------------------- -- -- -- -- -- -- -- F
12 BRAKES
1201 Handbrakes
Brakeshoe assembly, motor ---------- -- -- -- -- -- -- -- F F
O -- O O -- -- -- O
C-2
 TM 10-3930-609-12

Maintenance functions Note reference

A B C D E F G H I J K L M
Component assembly
nonmenclature Tools
and Remarks
equipment
Control linkage----------------------- - - - - - - O -- -- - - O
Drum, brake------------------------- - - - - - - - - - - -- - - F
Lever, handbrake--------------------- - - - - - - - - -- - - - - - -
1202 Service brakes
Brake assembly--------------------------- F - - - - O -- - - - - F F
Shoe assembly---------------------------- O -- -- O -- -- - - O
1204 Hydraulic brake system
Master cylinder-------------------------- O - - O - - - - -- - - O F - - - - - - B
Tube assembly, metal------------------- O - - - - - - -- -- - - O
Wheel, cylinder --------------------- O - - - - - - -- - - - - F F - - -- - - C
13 WHEELS
1311 Wheel assembly
Bearing and seals, rear wheels--------- O - - O O -- -- -- O
Wheel assembly--------------------------- -- - - - - - - - - - - - - O
1313 Tires
Tires, solid-------------------------------- O -- - - - - - - - - - - F
14 STEERING
1401 Steering assembly
Bearing, bellcrank-------------------- -- -- -- -- -- -- -- F
Bellcrank ------------------------------- -- -- -- -- -- -- -- F
Drag, link--------------------------- -- -- O F -- -- -- F
Rod assembly, tie--------------------- -- -- -- O -- -- -- F
Steering gear assembly----------------- -- -- O O
Wheel, steering----------------------- -- -- -- -- -- -- - - O
18 BODY, CAB, HOOD AND HULL
1801 Body, cab, hood, hull assemblies
Covers (Battery compartment)-------- - - -- - - - - - - -- - - O
Overhead guard------------------- - - - - - - - - - - -- - - O
1805 Floor
Plate, floor ---------------------------- - - - - - - - - - - -- -- O
1806 Seats
Seat assembly -------------------------- O - - - - - - -- -- -- O O
24 HYDRAULIC LIFT COMPONENTS
2401 Hydraulic pump
Pump, rotary, power driven,
hydraulic ---------------------------- O -- -- -- - - -- -- F F
2402 Hydraulic control valve
Valve, directional control---------- O -- -- -- -- -- -- F F
2403 Hydraulic control levers and linkage
Bracket, control valve--------------- - - - - - - - - - - -- -- O
Levers, control----------------------- - - - - - - - - - - -- -- O
2404 Hydraulic tilt cylinders
Cylinder assembly, tilt--------------- O - - - - - - -- -- -- O F
2405 Hydraulic mast column
Chain assembly------------------------ O -- O O -- -- -- O O
Crosshead --------------------------- -- -- -- -- -- -- -- F F
Cylinder assembly, actuating, hoist--- O -- -- -- -- -- -- F F
Forks--------------------------------- -- -- -- -- -- -- -- O
Roller assembly----------------- -- -- -- -- -- -- -- F
Upright assembly------------------- O -- O O -- -- -- F H H
2406 Hydraulic lines and fittings
Cap, oil breather----------------------- O -- O -- -- -- -- O
Filter element---------------------- O -- -- -- -- -- - - O
Hoses assembly, rubber------------ O -- - - -- -- -- - - O O
Tank, oil--------------------------- O -- O -- -- -- - - F
Valve, regulating------------------- -- -- - - -- - - - - - - F
C-3
TM 10-3930-609-12

Maintenance functions Note reference

A B C D E F G H I J K L M
Component assembly
nomenclature Tools
and Remarks
equipment
40 ELECTRIC MOTORS
4000 Motor assembly
Motor assembly, travel--------------- F F - - -- -- -- -- F F H
Motor assembly, pump--------------- F F - - -- -- -- -- F F H
4001 Rotor assemblies
Armature, travel motor------------- F F -- -- -- -- -- F F
Armature, pump motor-------------- F F -- -- -- - - -- F F
4002 Stator assemblies
Winding motor field------------------- F F - - -- -- -- -- F F
4003 Brush holders
Brush, electrical contact------------- O -- -- -- - - - - -- O
Holder, electrical contact, brush---- F -- -- -- - - - - -- F
Endbell----------------------------- F -- - - -- - - - - -- F
4005 Frame supports and housings
Bearing, ball annular, drive
motors--------------------------------- F -- -- -- - - -- -- F
4007 Drive components
Adapter assembly, gear reduction ---- O -- O -- - - - - -- F F
4010 Accelerator control assembly
Potentiometer -------------------------- F -- -- -- -- -- -- F
Control, accelerator--------------------- O -- -- -- -- -- -- O F
Switch, sensitive------------------------ -- -- -- -- -- - - -- F
4011 Fuse and fuse holder, circuit breaker
Fuse, cartridge------------------- O -- -- -- -- -- -- O
Fuse holder-------------------------- __ -- -- -- -- -- -- F
Link,fuse--------------------------- __ -- -- -- -- -- -- F
Oscillator module-------------------- F F -- -- -- -- -- F
4012 Switches
Lever,switch ------------------------ -- -- -- -- - - -- -- F
Switch, directional control---------- O -- -- -- - - - - -- F F
4014 Resistor
Resistor, fixed ------------------ -- O -- -- - - - - -- O
4015 Relay
Relay, armature----------------- O F -- -- -- - - -- F F
Contact, relay------------------ O -- -- -- - - -- -- O
Relay, thermal--------------------- O O -- -- - - - - -- O
4017 Rectifier, transformer
SCR assembly----------------------- F F -- -- - - - - -- F
4019 Radio interference suppression
Strap, static drag------------------ -- -- -- -- - - - - -- F

Section III. SPECIAL TOOL AND SPECIAL TEST EQUIPMENT

REQUIREMENTS
Reference Maintenance Nomenclature Tool No.
level
No special tools or equipment are required by organiza-
tional, direct, general support, and depot personnel
for performing maintenance on the truck, lift, fork.

C-4
 TM 10-3930-609-12

Section IV. REMARKS

Reference Remarks
code
A-H Repair includes installing repair kit.
B-H Repair includes installing repair kit.
C-H Repair includes installing repair kit.

C-5
 TM 10-3930-609-12

INDEX
Paragraph Page
Accelerator master assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-56 3-25
Air cleaner - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-60 3-28
Basic issue tools and equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-2 3-1
Battery compartment covers- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-17 3-8
Battery connector receptacle------------------------------------------------ 3-37 3-19
Battery connector receptacle switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-39 3-19
Battery maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-46 3-21
Brake pedal- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-32 3-17
Chain assemblies - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-24 3-12
Control panel cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-19 3-10
Controls - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-9 2-2
Control valve levers and linkage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-58 3-27
Demolition by explosives or weapons fire- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-5 4-1
Demolition to render the fork lift truck inoperative------------------------------------ 4-4 4-1
Depositing the load- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-15 2-6
Description - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-4 1-1
Detailed lubrication information- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-5 3-1
Difference in models- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-6 1-6
Directional control switch- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-52 3-25
Distant worksite- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-7 2-2
Drive axle wheels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-72 3-33
Driving the truck - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-12 2-4
Filter cartridges - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-61 3-28
Fire extinguisher (dry chemical type) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-21 2-6
Fire protection- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - A-1 A-1
Floor plate - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-18 3-9
Forks - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-23 3-12
Fuse access cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-20 3-11
Fuse and fusetron replacement- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-51 3-25
General lubrication information - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4 3-1
Handbrake cable and control linkage- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-28 3-14
Handbrake lever - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-27 3-14
Headlight- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-40 3-19
Hoist regulating valve - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-63 3-30
Horn - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-44 3-21
Horn button - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-45 3-21
Hourmeter - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-34 3-18
Hydraulic brakes fail - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-13 3-8
Hydraulic lines and fittings- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-62 3-29
Identification and tabulated data- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-5 1-4
Inspecting and servicing the equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-3 2-1
Installation of separately packed components- - - - - - - - - - - - - - - - - - - - - - - 2-4 2-1
Installation or setting up instructions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6 2-2
Instrumenta - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-10 2-4
Lamps - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-42 3-20
Light switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-35 3-18
Load backrest- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-22 3-12
Local worksite- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-6 2-2
Lubrication - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-4 3-1
Maintenance forms and records- - - - - - - - - - - - - - - - - - - - - - - - - - - - - 1-2 1-1
Master cylinder- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-31 3-16

l-1
TM 10-3930-609-12
Paragraph Page
Motor brush replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-48 3-23
Moving load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-14 2-5
Operating the extinguisher- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-22 2-6
Operation in dusty or sandy areas - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-18 2-6
Operation in extreme cold (below 0°F.)- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-16 2-5
Operation in extreme heat - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-17 2-5
Operation in salt-water areas- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-20 2-6
Operation under rainy or humid conditions- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-19 2-6
Operator’s maintenance - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-9 3-4
Organizational maintenance repair parts - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-3 3-1
Other demolition methods - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-6 4-2
Overhead guard - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-16 3-8
Panic switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-36 3-18
Picking up the load - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-13 2-4
Preparation of equipment for limited storage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-2 4-1
Preparation of equipment for shipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 4-1 4-1
Preventive maintenance checks and services ------------------------------------- 3-7 3-2
Pump motor switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-53 3-25
Rear wheel bearings - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-70 3-32
Rear wheels - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-69 3-32
Relay contact replacement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-49 3-23
Relay interlock switch replacement - - - - - - - - - - - - - - - - - - - - - - - - - - 3-50 3-24
Removal of preservatives - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 2-2 2-1
Reporting of equipment manual improvements - - - - - - - - - - - - - - - - - - - - - 1-3 1-1
Seat assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-15 8-8
Seat brake - and control linkage - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-29 3-14
Seat switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-54 3-25
Service brake- - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-30 3-14
Special tools and equipment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-1 3-1
Steering gear - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-66 3-31
Steering wheel - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-65 3-31
Stop and taillight - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-41 3-20
Stoplight switch - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-38 3-19
Taillight resistor - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-43 3-20
Thermal relay - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-55 3-25
Tilt cylinders - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-59 3-27
Truck will not start - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-12 3-8
Upright assembly - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-25 3-12
Valve cover - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-21 3-11
Wheel alinement adjustment - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-68 3-32
Wheel alinement measurement - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-67 3-31
Wiring harness - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 3-47 3-23

I-2
 TM 10-3930-609-12

By Order of the Secretary of the Army:

W. C. WESTMORELAND,
General, United States Army,
Official: Chief of Staff.
KENNETH G. WICKHAM,
Major General, United States Army,
The Adjutant General.
DISTRIBUTION:
To be distributed in accordance with DA Form 12-25, Section I, (qty rqr block no. 190) organizational mainte-
nance requirements for Trucks, Fork Lift, Electrical.
 TM 10-3930-609-12

TRUCK, FORK, LIFT, ELECTRIC, SOLID RUBBER TIRES - 1969

PIN: 028289-003