TM 10-3930-630-12

TECHNICAL MANUAL

OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL

TRUCK, LIFT, FORK, GASOLINE, SOLID

RUBBER TIRED WHEELS, 4000 LBS CAPACITY
100 AND 180 INCH LIFT ARMY MODEL
MHE-231 ALLIS-CHALMERS MODELS
ACC40-24PS100 AND ACC40-24PS180
NSN 3930-00-590-7814 (100 IN.)
NSN 3930-00-556-4955 (180 IN.)

HEADQUARTERS, DEPARTMENT OF THE ARMY

SEPTEMBER 1976
 TM 10-3930-630-12

WARNING

When servicing the battery, do not smoke or use a flame in the vicinity. Batteries generate hydrogen, a highly explosive
gas.

Always correct or report any faulty conditions that may result in further damage to the truck or cause injury to personnel.

Check the operating area to be sure that it is clear of personnel and obstructions.

Do not shift the forward and reverse control lever while the truck is in motion.

Do not operate the truck with the load in a highly elevated position.

When operating the truck, the mast should be tilted backwards slightly to prevent the load from falling off.

Make sure that the forks are lowered to the ground when the truck is parked. Check parking brake for proper operation
and engagement.

If the truck is parked on an incline, block at least two wheels to prevent the truck from moving in the event of a parking
brake failure.

Report or correct any faulty conditions that may result in damage to the truck or cause injury to personnel if operation of
the truck is continued.

Cleaning compound, solvent (Fed. Spec. P-D-680) is a potentially DANGEROUS chemical. Do not use near open
flame.
 TM 10-3930-630-12

TECHNICAL MANUAL HEADQUARTERS

No. 103930-630-12 } DEPARTMENT OF THE ARMY

WASHINGTON, DC, 13 September 1976

OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL

TRUCK, LIFT, FORK, GED, SOLID RUBBER TIRED WHEELS,
4000 LBS CAPACITY, 100 AND 180 IN LIFT
ARMY MODEL MHE-231
ALLIS CHALMERS MODELS ACC40-24PS100 AND ACC40-24PS180
(NSN 3930-0-590-7814 (100 IN.)
(NSN 393000-556-4955 (180 IN.)

REPORTING OF ERRORS
You can improve this manual by recommending improvements using DA Form 2028
(Recommended Changes to Publications and Blank Forms) or DA Form 2028-2
(Test) located in the back of the manual and mail the form direct to Commander, US
Army Tank-Automotive Command, ATTN: DRSTA-MSP, Warren, MI 48090. A reply
will be furnished direct to you.

Paragraphs Pages
CHAPTER 1. INTRODUCTION
Section I. General .........................................................................................................................1-1 1-1
II. Description and Data .....................................................................................................1-7 1-1

CHAPTER 2. OPERATING INSMRUCTIONS

Section I. Operating Procedures ...................................................................................................2-1 2-1
II. Operation under Unusual Conditions ............................................................................ 2-10 2-8
CHAPTER 3. OPERATOR/CREWMAINTENANCE INSTRUCTIONS
Section I. Lubrication .....................................................................................................................3-1 3-1
II. Operator's preventive Maintenance.................................................................................3-3 3-1
III. Operator's Troubleshooting ............................................................................................3-5 3-2
IV. Operator's Maintenance of Truck....................................................................................3-7 3-5
CHAPTER 4. ORGANIZATIONAL MAINTENANCE INSTRUCTIONS
Section I. Service Upon Receipt of Material....................................................................................4-1 4-1
II. Movement to a New Work Site .......................................................................................4-3 4-4
III. Repair Parts, Special Tools and Equipment....................................................................4-5 4-4
IV. Lubrication Instructions ..................................................................................................4-8 4-4
V. Organizational Preventive Maintenance checks and Senvice ........................................ 4-15 4-5
VI. Organizational Maintenance Troubleshooting .............................................................. 4-17 4-7
VII. Radio Interference Suppression ................................................................................... 4-19 4-10
VIII. Overhead Guard ......................................................................................................... 4-22 4-10
IX. Panels, Cowls and Plates............................................................................................. 4-24 4-11
X. Seat assembly ............................................................................................................. 4-29 4-14
XI. Instrument Panel.......................................................................................................... 4-31 4-15
XII. Hydraulic Lift Components .......................................................................................... 4-33 4-18
XIII. Electrical System ......................................................................................................... 4-45 4-38
XIV. Fuel System................................................................................................................. 4-56 4-53
XV. Cooling System............................................................................................................ 4-66 4-61
XVI. Exhaust System ........................................................................................................... 4-71 4-65
XVII. Steering System........................................................................................................... 4-73 4-66
XVIII. Engine ......................................................................................................................... 4-79 4-70
Section XIX. Wheels ........................................................................................................................ 4-84 4-76
XX. Brakes ......................................................................................................................... 4-86 4-78
XXI. Drive Axle .................................................................................................................... 4-93 4-87
XXII. Transmission ............................................................................................................... 4-97 4-89
APPENDX A. REFERENCES........................................................................................................................................... A-1
B. MAINTENANCE ALLOCATION CHART...................................................................................................... B-1
C. BASIC ISSUE ITEMS LIST, TROOP INSTALLED OR AUTHORIZED LIST ................................................. C-1
INDEX ....................................................................................................................................................................I-1

i
 TM 10-3930-630-12

LIST OF ILLUSTRATIONS

Figure
number Title Page

1-1 Fork lift truck with shipping dimensions, right side view 1-2
1-2 Fork lift truck, left side view. 1-3
1-3 Wiring diagram 1-4
2-1 Controls and instruments (Sheet 1 of 2) 2-2
2-1 Controls and instruments (Sheet 2 of 2) 2-3
2-2 Seat adjustment 2-3
2-3 Engine starting instructions 2-4
2-4 Truck stopping instructions 2-5
2-5 Lifting operation 2-6
2-6 Lowering operation. 2-7
3-1 Air cleaner and indicator 3-5
3-2 Radiator filler cap. 3-6
3-3 Oil filler cap and level gage 3-7
3-4 Transmission filler cap and level gage. 3-8
3-5 Hydraulic filter element indicator. 3-9
3-6 Hydraulic reservoir. 3-10
4-1 Removing, installing or adjusting carriage fork 4-1
4-2 Overhead guard, removal and installation 4-11
4-3 Cowls and floor plates, exploded view. 4-12
4-4 Counterweight and side panels, exploded view. 4-13
4-5 Seat assembly, exploded view. 4-15
4-6 Instrument panel components, exploded view. 4-16
4-7 Instrument panel, exploded view. 4-17
4-8 Hydraulic system diagram 4-19
4-9 Lift chains and anchors, installed view. 4-20
4-10 Lift chains and carriage. 4-21
4-11 Backrest, removal and installation 4-22
4-12 Carriage, removal and installation. 4-23
4-13 Spanning mast channels 4-24
4-14 Setting outside spanning tool 4-24
4-15 Checking bearing alinement. 4-24
4-16 Tilt cylinder, removal and installation. 4-25
4-17 Tilt cylinder yoke, installed view. 4-26
4-18 Checking degrees of mast tilt. 4-27
4-19 Mast assembly (model ACC40-24PS180), exploded view. 4-28
4-20 Mast assembly (model A(XA0-24PS100), exploded view. 4-29
4-21 Mast mounting, exploded view. 4-31
4-22 Control valve levers, installed view. 4-32
4-23 Hydraulic filter element indicator, installed view. 4-33
4-24 Hydraulic filter, installed view. 4-34
4-25 Hydraulic reservoir breather and oil level gage. 4-35
4-26 Hydraulic reservoir drain plug. 4-36
4-27 Hydraulic reservoir, exploded view. 4-37
4-28 Battery, installed view. 4-38
4-29 Headlight, installed view. 4-39
4-30 Combination rear light, exploded view. 4-40
4-31 Brake master cylinder, installed view. 4-41
4-32 Horn and relay, installed view. 4-42
4-33 Oil pressure and hourmeter actuator sending units installed view. 4-43
4-34 Fan belt adjustment. 4-44
4-35 Alternator, installed view. 4-45
4-36 Alternator connections 4-46
4-37 Checking alternator output. 4-46
4-38 Starter, removal and installation 4-47
4-39 Distributor, installed view. 4-47
4-40 Adjusting distributor breaker point gap, 4-48
4-41 Spark plugs and coil, exploded view. 4-49
4-42 Distributor, exploded view. 4-50
4-43 Flywheel timing marks 4-51
4-44 Ignition coil test wiring 4-52
4-45 Fuel system, exploded view. 4-54
4-46 Air cleaner, exploded view. 4-55

ii
 TM 10-3930-630-12

Figure
Number Title Page

4-47 Carburetor adjustment. 4-56

4-48 Governor adjustment. 4-57
4-49 Manifold, exploded view. 4-58
4-50 Accelerator linkage exploded view. 4-59
4-51 Engine coolant drain valve. 4-61
4-52 Water pump and fan, installed view. 4-62
4-53 Radiator and hoe, removal and installation 4-63
4-54 Thermostat, removal and installation. 4-64
4-55 Exhaust system, exploded view . 4-65
4-56 Tie rod, exploded view. 4-66
4-57 Spindle stop screw adjustment. 4-67
4-58 Drag link and steering cylinder, removal and installation. 4-68
4-59 Steering wheel and horn button, exploded view. 4-70
4-60 Cylinder head, exploded view. 4-72
4-61 Checking cylinder head for flatness lengthwise. 4-73
4-62 Checking cylinder head for flatness crosswise.4 4-73
4-63 Cylinder head torquing sequence. 4-73
4-64 Valve chamber cover, removal and .installation. 4-74
4-65 Checking valve tappet clearance. 4-75
4-66 Adjusting valve tappet clearance. 4-75
4-67 Drive wheel, removal and installation. 4-76
4-68 Rear wheel removal and installation. 4-77
4-69 Service brake pedal adjustment 4-78
4-70 Brake pedal and linkage, exploded view. 4-79
4-71 Service brake dust shield, installed view. 4-80
4-72 Service brake shoes, installed view. 4-80
4-73 Brake adjuster, disassembly and assembly. 4-81
4-74 Brake system bleeder crew. 4-82
4-75 Service brake master cylinder, removal and installation. 4-83
4-76 Parking brake lever, installed view. 4-84
4-77 Parking brake cable, installed view. 4-85
4-78 Parking brake, exploded view. 4-86
4-79 Drive hat, exploded view. 4-87
4-80 Ring or bull gear lubrication 4-88
4-81 Removing axle shat. 4-89
4-82 Removing spindle. 4-89
4-83 Transmission oil filter and hose, exploded view. 4-90
4-84 Transmission control adjustment 4-84

iii
 TM 10-3930-630-12

CHAPTER 1
INTRODUCTION

Section I. GENERAL

1-1. Scope

This manual is for your use in operating and maintaining Allis to prevent enemy use are defined in TM 750-244-3.
Chalmers fork lift trucks ACC40-24PS100 and ACC40-
24PS180 (Army model MHE-231). The manual provides 1-4. Equipment Serviceability Criteria
information on operation and organizational maintenance of
the equipment. Included in the manual are descriptions of the This equipment is not covered by an Equipment Serviceability
main units and their functions in relation to other components. Criteria

1-2. Maintenance Forms and Records 1-5 Administrative Storage

Maintenance forms and records that you are required to use Refer to TM 740-90-1 for instructions pertaining to
are explained in TM 38-750. administrative storage of the fork lift truck.

1-3. Destruction to Prevent Enemy Use 1-6. Orientation

Procedures to be used for destruction of equipment Throughout this manual the terms "right," left," "front" and
"rear," with respect to the truck, are determined from the
viewpoint of the operator sitting on the seat of the truck.

Section II. DESCRIPTION AND DATA

1-7. Description Army Models:

a. The Allis Chalmers fork lift trucks are 100 inch
nontactical trucks (fig.s 741-1 and 1-2) designed for (2540 mm) lift........................... MHE-231
warehouse operation. The trucks can be used to load, 180 inch
transport, unload and stack loads of as much as 4,000 (4572 mm) ............................... lift MHE-231
pounds (1812 kg) at a 24-inch (609.6 mm) load center. (The b. Dimensions and Weight.
load center is measured from the heel of the fork.) Ground clearance at
b. Loads weighing up to 4,000 pounds (1812 kg) mast center .............................. 5 in. (127 mm)
as described above can be lifted to a height of 100 inches Height
(2540 mm) (ACC40-24PS100 truck) or 180 inches (4572 mm) With uprights extended:
(ACC40-24PS180 Truck). ACC40-24PS100 ................. 168.3 in. (4281.5 mm)
c. The trucks are powered by a four-cylinder, four- ACC40-24PS180 ................. 259.3 in. (6586.2 mm)
stroke cycle, flat head, liquid cooled, gasoline engine. With uprights
Coupled to the engine is a single speed, powershift retracted 83.0 in. (2108.1 mm)
transmission. A short propeller shaft connects the Length:
transmission to the forward drive axle. Overall
d Hydraulic oil pressure for the steering gear and ACC40-24PS100 ................. 12187 in (30937 mm)
cylinder, lift cylinders, and tilt cylinders is supplied by a ACC40-24PS180 ................. 122.5 in. (3111.5 mm)
hydraulic pump driven by the engine crankshaft. Speed of lift Forks........................................ 40.0 in. (1016.0 mm)
is controlled by positioning control lever and increasing or Fork spread (maximum)................. 38.0 in. (965.2 mm)
decreasing engine speed. Width (maximum) .......................... 38.0 (965.2 mm)
Weight (gross):
1-8. Tabulated Data Weight390.0 (2894.6 kg)
a. Lift Truck. ACC40-24PS100 ................. 6390.0 lbs. (2894.6 kg)
Make ............................................ Allis Chalmers ACC40-24PS180 ................. 7315.0 lbs. (3313.7 kg)
Models: c. Performance
100 inch Axle width (minimum):
(2540 mm) lift ........................... ACC40-24PS100 Intersecting............................... 44.0 in. (1879.6 mm)
100 inch Right angle stacking:
(4572 mm) lift ........................... ACC40-24PS180 ACC40-24PS100 ................. 135.6 in (34406) mm)
ACC40-24PS180 ................. 136.2 in. (3459.5 mm)

1-1
 TM 10-3930-630-12

Figure 1-1. Fork lift tuck with shipping dimensions, right side view.

Lift height (maximum): Maximum speed (loaded):

ACC40-24PS100....................100.0 in. (2540.0 mm) Forward ..............................8 mph (12.8 km/h)
ACC40-24PS180....................180.0 in. (4572.0 mm) Reverse ..............................8 mph (12.8 km/h)

1-2
 TM 10-3930-630-12

Figure 1-2. Fork lift truck, left side view

Tilt limitations: Size:

ACC40-24PS100: ACC40-24PS100:
Backward 10° Drive...................................8 x 7 x 12.13
Forward; 3° Steer...................................1625 x 5 x 11.25
ACC40-24PS180: ACC40-24PS180:
Backward 5.5° Drive......................................18 x 8 x 12.25
Forward3° Steer......................................16.25 x 5 x 11.25
Turning radius 74.0 in. (1879.5 mm) e. Engine.
d. Tires Make.........................................Continental Motor
Type Solid Model........................................F13508019
Number 4 Cylinders...................................4

1-3
 TM 10-3930-630-12

Figure 1-3. Wiring diagram

1-4
 TM 10-3930-630-12

Firing order ...............................134-2 1-9 Differences in Models

Governed speed:
Under load............................2000 rpm Two models of the fork lift truck are covered in this
Without load .........................2700 rpm manual Allis Chalmers models AOCA-24PS100 and
Idle speed.............................600 rpm ACCA-24PS180. The only difference between the two
f. Battery is the mast and lift cylinders The AOCC40 24PS100 can
Voltage 12 lift 4,000 pounds (1812.0 kg) to a height of 100 inches
Ground Negative (2540.0 mm), employs a single cluster cylinder, and can
g. Hydraulic System. be tilted 10° to the rear and 3° forward. The AOC-
Pressure setting: 24PS180 can lift 4,000 pounds (1812.9 kg) to a height of
Engine speed 180 inches (4572.0 mm), employs a cluster cylinder and
2000 rpm..............................1950 psi a single lift cylinder, and can be tiled 5.5° to the rear and
h. Wiring Diagram. Refer to figure 1-3 for 3° forward. All differences affecting maintenance of the
wiring diagram of the fork lift truck. trucks or components will be covered in the applicable
i. Data Plates. The truck identification plate paragraphs.
and shipping plate are mounted on the inside of the right
cowl of the truck. 1-10. Abbreviation
(1) The identification plate includes type
of truck, type of tires and model number. Also included The following metric abbreviations appear in this
are the contract, serial and registration numbers, federal manual The list below will enable the user to understand
stock number and capacity. their meaning.
(2) The shipping plate includes capacity c centrigrade
of lift, shipping weight and wheel loading weight. It also cm centimeter
shows the center of gravity and applicable heights and kg kilogram
distances for the important parts of the truck. m meter
mm millimeter
N.m Non Newton meter

1-5
 TM 10-3930-630-12

CHAPTER 2
OPERATING INSTRUCTIONS

Section I. OPERATING PROCEDURES

CAUTION
If equipment fails to operate refer to b. Allow engine to reach operating
troubleshooting procedures in chapter 3. temperature (fig. 21).
c. Raise forks slightly to clear ground by
2-1. General pulling lift control lever (fig. 2-1) to rear.
d. With engine at idle speed, release parking
This section describes, locates, illustrates, and furnishes brake (fig. 2-1).
the operator, crew, or organizational maintenance e. Place transmission shift lever (fig. 2-1) in F
personnel sufficient information to insure proper position for forward movement or R for reverse
operation of the fork lift truck. movement.
f. Depress accelerator (fig. 2-1) to increase
2-2. Controls and Instruments engine speed and move truck. Control speed of
movement with pressure on accelerator.
Refer to figures 2-1 and 2-2 for the purpose, normal
readings, and location of all controls and instruments. WARNING

2-3. Operation Use caution when approaching doorways,

aisles, intersections or other workers.
a. The instructions in this paragraph are
published for the information and guidance of personnel g. Control direction of movement by turning
responsible for operation of the fork lift truck. steering wheel (fig. 2-1) to guide truck.
b. The operator must know how to perform
every operation of which the fork lift truck is capable. CAUTION
This section gives instructions on starting and stopping
the truck, operation of the truck, and, on coordinating Avoid sudden stopping and starting. Reduce
the basic motions, to perform the specific tasks for speed on turns.
which the equipment is designed. Since nearly every
job represents a different problem, the operator may h. To change direction of travel, release
have to vary given procedures to fit the individual task. accelerator and depress brake pedal (fig. 2-3) to halt
movement. Use inching pedal (fig. 2-1), where required,
2-4. Starting to prevent engine from stalling. After truck comes to a
complete stop, move transmission shift lever to direction
a. Preparation for Starting. Perform the desired (F for forward; R for reverse). Depress
before operation services (para 3-4). accelerator to increase engine speed and move truck.
b. Starting. Refer to figure 2-3 and start the i. The inching control pedal (fig. 21) is
truck. provided to aid the operator in moving into a load or
placing a load. Depressing the pedal will slow truck
2-5. Stopping travel while allowing the operator to maintain engine
speed at the rate required.
a. Refer to figure 24 to stop the truck. j. After completing movement and with truck
b. When stopping and parking the truck, set parked, refer to paragraph 2-5 to stop truck engine.
the parking brake (fig. 2-1). Park truck on a level surface if possible. If necessary to
c. If truck is to be parked after completion of park truck on an incline, set parking brake and block at
work, perform after-operation services (para 3-4). least two wheels in event of parking brake failure.

2-6. Operation of Equipment CAUTION

The following paragraphs and illustrations describe truck Lower forks to ground and set parking brake
operation under usual conditions. firmly.
2-7. Moving the Truck
a. Refer to paragraph 24 and start the truck

2-1
 TM 10-3930-630-12

Figure 2-1. Controls and instruments (sheet 1 of 2).

CONTROLS
1. PARKING BRAKE LEVER - PULL BACK ON LEVER TO APPLY PARKING BRAKE. MOVE LEVER
FORWARD TO RELEASE BRAKE.
2. HORN BUTTON - DEPRESS BUTTON TO SOUND HORN.
3. TRANSMISSION SHIFT LEVER - MOVE LEVER TO "F" POSITION TO MOVE TRUCK FORWARD. MOVE
LEVER TO "R" POSITION TO MOVE TRUCK TO REAR. POSITION LEVER IN "N" (NEUTRAL) WHEN
PARKING OR STARTING TRUCK.
4. LIFT CONTROL LEVER - MOVE LEVER TO REAR TO LIFT FORKS. MOVE LEVER FORWARD TO
LOWER FORKS
5. TILT CONTROL LEVER - MOVE LEVER FORWARD TO TILT MAST FORWARD. MOVE LEVER TO REAR
TO TILT MAST BACKWARD.
6. STEERING WHEEL - ROTATE WHEEL IN DIRECTION DESIRED TO TURN TRUCK.
7. ACCELERATOR - DEPRESS PEDAL TO INCREASE ENGINE SPEED. RELEASE PEDAL TO DECREASE
ENGINE SPEED.
8. IGNITION SWITCH - ROTATE SWITCH TO RIGHT TO ACTUATE STARTER. RELEASE KEY TO ALLOW
TO RETURN TO RUN POSITION. ROTATE KEY TO LEFT TO HALT ENGINE OPERATION.
9. SERVICE BRAKE PEDAL - DEPRESS PEDAL TO APPLY BRAKES AND STOP TRUCK.
10. INCHING CONTROL PEDAL - DEPRESS PEDAL TO SLOW TRANSMISSION SPEED AND ALLOW HIGH
ENGINE SPEED. GIVES OPERATOR PRECISE CONTROL FOR INCHING LOADS.
11. CHOKE CONTROL - PULL OUT TO CLOSE CHOKE VALVE DURING ENGINE START. PUSH ALL THE
WAY IN TO OPEN CHOKE FOR NORMAL OPERATION. 12.LIGHT SWITCH - PULL OUT TO TURN ON
LIGHTS.
12. LIGHTS SWITCH - PULL OUT TO TURN ON LIGHTS

INSTRUMENTS
1. FUEL GAGE - INDICATES AMOUNT OF FUEL IN FUEL TANK.
2. COOLANT TEMPERATURE GAGE - INDICATES OPERATING TEMPERATURE. NORMAL READING
SHOULD BE 160° TO 180°F (71° TO 82°C).
3. AMMETER - INDICATES AMOUNT OF CURRENT FLOWING TO OR FROM BATTERY. SHOULD SHOW
HIGH RATE OF CHARGE AFTER STARTING AND TAPER DOWN TO NEAR CENTER OF DIAL AFTER
OPERATING A SHORT TIME.
4. OIL PRESSURE GAGE - INDICATES WORKING OIL PRESSURE IN ENGINE. NORMAL OPERATION
SHOULD INDICATE IN RUNNING RANGE AT NORMAL OPERATING SPEED
5. HOURMETER - OPERATES WHEN ENGINE IS RUNNING. RECORDS HOURS OF OPERATIONS.
6. TRANSMISSION TEMPERATURE GAGE - INDICATES TEMPERATURE OF TRANSMISSION OIL.
NORMAL OPERATING TEMPERATURE SHOULD BE IN GREEN AREA.
7. HYDRAULIC FILTER ELEMENT INDICATOR - INDICATES CONDITION OF FILTER ELEMENT. IF
INDICATING LINE REACHES RED ZONE, REPLACE ELEMENT.
TA034764
2-2
 TM 10-3930-630-12

AIR CLEANER INDICATOR

WITH; ENGINE RUNNING, WINDOW SHOULD BE MOVE TO RIGHT TO RELEASE SEAT LOCK
CLEAR. IF RED SIGNAL IS LOCKED IN FULL
VIEW IN WINDOW, AIR CLEANER MUST BE TA034766
SERVICED.

TA034763
Figure 2-2. Seat adjustment.
Figure 2-1. Control and instruments (sheet 2 of 2)

2-3
 TM 10-3930-630-12

1. PULL PARKING BRAKE LEVER TO REAR TO SET PARKING BRAKE.

2. PLACE TRANSMISSION SHIFT LEVER IN "N" (NEUTRAL) POSITION.
3. IF ENGINE IS COLD PULL CHOKE CONTROL ALL THE WAY OUT.
4. DEPRESS ACCELERATOR APPROXIMATELY ONE-THIRD OF THE WAY.
5. TURN IGNITION SWITCH ALL THE WAY TO THE RIGHT TO ACTUATE STARTER. RELEASE KEY
WHEN ENGINE

CAUTION: DO NOT OPERATE STARTER CONTINUOUSLY FOR LONGER THAN 30 SECONDS. IF

ENGINE FAILS TO START AFTER 30 SECONDS, ALLOW STARTER TO COOL OFF FOR TWO
MINUTES BEFORE ATTEMPTING TO START ENGINE AGAIN

6. HOLD ACCELERATOR STEADY AND ALLOW ENGINE TO WARM UP AT FAST IDLING SPEED.
7. CHECK OIL PRESSURE GAGE AND AMMETER FOR NORMAL READINGS. AS ENGINE WARMS UP,
PUSH IN ON CHOKE CONTROL. WHEN ENGINE IS WARM, PUSH CONTROL ALL THE WAY IN.
8. WITH ENGINE AT OPERATING TEMPERATURE, CHECK FOR PROPER READINGS ON AMMETER,
OIL PRESSURE GAGE, AND COOLANT TEMPERATURE GAGE. CHECK FUEL GAGE AND
HOURMETER FOR PROPER OPERATION.
9. REPORT ANY MALFUNCTIONS TO PROPER AUTHORITY.

TA034766

Figure 2-3. Engine starting instructions

2-4
 TM 10-3930-630-12

1. RELEASE FOOT FROM ACCELERATOR.

2. DEPRESS SERVICE BRAKE GRADUALLY TO BRING TRUCK TO SAFE SMOOTH STOP.
3. PULL PARKING BRAKE LEVER TO REAR TO APPLY PARKING BRAKE.
4. MOVE TILT CONTROL LEVER FORWARD TO PLACE MAST IN VERTICAL POSITION.
5. MOVE LIFT CONTROL LEVER FORWARD AND LOWER FORKS TO GROUND.
6. TURN IGNITION SWITCH TO THE LEFT TO "OFF" POSITION TO STOP ENGINE.

TA034787
Figure 2-4. Truck stopping instructions

2-8. Lifting and Transporting a Load b. As truck nears the load, bring truck to a halt
and raise or lower forks to position them under a load.
a. Refer to paragraph 2-7 and move truck to Refer to figure 2-5 for lifting operations.
the vicinity of the load

2-5
 TM 10-3930-630-12

1. BRING TRUCK TO A HALT.

2. RAISE OR LOWER FORKS, USING LIFT CONTROL LEVER, TO BRING FORKS IN LINE WITH LOAD.
3. MOVE TRUCK FORWARD, USING INCHING CONTROL AND ACCELERATOR, TO BRING FORKS
UNDER LOAD.
4. PULL LIFT CONTROL LEVER TO REAR TO RAISE FORKS AND LOAD TO CLEAR GROUND OR
STACK. MOVE TRUCK IN REVERSE TO CLEAR STACK.
5. TILT MAST TO THE REAR BY PULLING TILT CONTROL LEVER TO REAR, TO SAFELY TRANSPORT
LOAD.
6. RAISE OR LOWER LOAD AS NECESSARY, USING LIFT CONTROL LEVER.

TA034768
Figure 2-5. Lifting operation.

c. If load is on pallet, center forks between upper

CAUTION and lower members of pallet. With mast in vertical
position, move truck forward (para 2-7) using
Never pick up a load until certain it can accelerator and inching control until load rests against
be carried safely. The load must be rear of forks and backrest.
steady on the forks before lifting. Keep d. Raise forks (fig. 25) enough to clear stack or
the load against the carriage backrest floor below the load. Tilt load back by pulling tilt control
.

2-6
 TM 10-3930-630-12

lever (fig. 2-5) to rear. Mast must be tilted far enough WARNING
back to travel safely with load. To increase speed of lift
or tilt movement, increase engine speed. Always travel with load tilted back and forks raised just
high enough to clear any uneven floor conditions.
CAUTION f. Obey speed limits and drive carefully.
When transporting bulky loads, travel in Avoid sharp turns at too high of a speed, which could
reverse. Always descend ramps in reverse cause load to slip off or tip truck.
when transporting a load.
e. Place transmission shift lever in reverse 2-9. Depositing a Load
and move truck and load to rear to clear stack or other
obstacle. Turn truck to face in direction of travel a. Move truck with load to place where load is
required. If load is raised, lower load to assure clear to be deposited. Refer to figure 2-5 to raise or figure 2-6
vision forward. If load is bulky and obstructs vision it to lower load and move truck as necessary to bring it in
may be required to travel in reverse to enable the line with top of stack or ground.
operator to see
.

1. MOVE TRUCK INTO POSITION WITH INCHING CONTROL PEDAL AND ACCELERATOR TO BRING
FORKS AND LOAD OVER PLACE TO DEPOSIT LOAD.
2. HALT TRUCK USING SERVICE BRAKE PEDAL. SHIFT TRANSMISSION TO NEUTRAL.
3. PUSH LIFT CONTROL LEVER FORWARD TO GRADUALLY LOWER LOAD. MOVE TILT CONTROL
LEVER FORWARD TO BRING MAST TO VERTICAL POSITION.
4. LOWER LOAD INTO POSITION.
5. PLACE TRANSMISSION SHIFT LEVER IN "R" (REVERSE) POSITION AND,USING INCHING CONTROL
PEDAL AND ACCELERATOR. MOVE TRUCK AWAY FROM LOAD.

TA034769
Figure 2-6. Lowering operation.

2-7
 TM 10-3930-630-12

b. Move tilt control lever forward to aline forks d. Refer to paragraph 2-7 and move truck
horizontally with stack or ground. away from load and return for further loading operations
c. Refer to figure 2-6 and lower load into or to a parking place.
desired position.

Section II. OPERATING UNDER UNUSUAL CONDITIONS

2-10. General (-18°C) to a -10°F (-23°C), add two parts of glycol

antifreeze to five parts of water. For temperatures from
Although the truck is designed primarily for warehouse a -10°F (-23°C) to a -30°F (-35°C), add one part of
operations, the truck could be operated under unusual glycol antifreeze to one part of water. Refer to TB ORD
conditions as described in the following paragraphs. 651 for the use of antifreeze solutions and cleaning
When operating under these conditions, extra care must compounds in engine cooling system.
be provided to maintain the truck in good operating c. Electrical System.
condition. To operate under these conditions, certain (1) Check specific gravity of battery more
additional services must be performed and certain often.
regular maintenance procedures may be required more (2) Do not add water to the battery unless
often. the engine is going to be operated immediately.
(3) Keep battery charged as much as
2-11. Operating in Extreme Heat possible to insure starting and prevent freezing at low
temperatures.
a. Cooling System. (4) Remove and store battery (on wooden
(1) Check adjustment of fan drive belt base) in a warm place if truck is not going to be parked
more often to see that the deflection is correct. Belt in a shelter.
should deflect three-eights of an inch when pressure is
applied midway between pulleys. 2-13. Operation in Sandy or Dusty Areas
(2) Check coolant level more often and
maintain level to bottom of filler neck on radiator. a. Protect fuel hydraulic and lubrication
Check radiator cap to be certain it is secure (para 3-12). systems from entrance of sand. Use a bag of single
(3) Keep grille and radiator free of dirt and layer cloth and loosely tie bag over entire air cleaner
debris to insure good air circulation. during sand storms.
(4) Flush and clean cooling system b. Clean fuel filter bowl, air cleaner, drive axle
frequently. breather, hydraulic reservoir breather, and oil filler
b. Electrical System. breather daily.
(1) Check battery electrolyte level more c. Remove all sand from axles, wheels,
often. Maintain level three-eights of an inch above spindles, radiator, and brake assemblies periodically.
plates. Check all parts often to prevent undue wear caused by
(2) Check specific gravity of battery (para sand.
4-46 more often. d. Protect lift, tilt and steering mechanisms
(3) Clean battery cables frequently. from entrance of sand. Cover exposed parts of lift, tilt
and steering cylinder rods, lift chains, bearings, and
2-12. Operation in Extreme Cold reservoir during sand storms.
a. Protection. The truck should be stored in a
heated building or shelter if possible. If a shelter is not 2-14. Operation In Damp Tropical Areas
available, park the truck with the front end facing the
wind and cover with a tarpaulin. Fasten tarpaulin a. Check all paint for shipping and scratching.
securely to prevent it from blowing away. Corrosive action from dampness will take place almost
b. Cooling System. Service the cooling immediately if bare metal is exposed.
system with antifreeze as follows. For temperatures b. Touch up all spots where paint is chipped
from 32°F (0°C) to 10°F (-18°C), add one part of glycol or scratched.
antifreeze to four parts of water. For temperature from
10°F

2-8
 TM 10-3930-630-12

CHAPTER 3
OPERATOR/CREW MAINTENANCE INSTRUCTIONS

Section I. LUBRICATION

3-1. General Lubrication Information lubrication clean of lubricants. Before lubricating the
a. These paragraphs contain general equipment, wipe all lubrication points free of dirt and
lubrication instructions and lubrication instructions which grease. Clean all lubrication points after lubricating to
are supplemental to, and not specifically covered in the prevent accumulation of foreign matter.
lubrication order. c. Points of Lubrication. Service the points of
b. Refer to DA PAM 310-4 for the current lubrication at the proper intervals as illustrated on
lubrication order. current lubrication order.
3-2. Detailed Lubrication Information
d Operation Immediately After Lubrication
a. General Keep all lubricants in sealed Operate the truck through all movements for 5 minutes
containers and stored in a clean dry place away from immediately after lubrication. Inspect filters and lines
external heat. Allow no dust, dirt, or other foreign for evidence of leakage. If crankcase oil was changed,
material to mix with the lubricants. Keep all lubrication operate engine for 5 minutes and again check oil level
equip- ment clean and ready to use. Open right side panel to gain access to engine oil gage.
b. Cleaning. Keep all external parts not
requiring.

Section II. OPERATOR'S PREVENTIVE MAINTENANCE

3-3. General will be recorded in accordance with TM 38750.

To insure that the fork life truck is ready to operate at all 3-4. Operator's Preventive Maintenance Checks
times, it must be inspected systematically so that and Services
defects may be discovered and corrected before they
result in serious damage or failure. The necessary a. This paragraph contains a tabular listing of
preventive maintenance checks and services to be preventive maintenance services which must be
performed by the operator are listed and described in performed by the operator at the indicated intervals
paragraph 3-4. The item numbers indicate the b. Table 3-1 list preventive maintenance
sequence of minimum inspection requirements. Defects services in item numbers listed consecutively and
discovered during operation of the unit will be noted for indicate the sequence of minimum requirements. The
future correction, to be made as soon as operation has intervals are listed under services to be performed by
ceased. Stop operation immediately if a deficiency is the operator. Columns indicate the item to be
noted during operation which would damage the inspected, the procedure, and the paragraph reference
equipment if operation were continued. All deficiencies in this manual where the procedure is described. When
and shortcomings operational checks are to be made, operator must be
seated on seat.
Table 3-1. Operator/Crew Preventive Maintenance Checks and Services

B - Before Operation D - During Operation A - After Operation

Time required: 15 Time required: 0.9 Time required: 12

interval and sequence No.

Work
time
B D A Item to be inspected Procedure (M/H)

NOTE
Visually inspect for evidence of lubricant and hydraulic leak concurrent with daily service check
1 INSTRUMENT PANEL 0.2
Inspect gages and instruments for broken glass and other damage.
2 FUEL LINES 0.2.
Inspect for leaks and damage and secure mounting.
3 RADIATOR 0.2
Check for leaks and for correct fluid level (para 12).

3-1
 TM 10-3930-630-12

Table 3-1. Operator/Crew Preventive Maintenance Checks and Services - Continued

B - Before Operation D - During Operation A - After Operation

Time required: 1.5 Time required: 0.9 Time required 1-2

Interval and sequence No.

Work
time
B D A Items to be inspected Procedures (M/H)
4 ENGINE 02
Check oil level and add oil if necessary (para 3-14).
5 TIRES 02
Check for imbedded material, check for gouges and other damage (para 3-15).
6 TRANSMISSION 02
Check oil level and add oil if necessary (para 3-16).
7 LIGHTS 0.1
Check lights for proper operation (para 2-2
8 HORN 0.1
Check horn for proper operation (para 2.2
9 FIRE EXTINGUISHER 0.1
Inspect for broken seal and correct pressure.
10 INSTRUMENTS 0.1
Check that all instruments indicate within required ranges (para 3-9
11 CONTROLS 02
Check that controls perform as required (para 2-2).
12 BRAKES 02
Check parking brake and service brake to assure safe operation (para 2-2).
13 AIR CLEANER 0.1
Check air cleaner indicator. Indicator should show green in window. If indicator shows red
locked in up position, check air filter element and reset indicator (para 3-10).
14 HYDRAULIC SYSTEM
Check hydraulic filter indicator. Indicator should show green band in line with indicating line
(para 3-17).
15 UNUSUAL NOISES AND VIBRATION 02
Listen for unusual noises and check for excessive vibration. If present, shut off truck and
report to organizational maintenance
16 FUEL LEVEL 02
Fill fuel tank.
17 TRANSMISSION 02
Check oil level Add oil as necessary (para 3.16).
18 HYDRAULIC RESERVOIR
Check oil level Add oil as necessary (para 3-18).
19 FAN BELT 02
Check for proper adjustment, three-eights of an inch between pulleys If belt is worn or
frayed, notify organizational maintenance.
20 TIRES 0.4
Remove imbedded material. Check for gouge and other damage.

Section III. OPERATOR'S TROUBLESHOOTING

3-5. General b. This manual cannot list all malfunctions that

may occur, nor all tests or inspections and corrective
a. This section contains troubleshooting actions. If a malfunction is not listed or is not correctly
information for locating and correcting most of the listed by corrective actions, notify organizational
operating troubles which may develop in the fork lift maintenance personnel
truck. Each malfunction for an individual component,
unit or system is followed by a list of tests or inspections 3-6. Operator's Troubleshooting
which will help you to determine probable causes and
corrective actions to take. You should perform the Malfunctions which may occur are listed in table 32.
test/inspections and corrective actions in the order Each malfunction stated is followed by a list of tests and
listed. inspections within the recommended corrective action.

3-2
 TM 10-3930-630-12

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

1. ENGINE FAILS TO TURN OVER

Step 1. Check to see if transmission shift lever is in neutral (N) position.
Place lever in neutral (N) position.
Step 2. Check for weak or defective battery.
Notify organizational maintenance.
Step 3. Check for defective or shorted wiring.
Notify organizational maintenance.
2. ENGINE FAILS TO START
Step 1. Check cranking speed.
If cranking speed is too slow, check battery connections If battery is defective, notify organizational
maintenance.
Step 2. Check choke and carburetor controls (para 2-2)
If controls are defective, notify organizational maintenance.
Step 3. Check fuel shutoff valve, fuel tank and fuel filter (para 3-11).
Fill tank if necessary. Notify organizational maintenance if filter requires service.
Step 4. Check distributor, coil, spark plugs and wires (para 3-14).
If distributor, coil plugs or wires are defective, notify organizational maintenance.
3 ENGINE HARD TO START.
Step 1. Check choke and carburetor controls (para 2-2).
If controls require adjustment or are defective notify organizational maintenance
Step 2. Check distributor, coil, spark plugs and wires.
If parts are not operating properly or are defective notify organizational maintenance.
Step 3. Check air supply to engine (para 4-7).
If air cleaner indicator indicates the air cleaner is dirty or clogged, clean or replace element.
4. ENGINE STALLS AND STOPS FREQUENTLY.
Step 1. Check fuel shutoff valve (para 3-11).
Open valve completely.
Step 2. Check idle speed (para 24).
If idle speed requires adjusting, notify organizational maintenance.
Step 3. Check governor operation (para 24).
If governor requires adjustment or replacement, notify organizational maintenance.
Step 4. Check carburetor and linkage operation (para 2-4).
If carburetor or linkage requires adjustment or service notify organizational maintenance.
5. ENGINE OVERHEATS.
Step 1. Check coolant level (para 3-12).
Replenish engine coolant if necessary.
Step 2. Check radiator air passages (para 3-12).
Clean air passages if necessary.
Step 3. Check radiator and hoses for leakage (para 3-12).
If leakage is present, notify organizational maintenance.
Step 4. Check thermostat operation (para 4-70)
If thermostat does not operate properly, notify organizational maintenance.
6. ENGINE EMITS BLACK SMOKE FROM EXHAUST.
Step 1. Check air supply to engine (para 3-10).
If indicator indicates air supply is restricted, notify organizational maintenance.
Step 2. Check carburetor operation.
If carburetor requires adjustment or service, notify organizational maintenance.

3-3
 TM 10-3930-630-12

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

7. ENGINE OIL PRESSURE LOW.

Step 1. Check crankcase oil level (para 4-14).
Refill crankcase with proper grade of oil. Refer to current Lubrication Order.
Step 2. Check oil lines for leakage (para 4-13).
If oil lines are leaking, notify organizational maintenance.
Step 3. Check oil filter (para 4-13).
If oil filter is dirty, refer to organizational maintenance.
Step 4. Check oil pressure gage (para 2-2).
If oil pressure gage is defective, notify organizational maintenance.
8. STARTER WILL NOT CRANK ENGINE.
Step 1. Check transmission shift lever.
Place transmission shift lever in neutral (N) position (para 2-4).
Step 2. Check battery and cables.
Tighten cables or notify organizational maintenance if battery or cables are defective.
Step 3. Check neutral start switch.
Notify organizational maintenance if switch is defective.
Step 4. Check starter connections and operation.
Tighten connections. Notify organizational maintenance if starter is defective.
9. TRUCK DOES NOT MOVE WHEN ACCELERATOR IS DEPRESSED.
Step. 1. Check transmission shift lever (para 2-6).
Place transmission shift in forward (F) or reverse (R) to move truck.
Step 2. Check parking brake (para 2-5).
Disengage parking brake if necessary.
Step 3. Check oil level in transmission (para 3-16).
Replenish transmission oil if necessary.
10. TILT AND LIFT MECHANISMS DO NOT OPERATE WHEN LEVERS ARE ACTUATED.
Step 1. Check hydraulic filter indicator (para 3-17).
If indicator is in red zone, notify organizational maintenance to service filter.
Step 2. Check hydraulic reservoir oil level (para 3-18).
Replenish hydraulic oil if necessary. Refer to current Lubrication Order. Check hydraulic system
for leaks. Notify organizational maintenance if service is required.
11. SERVICE BRAKES DO NOT STOP TRUCK PROPERLY.
Step 1. Check brake pedal and linkage (para 2-5).
If linkage and pedal require adjustment, refer to organizational maintenance.
Step 2. Check fluid level in master cylinder (para 4-11).
If fluid level is low, notify organizational maintenance.
12. PARKING BRAKE DOES NOT HOLD TRUCK ON SLOPE.
Step 1. Adjust parking brake lever.
Loosen setscrew and turn knurled top of lever clockwise to adjust parking brake. Tighten setscrew.
Step 2. Check parking brake (para 2-5).
Notify organizational maintenance if parking brake requires service.
13. TRUCK DOES NOT STEER PROPERLY.
Step 1. Check connections to steering valve and cylinder.
Tighten connections or notify organizational maintenance if valve or cylinder are defective.
Step 2. Check hydraulic system for leaks (para 3-18).
Tighten connections or notify organizational maintenance if components need replacement.

3-4
 TM 10-3930-630-12

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Step 3. Check drag link and tie rods.

Notify organizational maintenance if components require adjustment or replacement.
Step 4. Check steering axle mounting.
Notify organizational maintenance if steering axle requires adjustment.
14. HEAD AND TAIL LIGHTS DO NOT OPERATE WHEN SWITCH IS ACTUATED.
Step 1. Check connections to switch and lights (para 3-9).
Tighten connections if necessary.
Step 2. Check headlight and taillight.
If lights are defective, notify organizational maintenance.
Step 3. Check stoplight switch.
If stoplight switch is defective, notify organizational maintenance.
15. HORN DOES NOT SOUND.
Step 1. Check horn wiring and connections
Tighten connections if necessary.
Step 2. Check battery.
If battery is low and requires service, notify organizational maintenance.

Section IV. OPERATOR MAINTENANCE OF TRUCK

3-7. General

Operator's maintenance of the truck is limited to the

following items described in paragraphs 3-8 through 3-
18 below.

3-8. Lubrication

a. Lubricate truck in accordance with the

current lubrication order.
b. Refer to paragraph 3-2 for detailed
lubrication information.

3-9. Instrument Panel

a. General The instrument panel is mounted

across the front of the truck. Refer to paragraph 2-2 for
a description of instruments and their operation.
b. Inspection:
(1) Before operating truck, inspect the
instruments (fig. 2-1) for broken glass and other
damage.
(2) During operation monitor the
instruments for proper readings. If the instruments
indicate a malfunction, notify organizational
maintenance.
Figure 3-1. Air cleaner and indicator
3-10. Air Cleaner and Indicator

a. General The air cleaner is mounted on the

left side of the truck. Open the left side panel to gain
access to the air cleaner (fig. 3-1).

3-5
 TM 10-3930-630-12

b. Inspection. carburetor for leaks, dents, bends and other damage.

(1) With the engine running, inspect the (2) If lines are leaking, close shut off
air cleaner indicator. If the red signal is locked in full valve to prevent loss of fuel and notify organizational
view in the window, press reset button on top of the maintenance.
indicator (fig. 3-1).
(2) If the red signal is locked in full view, 3-12. Radiator
notify organizational maintenance to service the air
cleaner. a. General. The radiator is enclosed by the
(3) Check hose clamps for tightness and counterweight at the rear of the truck An opening at the
hose for leaks and damage. top of the counterweight allows access to the radiator
cap.
3-11. Fuel Lines CAUTION
Remove cap slowly. Coolant could be under pressure.
a. General Fuel lines connect the fuel pump
and filter to the fuel tank and carburetor. Shut off b. Service. Stop the engine and allow radiator
valves are located at the fuel tank outlet and at the fuel to cool before attempting to remove radiator cap.
filter. Pressure in cooling system is 7 psi.
b. Inspection. (1) Remove radiator cap (fig. 3-2) and
(1) Inspect fuel lines at tank, fuel filter and. check coolant level.
.

TA034771
Figure 3-2. Radiator filler cap.

(2) Coolant level should be one-half to 3-13. Muffler and Pipes

one inch above plates.
(3) If coolant level is low, add coolant as a. General The muffler is mounted on the
necessary to bring to proper level lower left side of the frame. An exhaust pipe connects
(4) Install radiator cap. the muffler to the exhaust manifold. Open left side
panel

3-6
 TM 10-3930-630-12

to gain access to the muffler. b. Service. Operator service for the engine is
b. Inspections. Inspect muffler and exhaust limited to checking the oil level in the crankcase and
pipe for evidence of holes and leakage. Check clamps adding oil to bring to operating level
for security. (1) With engine off, open right side panel
to gain access to oil level gage.
3-14. Engine Assembly (2) Remove engine oil level gage (fig. 33)
and check oil level Oil level should be between the ADD
a. General The engine is mounted in a and F marks on the gage.
compart- ment below the operator's seat. Open side
panels and tilt seat forward to gain access to the engine.
.

TA034772

Figure 3-3. Oil filler cap and level gage.

(3) To add oil remove filler cap (fig. 3-3) axle to turn the truck. The tires are the solid rubbe-
and add oil Refer to current lubrication order for correct cushion type.
grade of oil b. Inspection.
(1) Inspect the tires for cuts, gouges and
3-15. Wheels and Tires other damage.
(2) Check the wheels for secure
a. General The front wheels of the truck are mounting.
the drive wheels. A propeller shaft connects the (3) When operating truck listen for
transmission to the drive axle. Rear wheels are unusual noises that could come from loose wheel
mounted on the steering axle. A hydraulic cylinder, mounting or worn wheel bearings.
actuated by turning the steering wheel, rotates the
steering

3-7
 TM 10-3930-630-12

3-16. Transmission bring to operating level

(1) Lift hinged door on right end of floor
a General. The transmission is mounted plate.
forward at the engine and the torque converter is directly (2) With engine operating at idle speed
coupled to the flywheel with flex plates. remove transmission oil level gage (fig. 3-4), and check
b. Service. Operator service of the oil level. Level should be to full mark on gage.
transmission is limited to checking the oil level and
adding oil to
.

TA034773

Figure 3-4. Transmission filler cap and level gage.

(3) To add oil, remove filler cap and fill to full 3-17. Hydraulic Filter Element Indicator
mark on gage. Refer to current lubrication order for
proper grade of oil. a. General A hydraulic filter element
indicator (fig.3-5) is mounted below the hydraulic control
valve

3-8
 TM 10-3930-630-12

levers at the right front of the truck. The indicator shows

the condition of the element in the hydraulic filter.

TA034774

Figure 3-5. Hydraulic filter element indicator.

b. Inspection. With the engine operating, used in the hydraulic system. The reservoir is mounted
move the hydraulic control valve levers to actuate the on the frame at the lower right side of the engine
hydraulic system. Check the filter indicator as oil is compartment.
flowing in the system. b. Service. Open right side panel to gain
(1) If the green band is in line with white access to hydraulic reservoir.
indicating line, the element and system is operating (1) Remove level gage (fig. 3-6) and
properly. check oil level in reservoir. Level should be at full mark
(2) When the white indicating line is in line with with oil temperature at approximately 70'F (21lC).
any portion of the yellow band, the filter element is (2) If oil level is low, add oil to bring it to
becoming contaminated. proper level Refer to current lubrication order for proper
(3) When the white indicating line reaches any grade of oil Fill reservoir through oil gage opening.
portion of the red band, notify organizational (3) To remove hydraulic reservoir
maintenance to change the element. Do not operate breather from reservoir, unscrew breather from
truck when indicator is in this position. reservoir. If breather is dirty or contaminated, replace
breather.
3-18. Hydraulic Reservoir

a. General The hydraulic reservoir stores oil to be

.

3-9
 TM 10-3930-630-12

TO REMOVE BREATHER, TURN COUNTERCLOCKWISE

TA034775

Figure 3-6. Hydraulic reservoir

3-10
 TM 10-3930-630-12

CHAPTER 4
ORGANIZATIONAL MAINTENANCE INSTRUCTIONS

Section I. SERVICE UPON RECEIPT OF TRUCK

4-1. Inspecting and Servicing the Equipment damage that may have occurred in shipment.
c. Remove tape, paper and other packing
a. When a truck is received by the using materials. Remove forks from truck by removing strap-
organization, it must be serviced to prepare it for ping and tie downs. Install forks on carriage as shown in
operation. The services required are described below. figure 4-1.
b. Carefully inspect truck for any signs of
dents or
.

INSTALLATION
1. RELEASE FORK LOCK BY TURNING POINT UP.
2. SLIDE FORK IN LINE WITH SLOT ON CARRIAGE.
LIFT FRONT OF FORK UP AND SLIDE INTO
POSITION.
3. TURN POINT OF FORK LOCK DOWN TO LOCK
FORK IN NOTCH ON CARRIAGE.

REMOVAL
1. TURN POINT UP TO RELEASE FORK LOCK.
2. SLIDE FORK IN LINE WITH SLOT ON CARRIAGE.
LIFT FRONT OF FORK UP AND REMOVE FROM
CARRIAGE.

ADJUSTMENT
1. RELEASE LOCK.
2. SLIDE FORK IN LINE WITH NOTCH AND LOCK IN
POSITION.
TA034776
Figure 4-1. Removing, installing or adjusting carriage forks.

4-1
 TM 10-3930-630-12

d. Remove any preservative compound that use flame in the vicinity. Batteries generate hydrogen, a
has been sprayed on metal surfaces with cleaning highly explosive gas.
compound, solvent (Fed Spec. P-D-680), and dry f. Fill the battery with electrolyte to three-
thoroughly eights of an inch above the plates. Check specific
gravity of electrolyte as prescribed in TM 96140-200-12.
WARNING g. Lubricate the truck in accordance with the
Dry cleaning solvent, P-D480 used for current lubrication order.
cleaning is potentially dangerous to h. See that the cooling system contains the
personnel and property. Do not use prescribed amount of anti-freeze in accordance with
near an open flame. Flash point of table 4-1, if necessary.
solvent is 100' F (880C) to 188'F (5C). i. Check drive belts and adjust for proper
e. Preservative compound is not a lubricant. deflec- tion.
Take special care to completely remove the compound j. Refer to table 4-2 for a list of maintenance
from all wearing surfaces. and operating supplies required for initial operation of
the fork lift truck.
WARNING

When servicing battery, do not smoke or

.

Table 4-1. Freezing Points, Composition and Specific Gravities of Military Antifreeze Materials

Lowest expected Pints of inhibited Compound, antifreeze Arctic ³ Ethylene glycol coolant
ambient temperature °F glycol per al. Of coolant specific gravity at 68°F
+2 1% Issue full strength 1.022
+10 2 and ready mixed for 1.036
0 23/4 01 to 66F temperatures 1.047
-10 31/4 for both 1.066
-20 4 initial installation 1.062
-30 41/4 and replenishment of 1.067
-40 Arctic losses 1.073
-50 anti- DO NOT DILUTE WITH
-60 freeze WATER OR ANY OTHER
-75 Preferred SUBSTANCE

¹Maximum protection is obtained at 60 percent by volume (4.8 pints of ethylene glycol per gallon of solution)
² Military Specification MIL-C-11755 Arctic type, nonvolatile anti-freeze compound is intended for use in the cooling system of liquid-
cooled internal combustion engines. It is used for protection against freezing primarily in Arctic regions, where the ambient
temperature remains for extended period close to -40°F or drops below, to as low as -90°F.
³ Use an accurate hydrometer. To test hydrometer, use 1 part ethylene glycol to 2 parts water. This should produce a hydrometer
reading of 0°F.

NOTE
Fasten a tag near the radiator filler cap indicating the type antifreeze used.

4-2. Installation of Separately Packed fire extinguisher and install in bracket in operator's
Components compartment. Be certain clamp locks securely to hold
a. Components. The only components not fire extinguisher in position.
already installed are the forks, electrolyte and the fire c. Forks and Electrolyte. Refer to paragraph
extinguisher. 4-1 and install forks and electrolyte.
b. Fire Extinguisher. Remove separately
packed
.

4-2
 TM 10-3930-630-12
Table 4-2. Maintenance and Operating Supplies

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

Component National description Quantity Quantity Notes
application stock number f/initial f/8 hrs.
operation operation

--------- OIL, LUBRICATING: 55 gal. (1) Includes quantity

CRANKCASE (1) drums as follows: to fill out system as
9150-00-265-9364(2) OE/HDO-30 5 qt. (3) follows:
9150-00-265-2429(2) OE/HD-10 5 qr. (3) 1 qt. oil filter
9150-00-242-7604(2) OES 5 qt. (3) 4 qt crankcase
FUEL TANK 9130-00-264-6218 GASOLINE: bulk as follows: 4½ 8 gal.
Regular grade (4) (5)

RADIATOR 6850-00-243-1992 WATER ANTIFREEZE: ethylene 10 qt. (2) See C 100L for
glycol 1 gal. can. additional data and
6580-00-243-1990 ANTIFREEZE: ethylene requisitioning
glycol 55 gal. drum procedure
grade application and

TRANSMISSION OIL, LUBRICATING: (6) (3) See current LO for

OE/HDO-10 11 qt. (7) (3) grade application and
OES 11 qt. (7) (3) replenishment intervals.

HYDRAULIC BRAKE (4) Tank capacity.

OIL HYDRAULIC: 1 gal can
as follows: (5) Average fuel con-
9150-00262-9375 HBA-non-petroleum base, ½ pt. sumptim is 10 gal.
automotive, arctic-type (3) per hour of continuous
HBA-non-petroleum base, operation.
automotive, arctic-type ½ pt. (3)
OIL, LUBRICATING, GEAR: 55
DIFFERENTIAL 91504)0577-5845(3) gal. drum as follows: (6) Use oil as
9150-00;240-2244(3) GO90 6 pt. (3)
915040-257-5442(3) GO-75 6 pt. (3) (7) Includes quantity
GOS 6 pt. (3) to fill transmission
system as follows:
HYDRAULIC OIL, LUBRICATING: 55 gal. 10 qt. transmission
drum as follows: 1 qt. filter
SYSTEM 9150-00-265-9429(3) OE/HDO-10 14 ¼. (3)
(8) (8) Includes quantity
9150-00-242-7604(3) OES 14 ¼ (3) to fill hydraulic
8 qt. (3) system as follows:
1 qt. filter
GREASE, AUTOMOTIVE AND 2½ qy. lines
ARTILLERY: 35 lb can as 3¾ gal. reservoir
LUBRICATION follows:
FITTINGS 9150-00-1 90-07(3) GAA As required (3)
4-3
 TM 10-3930-630-12
Section II. MOVEMENT TO A NEW WORKSITE

4-3. Dismantling for Movement 4-4. Reinstallation after Movement If forks were removed to
The only components that may require dismantling for transport the lift truck, refer to figure 4-1 and install the forks
movement are the forks. If necessary to conserve space when on the carriage.
transporting the lift truck by means of another carrier, refer to
figure 4-1 and remove the forks.

Section III. REPAIR PARTS, SPECIAL TOOLS

AND EQUIPMENT

4-5. Tools and Equipment 4-7. Maintenance Repair Parts

Tools, equipment, and repair parts, with or authorized for the Repair parts and equipment are listed and illustrated in the
fork lift truck, are listed in the basic issue items list and items repair parts and special tools list (TM 10-39304630-20P, to be
troop installed or authorized, appendix C. published), for the fork lift truck.

46. Special Tools and Equipment

No special tools or equipment are required to perform
organizational maintenance on the fork lift truck.

Section IV. LUBRICATION INSTRUCTIONS

4-8. General b. Refer to paragraph 4-90 and service the master

cylinder.
These paragraphs contain lubrication instructions 4-11. Drive Axle
which are supplemental to and not specifically covered in the a. The drive axle requires addition of lubricant and
lubrication order. draining and filling at regular intervals.
b. The axle breather requires service at regular
4-9. Hydraulic Filter and Reservoir intervals.
c. To drain axle differential, remove drain plug at
a. Replacement of the filter is required at specified bottom of housing. Fill axle differential through level plug
intervals. located on cover side of the housing.
b. A hydraulic filter element indicator (fig. 3-5) is d. Refer to paragraph 4-95 to service axle and
located at the right side of the instrument panel The indicating breather.
line (fig. 3-5) should be in line with the green band. This
indicates filter element is operating properly. If indicating line is 4-12. Transmission
in line with the yellow band, element is becoming
contaminated and should be changed at earliest convenience. a. The transmission requires service at regular
When white indicating line reaches any portion of the red intervals. A daily check of the oil level is required.
band, change element immediately. b. To drain transmission, place a suitable
c. Refer to paragraph 4-43 and service the container under the drain plug, remove drain plug and drain
hydraulic filter. transmission.
d. The hydraulic reservoir and breathers must be c. A filter screen is mounted in the transmission
serviced at regular intervals. sump. The screen should be serviced every time the
e. Refer to paragraph 4-44 and service the transmission oil is change
reservoir and breather. d. Refer to paragraph 4-101 to service transmission
f To drain reservoir, place a suitable container and screen.
under reservoir. Remove drain plug and drain reservoir.
g. Install drain plug and fill reservoir through level 4-13. Engine Oil Filter
gage hole.
a. The engine oil filter must be changed at regular
4-10. Brake Master Cylinder intervals; the filter is replaceable and requires no servicing.
b. Refer to paragraph 4-80 and replace the engine oil
a. The brake system must be checked and filter when necessary.
serviced at regular intervals.
4-4
 TM 10-3930-630-12

4-14. Engine Crankcase

a. The oil level in the engine crankcase should be c. To drain engine crankcase, place a suitable
inspected daily. Add oil as necessary to maintain proper container below engine and remove drain plug at left side of
operating level oil pan. Install drain plug and fill crankcase to proper level
through filler cap hole.
b. A breather, mounted in the filler cap, should be d Refer to paragraph 4-80 to service the engine
cleaned periodically. crankcase.

Section V. ORGANIZATIONAL PREVENTIVE MAINTENANCE

CHECKS AND SERVICES
4-15. General 4-16. Organizational Preventive Maintenance
Services
To insure that the fork lift truck is ready for operation
at all times, it must be inspected systematically so that a. This paragraph contains a tabular listing of
defects may be discovered and corrected before they result in preventive maintenance services which must be performed by
serious damage or failure. The necessary preventive organizational maintenance personnel at the indicated
maintenance checks and services to be performed by the intervals.
operator are listed and described in paragraph 3-4. b Table 4-3 lists preventive maintenance services
Organizational maintenance checks and services are listed in item numbers listed consecutively and indicates the
and described in paragraph 4-16. The item numbers indicate sequence of minimum requirements. The intervals are listed
the sequence of minimum inspection requirements. All under services to be performed by organizational
deficiencies and shortcomings will be recorded, together with maintenance personnel Columns indicate the interval and
the corrective action taken, in accordance with TM 38-750. sequence number, the item to be inspected, the procedure,
and the paragraph reference in this manual where the
procedure is described. When operational checks are to be
made, an operator must be seated on seat.

Table 4-3. Organizational Preventive Maintenance Checks and Services

Q—Quarterly
Total man-hours required: 3.0

Sequence No. Item to be inspected Work

. procedure Time
(M/H)

1 OVERHEAD GUARD 0.1

Check for cracked welds and other damage (para 4-22)
OPERATOR'S SEAT 0.1
Check for secure mounting; damage to cushions and adjustment operation (para 4-29
3 BODY, PANELS AND COWLS 0.1
Check for dents, cracks and secure mounting.(para 4- 24).
4 INSTRUMENT PANEL
Check for cracked and damaged instrument Inspect electrical and tubing connections and tighten if
necessary
5 MAST ASSEMBLY 0.2
Check for smooth operation Adjust bed if necessary. Check operation of carriage Inspect for
cracked or damage welds. (para 4-40).
6 HYDRAULIC LINES AND FITTINGS 0.1
Inspect lines for leaks, deterioration, secure connection and any evidence of damage (para 4-34).
7 LIFT CHAINS 0.1
Check chains for smooth operation. Inspect chain mounting. Check cir head bearings for good condition.
Lubricate chain if necessary (para 4-.3
8 LIFT CYLINDERS 0.1
Operate lift mechanism and observe cylinder operation (4-38)
9 TILT CYLINDERS 02
Operate tilt mechanism and observe cylinder operation. Check tilt Iimits if necessary. Check tilt cylinder.
mounting and hoses (para 43).
10 HYDRAULIC RESERVOIR 0.1
Check breather for contamination Inspect reservoir for leaks and damage (para 4.44).
11 ELECTRICAL SYSTEM 02
Check all wiring and harness for a secure connections. Check wire for fraying and other damage (para
4-45)
4-5
 TM 10-3930-630-12

Table 4-3. Organizational Preventive Maintenance Checks and Services - Continued

Q—Quarterly
Total man-hours required: 3.0

Sequence No. Item to be inspected Work

. procedure Time
(M/H)

12 BATTERY 0.1
Check battery for loose cables Remove corrosion Fill battery to 3; inch above plates Clean vent holes in
18 LIGHTS 0.1
Check lights for proper operation Inspect lights for broken lens and other damage (para 4-47).
14 ALTERNATOR 0.1
Operate engine and check ammeter. Alternator should be charging and taper down to a minimum
charging rate. Inspect wires and connections to alternator and tighten if necessary (par 4-51).
15 STARTER 0.1
Operate starter to start engine and check operation. Check wires connected to starter and tighten if
necessary (para 4-2)
16 STARTER
Check engine operation Adjust distributor points if necessary (para 453).
17 SPARK PLUGS AND COIL 0.1
Check engine operation If engine runs erratically or seems to lack power, check spark plugs and coil
(para 4-45).
18 AIR CLEANER 0.1
Check air cleaner indicator. If indicator is locked with red in the up position, clean or replace element.
Reset indicator (para 4-57).
19 CARBURETOR 0.1
Reset indicator (para 4-5).
Operate engine and check carburetor operation. Test and adjust if necessary (para 4-58).
20 FUEL PUMP 02
Check fuel pump pressure (para 4-60).
21 CRANKCASE VENT VALVE 0.1
Remove vent valve and check valve (para 4-62).
22 GOVERNOR 0.1
Operate engine and check governor operation (par 4-59
28 ACCELERATOR 0.1
Operate pedal and linkage Check operation (para 4658
24 FUEL TANK FILLER CAP AND SCREEN 0.1
Remove filler cap and check screen Clean screen if necessary (para 4-61).
26 FUEL LINES 02
Check fuel lines for leakage and damage. Tighten connections (para 4-68).
2a DRIVE BELT 02
Check belt for stretching and wear. Adjust belt to obtain 3/4-inch deflection between pulleys (para 4-1).
27 FAN AND WATER PUMP 0.1
Check fan for bent or dented blades If engine is overheating check water pump operation (para 4/8).
28 RADIATOR 02
Check radiator for leaks and damage. Test radiator and cap for correct pressure (par 469).
29 HOSES AND THERMOSTAT 0.1
Check hoses for leaks and good condition Tighten hose clamps if necessary. Check thermostat operation
(para 670).
80 MUFFLER AND PIPES 02
Check muffler and pipes for leaks and damage. Tighten clamps if necessary (para 4-75
31 DRAGLINK AND TIE RODS 0.1
Operate steering and check drag link and tie rods (para 4-74)
32 ENGINE 02
Check engine operation Inspect engine for leaks and damage. Change engine oil if necessary (para 4-80).
33 ENGINE OIL FILTER 02
Check engine oil filter. Replace filter according to interval specified in current Lubrication Order.
34 MANIFOLDS 02
Check manifolds for cracks or leakage (pars 4-81
35 CYLINDER HEAD 0.1
Check cylinder head for leakage and damage (para 4-82).
36 VALVE 0.1
Check engine and valve operation (para 4-8-3)
37 WHEELS AND BEARINGS 0.1
Check drive and steer wheels for proper operation Adjust steering stops if necessary (pars 485).
38 TIRES 02
Check tires for wear, cuts and damage. Notify direct and general support maintenance if tires require
replacing (para 3-15

4-6
 TM 10-3930-630-12

Table 4-3. Organizational Preventive Maintenance Checks and Services - Continued

Q—Quarterly
Total man-hours required: 6.9

Sequence No. Item to be inspected Work

. procedure Time
(M/H)

39 SERVICE BRAKE SHOES 0.2

Inspect shoes for wear (para 4-88)
40 WHEEL CYLINDERS 0.1
Check wheel cylinder operation Bleed brake system if necessary (para 489).
41 MASTER CYLINDER 0.1
Check master cylinder operation. Brakes should stop truck smoothly and evenly. Check master cylinder
for leaks (para 4-90)
BRAKE PEDAL AND LINKAGE
Check brake operation (para 4-87).
43 PARKING BRAKE 0.1
Check lever and brake operation (para 4-91 and 4-92)
44 DRIVE AXLE 0.4
Check axle shafts and drive gears for good condition and proper operation. Lubricate axle according to
current Lubrication Order (para 4-93)
45 STEERING AXLE 0.2
Check steering axle mounting. Tighten screws if necessary. Check stop and alignment adjustment
Adjust if necessary (para 4-73)
46 TRANSMISSION OIL FILTER 0.2
Check hoses for leaks Tighten connections or replace hoses if necessary. Change filter element in
accordance with current Lubrication Order (para 4-73)
47 CONTROL LEVER AND LINKAGE 0.2
Operate truck and check transmission operational Operate inching pedal and check operation (par 4-99)

Section VI. ORGANIZATIONAL MAINTENANCE TROUBLESHOOTING

may occur, nor all tests or inspections and corrective

4-17. General actions. If a malfunction is not listed or is not corrected by
listed corrective actions, notify direct support maintenance.
a. This section contains troubleshooting
information for locating and correcting most of the operating 4-18. Organizational Maintenance
troubles which may develop in the fork lift truck. Each Troubleshooting
malfunction for an individual component, unit, or system is The following table, Table 4-4, lists the malfunctions,
followed by a list of tests or inspections which will help you to tests and inspections, and corrective actions as applicable to
determine probable causes and corrective actions to take. organizational maintenance.
You should perform the tests/inspections and corrective
actions in the order listed
b. This manual cannot list all malfunctions that

Table 4-4. Organizational Maintenance Troubleshooting

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

1. ENGINE FAILS TO TURN OVER

Step 1. Check for weak or defective battery.
Charge battery or replace battery (para 4-46).
Step 2. Check for defective or shorted wiring.
Repair or replace wiring as necessary.
Step 3. Check for defective starter.
Replace defective starter (para 4-52).
2. ENGINE FAILS TO START
Step 1. Check cranking speed.
If speed is low check battery connections and battery. If battery is dead, charge or
replace battery (para 4-52).
Step 2. Check choke and carburetor controls.
Adjust controls if necessary (para 4-58).

4-7
 TM 10-3930-630-12

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

Step 3. Check fuel filter.

Service fuel filter if necessary (para 4-61).
Step 4. Check distributor, coil and spark plugs.
Adjust distributor points or replace points if defective. Check coil and spark plugs and
replace if defective. Replace defective distributor, coil and spark plug wires (para 444).
3. ENGINE HARD TO START
Step 1. Check choke and carburetor controls.
Adjust choke and carburetor and controls if necessary (para 4-58).
Step 2. Check distributor, coil, spark plugs and wires.
Adjust distributor, coil, spark plugs and wires.
Adjust distributor points or replace points. Replace defective coil, spark plugs and
wires (para 4-54).
Step 3. Check air supply to engine.
If air cleaner indicator indicates cleaner is clogged, clean or replace air cleaner
element (para 4-57). Reset indicator.
4. ENGINE STALLS AND STOPS FREQUENTLY
Step 1. Check idle speed.
Adjust idle speed if necessary (para 4-58).
Step 2. Check governor operation.
Adjust or replace governor if necessary (para 4-59).
Step 3. Check carburetor and linkage operation.
Adjust linkage or replace carburetor if necessary (para 458).
5. ENGINE OVERHEATS
Step 1. Check fan belt for wear, stretching and proper adjustment.
Replace worn or stretched belt. Adjust belt to %inch deflection between pulleys (para
451).
Step 2. Check radiator and hoses for leakage.
Tighten hose clamps or replace hoses if necessary. Repair leaks if possible (para 4-69).
Step 3. Check thermostat operation.
Replace defective thermostat (para 4-70).
6. ENGINE EMITS BLACK SMOKE FROM EXHAUST
Step 1. Check air supply to engine.
If indicator shows air cleaner is restricted, clean or replace element and reset
indicator (para 457).
Step 2. Check carburetor settings and adjustments.
Adjust carburetor, carburetor linkage or replace defective carburetor (para 4-58).
7. ENGINE OIL PRESSURE LOW
Step 1. Check oil lines for leakage
Repair or replace oil lines.
Step 2. Check oil pressure regulator valve.
Adjust regulator valve.
Step &. Check oil pressure gage.
Replace defective oil pressure gage (para 432).
8. STARTER WILL NOT CRANK ENGINE
Step 1. Check battery and cables.
Tighten, clean or replace battery and/or cables (para 4.46).
Step 2. Check neutral start switch.
Replace defective neutral start switch (para 4-100).
Step 3. Check starter operation.
Tighten connections or replace defective starter (para 4-52)

4-8
 TM 10-3930-630-12

MALFUNCTION
TEST OR INSPECTION
CORRECTIVE ACTION

9. TRUCK DOES NOT MOVE WHEN ACCELERATOR IS DEPRESSED

Step 1. Check accelerator linkage.
Adjust or replace carburetor linkage.
Step 2. Check transmission linkage.
Adjust transmission lever and linkage (para 4-58).
Step 3. Check drive axle.
Adjust drive axle bearings (para 486) or notify direct and general support maintenance if drive axle is
defective.
10. TILT AND LIFT MECHANISMS DO NOT OPERATE WHEN LEVERS ARE ACTUATED
Step 1. Check hydraulic filter element indicator.
If indicator shows element is restricting flow, replace element (para 4-43).
Step 2. Check hydraulic reservoir and lines for leaks.
Tighten connections or replace lines and/or reservoir (para 444).
Step 3. Check control lever operation.
Adjust or replace defective levers (para 4-41). Notify direct and general support maintenance if control valve
is defective
11. SERVICE BRAKES DO NOT STOP TRUCK PROPERLY
Step 1. Check brake pedal and linkage.
Adjust or replace pedal and linkage (para 4-87).
Step 2. Check master cylinder.
Fill master cylinder or replace defective master cylinder (para 4-90)
Step 3. Check wheel cylinders.
Bleed brake system or replace defective wheel cylinder (para 4-89)
Step 4. Check service brake shoes.
Replace unserviceable springs or brake shoes (para 4-88).
12. PARKING BRAKE DOES NOT HOLD TRUCK ON SLOPE
Step 1. Check parking brake linkage.
Adjust or replace defective parking brake linkage or lever (para 4-91)
Step 2. Check parking brake.
Repair or replace parking brake (para 4-92)
13. TRUCK DOES NOT STEER PROPERLY
Step 1. Check drag link and tie rod.
Adjust, repair or replace defective drag link and/or tie rods (para 4-7).
Step 2. Check steering axle mounting.
Adjust mounting or adjust steering axle (para 4-78).
Step 3. Check steering valve and cylinder.
Notify direct and general support maintenance if valve is defective. Replace defective steering cylinder (para
4-76).
14. HEAD AND TAILLIGHTS DO NOT OPERATE WHEN SWITCH IS ACTUATED
Step 1. Check headlight and taillight.
Repair or replace defective lights (para 4-47).
Step 2. Check light switch.
Repair or replace defective light switch (para 4-31).
Step 3. Check stoplight switch.
Replace defective switch (para 4-90).
16. HORN DOES NOT SOUND
Step 1. Check horn button.
Replace defective horn button (para 4-77).
Step 2. Check battery.
Charge or replace defective battery (para 446). 4-48
Step . Check horn and relay.
Replace defective horn and/or relay (para 448).

4-9
 TM 10-3930-630-12

Section VII. RADIO INTERFERENCE SUPPRESSION

4-19. General Methods to Obtain Proper
Suppression (1) Leads to instrument panel

Essentially, suppression is obtained by providing (2) Battery ground wire.

a low resistance path to ground for stray currents The
methods used include grounding the frame with ground c. Spark plugs are the resistor type.
straps and installing internal or external teeth
lockwashers in critical mounting areas. d. Spark plug and ignition coil leads and cable
are nonmetallic conductor type.
4-20. Interference Suppression Components
4-21. Replacement of Suppression
a. A ground strap is connected between the Components
instrument panel and frame.
b. The following ground and mounting parts Since no major components such as capacitors
utilize internal-external teeth lockwashers to provide or resistors are installed to provide radio suppression,
positive grounding. removal of the components is not required. In normal
removal and disassembly procedures the lockwashers
will be removed and be labeled as suppression
components at that time.

Section VIII. OVERHEAD GUARD

4-22. General
(2) Remove screws (1 and 2, fig. 4-2), nuts,
The overhead guard is incorporated in the truck lockwashers (3), washers (4) and nuts (5).
to provide protection for the operator. The guard is
mounted to the frame at the four corners. (3) Carefully lift overhead guard (6) from truck,
using hoist.
4-23. Overhead Guard
b. Installation.
a. Removal
(1) Lift overhead guard (6, fig. 4-2) into position
(1) Attach a suitable hoist to the overhead on truck.
guard and raise hoist to relieve tension on mounting
screws. (2) Secure overhead guard to truck with screws
(1 and 2), lockwashers (3), washers (4) and nuts (5).

(3) Detach hoist from guard.

4-10
 TM 10-3930-630-12

TA034777
1 Screw 4 Washer
2 Screw 5 Nut
3 Lock Washer 6 Overhead guard

Figure 4-2. Overhead guard, removal and installation.

Section IX. PANELS. COWLS AND PLATES

4-24. General
compartment. Two cowls, one on each side of
a. Panels and Cowls. The major portions of the front of the frame, enclose the fuel tank on the left
the truck are enclosed with sheet metal panels and and the hydraulic oil filter control valve and horn on the
cowls. Two side panels are hinged and can be swung right.
out and to the rear to gain access to the engine b. Floor and Toe Plates. The floor and toe
plates

4-11
 TM 10-3930-630-12

provide the base for the operator’s compartment. They

provide protection for the transmission, shifting, inching d Seat Support and Deck. The seat is mounted
pedal and accelerator linkages. A hinged cover welded on a support hinged at the front to allow the seat to be
to right side of the floor plate beneath the seat allows tipped forward. A prop is provided to hold the seat in
access to the transmission level gage and master the open position. Attached to the rear of the support is
cylinder. a deck which protects the upper rear of the engine
compartment.
c. Grilles. A large grille is mounted at the rear 4-25. Cowls
of the counterweight to protect the radiator. Below the a. Removal. Removal screws (1 and 3, fig.
front of the operator seat is an engine screen to protect 4-3), washers (2) and nuts (4 and 7) and remove cowls
the engine compartment and allow air to enter for (5 and 6) from the front corners of the frame.
engine operation.

1 Screw 8 Screw 15 Screw

2 Lockwasher 9 Lockwasher 16 Nut
3 Screw 10 Nut 17 Washer, flat
4 Nut 11 Floor Plate 18 Nut
5 Left cowl 12 Screw 19 Toe plate
6 Right cowl 13 washer, lock
7 Nut 14 Nut

Figure 4-3. Cowls and floor plates, exploded view.

4-12
 TM 10-3930-630-12

b. Installation. Install cowls (5 and 6, fig. 4-3) 4-26. Side Panels

on frame and secure with screws (1 and 3), lockwashers
(2) and nuts (4 and 7). a. Removal.
(1) Open side panels and swing them to the
rear.
(2) Lift side panels up and away from hinges
(27 and 28, fig. 4-4).

Figure 4-4. Counterweight and side panels, exploded view.

4-13
 TM 10-3930-630-12

(3) Inspect grommets (11) and replace if damaged or washers (3) and remove grille (4). Remove spacers (56)
deteriorated. (2) Refer to paragraph 4-30 and remove seat from
truck.
b. Installation (3) Remove screws (19), washers (20), nuts (21) and
lockwashers (22) and remove deck (23) from seat support.
(1) Install side panels (12 and 13, fig. 4-4) on hinges (4) Remove screws (33), lockwashers (34), nuts (35)
Install grommets (11) in panels if they were removed. and washers (36) and remove seat support (37).
(2) Close side panels. (5) Remove long screws (38), lockwashers (39) and
nuts (40) and remove angles (41) from screen.
4-27. Floor and Toe Plates (6) Remove screws (42), lockwashers (43) and nuts
a. Removal (44) and remove engine screen (45) from truck.
(1) Remove screws (8, fig. 4-3) and washers (9). (7) Remove remaining parts, if necessary, by
(2) Remove floor plate (11) from operator's removing attaching parts.
compartment.
(3) Remove screws (12 and 15), washers (13 and b. Installation.
17) and nuts (16). (1) Install engine screen (45, fig. 4-4) on supports
(4) Carefully slide toe plate (19) to the rear and lift and secure with screws (42), lockwashers (43) and nuts (44).
toe plate away from accelerator, brake and inching (2) Install angles (41) on screen and install long
pedals screws (38), lockwashers (39) and nuts (40).
(3) Install seat support (37) on angles and secure
c. Installation. with screws (33), lockwashers (34), nuts (35) and washers
(1) Carefully slide toe plate (19, fig. 4-3) into (36).
position in truck. Align cutouts in plate with pedals (4) Install deck (23) on rear of seat support and
and accelerator. secure with screws (19), washers (20), nuts (21) and
(2) Secure plate to frame with screws (12 and 15), lockwashers (22).
washers (13 and 17) and nuts (16). (5) Refer to paragraph 4-30 and install seat
(3) Install floor plate (11) behind toe plate over assembly.
transmission. (6) Install spacers (5) and grille (4) on rods (6).
(4) Secure floor plate with screws (8) and washers Secure grille with nuts (1), lockwashers (2) and washers (3).
(9).

4-28. Grille and Screen

a. Removal
(1) Remove nuts (1, fig. 4-4), lockwashers (2) and

Section X. SEAT ASSEMBLY

4-29. General (3) Disconnect spring (14) from slide adjuster.
Remove screws (11), lockwashers (12) and nuts (13) and
a The operator's seat is mounted above the engine remove slide adjuster (15) and slide (16) from frame (17).
compartment. Placement of the seat allows easy access to (4) Remove plastic plugs (18) from frame.
all operating controls. Cushions on the seat and back provide c. Assembly.
comfort for operator. (1) Install plastic plugs (18, fig. 4-5) in ends of frame.
v (2) Position slide (16) and slide adjuster (15) on
b. The seat is adjustable, fore and aft. It is mounted frame (17) and secure in place with screws (11), lockwashers
on a hinged support, allowing it to be tilted up and forward to (12) and nuts (13).
allow access to the top of the engine. A prop, set on a pivot, (3) Install spring (14) on slide adjuster.
can be raised and set in place to an open position. (4) Place seat cushion (10) on frame and align hooks
4-30. Seat Assembly at rear of cushion with holes in frame. Slide rod
a. Removal (9) through frame and cushion hooks and secure with
(1) Lift and tilt seat forward and prop into cotter pins (8).
position. d. Installation.
(2) Support seat and remove nuts (1, fig. 4-5) and lift (1) Position seat assembly on seat support (37, fig.
seat assembly from support. hold the seat in an open 4-4).
(2) Secure seat to support with nuts (1, fig. 4-5).
position.
(3) Remove prop and lower seat and support into
position on truck.
b. Disassembly.
(1) Remove screws (2, fig. 4-5), washers (3) and
nuts (4) and remove backrest (5) from frame. (2) Remove
cotter pins (8) and rod (9) and remove seat cushion (10) from
frame.

4-14
 TM 10-3930-630-12

TA0M34780

1 Nut 10 Seat cushion

2 Screw 11 Screw
3 Washer 12 Lockwasher
4 Nut 13 Nut
5 Backrest 14 Spring
6 Screw 15 Slide adjuster
7 Hinge 16 Slide
8 Cotter pin 17 Frame
9 Rod 18 Plug

Figure 4-5. Seat assembly, exploded view.

Section XI. INSTRUMENT PANEL

4-31. General
a. The instrument panel is mounted across the instruments for correct reading (fig. 2-1). Test fuses with
front of the truck forward of the steering wheel All the an ohmmeter for continuity.
instruments relative to truck operation are mounted on b. Removal
the pane (1) Remove clamps (1, fig. 4-8). Remove
b. Also mounted on the panel are the ignition screw (2), lockwasher (3) and nut (4) and remove clamp
switch and choke control The ignition switch serves to (5).
start the truck, as a starter switch and the main switch in (2) Disconnect frame wiring harness (7) from
the electrical system. instrument panel harness.
(3) Remove clamp (6). Remove screws (9),
4-32. Instrument Panel lockwashers (10) and nuts (11) and remove adapter (12)
a. Test. Operate truck engine and truck. and choke control (8) from panel Remove harness (7).
Check
4-15
 TM 10-3930-630-12

1 Clamp 14 Plate
2 Screw 15 Light switch
3 Lockwasher 16 Plate
4 Nut 17 20 amp fuse
5 Clamp 18 Switch cable
6 Camp 19 Terminal
7 Frame wiring 20 Sleeve
harness 21 Fuseholder
8 Choke control 22 Transmission
9 Screw pressure gage
10 Lockwasher 23 Screw
11 Nut 24 Screw
12 Adapter 26 Nut
13 Ignition switch 26 Instrument panel

Figure 4-6. Instrument panel components, exploded view.

4-16
 TM 10-3930-630-12

(4) Tag and disconnect harness wires and c. Disassembly.

cable (18) from light switch (15). Disconnect fuseholder NOTE
(21) and remove fuse (17). Most of the instruments removed in the
(5) Disconnect tube from transmission following paragraphs can be removed
pressure gage (22) and remove gage from panel. with-out removing the instrument panel
(6) Tag and disconnect wires from ignition from the truck.
switch (18). Remove ignition switch and plate (14) from (1) Tag and disconnect leads (1, 4 and 5, fig.
instrument panel. 4-7) from instruments and fuseholder.
(7) Disconnect panel ground wire (29, Fig. 4-7) (2) Remove screw (6), lockwasher (7) and nut
from panel and frame. Remove screws (23 and 24, fig. (8) and remove clamp (9). Tag leads from wiring
4-6) and nuts (25) and remove instrument panel (26) harness and disconnect leads from instruments and
from truck. fuseholder. Remove wiring harness (10).

Figure 4-7. Instrument panel, exploded view. 17

4-17
 TM 10-3930-630-12

(3) Remove fuses (11 and 12) from fuseholder. coolant temperature gage.
Remove screws (13), lockwashers (14) and nuts (15) (7) Connect lead (1) to fuel gage and to connector
and remove fuseholder (16). (2). Connector (4) is connected to the wire from the fuel gage
(4) Remove screws (17) and remove hourmeter transmitter installed in the fuel tank.
(18). e. Installation.
(5) Remove remaining gages and ammeter (19, (1) Install instrument panel (26, fig. 4-6) on truck
20, 21 and 22) by removing attaching parts. frame and secure panel with screws (23 and 24) and nuts
d. Assembly. (25).
(1) Install coolant temperature gage (19, fig. 4-7), (2) Connect panel ground wire (29, fig. 4-7) to
fuel gage (20), oil pressure gage (21) and ammeter (22) on instrument panel and frame. Use lockwashers (26, fig. 4-7)
instrument panel and secure with screws, nuts and when connecting ground wire.
lockwashers. NOTE
(2) Install hourmeter (18) and secure with screws Internal-external teeth lockwashers (26, fig.
(17). 4-7) must be installed to provide radio
(3) Install fuseholder (16) on rear of instrument interference suppression.
panel and secure with screws (13), lockwashers (14) and nuts
(15). Install fuses (11 and 12) in fuseholder. (3) Install transmission pressure gage (22, fig. 4-6)
NOTE and connect tube leading from transmission to pressure gage.
Refer to figure 13 and check wire locations (4) Install ignition switch (13) and plate (14).
and connections on wiring diagram. (5) Install light switch (15) and plate (16). Connect
cable (18) to light switch. Install fuse (17) in fuseholder (21)
(4) Check tags on wiring harness (10) and connect and connect fuseholder.
leads to instruments and fuseholder. Secure wiring harness (6) Connect frame wiring harness (7) to panel
to panel with clamp (9) and screw (6), lockwasher (7) and nut harness (10), fig. 4-6) and install clamps (1 and 5, fig. 4-6).
(8). Secure clamp (5) with screw (2), lockwasher (3) and nut (4).
(5) Connect lead (4) to fuseholder and coolant (7) Install choke control (8, fig. 4-6) and adapter
temperature gage. Use lockwashers (3) when connecting (12). Secure adapter with screws (9), lockwashers (10) and
lead. nuts (11). Install clamp (6) to secure choke cable.
NOTE (8) Start truck and check operation of instruments.
Internal-external teeth lockwashers (3) must
be installed to provide radio interference
suppression.

(6) Connect lead (5) between fuel gage and

Section XII. HYDRAULIC LIFT COMPONENTS

4-33. General
a. The hydraulic lift components provide the d. When the cluster cylinder center cylinder has
means to elevate the carriage and forks. Hydraulic pressure reached the limit of travel, hydraulic pressure is delivered to
induced into the lift cylinders extend the cylinder rods in the single lift cylinder (fig. 4-8) (model ACC40-24PS180 only).
sequence to lift the carriage, and the masts to raise the load. The single lift cylinder is attached to the intermediate mast at
b. Chains attached to the cluster cylinder (fig. 4-8) the top and to the bottom of the outer mast. The rod extends
lift the carriage to the end of chain travel The outer cylinders from the bottom of the cylinder, raising the cylinder and
of the cluster cylinder lift the crossheads and the chains roll intermediate mast.
over the crosshead bearings, lifting the carriage. e. As the intermediate mast rises, it carries the
c. When the outer cylinders reach the end of their inner mast, cluster cylinder and carriage forks upward. When
travel, the center or inner cylinder rod is forced down raising the single lift cylinder reaches the limit of travel, the carriage
the entire cluster cylinder, carriage and inner mast. and forks are at their 180-inch elevation.
f. An interlock assembly, mounted on the inner
NOTE mast serves to keep the masts in the proper sequencing
procedures. The masts telescope within each other providing
The above sequence applies to both model a compact assembly.
ACC4024PS100 and ACC40-24PS180 lift g. When the lift control lever is pulled to the rear,
trucks. On the ACC40-24PS100, the mast or lowering position, the carriage and forks start to drop. The
at this point will have lifted the forks to their load and/or carriage drop because of their own weight. Speed
100-inch limit. of the lowering operation is governed by a flow regulator valve
(fig. 4-8).

4-18
 TM 10-3930-630-12

DEVICE AND SYMBOL LEGEND

→ DIRECTION OF FLOW
LINES CROSSING
REGULATOR
PC PRESSURE CONTROLLED
PF FIXED DISPLACEMENT
NOTE: LIFT CYLINDER IS NOT USED
ON MODEL ACC40-24PS100.

Figure 4-8. Hydraulic system diagram.

TA03478
Figure 4-8. Hydraulic system diagram. carriage at the height desired
Hydraulic oil is forced from the cylinders to maintain a h. To further understand the fork lift hydraulic
safe lowering speed. Release of the lift control lever, system, refer to the hydraulic system diagram,
allowing it to reach a neutral position, will hold the

4-19
 TM 10-3930-630-12

figure 4-8. plug cylinder, valve or filter ports to prevent entrance of

i. A hydraulic pump (fig. 48), directly driven by the foreign matter.
engine crankshaft, supplies hydraulic oil under pressure to the c. Installation. Before installing fittings, check to
control valve (fig. 4-8). As the lift and tilt levers are moved, oil see if packing is required.
flows to the lift cylinders to raise the mast or to the tilt (1) Remove plugs from ports and install fittings in
cylinders (fig. 4-8) to tilt the mast. cylinders, valves or filter.
j. Oil for the system is stored in the hydraulic (2) Remove plugs from ends of hoses and connect
reservoir (fig. 4-8). As the oil returns to the reservoir, it flows hoses to fittings.
through the hydraulic oil filter (fig. 4-8). A filter element (3) Operate truck and lift and tilt mast and steer
indicator (fig. 4-8) is connected across the inlet and outlet of truck to actuate hydraulic system.
the filter. If the filter element becomes clogged and (4) Stop truck engine and check level of oil in
contaminated, the indicator will show filter element condition. hydraulic reservoir. Add oil as necessary to fill reservoir to
k. Tilt cylinders are connected to the outer mast proper operating level Refer to current lubrication order for
and to the frame below the toe plate. Hydraulic pressure proper grade of oil
applied on either side of the cylinder rod will extend or retract (5) Bleed hydraulic system as follows.
the rod. As the rod extends, it tilts the mast forward. As the (a) Raise mast until forks are approximately three
rod is retracted, the mast tilts backward. feet off the ground.
4-34. Hydraulic Lines and Fittings (b) Open bleed screws located at the top of the
a. Inspection. Inspect hydraulic hoses and tubes cylinder until hydraulic oil comes out.
frequently. Check for leakage, damage, chafing and wear. (c) Observe oil and check for air bubbles. When
Check all fittings for leakage and damage. Replace stream of oil is free of air bubbles, close bleed screws.
unserviceable components. (d) Check level of hydraulic oil in reservoir. Fill
b. Removal Before attempting to remove any reservoir if necessary.
hydraulic lines or fittings, refer to paragraph 440 and drain (e) Raise and lower mast and check for leaks and
reservoir if necessary. Remove toe and floor plates and front proper operation. Tighten connections if necessary.
cowls or open side panels to gain access to hydraulic lines.
(1) Disconnect hoses or tubes at valve, cylinders, 4-35. Lift Chains
filter or reservoir by removing hose clamps or disconnecting a. General. Extension of the two outer cylinders of
at fittings. the cylinder cluster raises the chain bearing and crosshead.
(2) If necessary, remove any clamps mounting the As the bearing raises the chains which are anchored at the
hose or tube to the truck. rear of the cylinder cluster, the action raises the carriage.
(3) If preformed packings are present when a fitting b. Inspection. Inspect chains for wear, cracks and
is removed, mark fitting to insure installing packing when other damage.
installing new fitting. (1) Lower carriage and forks to the floor.
(4) Immediately plug ends of hose or tube and (2) Refer to figure 4-9 and remove other pins and
chain links from chain anchors attached to cluster cylinder.

Figure 4-9. Lift chain and anchors, installed view.

TA034784

4-20
 TM 10-3930-630-12

(3) Disconnect lift chains from carriage by

removing cotter pins (fig. 4-10) and chain links from
both chains.

Figure 4-10. Lift chains and carriage.

4-21
 TM 10-3930-630-12

(4) Lift chains over chain bearings and off of (4) Tension must be equal on both chains and
crossheads and remove chains from mast. carriage must be level.
d. Cleaning and Inspection. (5) Tighten locknuts. Check adjustment to see
(1) Clean chains with cleaning compound, it has not been disturbed.
solvent (Fed. Spec. P-D-680) and dry thoroughly. (6) Operate lift mechanism and check chain
(2) Inspect chains for bent, cracked or operation.
damaged links. Replace defective links. (7) Lower carriage and fully retract cylinder
(3) Lubricate chains with oil (OE/HDO). cluster. Check for carriage level and forks clearing
e. Installation. floor.
(1) Refer to figure 4-9 and place chains 4-36. Carriage, Backrest and Forks
through crossheads and around chain bearings. a. General. The carriage rides in the masts
(2) Connect chains to chain anchors with chain and rolls on bearings. Lift forks are attached to the
links (fig. 4-9) and cotter pins. carriage. Connections for the lift chains are provided on
(3) Lower ends of chains to anchors on the rear of the carriage. The backrest helps to support
carriage (fig. 4-10) and attach chains to anchors with and steady the load.
chain links and cotter pins. b. Inspection.
(4) Operate lift mechanism and check chains (1) Operate lift mechanism and check carriage
for bending or uneven operation. If cylinders are fully movement. Carriage should move smoothly through
retracted, carriage should be level and forks should not entire length of inner mast. If carriage binds or catches
touch floor. Refer to f. below to adjust chains. in mast, inspect bearing alignment and bearings for
f. Chain Adjustment. damage.
(1) Check to see that mast is in a vertical (2) Inspect welds on carriage and backrest for
position and that cylinder cluster is fully retracted. breaks and damage. Check backrest for bent frame.
(2) Loosen locknuts and adjusting nuts (fig. 4- (3) Inspect forks and locking pins for damage.
9) on the chain anchors. c. Removal.
(3) Turn the adjusting nuts to vary chain (1) Remove screws (1, fig. 4-11), lockwashers
length. Tighten or loosen the chains until the chains are (2), washers (3) and nuts (4). Remove backrest (5) from
a snug fit and forks barely clear the floor. carriage.

Figure 4-11. Backrest, removal and installation.

4-22
 TM 10-3930-630-12

(2) Place two pieces of wood at least two (3) Remove screws (2 and 4, fig. 4-12),
inches (508 mm) thick under forks (one under front of lockwashers (3) and spacers (5).
forks and one under carriage frame).

TA034797

1 Link 7 Bearing
2 Screw 8 Shim
3 Lockwasher 9 Shim
4 Screw 10 Carriage
5 Spacer 11 Stud
6 Screw 12 Stud

Figure 4-12. Carriage. removal and insulation.

(4) Refer to figure 4-10 and disconnect lift tag shims as above.
chains from carriage. (3) Inspect studs for damage. If studs require
(5) Start engine and raise mast until carriage replacement, notify direct and general support
bearings clear inner mast channels. maintenance.
(6) Back lift truck away from carriage. Refer to e. Reassembly.
figure 4-1 and remove lift forks. Support carriage with (1) Install shims (8 and 9, fig. 4-12) and
blocks. bearings
d. Disassembly. (7) on same studs as before disassembly.
(1) Remove screws (6, fig. 4-12) and remove (2) Secure bearings on upper studs with
upper bearings (7) from studs. Count number of shims screws (6).
(8 and 9) used with each bearing. Tie shim groups f: Adjustment.
together and mark for correct installation. (1) Use an inside spanning tool (fig. 4-13) and
(2) Remove remaining bearings from studs determine narrowest point along channels of inner mast.
and

4-23
 TM 10-3930-630-12

Figure 4-13. Spanning mast channels

(2) Set outside spanning tool to match inside

spanning tool distance as shown in figure 4-14.
Lock outside tool at this setting.

Figure 4-14. setting outside panning tool.

(3) Check bearings (7, fig. 4-12) on roller studs.

Span bearings on carriage at the maximum camber
point with outside spanning tool. Span all three sets of
bearings. Remove bearings if necessary and shim Figure 4-15. Check bearing alinement
bearings to produce a maximum of 0.015-inch (0.38
mm) clearance between end of spanning tool and
bearings.

4-24
 TM 10-3930-630-12

(4) Check bearing alinement by placing a (5) Refer to figure 4-10 and connect lift chains
straightedge as shown in figure 4-15. Place straightedge to carriage.
against stud centerline of all three bearings on both sides (6) Install backrest (5, fig. 4-11) on carriage
of carriage. No visible gap should be seen between and secure with screws (1), lockwashers (2), washers (3)
bearings and straightedge. and nuts (4).
(5) Check to see that upper bearing mounting (7) Operate lift mechanism and check carriage
screw s tightened to a secure fit. travel.
g. Installation. 4-37. Tilt Cylinders
(1) Refer to figure 4-1 and install lift forks on a. General Tilt cylinders, anchored at the
carriage. Place wood under carriage and forks as frame and attached to the outer mast, extend through
described in c. above. Adjust wood and blocks to bring the front of the frame. Hydraulic pressure from the
carriage to a straight upright position. control valve extends or retracts cylinder rods to tilt the
(2) Operate engine and raise mast high enough mast.
for inner mast channels to clear carriage bearing. b. Inspection
(3) Move truck to bring inner mast channels (1) Operate truck and check tilt cylinder opera-
directly above and centered over carriage bearings. tion. Check degrees of tile (e. below).
Slowly lower inner mast, making sure carriage bearings (2) Remove floor and toe plates from
enter inner mast channels smoothly. operator’s compartment.
(4) Install screws (2 and 4, fig. 4-12), (3) Inspect hoses (fig. 4-16) and fittings at tilt
lockwashers cylinder for leaks and damage.
(3) and spacer (5).

Figure 4-16. Tilt cylinder, removal and installation.

4-25
 TM 10-3930-630-12

(4) Check tilt cylinder (fig. 4-16) for secure (3) Support tilt cylinder with a block of wood.
mounting at frame and mast. c. Removal. (4) Remove screw (fig. 4-16) and lockwasher
(1) Remove floor and toe plates. securing locking pin and remove locking pin and pivot
(2) Disconnect hoses (fig. 4-16) from tilt pin (fig. 4-16).
cylinder. (5) Remove cotter pins and remove yoke pin
Plug hose ends and cylinder ports. (fig.
4-17) from cylinder and mast.

Figure 4-17. Tilt cylinder yoke, install view.

(6) Remove cylinder from truck. e. Tilt Adjustment.
d. Installation. NOTE
(1) Position cylinder in truck with yoke in line Place truck on a flat level surface
with mast. Install pin (fig. 4-17) through mast and yoke. to check and adjust mast tilt.
Secure pin with two cotter pins (fig. 4-17).
(2) Install pivot pin (fig. 4-16) through end of (1) Normal tilt on model ACC40-24PS100
cylinder and frame and secure with locking pin (fig. 4- trucks is 3° forward and 10° backward. Operate tilt
16), screw and lockwasher. cylinders and check tilt angle with a protractor (fig. 4-
(3) Install floor and toe plates. 18). Make sure both cylinders have reached the end of
(4) Bleed hydraulic system (para 4-32). their stroke.

4-26
 TM 10-3930-630-12

Figure 4-18. Checking degrees of mast tilt

(a) Set protractor to measure ten degrees of raise the carriage and mast. The cylinder includes two
tilt. Place protractor against mast as shown. Tilt mast outer cylinders and a center cylinder. The crossheads
to end of cylinder backward stroke. Bubble must be are secured to the top of the outer cylinder rods. As
centered if tilt is correct. rods extend the crossheads rise and carry the chains
(b) If tilt is not correct, tilt mast as far forward over the bearings, lifting the carriage and forks.
as possible (end of stroke). Loosen clamp screw (fig. b. Inspection.
k17) on yoke at front of cylinder. Turn adjusting hex on (1) Inspect the cylinders and connections for
cylinder rod (fig. 4-17) to extend or retract rod as leaks and damage.
necessary to adjust tilt. (2) Inspect crosshead bearings for good
(c) After adjusting, check degree of tilt. condition.
Continue adjusting piston rod until ten degrees (3) Operate lift mechanism and check chain
of backward tilt is obtained. Tighten clamp screw (fig. 4- and cylinder operation.
17) on yoke. c. Removal (Model ACC40-24PS180).
(d) Forward tilt is automatically adjusted to (1) Lower mast to bring cluster cylinder to fully
proper angle when backward tilt is correct. lowered position.
(e) Install floor and toe plates. (2) Refer to paragraph 4-33 and remove the lift
(2) Normal tilt of the mast on model ACC40- chains.
24PS180 trucks is 3° forward and 5.5° backward. Check (3) Refer to paragraph 4-34 and remove
and set tilt as described in (1) above to these limits. carriage.
4-38. Cluster Cylinder (4) Remove screw (1), fig. 4-19) and
a. General Both models use a cluster cylinder lockwasher (2) and remove guard (3) from tube.
to

4-27
 TM 10-3930-630-12

Figure 4-19. Mast assembly (model ACC40-24PS180), exploded view.

(5) Disconnect tube (5, fig. 4-19) from the (28) securing cluster cylinder (48) to inner and
cluster and single lift cylinders. Plug ends of tube and intermediate masts.
cylinder ports. (7) Carefully lift cluster cylinder from mast.
(6) Have two persons support the cluster d. Removal (Model ACC40-24PS100)
cylinder. Remove screw (26), lockwasher (27) and nut (1) Perform steps (1) thru (3) above.

4-28
 TM 10-3930-630-12

(2) From beneath truck disconnect hose from (29).

elbow (13, fig. 4-20). Plug hose. Remove regulator (4) Remove two screws (30), lockwashers (31)
(14), body (15) and packing (16) from cylinder. Plug and nut (32) and remove retainer (33). Carefully lift
cylinder port. cluster cylinder (46) from mast.
(3) Have two persons support the cluster e. Installation (Model ACC40-24PS100).
cylinder (46). Remove screw(27) and nut (28) securing (1) Lift cluster cylinder (46, fig. 4-20) into
cylinder to retainer and outer mast. Remove position on outer mast and retainer.
spacer

Figure 4-20. Mast assembly (model ACC40-24PS100), exploded view.

4-29
 TM 10-3930-630-12

(2) Secure cylinder to outer mast to outer with nut (3) Refer to paragraph 4-38 and install cluster
(28). Install spacer (29) on top of cylinder and secure cylinder cylinder, carriage and chains. 4-40. Mast Assembly
to retainer with screw (27). 4-40. Mast Assembly
(3) Install retainer (33) behind cylinder and secure a. General. The telescoping mast assemblies
with screw (30), lockwasher (31) and nut (32). raise and support the carriage and load. Canted roller-type
(4) remove plug and install new packing (16), body construction uses ball bearings to provide friction free
(15), regulator (14) and elbow (13) inlet port of cylinder. operation within the telescoping channels.
Remove plug and connect to elbow. (1) Model ACC40-24PS100 lift trucks incorporate a
(5) Refer to paragraph 4-36 and install carriage and two-section mast and one cluster cylinder. The inner mast
forks. (42, fig. 4-20) rides inside the outer mast channels on bearings
(6) Refer to paragraph 4-35 and install lift chains. attached to the bottom of the inner mast and inside the top of
(7) Operate lift mechanism and check operation. the outer mast.
f. Installation (Model ACC40-24PS180). (2) Model ACC40-24PS180 lift trucks incorporate a
(1) Lift cluster cylinder (48, fig. 4-19) into position three-section mast, a cluster cylinder and a single-lift cylinder.
on intermediate and inner masts. Secure cylinder to masts The inner mast (42, fig. 4-19) rides inside the intermediate
with screw (26), lockwasher (27) and nut (28). mast channels. Bearings at the bottom of the inner mast and
(2) Remove plugs and connect tube (5) to cluster top inside of the intermediate mast guide the mast. The
cylinder and single cylinder. Install guard (3) over tube and intermediate mast (44, fig. 4-19) operates in the same manner
secure with screw (1) and lockwasher (2). inside the outer mast.
(3) Refer to paragraph 4-36 and install carriage, b. Inspection.
forks and backrest. (1) Operate lift mechanism and che ck operation.
(4) Refer to paragraph 4-35 and install lift chains. Masts should function smoothly and sequence
(5) Operate lift mechanism. Refer to paragraph 4- properly.
34 and bleed hydraulic system, if necessary. (2) Inspect bearings for wear and damage.
(3) Inspect mast channels for wear and damage.
4-39. Single Lift Cylinder (Model ACC40-24PS180) Check all welds for good condition.
a. General. In addition to the cluster cylinder, c. Removal (Model ACC40-24PS180).
model ACC40-24PS180 trucks have a single lift cylinder to (1) Refer to paragraph 4-35 and remove lift chains.
supply the final stage of the three-stage lift A tube connects (2) Refer to paragraph 436 and remove carriage,
from single cylinder to the cluster cylinder to provide hydraulic backrest, and forks.
pressure. (3) Refer to paragraphs 4-38 and 4-39 and remove
b. Removal cluster and lift cylinders.
(1) Refer to paragraph 438 and remove the cluster (4) Attach a hoist of sufficient capacity to mast
cylinder. lifting eyes on outer mast.
(2) From beneath the truck, disconnect the hose (5) Refer to paragraph 437 and disconnect tilt
from elbow (12, fig. 4-19). Plug end of hose. cylinders from outer mast.
(3) Remove elbow (12), flow regulator (13), body (6) Remove lockwire (3, fig. 4-21) securing screws
(14) and packing (15) from the inlet port of the single cylinder. (4). Remove screws (4) and lockwashers (5). Raise mast with
Plug cylinder port. hoist to relieve tension on pins.
(4) Support the cylinder (49) and remove screw (7) Remove pins (6) from both sides of mast.
(26), lockwasher (27) and nut (28) securing cylinder to bracket (8) Use the hoist and lift mast assembly from truck
(36) and outer mast. and place mast on suitable supports.
(5) Remove screws (29) and lockwashers (30) and d. Removal (Model ACC40-24PS100).
remove clamp (31) and spacer (32) securing bottom of (1) Refer to paragraph 4-35 and remove lift chains.
cylinder to mast. (2) Refer to paragraph 4-36 and remove carriage,
(6) Carefully remove cylinder from mast. backrest and forks.
c. Installation. (3) Refer to paragraph 4-38 and remove cluster
(1) Place cylinder (49, fig. 4-19) into position on cylinder.
mast and install clamp (31) and spacer (32). Secure clamp (4) Attach a hoist of sufficient capacity to mast
around cylinder with screws (29) and lockwashers (30). lifting eyes on outer mast.
(2) Secure top and bottom of cylinder to retainer (5) Refer to paragraph 4-37 and disconnect tilt
and mast with screw (26), lockwasher (27) and nut cylinders from outer mast.
(28). (6) Remove lockwire (3, fig. 4.21) securing screws

4-30
 TM 10-3930-630-12

position on truck. Block mast as necessary.

(2) Install pins (6, fig. 4-21) through mast and
frame. Secure pins with screws (4) and lockwashers (5).
Install lockwire (3) to secure screws.
(3) Refer to paragraph 4-37 and connect tilt
cylinders to mast. Remove hoist.
(4) Refer to paragraphs 4-38 and 4-39 and install
cluster and lift cylinders.
(5) Refer to paragraph 4-36 and install carriage,
backrest and forks.
(6) Refer to paragraph 4-35 and install and adjust
lift chains.
(7) Bleed hydraulic system (para 4-34).
(8) Check mast tilt and adjust if necessary (para 4-
37).
(9) Operate lift mechanism and check for smooth
operation.
4-41. Control Valve Levers
a. General. Two levers, attached to the control
valve at the right front of the truck, allow the operator to
control lift and tilt functions. When the inner lever is pulled to
the rear, the carriage and mast will lift. When the lever is
pushed forward, the load and carriage will lower. When the
lever is in the center or neutral position, the carriage will
remain where it is halted. The outer lever operates the tilt
function. Pulling the lever to the rear will tilt the mast to the
rear. Pushing the lever forward will tilt the mast forward.
b. Inspection
(1) Remove screws and remove right-hand cowl
Figure 4-21. Mast mounting, exploded view.
from truck.
(4) Remove screws (4) and lockwashers (5).
(2) Check control valve levers (fig. 2-1), for secure
Raise mast with hoist to relieve tension on pins.
attachment to control valve.
(7) Remove pins (6) from both sides of mast.
(3) Move levers through entire range of opera-tion.
(8) Use the hoist and lift mast assembly from truck
Movement should be smooth and positive.
and place mast on suitable supports
c. Removal.
e. Installation (Model ACC40-24PS100).
(1) Remove nuts and screws attaching control
(1) Use a hoist and lift mast assembly into position
levers (fig. 4-22) to control valve. Remove links (fig. 4-22).
on truck. Block mast as necessary.
(2) Remove retaining rings (fig. 4-22) and pins
(2) Install pins (6, fig. 4-21) through mast and
securing levers to control valve plungers. Remove levers.
frame. Secure pins with screws (4) and lockwashers (5).
d. Installation.
Install lockwire (3) to secure screws.
(1) Install control valve levers (fig. 4-22) in position
(3) Refer to paragraph 4-37 and connect tilt
on control valve.
cylinders to mast: Remove hoist.
(2) Secure levers to control valve plungers with
(4) Refer to paragraph 4-38 and install cluster
pins and retaining rings (fig. 4-22).
cylinder.
(3) Install links (fig. 4-22) and control levers on
(5) Refer to paragraph 4-36 and install carriage,
control valve. Install screws through levers and links and
backrest and forks.
secure with nuts.
(6) Refer to paragraph 4-35 and install and adjust
(4) Install right hand cowl on truck.
chains.
442. Hydraulic Filter Element Indicator
(7) Bleed hydraulic system (para 4-34).
a General The hydraulic filter element indicator is
(8) Check mast tilt and adjust if necessary (para
mounted on the front of the truck next to the control
4437).
(9) Operate lift mechanism and check for smooth
operation.
f. Installation (Model ACC40-24PS180).
(1) Use a hoist and lift mast assembly into
4-31
 TM 10-3930-630-12

Figure 4-22. Control valve levers, installed view.

levers. It enables the operator to check the (2) Inspect indicator for damage and proper
condition of the filter element. operation.
b. Inspection. c. Removal
(1) Check indicator hoses for leaks. Tighten (1) Disconnect hoses at rear of indicator (fig.
connections if necessary. 4-23). Plug hoses and indicator.

4-32
 TM 10-3930-630-12

Figure 4-23. Hydraulic filter element indicator, installed view.

(2) Remove screws, lockwashers and nuts filter housing. (fig. 4-24).
securing indicator to bracket and remove indicator. (3) Remove hydraulic filter housing.
d. Installation. Remove packing from filter head (fig. 4-24).
(1) Install indicator (fig. 4-23) in position (4) Remove filter element from housing.
on bracket. Secure indicator with screws, lockwashers (5) Clean inside of filter body and filter
and nuts. head with cleaning compound, solvent (Fed. Spec. P-D-
(2) Remove plugs from indicator and 680) and dry thoroughly.
hoses. Connect hoses to indicator. (6) Install new filter element in filter
(3) Check oil level in reservoir and fill to housing.
proper level Refer to current lubrication order for (7) Install new packing in filter head and
correct oil install housing and filter element by screwing housing
(4) Bleed hydraulic system (para 4-34). into head.
(5) Operate truck and observe indicator. (8) Tighten housing to 20 to 30 pound-feet
Indicator should register filter element condition. (27.1 to 40.6 N-m).
(9) Check oil level in hydraulic reservoir
4-43. Hydraulic Filter and add oil if necessary. Refer to current lubrication
order for correct oil.
a. General. The hydraulic filter is mounted at (10) Operate hydraulic system and check
the right front of the truck. All hydraulic oil flows from for leaks. Correct leaks if necessary.
the control valve and steering valve through the filter (11) Bleed hydraulic system (para 4-34).
and returns to the reservoir. (12) Install right front cowl
b. Service. The filter element must be c. Filter Replacement.
replaced at intervals shown on the current lubrication (1) Removal.
order. It should also be replaced at any time the filter (a) Remove right front cowl
element indicator shows flow through the element is (b) Disconnect steering system
restricted. To replace the element, proceed as follows: return hose (fig. 4-24) from elbow at inlet hose (fig. 4-
(1) Remove attaching parts and remove 24). Remove elbow and packing from inlet elbow.
right front cowl
(2) Place a suitable container below filter.
Use an appropriate wrench on the large hex on hydraulic
4-33
 TM 10-3930-630-12

Figure 4-24. Hydraulic filter, installed view.

(c) Loosen hose clamps and (2) Installation.

disconnect inlet outlet hoses (fig. 4-24) from filter head. (a) Install correct elbows and fittings
Plug hoses and filter. in filter head. Check to see that new packing is installed
(d) Disconnect indicator hoses from with elbow used with steering system return hose.
filter head. (b) Install new filter on bracket and
(e) Remove screws and lockwashers secure with screws and lockwashers.
attaching filter head to bracket. Remove filter from (c) Unplug and connect indicator
bracket. hoses to fittings in filter.
(f) Remove all elbows and fittings (d) Remove plugs from inlet and
from filter head. outlet hoses

4-34
 TM 10-3930-630-12
on the right side of the frame.
(fig. 424) and install hoses on elbows in filter head. b. Service. Open right side panel to gain
Tighten clamps securely. access to the top of the reservoir.
(e) Remove plug from steering (1) Oil Level.
system return hose (fig. 4-24) and connect hose to (a) Lower mast and retract all
elbow in filter head inlet elbow. cylinders.
(f) Check oil level in hydraulic (b) Remove oil level gage (fig. 4-25)
reservoir and add oil if necessary. Refer to current and check oil level. Oil level should be to full mark on
lubrication order for correct oil gage with oil temperature at approximately 70°F (21°C).
(g) Operate hydraulic system and (c) Fill reservoir to correct level
check for leaks. Correct if necessary. Refer to current lubrication order for correct Oil
(h) Bleed hydraulic system (para (d) Install oil level gage.
434). (2) Breather and Screen. Every 200
(I) Install front Cowl hours the breather should be replaced. Unscrew
breather (fig. 4-25) from top of reservoir. Install new
4-44. Hydraulic Reservoir breather. Remove oil level gage and remove screen.
Clean screen in cleaning compound solvent (P-D-680)
a. General. The hydraulic reservoir serves as and dry thoroughly. Install screen and gage.
a storage receptacle for the hydraulic oil It is mounted

TA034800

Figure 4-25. Hydraulic reservoir breather and oil level gage..

4-35
 TM 10-3930-630-12

(3) Draining and Refueling. At interval hydraulic reservoir drain.

specified in current lubrication order, drain and refill (b) Remove drain plug (fig. 4-26) and
reservoir. washer from bottom of reservoir (fig. 4-26) and drain
(a) Raise and block truck as reservoir.
necessary. Place a suitable container beneath the

Figure 4-26. Hydraulic reservoir drain plug.

(c) Refill reservoir with proper grade (1) Remove nuts (13, fig. 4-27) and
of oil. Refer to current lubrication order. remove cover (14) and gasket (15).
(d) Operate hydraulic system and (2) Flush inside of reservoir with cleaning
check for leaks. Correct if necessary. compound solvent (P-D80). Dry interior of reservoir
(e) Bleed hydraulic system (para 4- thoroughly.
34) (3) Install cover (14) and new gasket (15)
c. Removal on reservoir (12). Secure cover with nuts (13).
(1) Refer to b above and drain hydraulic e. Installation.
reservoir. (1) Lift reservoir into position on right side
(2) Loosen clamps and remove outlet of frame. Secure reservoir to frame with screws (7 and
hose (fig. 4-26) from reservoir. Plug tube to pump. 8, fig. 427), lockwashers (9), and washers (10).
(3) Remove screws (7 and 8, fig. 4-27), (2) Remove plug from tube and install
lockwashers (9) and washers (10) securing reservoir to outlet hose (fig. 4-26) on reservoir and tube. Tighten
frame. Remove reservoir from truck. clamps securely.
d. Cleaning. (3) Refer to b above and fill reservoir.

4-36
 TM 10-3930-630-12

1 Breather 9 Lockwasher
2 Level gage 10 Washer
2 Screen 11 Nut
4 Plug 12 Reservoir
5 Drain plug 13 Nut
6 Washer 14 Cover
7 Screw 15 Gasket
8 Screw

Figure 4-27. Hydraulic reservoir, exploded view.

4-37
 TM 10-3930-630-12

Section XIII. ELECTRICAL SYSTEM

4-45. General
CAUTION
a. This section provides organizational
maintenance of the truck electrical system, except for Before attempting any replacement or repairs to
electrical applications of the instrument panel which are the electrical system, refer to paragraph 4-46
contained in paragraph 4-32. and disconnect the battery ground (negative)
b. The electrical system is protected by three cable.
fuses.
A 10-amp fuse mounted beneath the instrument panel 4-46. Battery and Cables
protects the instrument system. The horn electrical
system is protected by a 20-amp fuse mounted on the a. General. The battery is mounted at the
same fuse holder as the 10-amp fuse described above. front of the engine compartment. It stores electrical
Lights are protected by a 20-amp fuse mounted in a energy and supplies power to start the truck engine and
fuse holder which is part of the cable supplying the operate the lights and instruments.
headlight. b. Inspection.
c. To further understand the electrical system, (1) Lift seat up and tilt seat and support
refer to figure 3-1. This electrical schematic diagram forward
illustrates the system and shows interconnections and (2) Lift seat prop from right side of
routing. compartment and install prop to hold seat in an open
position.
(3) Inspect battery (fig. 4-28) for good
condition and any evidence of leakage.

Figure 4-28. Battery, installed view.

4-38
 TM 10-3930-630-12

(4) Inspect cables for secure connection the headlight allows it to be rotated and directed as
and evidence of corrosion. necessary to illuminate the work area.
(5) Remove caps from battery and check (2) Inspection.
level of fluid in battery. Level should be three eighths of (a) Turn on light switch and check switch and
an inch above plates.
c. Service.
(1) Fill battery to proper level if
necessary.
(2) Check filler caps for tight fit and cover
vent holes.
(3) Clean top of battery, posts and cable
terminals with a solution of baking soda and water. Do
not allow solution to enter battery cells.
(4) When foaming stops flush battery and
cables terminals with clean, fresh water. Remove
covers from vent holes in caps.
(5) Replace damaged or frayed cables.
Disconnect cables from battery, starter and ground at
engine. Install new cables and tighten securely. Install
ground cable (negative) last.
(6) Check condition of battery using a
hydrometer. If specific gravity is 1.225 or lower,
recharge battery. A fully charged battery should read
1.265 to 1.290 specific gravity.
d. Removal
(1) Lift and prop seat in open position.
(2) Disconnect battery cables (fig. 4-28)
from battery.
(3) Remove wing nut (fig. 4-28) and
washer and lift battery holddown up and to the right to
free battery. Figure 4-29. Headlight, installed view.
(4) Use a suitable battery lifting tool and
lift battery from battery tray. (b) To remove headlight, slide boot
(5) Remove screws and remove battery down wire and disconnect wire from headlight.
box and holddown. (c) Unscrew knob (fig. 4-29) from
e. Installation. rear of headlight. Remove nut and washer from bracket
(1) Install battery box and holddown (fig. and remove headlight.
4-28) and secure with screws, lockwashers and nuts. (d) To remove wire from mast,
(2) Use a suitable battery lifting tool and remove screws and remove clamp. Disconnect wire at
lift battery (fig. 4-28) into position in battery tray. double connector and remove wire.
(3) Place battery holddown into position to (4) Installation.
secure battery. Install wing nut (fig. 4-28) and washer (a) Connect wire to double connector
and tighten wing nut securely. and secure wire to mast with clamp.
(4) Connect battery cables to battery (b) Install headlight with stud at rear
posts and tighten securely. Install ground cable of headlight (fig. 4-29) through bracket. Secure light
(negative) last. with washer and nut. Install knob.
(5) Remove prop and lower seat and (c) Connect wire to headlight and
support into position. slide boot into position to protect connection.
4-47. Lights b. Combination Rear Light. The light mounted
a. Headlight. at the top of the counterweight is a combination light.
(1) General. The truck headlight is When the light switch is on, it is lit to function as a
mounted on the left side of the mast. Operation is taillight. Depressing the brake pedal actuates a
controlled through a push-pull light switch (fig. 21)
mounted on the instrument panel Bracket mounting of
4-39
 TM 10-3930-630-12
pressure switch and closes the circuit. The light then stoplight operation.
operates as a stoplight. (c) Inspect light for broken lens and
(1) Inspection. other damage.
(a) Check light for secure mounting (2) Removal
and secure wire connections. (a) To replace lamps in combination
(b) Turn on light switch and check rear light, remove retaining ring and lens (fig. 4-30).
taillight operation. Depress brake pedal and check

Figure 4-30. Combination rear light, exploded view.

(1) Inspection.
(b) Depress lamp and turn one- (a) Remove the floor plate to gain
quarter turn counterclockwise to remove from socket. access to the master cylinder mounted on the right side
(c) To remove combination light, of the frame.
disconnect wires from connectors at rear of light. (b) Check stoplight switch (fig. 4-31)
(d) Remove nuts and lockwashers wires for secure connections and good condition.
(fig. 4-30) and remove light from mounting bracket. (c) Check around switch for evidence
(3) Installation. of oil leakage.
(a) Install combination rear light on (d) Depress brake pedal and check
bracket and secure with nuts and lockwashers (fig. 4- stoplight operation.
30). (2) Removal.
(b) Connect wires to connectors at (a) Remove floor plate.
rear of light. (b) Disconnect wires from stoplight
(c) Install new lamps (fig. 4-30) by switch (fig. 4-31).
depressing lamps in socket and turning one-quarter turn (c) Remove stoplight switch from
clockwise. fitting connected to master cylinder (fig. 4-31).
(d) Install lens (fig. 4-30) in light and (3) Installation.
secure with retaining ring. (a) Install stoplight switch (fig. 4-31)
c. Stoplight Switch. The stoplight switch is a in fitting in master cylinder.
pressure switch mounted on the forward end of the (b) Connect wires to stoplight switch.
brake master cylinder. When the brake pedal is (c) Install floor plate.
depressed, hydraulic pressure closes the switch and
operates the stoplight.

4-40
 TM 10-3930-630-12

Figure 4-31. Brake master cylinder, installed view.

4-48. Horn (4) If horn is producing a weak signal
a. General. A horn is installed on the truck as proceed as follows:
a warning device. The circuit for the horn includes a (a) Connect a voltmeter between the
relay. Depressing the horn button in the center of the horn terminal and ground. Press the horn button and
steering wheel closes the circuit and operates the horn. observe the voltage on voltmeter.
The horn is mounted on the right side of the truck (b) If voltage is between 0 and 10.7
behind the hydraulic oil filter. volts, check for an open circuit, defective horn relay,
b. Inspection. defective
(1) Depress horn button and check horn wiring or shorted horn coil Check horn button-to-ground
operation. contact.
(2) Remove right front cowl Check horn (c) If voltage is normal and horn
and relay connections. signal is
(3) Check horn and relay for secure
mounting.

4-41
 TM 10-3930-630-12

weak, replace horn. (2) Tag and disconnect wires from horn
c. Removal (fig. 4-32) and relay.
(1) Remove right front cowl.

Figure 4-32. Horn and relay, installed view.

(3) Remove screw, lockwasher and nut secure with screw, lockwasher and nut. Connect wires
securing horn to frame. Remove horn. to horn and relay.
(4) Remove screws, lockwashers and nuts (3) Operate horn button and check horn
and remove relay (fig. 4-2) from frame. operation.
d. Installation.. (4) Install right front cowl.
(1) Install relay (fig. 4-32) on frame and
secure with screws, lockwashers and nuts.
(2) Install horn (fig. 4-32) on frame and

4-42
 TM 10-3930-630-12
4-49. Wiring electrical tape if possible.
a. General. Electrical wiring for the truck (3) Replace damaged wires and
consists mainly of two harnesses. A harness with a terminals.
multiple plug connects the instruments and fuses on the (4) Tighten clamp mounting screws and
instrument panel Connection to the frame harness is install missing clamps if necessary.
made with a matching multiple plug at the right side of
the instrument panel Additional wires connect to the 4-50. Sending Units
horn, transmission neutral start switch, fuel level gage
and transmitter, and between instruments on the panel a. General. The engine oil pressure gage,
The engine ignition and associated wiring are covered in hourmeter, coolant temperature gage, and fuel level
their appropriate paragraphs. gage are actuated by sending units mounted on the
b. Inspection. engine and fuel tank. Connections are made to the oil
and temperature gages through the frame wiring
CAUTION harness. Two wires connected by a quick-disconnect
coupling lead from the fuel tank to the fuel gage. The
Before attempting any replacement or fuel level gage sending unit is covered with the fuel
repairs to the electrical system, refer to tank.
paragraph 446 and disconnect the battery b. Oil Pressure Gage Sending Unit. The oil
ground (negative) cable. pressure and hourmeter actuator sending units are
(1) Check electrical connections for mounted on the engine crankcase on the left side below
security. the air cleaner.
(2) Inspect wires for damage to insulation, (1) Inspection. Open left side panel to
wire and terminals. gain access to the oil pressure gage sending unit.
(3) Check clamp for secure mounting. (a) Check wire connections to
c. Repair. sending units
(1) Tighten loose connections if
necessary.
(2) Cover damaged insulation with

Figure 4-33. Oil pressure and hourmeter actuator sending units, installed view.
4-43
 TM 10-3930-630-12
(b) Inspect sending units for CAUTION
evidence of oil leakage where unit and fittings thread Apply pressure with pry bar against stator
into crank-case. laminations, not against end frames.
(2) Removal (5) Place pry bar as shown on figure 4-34
(a) Remove nuts and lockwashers and pry alternator away from engine until correct
and disconnect wires from sending units (fig. 4-33). deflection
(b) Use a wrench on the hex and
remove oil pressure sending unit from crankcase.
Remove hourmeter actuator sending unit.
(c) Remove elbow and tee from
crankcase.
(3) Installation.
(a) Install tee and elbow in
crankcase.
(b) Install sending units (fig. 4-33) in
tee.
(c) Install wires on sending units and
secure with nuts and lockwashers.
c. Coolant Temperature Gage Sending Unit.
The coolant temperature sending unit (fig. 4-28) is
mounted on the top rear end of the cylinder head.
(1) Inspection. Lift seat and prop in open
position to gain access to coolant temperature sending
unit.
(a) Check wire connection at coolant
temperature sending unit (fig. 4-28). Figure 4-34. Fan belt adjustment.
(b) Check sending unit installation in is obtained.
head for evidence of leakage. (6) Tighten adjusting brace screw to hold
(2) Removal alternator in position. Remove pry bar.
(a) Drain radiator (para 4-68). c. Voltage Test. Turn ignition switch on.
(b) Remove nut and lockwasher and (1) Connect a voltmeter between "BAT"
disconnect wire from coolant temperature sending unit terminal (fig. 4-36) and ground. Voltmeter should read
(fig. 4-28). 10.7 to 12 volts.
(c) Remove temperature sending (2) Connect a voltmeter between No. 1
unit from cylinder head. terminal (fig. 4-36) and ground. Voltmeter should read
(3) Installation. 10.7 to 12 volts.
(a) Install coolant temperature (3) Connect a voltmeter between No. 2
sending unit (fig. 4-28) in threaded opening in cylinder terminal (fig. 436) and ground. Voltmeter should read
head. 10.7 to 12 volts.
(b) Connect wire to sending unit and (4) A zero reading on the voltmeter
indicates an open circuit. Check wiring harness and
secure with nut and lockwasher.
wiring and correct.
(c) Fill cooling system (para 4-68).
(5) If there is an open circuit from No. 2
terminal the alternator internal circuits will prevent
4-51. Alternator
current output.
a. General. The alternator is mounted on the
d. Amperage Test.
right side of the engine. A belt drives the alternator and
(1) Disconnect battery ground cable.
fan. Incorporated into the alternator is a voltage
(2) Connect a carbon pile or load rheostat
regulator which prevents over-charging the battery.
in series with the "BAT" terminal (fig. 4-36) as shown on
b. Belt Adjustment.
figure 4-37.
(1) Open right side panel.
(3) Connect battery ground cable.
(2) Check belt deflection between
(4) Operate engine at moderate speed
alternator pulley and fan pulley (fig. 4-34).
and adjust load rheostat to obtain maximum alternator
(3) Deflection should be %-inch midway
output.
between pulleys.
(5) If ammeter reads 27 to 37 amps,
(4) If adjustment is necessary, loosen
alternator is not defective.
screw attaching alternator to adjusting brace (fig. 435).

4-44
 TM 10-3930-630-12

Figure 4-35. Alternator, installed view.

e. Removal.
CAUTION (1) Open left side panel to gain access to
alternator (fig. 4-35).
Tab for screwdriver in test hole is within (2) Remove nut and lockwasher and
3/4 inch of casting surface. Do not disconnect wire from alternator (fig. 4-35).
force screwdriver deeper than one inch (3) Refer to figure 4-35 and loosen
into hole. alternator adjusting brace screw. Loosen nuts on long
(6) If ammeter reads less than 27 amps, screw attaching bottom of alternator to alternator
ground the field winding by inserting a screwdriver into bracket.
the test hole (fig. 4-36). (4) Push alternator towards engine and
(7) Operate engine at moderate speed disengage drive belt (fig. 4-35) from alternator pulley,
and adjust load rheostat to obtain maximum current fan
output. If output exceeds 27 amps, replace alternator.

4-45
 TM 10-3930-630-12

pulley and fan drive adapter.

(5) Support alternator and remove
alternator adjusting brace screw, lockwasher and washer
from alternator brace.
(6) Remove nut and lockwasher from long
screw at bottom of alternator, at bracket. Remove
screw and remove alternator from bracket.
f. Installation.
(1) Lift alternator (fig. 4-35) into position
on bracket and install long screw through alternator
mounting holes and bracket. Install nut and lockwasher
on long screws and tighten only finger tight.
(2) Install washer and lockwasher and
insert screw through alternator and adjusting brace.
Tighten only finger tight.
(3) Lift alternator up and install drive belt
(fig. 4-35) over alternator pulley, fan drive pulley and
drive adapter pulley.
(4) Refer to b above and adjust belt
deflection. Tighten brace and mounting screws.

4-52. Starter

a. General The starter rotates the flywheel Figure 4-36. Alternator connections.
and starts the engine. When the ignition switch is
turned

Figure 4-37. Checking alternator output

all the way to the right the starter will operate. An c. Removal
overrunning clutch will disengage the starter from the (1) Open left side panel to gain access to
flywheel when the engine starts. the starter.
b. Starter Testing. No tests can be performed (2) Disconnect battery ground (negative)
with the starter installed in the truck If starter is removed cable.
and tests are required refer to direct and general support (3) Tag and disconnect wires from starter
maintenance. solenoid (fig. 4-38).

4-46
 TM 10-3930-630-12

Figure 4-38. Starter, removal and installation Figure 4-39. Distributor, installed view.

(4) Support starter (fig. 4-38) and remove (3) Inspect interior of cap for burned or
screws and lockwashers securing starter to flywheel worn contacts, carbon tracks and cracks. Wipe
housing. distributor cap with a clean cloth.
(5) Carefully pull starter from housing and (4) Inspect breaker points for pitting and
remove from truck. wear. Refer to figure 4-40 and check breaker point gap.
d. Installation. Rotate cam to bring breaker lever to high point on cam.
(1) Lift starter (fig. 4-88) into position on Insert feeler gage between breaker points Gap should
flywheel housing with starter drive in line with flywheel be 0.020 inches (0.50 mm) between points. If points
ring gear. require adjustment, loosen lockscrew (fig. 4-40) and
(2) Install screws and lockwashers to place screwdriver in adjusting slot. Move breaker lever
attach starter to flywheel housing. Tighten screws until correct gap is obtained. Tighten lockscrew to hold
securely. adjustment. Correct dwell angle is 66 to 72°.
(3) Check tap and connect wires to starter (5) Apply a light coat of grease (GAA) to
solenoid (fig. 4-38). distributor cam. Place a few drops of oil (OE/HDO) in
oil cup.
4-53. Distributor (6) Install dust seal, rotor and distributor
cap and secure cap with clamps
a. General. The distributor is mounted on the (7) Remove prop and lower seat and
top of the cylinder head. High tension wires connect the support into position above engine.
distributor to the spark plugs and coil A shaft, driven by c. Removal
the engine, extends up to a coupling and drives the (1) Lift and tip seat forward and prop in
distributor. open position.
b. Service. (2) Disconnect spark plug wires (2, fig. 4-
(1) Lift and tip seat forward and prop in an 41) from distributor cap. Disconnect coil wire (1) from
open position. distributor cap. Disconnect primary lead from coil
(2) Disengage clips at sides of distributor (3) Remove screw (12) and lockwasher
(fig. 4-89) and lift cap from distributor. Remove rotor (18) and lift distributor, with clamp (14) attached, from
and dust seal engine.
d. Disassembly.
(1) Disengage clamps (2, fig. 4-42) and
remove distributor cap (3) from distributor.

4-47
 TM 10-3930-630-12
points. Inspect set for worn cam arm.
(6) Check cam for wear and damage.
(7) Check capacitor for leakage and
damage.
(8) Check distributor cap and rotor for
cracks, burned or pitted contacts, carbon streaks and
damage.
(9) Replace unserviceable parts.
f. Assembly.
(1) If bearings (20, fig. 4-42) were
removed, press new bearings into housing. Do not
ream, scrape or file bearing surfaces. Drill 0.125 inch
(3.18 mm) hole in bearing through oil cup hole. Clean
bearing thoroughly after drilling.
(2) Install weights (14) and springs (13) on
shaft
(18).
(3) Install washers (19) and shaft (18)
through bearings. Install seal (17) and coupling (16) on
end of shaft. Make sure scribe marks are aligned.
Drive pin (15) through coupling and shaft. Peen ends of
pin to secure coupling.
(4) Install bushing (12) and cam (11) on
shaft and secure with retaining ring (10).
(5) Install contact set (7) and capacitor (8)
TA034815
on plate assembly (6). Connect primary lead (9) to plate
and install plate in housing. Pull primary lead through
Figure 4-40. Adjusting distributor breaker point gap.
grommet in housing.
(6) Refer to b above and set breaker point
(2) Mark position of rotor and remove
gap. Apply a light coat of grease (GAA) to cam.
rotor (4) and dust seal (5) from shaft.
(7) Install dust seal (5) and rotor (4) on
(3) Remove screws and remove contact
shaft. Install rotor in same position as it was when
set (7) and capacitor (8) from plate (6). Disconnect
removed. Install oil cup (11).
primary lead (9) from contact set.
g. Installation.
(4) Carefully remove plate (6) from
(1) Install distributor through cylinder
distributor being careful not to damage primary lead or
head. Coupling and shaft must mate with distributor
rubber grommet.
drive shaft. Rotate distributor until tongue on distributor
(5) Scribe a mark on shaft and coupling to
shaft mates with slot in drive shaft.
assure proper installation and grind off head of coupling
(2) Secure distributor clamp (14, fig. 441)
pin (15). Remove pin, coupling (16) and seal (17) from
to cylinder head with capscrew (12) and lockwasher
shaft.
(13). Install distributor cap (3, fig. 442).
(6) Remove retaining ring (10) and
(3) Connect spark plug wires (2) to
remove cam (11) from shaft.
distributor and spark plugs. Connect high tension coil
(7) Lift shaft (18) from distributor and
wire (1) to distributor. Connect primary lead from
remove springs (13) and weights (14) from shaft (18).
distributor to coil (10).
(8) Do not remove bearings (20) from
(4) Place a few drops of oil (OE/HDO) in
housing (21) unless replacement is necessary. Press
oil cup on distributor.
bearings from housing to remove.
(5) Check ignition timing (h below).
e. Cleaning, Inspection and Repair.
h. Ignition Timing Check.
(1) Clean all metal parts in cleaning
(1) Remove distributor cap, rotor and dust
compound, solvent (P-D680) and dry thoroughly.
seal (d above). Check contact point gap (b above).
(2) Wipe distributor cap, dust seal, rotor,
Disconnect wire and remove number one spark plug
capacitor and housing clean with a dry cloth.
(located nearest fan) (para 4-54).
(3) Check weights, springs and plate for
(2) Refer to timing marks on flywheel flex
wear and damage.
plate.
(4) Replace dust seal if hard, worn or
(a) To gain access to flex plate timing marks (fig. 4-43),
dirty.
remove battery and battery tray (para 4-54).
(5) Inspect contact set for burned or pitted

4-48
 TM 10-3930-630-12

1 Coil wire 10 Coil

2 Spark plug wire 11 Resistor
3 Spark plug 12 Screw
4 Coil to resistor wire 13 Lockwasher
5 Screw 14 Distributor clamp
b Lockwasher 15 Distributor
7 Washer 16 Primary wire
8 Lockwasher 17 Primary terminal
9 Nut 18 High tension terminal

Figure 4-41. Spark plugs and coils, exploded view.

443) at fuel pump location are accessible through hole
(b) Timing marks on flywheel (fig. in flywheel housing.
4-49
 TM 10-3930-630-12

TA034817

1 Oil cup 8 Capacitor 15 Pin

2 Clamp 9 Primary lead 16 Coupling
3 Cap 10 Retaining ring 17 Seal
4 Rotor 11 Cam 18 Shaft
5 Dust seal 12 Bushing 19 Washer
6 Plate assembly 13 Spring 20 Bearing
7 contact set 14 Weight 21 Housing

Figure 4-42. Distributor, explode view.

4-50
 TM 10-3930-630-12

TA034818

Figure 4-43. Flywheel timing marks.

(3) Place thumb over spark plug hole and their maximum opening. Gap should be 0.020 inch
crank engine until an outward pressure is felt through (0.50 mm). Refer to b above to adjust gap.
hole. (6) Tighten screw (12, fig. 441) to secure
(4) Continue cranking until "DC" mark (fig. distributor in position. Check point gap to be certain it
443) on flywheel is aligned with timing pointer. did not change.
(5) Loosen screw (12, fig. 441) securing (7) Install dust seal rotor and distributor
distributor clamp. Slowly rotate distributor until breaker cap on distributor.
point lever is at high point on cam. Points should be at
4-51
 TM 10-3930-630-12
(8) Install No. 1 spark plug and connect (3) Use a fine mill file and file electrodes
wire (para 4-54). to provide a square or flat surface at gap area
(9) If removed, install timing cover on the e. Adjustment.
top of flywheel housing. Install battery box and battery (1) Adjust spark plug gap by bending
(para 446). outside electrode. Do not bend center electrode.
(2) Use a round feeler gage to measure
4-54. Spark Plugs gap between electrodes. Adjust gap to 0.025 inch
(0.634 mm).
a. General. The four spark plugs are f. Testing.
mounted along the left side of the cylinder head. (1) Test all spark plugs after cleaning and
b. Inspection. adjusting. Test plugs in a standard plug machine.
(1) Lift seat up and tilt forward and prop in Discard all plugs showing an unsatisfactory test.
open position. g. Installation.
(2) Inspect spark plugs and wires for (1) Use new copper gaskets and install
cracks and breaks in insulation and porcelain. plugs in cylinder head.
(3) Inspect contact at top of plug and in (2) Tighten plugs by hand and then
wires for good condition and clean contact surfaces. tighten plugs to 30 to 40 pound-feet (40.6 to 54.2 N⋅m).
(4) Clean dirt and grease from plugs and (3) Connect spark plug wires (2, fig. 4-41)
wires. to plugs.
c. Removal
(1) Disconnect spark plug wires (2, fig. 4- 4-55. Ignition Coil
41) from spark plugs. Blow dirt from spark plug wells
with compressed air. a. General. High voltage required to provide
(2) Remove spark plugs (3) from cylinder a spark for engine operation is provided by the ignition
head using a suitable spark plug wrench. coil The coil (10, fig. 441) is mounted on a bracket on
(3) Remove copper gaskets from spark the right side of the engine block. A 50-ohm resistor is
plug wells. connected in series with the coil A limit of 12 volts is
d. Cleaning. provided to the primary side of the coil from the
(1) Scrape carbon and lead deposits from alternator.
electrodes and insulator body of plugs. b. Amperage Draw Test. Open right side
(2) Sand blast spark plug electrodes with panel and lift seat into open position.
care. Do not leave plug in sand blast machine too long. (1) Connect the ignition coil in a circuit as
Damage to glaze could result. shown in figure 4-44.

Figure 4-44. Ignition coil test wiring..

4-52
 TM 10-3930-630-12

(2) A test ammeter is required as shown to voltmeter.

give an accurate measurement. (11) Install dust seal, rotor and distributor cap
(3) Close ignition switch and adjust voltage (para 4.53).
with adjustable resistance (fig. 444) to 12 volts. d Coil Primary Continuity Test.
(4) Test ammeter should read 2 to 3 amperes. (1) With ignition switch off, connect an
(5) If reading is not correct, replace coil ohmmeter across coil primary terminals.
(6) Turn ignition switch off. Remove (2) Ohmmeter reading should be steady. If
connections and instruments used for the test. ohmmeter fluctuates, replace coil
c. Primary Ignition Circuit Resistance Test. (3) Disconnect ohmmeter.
(1) Disconnect wire from resistor to coil e. Coil Secondary (High Tension) Continuity Test).
primary from coil primary terminal (1) Disconnect high tension coil wire (1, fig. 4-
(2) Connect a voltmeter with a one volt scale 41) from top of ignition coil (10).
in series with the positive battery terminal and coil (2) Connect an ohmmeter across the high
primary terminal tension terminal (18) at top of coil to primary terminal
(3) Remove distributor cap, rotor, and dust (17) on distributor.
seal (para 4-53) and rotate engine to close breaker (3) Ohmmeter should read less than 20,000
points in distributor. ohms resistance. If reading exceeds this value, replace
(4) Turn ignition switch on. Voltmeter should coil.
not read more than 0.20 volts. (4) Disconnect ohmmeter and install high
(5) Turn ignition switch off. Disconnect tension coil wire on coil.
voltmeter leads from battery and coil Connect resistor to f. Removal
coil terminal (1) Disconnect high tension coil wire (1, fig. 4-
(6) Connect one voltmeter lead to coil primary 41) from top of coil Disconnect distributor primary wire
terminal that holds the distributor primary lead. (16) and coil to resistor wire (4) from terminals on top of
(7) Ground other voltmeter lead on distributor coil Disconnect wires from resistor (11).
housing. (2) Remove screws (5), washers (7),
(8) Turn ignition switch on. Voltmeter should lockwashers (6 and 8) and nuts (9) and remove coil (10)
read less than 0.10 volts. and resistor (11) from bracket.
(9) If readings exceed voltage specified, g. Installation.
replace coil. (1) Install coil (10, fig. 4-41) and resistor (11)
(10) Turn ignition switch off and disconnect on bracket and secure with screws (5), lockwashers (6
. and 8), washers (7) and nuts (9).

Section XIV. FUEL SYSTEM

4-56. General (2) Open left side panel and tilt seat up and
forward
The fuel system (fig. 445) consists of the fuel tank (51), (3) Remove wing nut (10, fig. 4-46) and lock
fuel filter (52), fuel pump (21), carburetor(32) and washer (11).
governor (28). Fuel is drawn from the tank by the fuel (4) Remove cover (13) and remove filter
pump through the fuel filter. The fuel pump delivers it to element (14).
the carburetor where it is mixed with air from the air (5) Install new element into cover and install
cleaner and the mixture is supplied to the intake cover and element on base.
manifold. The velocity type governor monitors the (6) Secure cover and element to bracket with
amount of fuel to the manifold and regulates engine wing nut and lockwasher.
speed. The air cleaner is mounted on the trunk frame (7) Close side panel and lower seat into
and connected to the carburetor with hoses. An position.
indicator, mounted in the air line, indicates condition of e. Removal.
the air cleaner element. (1) Lift seat up and forward. Position rod to
hold seat in open position. Open left side panel.
4-57. Air Cleaner (2) Loosen tywrap (3, fig, 4-46). Loosen
clamps (1) and remove hose (2) from air cleaner and
a. General. The dry-type air cleaner (fig. 446) is engine.
mounted on the left side of the engine compartment. (3)Remove indicator (6) from tube. Loosen
The air cleaner bracket is attached to the truck frame. clamps (4) and remove hose (5) and tube (7) from
b Service. carburetor.
(1) When the air cleaner indicator (fig. 3-1) (4)Loosen clamp (9) and remove hose (8) from
shows the element requires replacement remove air cleaner.
element as follows: (5) Remove wing nut (10) and lock washer
. (11) and remove air cleaner cover and base (13) and

4-53
 TM 10-3930-630-12

Figure 4-45. Fuel system exploded view.

4-54
 TM 10-3930-630-12

1 Clamp 10 Wire nut

2 Hoe 11 Lockwasher
3 Tywrap 12 Rubber washer
4 Clamp 13 Cover and base
5 Hose 14 Element
6 Indicator 15 Screw
7Tube 16 Lockwasher
8 Hose 17 Nut
9 Clamp 18 Bracket

Figure 4-46. Air cleaner, exploded view

element (14) from truck. of air cleaner. Do not fully tighten clamp.
d. Inspection and Repair. (3) Connect clamps (4), tube (7) and hose (5)
(1) Inspect hoses for damage and to air cleaner hose and carburetor. Aline hoses and
deterioration. tube and tighten clamps
(2) Inspect tube and indicator for dents and (4) Connect hose (2) to air cleaner and engine
damage. Check for restrictions in tube. Remove with clamps (1). Install tywrap (3).
restriction if present. (5) Close side panel and lower seat.
(3) Check clamps for damaged threads and
cracks. 4-58. Carburetor
(4) Check air cleaner cover for dents and
damage a. General. The carburetor is mounted below the
(5) Replace unserviceable parts. intake manifold on the left side of the engine. Cables
e. Installation connect the accelerator pedal and choke control knob to
(1) Install assembled air cleaner cover and the carburetor.
base (13, fig. 4-46) with element on bracket and secure b. Adjustments. Open left side panel to gain
with wing nut (10) and lockwasher (11). access to the carburetor (fig. 4-47).
(2) Connect hose (8) and clamp (9) to bottom

4-55
 TM 10-3930-630-12

TA034822

Figure 4-47. Carburetor adjustment

(1) Choke adjustment. to provide correct throttle motion. Tighten lock nut.
(a) Loosen clamps and remove inlet hose (3) Idle Adjustment
(fig. 4-47) from carburetor. (a) Start engine and allow to reach
(b) Pull choke control knob on instrument operating temperature. Adjust governor if necessary
panel all the way out. (para 4-59).
(c) Observe position of choke plate (b) Adjust throttle stop screw (fig. 447) to
through air inlet hose opening in carburetor. Choke an idle speed of 500 to 550 rpm.
plate should completely close opening to carburetor. (c) Gradually turn idle adjusting screw
(d) If choke plate is not completely (fig. 447) in until engine begins to miss. Slowly turn
closed, loosen clamps and move choke cable (fig. 4-47) screw out until engine begins to run unevenly. Count
until choke is completely closed. Tighten clamps. number of turns between two points.
(e) Move choke control knob in and out (d) Rotate screw to bring it to
and check choke operation. Cable should operate approximately midpoint between the two points reached
smoothly and should completely close choke plate. in (4) above, or until engine runs smoothly. Stop
(f) Install air inlet hose on carburetor and engine.
tighten clamps. (e) Close side panel.
(2) Throttle Adjustment. c. Removal
(a) Depress accelerator and observe (1) Open left side panel
throttle cable (fig. 4-47) movement at carburetor. (2) Disconnect throttle cable (fig. 447) and
(b) Release accelerator and observe choke cable from carburetor.
action of return spring (fig. 4-47). Throttle cable should (3) Loosen clamp and disconnect air inlet hose
return carburetor to idle position. If necessary, loosen from carburetor.
lock nut and adjust spring tension with adjusting screw (4) Disconnect fuel hose (17, fig. 4-45) from
carburetor.

4-56
 TM 10-3930-630-12

(5)Remove nuts (26) and lockwashers (27) and

remove carburetor (32) and governor (28) from
manifold.
(6) Lift governor, gaskets (29) and spacer (30)
from carburetor. Remove elbow (7) from carburetor.
(7) Remove studs (31) from carburetor.
d. Installation.
(1) Install studs (31, fig. 445) in carburetor
(32).
(2) Install new gaskets (29), spacer (30) and
governor (28) on carburetor.
(3) Install assembled carburetor and governor
on manifold, using a new gasket. Carburetor studs
should extend through manifold flange.
(4) Secure carburetor in position with nuts (26)
and lockwashers (27).
(5) Install elbow (7) in carburetor and connect
fuel hose (17) to elbow.
(6) Slide air inlet hose on carburetor and Figure 4-48. Governor adjustment
tighten clamp.
(7) Connect throttle cable (fig. 447) and choke c. Removal. Refer to paragraph 4-58 to remove
cable to carburetor levers. governor.
(8) Operate engine and adjust carburetor (b c. Installation. Refer to paragraph 4-58 and install
above). governor.
(9) Close left side panel
4-60. Fuel Pump
4-59. Governor
a. General. The mechanically operated fuel pump
a. General The velocity type governor is mounted is located on the left front side of the engine below the
between the carburetor and manifold. Operation of the air cleaner.
governor prevents the engine speed from exceeding b. Pressure Test.
2450 rpm. Air mixed with gas flows through the (1) Open left side panel
governor throat. Velocity of the air creates a pressure (2) Disconnect fuel outlet hose (17, fig. 4-45)
above the governor valve. A regulating spring is from fuel pump. Use appropriate fittings and connect a
attached to the throttle valve and tends to keep the 0-15 psi pressure gage between fuel pump and
valve open. When the pressure above the valve carburetor.
exceeds the force exerted by the spring the valve will (3) Start engine and allow to reach operating
move toward the closed position. The closing action of temperature. Check pressure on gage at idle and
the valve will exactly balance he spring and when this maximum speed. At 1800 rpm gage should register
occurs governing action takes place and maximum between 1½ to 214 psi.
speed is fixed at this point. An adjusting screw varies (4) If pressure is not within limits described
spring tension and thereby regulates top speed. above, replace fuel pump.
b. Adjustment. (5) Remove gage and connect hose (17) to
(1) Start engine and allow engine to reach fuel pump. Stop engine and close side panel.
operating temperature. c. Removal
(2) Open left side panel (1) Close fuel tank shutoff cock (46, fig. 445).
(3) Adjust accelerator and choke cable (2) Open left side panel.
operation (para 4-58) if necessary. (3) Disconnect fuel hose (6) from fuel filter
(4) Depress accelerator and check maximum (52).
speed of engine. Speed should be 2350 to 2450 rpm (4) Disconnect hose (17) from fuel pump (21).
(5) If engine speed is not within the above Remove screws (19) and lockwashers (20) and remove
limits, adjust governor with the adjusting screw (fig. 4- fuel pump (21) from side of engine. Remove gasket
48). The screw is located on the left bottom side of the (22).
governor. Turn screw clockwise to increase engine (5) Remove fuel filter (52) and fittings from
speed and counterclockwise to decrease engine speed. fuel pump.
(6) Stop engine and close left side panel d Installation.
. (1) Install fittings (8, 16, and 18, fig. 4-45) in fuel

4-57
 TM 10-3930-630-12

pump (21) inlet and outlet. Install fuel filter on fuel (6) Swing clamp (10) down into position and
pump. secure bowl by tightening nut (11).
(2) Use a new gasket (22) and install fuel (7) Open fuel tank shutoff cock (46) and
pump and filter on engine. Secure fuel pump with operate engine and check fuel filter for leaks.
screws (19) and lockwashers (20). (8) Shut off engine and close side panel
(3) Connect hose (17) to fuel pump. Connect c. Removal
fuel hose (6) to fuel filter (1) Refer to paragraph 4-60 and remove fuel
(4) Open fuel shutoff cock (46). Operate filter from fuel pump.
engine and check fuel pump operation. Test outlet (2) Remove fittings (7 and 8, fig. 4-45) from
pressure (b above) if necessary. fuel filter (52).
(5) Shut off engine and close left side panel. d. Installation.
(1) Install fittings (7 and 8, fig. 4-45) in fuel
4-61. Fuel Filter filter (52).
a. General. The fuel filter is the bowl and screen (2) Refer to paragraph 4.60 and install fuel
type and is mounted at the fuel pump inlet. Fuel from filter and fuel pump on engine.
the fuel tank is drawn through the filter before being
pumped to the carburetor. 4-62. Crankcase Ventilation
b. Service
(1) Close fuel tank shutoff cock (46, fig. 4-45). a. General The positive crankcase ventilation
(2) Open left side panel. valve is connected to an elbow in the manifold. A hose
(3) Loosen nut (11) and remove bowl (12) and connects the valve to a pipe in the valve chamber
gasket (13) from cover (15). Remove screen (14). cover.
(4) Inspect screen and if damaged or clogged, b. Removal.
replace screen. (1) Open left side panel
(5) Install screen (14) in cover (15). Use a (2) Disconnect hose (1, fig. 449) from
new gasket (13) and install bowl (12) on cover. chamber cover and valve (2).
.

Figure 4-49. Manifold, exploded view

4-58
 TM 10-3930-630-12

(3) Remove hose (3) and elbow (4) from speed of the truck engine. Depressing the pedal
manifold. increases the speed. A cable connects the pedal to the
c. Installation. carburetor. The cable is in turn connected to a return
(1) Install elbow (4, fig. 449) in tapped hole in spring and bracket.
manifold (11) b. Adjustment. Refer to paragraph 4-58 to adjust
(2) Connect hose (3) to elbow and install valve the accelerator cable.
(2) in hose. c. Removal
(3) Connect valve to valve chamber cover (1) Remove floor and toe plates.
with hose (1). (4) Close side panel. (2) Remove retaining rings (1, fig. 4-50) and
pin (2). Remove pedal (3) from toe plate.
4-63. Accelerator Pedal and linkage

a. General The accelerator pedal controls the

.

Figure 4-50. Accelerator linkage, exploded view.

4-59
 TM 10-3930-630-12

(3) Remove screw (8), nut (9) and lockwasher fittings from hoses or tube and install fittings in new
(10) and remove bearing (12) and washers (11) from hose or tube. Inspect elbows and adapters for damaged
shaft threads and evidence of leakage. Replace
(4) Remove cotter pin (27) and pin (28) and unserviceable parts.
disconnect accelerator cable from lever (29). d. Installation. Refer to figure 4-45 and install fuel
(5) Remove screws (20), lockwashers (21) and lines in fuel system.
from bracket.
(6) Remove pin (13) from shaft and lever. 4-65. Fuel Tank
Slide bearings (23), spring (19), lever (29) and washers
(15) from shaft. a. General. The fuel tank is mounted on the left
(7) Remove screws and remove clamps (30 front of the truck. A shutoff cock is provided at the fuel
and 31) from cable. Remove retaining ring (32) from tank outlet. Level of fuel is sent to the fuel level
end of cable. indicator on the instrument panel by a sending unit
(8) Open left side panel. Remove retaining installed in the tank.
ring (32) from bracket (33) and cable. b. Removal.
(9) Mark position of yoke (36) on cable. (1) Remove left front cowl
Remove nut (37) and yoke. (2) Close shutoff cock (46, fig. 445). Place a
(10) Check and mark length of adjusting screw. suitable container under tank. Remove drain plug (43)
Remove nuts (41) and remove adjusting screw (42), and drain fuel from tank.
spring (39) and clip (40) from bracket (45). (3) Disconnect wire (35) from sending unit
c. Installation. (38). Remove screws (36) and lock washers (37) and
(1) Install bearings (23, fig. 4-50), spring (19), remove sending unit and gasket (39) from fuel tank.
washers (15) and lever (29) on accelerator shaft (14). (4) Remove filler cap (41) and screen (42)
Install pin (13) through lever and shaft. from fuel tank.
(2) Position assembled shaft and bearings on (5) Disconnect tube (4) from shutoff cock.
bracket (26) and secure bearings to bracket with screws (6) Remove screws (49) and lockwashers (50)
(20), lockwashers (21) and nuts (22) and lift fuel tank from truck frame
(3) Install bearing (12) on shaft and secure (7) Remove shutoff cock, plug (40) and elbows
with screw (8), nut (9), lockwashers (10) and washers and fittings from fuel tank
(11). c. Cleaning, Inspection and Repair
(4) Connect cable (38) to lever (29) with pin (1) Remove any sediment and water from
(28) and cotter pin (27). Install retaining ring (32) on tank.
cable (2) Clean inside and outside of tank with
(5) Secure cable to truck with clamps (30 and cleaning compound (Fed. Spec. P-D-680). All solvent
31). Install cable in bracket (33) and secure with other must be out of tank and tank dried thoroughly before
retaining ring (32) filling with fuel.
(6) Install yoke (36) and nut (37) on cable in (3) Clean inlet screen with solvent and dry with
same position as marked at removal. Install clip (40) compressed air.
and yoke on throttle lever at carburetor and secure with (4) Inspect tank for evidence of leakage,
pin (35) and cotter pin (34) cracked welds and damage. If tank requires repair,
(7) Connect return spring to clip and adjusting refer to direct and general support maintenance.
screw (42). Install adjusting screw in bracket (45). (5) Inspect screen for dents and damage.
Adjust length of adjusting screw to length marked at Replace unserviceable screen
removal with nuts (41) (6) Check fittings for damaged threads and
(8) Install pedal (3) in bracket on toe plate and evidence of leakage. Replace damaged parts
secure with pin (2) and retaining rings (1). (7) Check operation of sending unit (38). Float
(9) Check operation of accelerator and cable. arm should swivel smoothly and without binding.
Ad just length of adjusting screw or cable as necessary Replace sending unit if defective.
(para 4-58) to provide proper operation and engine d. Installation.
speed. (1) Install fittings and elbows (44, 45, 47 and
(10) Install floor and toe plates. Close side 48, fig. 445) in fuel tank. Install shutoff cock (46) and
panel. drain plug (43). Install plug (40).
(2) Use a new gasket (39) and install sending
4-64. Fuel Lines unit (38) in tank. Secure unit with screws (36) an
lockwashers (37).
a. General The fuel lines illustrated on figure 4-45 (3) Install filler cap (41) and screen (42) in
connect the components of the fuel system. tank. Position fuel tank (51) on truck frame and secure
b. Removal To identify and remove fuel lines and with screws (49) and lockwashers (50).
fittings refer to figure 4-45. (4) Connect wire (35) to sending unit. Connect
c. Repair. If fuel lines require repair, remove tube (4) to shutoff cock.

4-60
 TM 10-3930-630-12

(5) Fill fuel tank with correct grade of fuel. fuel tank and lines for leaks.
(6) Open shutoff cock and start engine. Check (7) Shut off engine. Install left front cowl.

Section XV. COOLING SYSTEM

4-66. General drive belt.

d. Installation. Refer to paragraph 4-51 and install
The cooling system for the lift truck engine consists of a and adjust drive belt. Close side panels and lower seat.
water pump, a fan drive adapter, and cooling fan, drive
belt, radiator, thermostat and connecting hoses. A gear 4-68. Water Pump and Fan
in the fan drive adapter is driven by the camshaft gear.
This gear drives a pulley. The belts are driven by the a. General. The water pump is mounted on the
pulley and, in turn, drive the fan and alternator pulleys. top front of the engine block. It is connected to the
A tank, mounted below, and an integral part of the radiator with a rubber hose. Coolant is circulated by the
radiator, cools the transmission oil Capacity of the water pump from the radiator through the engine. The
system is 9 quarts of coolant. coolant then is discharged through the coolant outlet
elbow and returns to the radiator.
4-67. Drive Belt b. Inspection
(1) Open side panels and lift seat to an upright
a. General. The drive belt provides the motive position.
force for the fan and alternator pulleys. It is driven by (2) Inspect fan blades for bent or damaged
the fan drive pulley. condition. Check fan for secure mounting
b. Inspection. (3) Operate engine and check water pump and
(1) pen side panels and lift seat to upright hoses for leaks. Shutoff engine.
position. c. Removal.
(2) Inspect belts for fraying, wear, oil spots and (1) Remove radiator cap (para. 3-12) and
evidence of stretching. drain radiator by opening drain valve in radiator outlet
(3) Check belt tension (para 4-51) and adjust if elbow. Drain engine block by opening drain valve (fig.
necessary. 4-51
(4) Replace unserviceable belts.
c. Removal Refer to paragraph 4-51 and remove
.

TA034826
Figure 4-51. Engine coolant drain valve.

(2) Refer to paragraph 4-51 and remove drive (3) Remove four screws and remove fan (fig.
belt. 4-52) from water pump pulley.

4-61
 TM 10-3930-630-12

Figure 4-52. Water pump and fan, installed view.

(4) Loosen clamp and disconnect lower hose (5) Install drive belt over fan and water pump
(fig. 4-53) from water pump inlet drive pulley, drive adapter pulley and alternator pulley
(5) Loosen clamp and disconnect bypass hose (fig. 4-34). Refer to paragraph 451 and adjust belt
(fig. 4-52) from water pump (fig. 4-52). tension.
(6) Remove mounting screws and remove (6) Install fan (fig. 4-52) on pulley and secure
water pump and gasket from engine block. Move wit four screws.
alternator adjusting brace (fig. 4-52) away from water (7) Close drain valve (fig. 4-53) in radiator
pump to remove pump. outlet
d Installation. elbow. Close drain valve (fig. 4-51) in engine block.
(1) Clean pump mounting surface. Remove Refer to paragraph 3-12 and fill radiator.
all rust and old gasket material from surface (8) Operate engine and check water pump and
(2) Install new gasket and water pump (fig. 4- hoses for leaks. Shutoff engine.
52 on engine block. Secure pump to block with (9) Close side panels and lower seat into
mounting screws. Attach alternator adjusting brace (fig. position.
4-52) with upper pump mounting screw
(3) Install bypass hose (fig. 4-52) on pump 4-69. Radiator
and secure hose by tightening clamp a. General The radiator stores coolant and provides
(4) Connect lower hose (fig. 4-53) to pump cooling surfaces for the fan driven air to pass over and
inlet and secure with clamp. lower the temperature of the coolant. It is mounted at
. the rear of the truck in a cutout in the counterweight. A
grille protects the radiator.

4-62
 TM 10-3930-630-12

TA034828
Figure 4-53. Radiator and hoses, removal and installation

b. Inspection and Test. (3) Place a suitable container under radiator

(1) Open side panels and raise seat. and disconnect transmission hoses from fittings in
(2) Check radiator (fig. 4-53) and hoses for bottom tank of radiator. Plug or cap hoses to prevent
evidence of leaks. Inspect hoses for cracks and loss and spillage of transmission oil.
deterioration. (4) With grille removed, remove mounting
(3) Remove grille (para 4-28) and inspect screws (fig. 4-53) and remove radiator. Slide bottom of
radiator for dirt and debris in cooling passages. Clean radiator out of counterweight by puling out. When
out with compressed air. radiator filler neck has cleared hole in counterweight lift
(4) Check coolant in radiator for presence of radiator out of truck.
oil If oil appears in coolant, bottom tank is damaged. (5) If radiator requires repair notify direct and
(5) Replace radiator and hoses if leaking or general support maintenance.
damaged. d. Installation.
c. Removal (1) Lift radiator into opening in Tilt radiator to
(1) Drain radiator (para 4-70). guide filler neck up into hole in top of counterweight and
(2) Disconnect upper and lower hoses (fig. 4- slide radiator into position.
53) from radiator. (2) Secure radiator with mounting screws (fig.
. 4-53).

4-63
 TM 10-3930-630-12

(3) Install grille (para 4-28). coolant outlet elbow on the cylinder head. The
(4) Remove caps or fittings in bottom tank of thermostat retains the coolant in the engine, bypassing it
radiator before it reaches the radiator. This allows the coolant to
(5) Connect upper and lower hoses (fig. 453) to reach operating temperature faster for more efficient
radiator. engine operation. When operating temperature is
(6) Close valve at bottom of radiator. Fill reached, thermostat opens and allows coolant to
radiator with coolant (para 3-12) circulate through radiator.
(7) Check and add oil to transmission if
necessary (para 3-16). b. Removal
(8) Operate engine and check radiator and (1) Open side panels and lift and tilt seat
hoses for leaks. Shutoff engine. forward.
(9) Close side panels and lower seat into (2) Drain radiator and engine block (para 4-
position. 68).
(3) Loosen clamp and disconnect radiator
4-70. Thermostat upper
hose (fig. 4-2) from thermostat housing.
a. General. The thermostat is installed in the (4) Remove nuts (1, fig. 4-54) and lock
. washers (2) and remove water output elbow (3) from
cylinder head. Remove gasket (4).

TA034829
1.Nut
2. Lockwasher
3.Outlet
4. Gasket
5. Thermostat
6. Adapter ring
7. Stud

Figure 4-54. Thermostat, removal and installation.

4-64
 TM 10-3930-630-12

(5) Remove adapter ring (6) and thermostat d. Installation.

(5). (1) Clean elbow mounting surface on cylinder
c.Test. head. Remove all rust and gasket material.
(1) Attach a wire or other means of suspension (2) Install thermostat (5, fig. 4-54) and adapter
and submerge thermostat in a container of clean water ring (6) in outlet elbow (3).
(2) Heat water and stir with an accurate (3) Use a new gasket (4) and install assembled
thermometer. Check water temperature. elbow on cylinder head. Secure elbow with nuts (1) and
(3) As the water temperature approaches 180° lock washers (2).
F (82° C) observe the thermostat. If the thermostat (4) Connect radiator upper hose (fig. 4-52) to
does not start to open at 180° F (82° C) to 200° F (93° outlet elbow and secure hose with clamp.
C) or if it opens well below 180° F (82° C), thermostat (5) Close drain valves and fill radiator with
must be replaced. coolant (para 3-12).
. (6) Close side panels and lower seat into
position.

Section XVI. EXHAUST SYSTEM

4-71. General
(2) If truck has been operating allow sufficient
The exhaust system on the truck consists of a exhaust time to elapse to allow the muffler and pipes to cool.
pipe leading from the manifold to the muffler and a tail (3) Remove nuts (1, fig. 4-55) and disconnect
pipe leading out the rear of the truck The muffler is exhaust pipe (3) from manifold. Remove gasket (4)
mounted on the lower left side of the truck frame Loosen clamp (2) and remove exhaust pipe from truck.

4-72. Muffler and Pipes

a. Removal
(1) Open left side panel and lift seat into an
upright position.

TA034830
1 Nut 10 Clamp
2 Clamp 11 Clamp
3 Exhaust pipe 12 Tail pipe
4 Gasket 13 Tail pipe
5 Screw 14 Nut
6 Lock washer 15 Washer
7 Washer 16 Grommet
8 Nut 17 Muffler
9 Support

Figure 4-55. Exhaust system, exploded view

4-65
 TM 10-3930-630-12

(4) Remove washer (7) and nut (8) and (2) Slide clamp (10) on tail pipe (12) and
disconnect clamp (10) from support (9). install tail pipe and clamp (11) on muffler. Secure
(5) Loosen clamp (11) and remove tail pipe clamp (10) to support (9) with screw (5), lock washer (6),
screw (5), lock washer (6), (12) from muffler and truck. washer (7) and nut (8). Tighten clamp (11) to secure tail
Remove clamp (10) from tail pipe. pipe to muffler.
(6) Remove screws (13), nuts (14) and washers (3) Slide clamp (2) and exhaust pipe (3) on
(15) and remove muffler (17) from frame. Remove muffle inlet. Position exhaust pipe on manifold, using a
grommets (16) from muffler new gasket (4). Secure pipe to manifold with nuts (1).
c. Installation. Tighten clamp (2).
(1) Install grommets (16, fig. 4-55) in muffler (4) Operate engine and check exhaust system
(17). Install muffler on frame and secure with screws for leaks. Shutoff engine.
(13), nuts (14) and washers (15). (5) Close side panels and lower seat into
position.

Section XVII. STEERING SYSTEM

4-73. General b. Toe-In.

(1) Raise the rear end of the truck so that the
The power steering system consists basically of the steer wheels clear the floor. Use suitable blocking under
steering wheel, steering valve, steering cylinder, truck to hold in this position. Block front
steering axle and wheels. The steering axle is mounted wheels to prevent movement.
at the rear of the truck. Hydraulic pressure for the (2) Remove floor and toe plates.
system is supplied by the hydraulic pump. Rotation of (3) Operate truck and, sitting in operator's
the steering wheel operates the steering valve, sending seat, turn wheels to bring them into position parallel with
hydraulic pressure to the steering cylinder. Movement frame. Shut off truck engine
of the cylinder rod rotates a pivot arm on the axle. Two (4) Measure distance between centers of
tie rods connected to the pivot arm are attached to the wheel treads at the rear of the tires and the frame and
wheel spindles As the arm rotates, the spindles are then at the front of the tires and the frame.
pulled or pushed in the direction of the turn, turning the (5) If the measurements are the same, no
wheels. adjustment is required. If measurements are unequal,
adjust the tie rods.
4-74. Steering Adjustments (6) Remove cotter pin (12, fig. 4-56) and nut
(11). Remove boot (10) and tap ball socket (9) from
a. General. Adjustments required consist of wheel wheel spindle.
toe-in, drag link and spindle stops.
.

Figure 4-56. Tie rod, exploded view

4-66
 TM 10-3930-630-12

(7) Loosen nut (7) and adjust length of rods by prevent bottoming of steering cylinder.
turning ball socket in or out on tube to bring both (1) Operate truck and turn wheels full right and
measurements ((5) above), equal Torque nut to 50 to 70 full left. Measure distance between tire and steering
pound-feet (6.9 to 9.6 m/kg) to secure adjustment. axle housing at both wheels. Clearance should be a
Repeat for both wheels minimum of 0.50 inch (12.7 mm). Shut off truck engine
(8) Install ball socket on spindle and secure (2) Loosen lock nut (fig. 4-7) and adjust stop
with boot (10), nut (11) and cotter pin (12). screw to stop spindle with proper clearance. Hold stop
c. Spindle Stops. Two stop screws (fig. 4-7), screw and tighten lock nuts to secure adjustment.
secured by lock nuts, extend through the axle and
prevent extreme inward pivoting of spindles and to

Figure 4-57. Spindle stop screw adjustment.

d Drag Link Adjustment. cotter pin (2) in drag link to secure adjusting plug.
(1) Position the rear wheels straight ahead and e. Adjustment Checks
parallel with the frame. (1) Remove blocks and lower rear of truck to
(2) Remove cotter pin (2, fig. 4-58) from the rest on wheels
end of the drag link (3) and loosen adjusting plug (1). (2) Sit in operator's seat and operate truck.
(3) Lift drag link from ball stud on pivot arm. Turn steering wheel to full left and full right positions
(4) Position the cylinder plunger rod halfway Wheel spindles should contact stop screws in each
out of the steering cylinder (5). Loosen lock nut (4). direction and cylinder plunger rod should extend and
(5) Turn drag link in or out on cylinder rod. retract an equal distance.
Place (3) Shut off truck. Install floor and toe plates.
wrench on flats of cylinder plunger rod to hold rod while
adjusting ball socket. Adjust drag link until it is centered 4-75. Tie Rods and Drag Link
over pivot arm ball stud with the rear wheels in a straight
ahead position and parallel with the frame. a. General . The tie rods connect the axle spindles
(6) Connect drag link (3) to ball stud. Tighten to the steering axle pivot arm. Connection of the
adjusting plug (1) to secure drag link on stud. Install steering cylinder to pivot arm is accomplished with the
. adjustable drag link.

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 TM 10-3930-630-12

Figure 4-58. Drag link and steering cylinder, removal and installation

b. Tie Rods. (b) Inspect spring, ball seat and adjusting

(1) Adjustment. Refer to paragraph 4-74 to plug for wear and damage.
adjust tie rods for correct steering. (c) Inspect ball socket, tube and boot for
(2) Removal. wear, damage and deterioration.
(a) Refer to paragraph 4-74 to disconnect (d) Replace unserviceable parts.
tie rod from spindle. (4) Installation.
(b) Raise rear of truck and block surely. (a) Install spring (3, fig. 4-56), ball seat
Block front wheels. (2) and adjusting plug (1) in tube (6). Do not tighten
(c) Working from under truck, remove adjusting plug.
cotter pin (4, fig. 4-56) and loosen adjusting plug (1) (b) Install tie rod on pivot arm and tighten
and remove tie rod from pivot arm ball stud. Remove adjusting plug. Secure adjusting plug with cotter pin (4).
tie rod from truck. (c) Refer to paragraph 4-74 and install tie
(3) Inspection and Repair. rod on spindle. Adjust tie rod for proper operation (par.
(a) Remove adjusting plug (1, fig. 4-56), 4-74)
ball seat (2) and spring (3) from tie rod.
.

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 TM 10-3930-630-12

(d) Lower truck to ground and operate pins (6).

truck to check tie rod movement and adjustment. Refer to paragraph 4-74 to install and adjust drag link to
c. Drag Link. position wheels correctly.
(1) Removal. (4) Remove caps or plugs from cylinder and
(a) Lift rear of truck and block into hoses and connect hoses to cylinder fittings.
position. Block rear wheels. (5) Check steering cylinder operation as
(b) Working under truck, disconnect drag described in paragraph 4-74.
link (3, fig. 4-68) from cylinder. (6) Check hydraulic reservoir (para 3-18) and
(c) Remove cotter pin (2) and loosen add hydraulic oil if necessary.
adjusting plug (1). Lift drag link from ball stud on pivot (7) Check hydraulic connections for leaks.
arm. (8) Lower truck to ground. Operate truck and
(d) Loosen nut (4) and unscrew drag link again check steering operation.
from steering cylinder.
(2) Inspection and Repair. 4-77. Steering Wheel
(a) Remove adjusting plug (1, fig. 4-58)
and remove ball seat, spring and link plug from socket. a. General. The steering wheel is mounted at the
(b) Inspect ball seat, spring and adjusting top of the steering column above the instrument panel
plug for wear and damage. Rotation of the wheel actuates the steering valve and
(c) Inspect ball socket for dents and operates the steering cylinder.
damage. b. Removal
(d) Replace unserviceable parts. (1) Remove horn cover (1, fig. 4-59) by
(3) Installation. pressing down and turning counterclockwise.
(a) Install plug, spring and ball seat in (2) Remove horn button (2), contact cap (3)
socket. Install adjusting plug (1, fig. 4-58) in socket but spring (4) and cup(5) from steering wheel
do not tighten. (3) Remove screws (6) and disconnect wire (8)
(b) Install drag link on steering cylinder from contact plate (7). Remove contact plate
(5) by screwing on cylinder rod. (4) Remove nut (9) and lockwasher (10) from
(c) Connect drag link to ball stud on pivot steering column. Use a suitable puller and remove
arm. steering wheel (11) from column.
(d) Refer to paragraph 4-74 and adjust c. Installation.
steering cylinder and drag link. Install cotter pin (2) to (1) Install steering wheel (11, fig. 4-59) on
secure adjusting plug. splines of steering column and push or tap in place.
(e) Lower truck to ground Operate truck Secure wheel with nut (9) and lockwasher (10).
and check steering cylinder action. (2) Install wire (8) on contact plate (7) and
secure contact plate with screws (6).
4-76. Steering Cylinder (3) Install cup (5), spring (4) and cap (3) under
horn button (2). Install cover (1) in steering wheel by
a. Removal pressing cover down and turning clockwise
(1) Lift rear of truck and block in position. (4) Depress horn button to check horn
Block front wheels. operation
(2) Disconnect hoses from steering cylinder (5,
fig. 4-58). Cap or plug hoses and fittings to prevent 4-78. Steering Axle
entrance of foreign material into hydraulic system.
(3) Remove cotter pin (2) and loosen adjusting a. General. The steering axle is mounted under
plug (1) and lift drag link (3) from pivot arm ball stud the rear of the truck. It mounts the rear wheels and tie
(4) Support cylinder and remove cotter pins rods.
(6). and washers (7). Tap or drive pin (8) from frame b. Service
bracket and cylinder. (1) Inspect steering axle for secure mounting.
(5) Remove cylinder from truck. Loosen lock (2) Check steering axle by pressing axle and
nut (4) and remove drag link from cylinder. attempting to shift axle in mounting. There should be no
b. Installation. end play of axle. If axle shifts, loosen lock nut on
(1) Install drag link (3, fig. 4-58) and lock nut adjusting screw at rear of truck. Turn screw
(4) on threaded end of cylinder rod. Do not tighten lock counterclockwise to tighten axle in mounts. Tighten lock
nut. nut.
(2) Install cylinder and drag link in truck with (3) Service the axle by lubricating. Refer to
cylinder in line with hole in frame bracket. Secure current Lubrication Order for points of lubrication and
cylinder to bracket with pin (8), washer (7) and cotter intervals.

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 TM 10-3930-630-12

Figure 4-59. Steering wheel and horn button, exploded view

Section XVIII. ENGINE

4-79. General (2) Check engine oil and coolant levels.

(3) Inspect drive belt for proper tension and
The engine is a four cylinder, four cycle, L-head type serviceable condition.
engine. It is mounted at the rear of the truck beneath (4) Check mounting of starter, alternator, fuel
the operator's seat. The flywheel end is directly coupled pump and carburetor. Tighten mounting bolts i
to the torque converter. A hydraulic pump i directly necessary.
driven by the other end of the crankshaft. (5) Inspect engine mounts for security.
Resilent mounts should be in good condition.
4-80. Engine Assembly b. Service
(1) Check engine crankcase oil level (para 3-
a. Inspection To gain access to the engine open 2) and add oil if necessary.
the side panels and lift the seat and prop in the open (2) Change oil at intervals specified on current
position. Lubrication Order.
(1) Inspect engine for oil and coolant leaks.
.

4-70
 TM 10-3930-630-12

(a) Remove engine oil filler cap (fig. 3- the engine and contains recesses which form the top f
2). Place a suitable container beneath engine. Remove the cylinders. It also contains passages for engine
drain plug from oil pan and drain oil from engine coolant flow. The engine coolant outlet elbow is
(b) Install drain plug and fill crankcase mounted on the cylinder head and contains the
with correct grade of oil. Refer to current Lubrication thermostat. Spark plugs and distributor are mounted on
Order for quantity and grade. the top of the cylinder head
(3) When the crankcase oil is changed the oil b. Removal.
filter should be changed as follows. (1) Open side panels and lift seat into upright
(a) Drain oil from engine as described position.
above. (2) Refer to paragraphs 4-58 and 4-54 and
(b) Unscrew oil filter (fig. 3-2) from filter remove distributor and spark plugs from cylinder head.
base. Discard oil filter. (3) Refer to paragraph 4-50 and remove
(c) Clean base and bracket with a clean coolant temperature sending unit from cylinder head
lint-free cloth. (4) Refer to paragraph 4-70 and remove
(d) Spread a light coat of clean engine oil coolant outlet elbow and thermostat from cylinder head
on gasket surface of new filter. Install filter on filter and disconnect coolant bypass hose.
base and hand tighten only (5) Mark locations of screws (4, fig. 460).
(e) Fill crankcase with oil as described in Remove screws (4 and 5) and carefully remove cylinder
(2) above. head from engine.
(4) Close side panels and lower seat. (6) Remove gasket (10) from engine block
(7) Remove remaining screws, studs and pipe
4-81. Manifolds plugs from cylinder head.
(8) Wipe all exposed internal engine areas
a Inspection. with a clean dry cloth to remove all engine coolant.
(1) Open left side panel Cover exposed areas with a protective cover such as a
(2) Inspect manifold for cracks and damage plastic sheet.
and for evidence of leaks. c. Inspection and Service.
(3) Check manifold mounting screws and nuts (1) Use a scraper and wire brush and remove
Tighten if necessary. all carbon from combustion areas.
b. Removal. (2) Clean the cylinder head with cleaning
(1) Refer to paragraph 4-58 and remove compound, solvent (Fed. Spec. P-D480) and dry
carburetor and governor from manifold. thoroughly with compressed air.
(2) Refer to paragraph 4-62 and disconnect (3) Check gasket contact surfaces to be sure
crankcase ventilation hose and remove ventilation valve they are clean, smooth and flat.
and elbow from manifold. (4) Inspect cylinder head for cracks, holes,
(3) Refer to paragraph 4-72 and disconnect warpage and other damage.
exhaust pipe from top of manifold. (5) Check cylinder head for flatness shown in
(4) Remove screws (6, fig. 4-49) and washers figures 4-61 and 4-62.
(7) Remove nuts (8) and washers (9). (a) Use a straightedge and feeler gage as
(5) Remove manifold (11) and gasket (12) shown in the illustrations to check flatness
from cylinder block. (b) Maximum out-of-flatness should not
c. Installation. exceed 0.000765 inch (0.019 mm) per inch of width or
(1) Clean carbon deposits from manifold and length. On a cylinder head 16 inches (40.6 mm) long,
gasket surface on cylinder block with a wire brush. maximum lengthwise out-of-flatness is 0.012 inch (0.305
(2) Install a new gasket (12, fig. 449) on mm). Any out-of-flatness should vary gradually and
cylinder block and install manifold (11). uniformly from end to end and side to side. Localized
(3) Secure manifold to engine with screw (6) depressions or high spots should not exceed 0.008 inch
washer (7), nuts (8) and washers (9). Tighten nuts to a (0.076 mm).
torque of 25 to 30 pound-feet (33.7 to 40.6 N.m). (c) If cylinder head requires grinding refer
(4) Refer to paragraph 4-72 and connect to direct and general support maintenance. (d)
exhaust pipe to top of manifold. Replace unserviceable cylinder head.
(5) Refer to paragraph 4-62 and install ventila- d. Installation.
tion valve and elbow and connect hose to manifold (1) Install stud (8, fig. 4-60), screw (8) and
(6) Refer to paragraph 4-58 and install washer (9), screw (1) and washer (2), and pipe plugs (7)
carburetor and governor on manifold. in cylinder head.
(7) Close left side panel (2) Install a new gasket (10) on engine block
and install cylinder head.
4-82. Cylinder Head (3) Install screws (4) in locations marked at
a. General. The cylinder head encloses the top of removal. Install screws (5) in remaining holes. Torque
screws in the sequence shown in fig. 4-63.

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 TM 10-3930-630-12

1 Screw
2 Washer
3 Stud
4 Screw
5 Screw
6 Cylinder head
7 Pipe
8 Screw
9 Washer
10 Gasket

Figure 4-60. Cylinder head, exploded view

4-72
 TM 10-3930-630-12

Figure 4-61. Checking cylinder head for flatness lengthwise

Figure 4-62. Checking cylinder head for flatness crosswise.

Figure 4-63. Cylinder head torquing sequence.

4-73
 TM 10-3930-630-12

(4) Tighten screws in successive stages to 4-83. Engine Valves

ensure equal pressure over entire surface of cylinder
head and gasket. Hold tension on each screw for a few a. General The intake and exhaust valves are
seconds before releasing torque wrench. mounted in the engine block and are operated by the
(5) At first pass apply approximately one-half camshaft.
of the recommended torque and then increase the b. Adjustment. The valve tappet clearance may
torque one-half each pass until recommended torque is require adjustment.
obtained. Torque all screws to 70 to 75 pound-feet (1) Open left side panel
(94.9 to 101.5 N-m). (2) Refer to paragraph 4-57 and remove the
(6) Refer to paragraph 4-50 and install cooling air cleaner.
temperature sending unit in cylinder head. (3) Refer to paragraph 4-58 and remove
(7) Refer to paragraph 4-70 and install engine carburetor and governor and associated linkage.
coolant outlet elbow and thermostat and connect coolant (4) Refer to paragraph 4-50 and remove oil
bypass hose to cylinder head. pressure and hourmeter actuator sending units.
(8) Refer to paragraphs 4-53 and 4-54 and (5) Disconnect crankcase ventilation hose
instal spark plugs and distributor in cylinder head. from valve chamber cover and remove valve chamber
(9) Close side panels and lower seat into cover (fig. 4-64) and gasket from left side of engine
position. beneath manifold.

Figure 4-64. Valve chamber cover, removal and installation

.
(6) Disconnect high tension wire from top of (10) When timing pointer is in this position both
distributor. Clean area around spark plug and remove valves on number one cylinder are closed on
spark plug from number one cylinder (spark plug closest compression stroke
to coolant outlet elbow). (11) Check valve tappet clearance with a feeler
(7) Refer to timing marks on flywheel or flex gage as shown on figure 4-65.
plate. (12) Clearance should be 0.012 inch (0.304
(a) To gain access to flex plate timing mm) for intake valves and 0.020 inch (0.508 mm) for
marks (fig. 4-43) remove battery and battery box (para exhaust valves.
4-46). Remove access from flywheel housing. (13) If clearances are not as specified use two
(b) Timing marks (fig. 443) at fuel pump thin wrenches as shown in figure 4-66 to adjust valve
location are accessible through hole in flywheel housing. tappet clearance. Loosen the lock nut. Use the lower
(8) Place a thumb over the spark plug opening wrench to hold the tappet and the upper wrench to raise
and slowly crank engine until outward pressure can be or lower tappet adjusting screw.
felt against thumb. This pressure indicates number one (14) Continue to raise or lower adjusting screw
piston is moving toward Top Dead Center of the and checking with feeler gage until proper clearance is
compression stroke. obtained.
(9) Continue cranking until timing pointer (15) Tighten lock nut when correct clearance is
(fig.4-43) is in line with Dead Center mark on flywheel. obtained. Check clearance after tightening.

4-74
 TM 10-3930-630-12

TA034840
Figure 4-65. Checking value tappet clearance

TA034841
Figure 4-66. Adjusting value tappet clearance

(16) Crank the engine one-half revolution at a housing.

time and check clearance at each remaining set of (19) Refer to paragraph 4-50 and install the oil
valves in succession according to the engine firing order pressure and hourmeter actuator sending units.
(1-4-2). Adjust valves to proper clearance i necessary. (20) Refer to paragraph 4S8 and install the
(17) Install new gasket (fig. 4-4) and valve carburetor, governor and linkage.
chamber cover on engine block and secure with nuts. (21) Refer to paragraph -57 and install the air
Connect ventilation hose to cover. cleaner.
(18) Install timing hole cover on top of flywheel (22) Close left side panel.
.

4-75
 TM 10-3930-630-12

Section XIX. WHEELS

4-84. General wheels clear the floor. Tilt mast to full backward
position. Place a wooden block under the mast
Four wheels support and propel the lift truck. The front assembly and tilt mast forward to vertical position.
wheels are connected to the differential and drive the Movement of the mast will elevate drive wheels clear of
truck. Steering of the truck is accomplished with the the floor.
rear wheels which are mounted on the spindles of the (b) Remove three screws (1, fig. 4-67)
rear steering axle. and lockwashers (2) and remove hub cap (3).
(c) Remove cotter pin (4) and wheel nut
4-85. Wheels (5) and remove nut and washer (6) from axle.
(d) Remove outer wheel bearing (7) from
a. Front Drive Wheels. wheel and axle.
(1) Removal
(a) Raise the front of the truck until the
.

1 Screw 6.Washer
2 Lockwasher 7 Outer wheel bearing
3 Hub cap 8 Wheel and tire assembly
4 Cotter pin 9 Inner wheel bearing

Figure 4-67. Drive wheel, removal and installation.

(e) Remove wheel carefully to prevent spots,excessive wear and damage.

damage to brake shoes or drums. assembly (8). (c) Inspect bearings and bearing cups in
Remove wheel wheel for wear and damage.
(f) Remove inner wheel bearing (9). (d) Clean bearings and bearing surfaces
(2) Inspection. with cleaning compound, solvent (Fed. Spec. P-D-680)
(a) Inspect wheel and tire for damage. and dry thoroughly.
Check teeth on ring or bull gear inside wheel for (3) Installation.
damage. (a) Repack outer and inner bearings (7
(b) Inspect brake drum for cracks, flat and 9,

4-76
 TM 10-3930-630-12

Fig. 4-67) with grease (GAA). play is evident.

(b) Install inner bearing (9) on axle (f) Install cotter pin (4) to secure nut.
spindle with tapered side out. (g) Install hub cap (3) and secure with
(c) Install wheel assembly (8) on bearing screws (1) and lockwashers (2).
and spindle. Hold wheel assembly in place and install (h) Tilt mast backward to lower wheels to
outer wheel bearing (7) on spindle and inside wheel, floor. Remove blocks from mast and wheel
tapered side in. b. Rear Steer Wheels.
(d) Install washer (6) and wheel nut (5) on (1) Removal
spindle. Tighten nut and as nut is tightened rotate wheel (a) Use a suitable jack and raise rear of
under power. Block other wheel to prevent turning. truck until wheels clear the floor. Block front wheel to
Continue tightening nut until heavy drag is felt while prevent truck from rolling.
rotating wheel. Tighten nut to 120 pound-feet (162.7 N- (b) Remove screws (1, Fig. 4-68) and
m). lockwashers (2) and remove hub cap (3).
(e) Slowly loosen nut to aline cotter pin
hole. Be sure wheel rotates freely and no bearing end

1 Screw 6 Washer
2 Lockwasher 7 Outer wheel bearing
3 Hub cap 8 Wheel and tire assembly
4 Cotter pin 9 Inner wheel bearing
5 Wheel nut

Figure 4-68. Rear wheel, removal and installation

(c) Remove cotter pin (4) and remove (3) Installation.

wheel nut (5) from axle spindle. Remove washer (6). (a) Repack inner and outer bearings (7
(d) Remove outer wheel bearing (7) and and 9) with grease (GAA>.
wheel assembly (8) from axle spindle. (b) Install inner wheel bearing (9, Fig.
(e) Remove inner bearing (9) from 448), tapered side out, on axle spindle. Install wheel
spindle. assembly (8) over bearing.
(2) Inspection. Refer to b. above and inspect (c) Hold wheel in place and install
and clean wheel assembly. outer wheel bearing (7), tapered side in, in wheel.

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 TM 10-3930-630-12

(d) Refer to b. above to adjust wheel bearings. (e) Install hub cap (3) and secure with
Rotate wheels by hand. Torque wheel nuts (5) to 50 screws (1) and lockwashers (2).
pound-feet (67.7 N.m), rotating wheel six times in each (f) Lower jack and remove jack and
direction. Back off nut and re-torque to 25 pound-feet blocks from truck.
(33.8 N.m). Install cotter pin (4).

Section XX. BRAKES

4-86. General 4-87. Service Brake Pedal and Linkage

a. The brakes on the fork lift truck consist of two a Adjustment. Pedal free play should be adjusted
systems; a lever operated parking brake on the drive to one-half inch (12.7 mm) to allow master cylinder to
shaft and service brakes on the two front wheels. return to released position and reduce unused length
b. The parking brake is a dual-shoe mechanical of stroke in the master cylinder.
operated type. When the lever in the truck is pulled to (1) Remove the floor and toe plates.
the rear the brake shoes are forced outward against the (2) Slowly depress brake pedal (Fig. 4-69) and
brake drum. This pressure keeps the shaft from check free travel. Observe push rod action at master
rotating, locking the front wheels and holding the truck in cylinder.
position. (3) If free travel is more or less than one-half
c. The service brakes are hydraulically actuated inch (12.7 mm), loosen lock nut on clevis at master
through a pedal and master cylinder. Depressing the cylinder and remove cotter pin and clevis pin and
pedal operates the master cylinder sending hydraulic disconnect clevis from pedal.
pressure to the wheel cylinders. The wheel cylinders (4) Adjust clevis on operating rod to bring
are the double end type and hydraulic pressure extends pedal travel to correct limits.
the ends of the cylinder pivoting the brake shoes against (5) Tighten lock nut. Connect clevis to brake
the brake drum inside the wheel The pressure of the pedal and install clevis pin and cotter pin. Check pedal
master cylinder also closes the stop light switch and travel and adjust if necessary to bring travel within limits
operates the stop light. When the pedal is released, specified.
springs return the pedal and brake shoes to the released (6) Install floor and toe plates.
position. The brakes are self-adjusting. b. Removal
(1) Remove floor and toe plates.
(2) Refer to paragraph 4-90 and remove
master cylinder.
(3) Disconnect return spring (17, Fig. 4-70) and
remove pin (16).
(4) Remove screws (18) and lockwashers (19)
and remove bearings (20) from frame. Remove pedal
(23) from frame.
(5) If worn or damaged, remove pad (22) from
pedal
c. Installation.
(1) If pad (22, Fig. 4-70) was removed, glue
new pad
on pedal.
(2) Install shaft of pedal (23) in bearings (20)
and secure bearings (20) to frame with screws (18) and
lockwashers (19).
(3) Attach spring (17) to pedal and pin (16).
(4) Refer to paragraph 4-90 and install master
cylinder.
(5) Install floor and toe plates.

4-88. Service Brakes

a. General. The service brakes are mounted in
the front wheels. The brakes are self-adjusting.
Figure 4-69. Service brake pedal adjustment b. Removal
(1) Refer to paragraph 4-85 and remove front
wheel

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 TM 10-3930-630-12

Figure 4-70. Brake pedal and linkage, exploded view.

.
(2) Refer to figure 4-1 and remove dust around axle pinion.
shield from front wheel (5) Remove three springs (Fig. 4-72) from
(3) Remove four screws and lockwashers brake shoes.
securing dust shield to axle. Remove wheel bearing (6) Disconnect brake shoes from wheel
from axle. cylinder
(4) Carefully remove dust shield from

4-79
 TM 10-3930-630-12

adjuster assembly and remove adjuster assembly from

brake shoes.
(8) Remove pins securing cylinder links to
brake shoes and remove links.
(9) Disassemble the brake adjuster by
removing two screws (5, Fig. 4-73), nuts (6) and
washers (3 and 4). Separate slide assemblies (1) and
remove nylon washers (2).
c. Inspection.
(1) Inspect linings for wear, dirt, grease and
brake fluid.
(2) Clean linings to remove foreign matter.
(3) Inspect brake drums in wheels for cracks,
deep scratches and other defects.
(4) If linings are worn to less than 0.125 inch
(3.17 mm) or if linings are saturated with fluid or grease,
replace shoes.
(5) Inspect brake shoes for wear, cracks,
elongated holes and other damage.
(6) Inspect return springs for broken, nicked or
fatigued coils.
d. Installation.

CAUTION
TA034846
Figure 4-71. Service brake dust shield, Brake shoes are free floating and self-
installed view. adjusting. Check for obstructions during
installation that could interfere with
and lift brake shoes and attached adjuster assembly and floating action.
cylinder links from backing plate.
(7) Using a brass drift, drive spring pins from

Figure 4-72. Service brake shoes, installed view

4-80
 TM 10-3930-630-12

TA034848
1 Slide assemblies 4 Lockwasher
2 Nylon washer 5 Screw
3 Washer 6 Nut

Figure 4-73. Brake adjuster, disassembly and assembly

(1) Install slide assemblies (1, Fig. 4-73) with wheel cylinder.
nylon washers (2) between slides. c. Installation.
(2) Secure slides with screws (5), nuts (6) and (1) Install wheel cylinder (Fig. 4-72) on backing
washers (3 and 4). Tighten only finger tight. plate.
(3) Move slides along slot until center-to-center (2) Secure wheel cylinder to backing plate with
distance of holes in ends of slides is 5.15 inches (133.5 two screws (Fig. 4.74).
mm). Tighten screws (5) to a torque of 14 to 16 pound- (3) Refer to paragraph 4-88 and install service
inches (1.58 to 1.80 N-m). brake shoes and backing plate.
(4) Hold screws in position and tighten nuts (6) (4) Refer to paragraph 4-85 and install front
to a torque of 29 pound-inches (3.2 N-m). wheels.
(5) Check slip resistance of slide assemblies. (5) Refer to & below and bleed brake system.
Resistance should be 250 to 300 pounds (113 to 135 d. Bleeding Brake Hydraulic System. Each time
kg). the system has been drained and refilled or a part-has
(6) Install wheel cylinder links (Fig. 4-72) on been disconnected or replaced the system must be bled.
bottom of brake shoes and secure with pins. (1) Remove filler cap from master cylinder and
(7) Install adjuster assembly (Fig. 4-72) on fill to proper level (0.375 to 0.50 inch (9.5 to 12.7 mm)
brake shoes and secure to brake shoes with spring pins from top).
(fig. 4-72). (2) Connect a bleeder hose to bleeder screw
(8) Install brake shoes (Fig. 4-72) on backing (fig. 4-74) on front wheel. Submerge other end of hose
plate, with links installed in ends of wheel cylinder (fig. in a glass jar filled with brake fluid.
4-72). Hold shoes in position with three return springs (3) Open bleeder screw one turn.
(Fig. 4-72). (4) Slowly depress brake pedal to end of travel
(9) Install dust shield (Fig. 4-71) on axle and and release pedal Repeat several times. Observe hose
secure with four screws and lockwashers. in jar and repeat pumping of brake pedal until no
(10) Refer to paragraph 4-85 and install front bubbles escape from hose. Hold pedal at bottom of
drive wheels. travel and close bleeder screw to keep additional air
from entering system.
4-89. Service Brake Wheel Cylinder
a. Inspection. Refer to paragraph 4-88 and NOTE
remove front wheel and dust shield. Inspect wheel
cylinder for leaks, damage and proper link movement. While pumping pedal check fluid level in master
Replace wheel cylinder if necessary. cylinder. Add fluid to keep cylinder close to full
b. Removal at all times.
(1) Refer to paragraph 488 and remove brake
shoes (5) Close bleeder screw and disconnect hoses
(2) Disconnect hydraulic brake line (Fig. 4-74) Repeat operation on bleeder screw on other front wheel
from fitting in wheel cylinder. (6) Fill master cylinder to proper level after
(3) Remove two screws and lockwashers bleeding operation. Install filler cap.
securing wheel cylinder to backing plate and remove
4-81
 TM 10-3930-630-12

Figure 4-74. Brake System bleeder raw

CAUTION (3) Operate brake pedal and check stop light .

Discard fluid salvaged from brake system When brake pedal is depressed stop light switch (fig 4-
during bleeding operation. Do not use in 31) should actuate stop light.
system. c. Removal
(1) Disconnect wires from stop light switch (fig.
4-90. Master Cylinder 3-4) and remove stop light switch from master
a. General. The master cylinder is mounted on the cylinder. Disconnect brake line from master cylinder.
right side of the truck frame. (2) Disconnect clevis (Fig. 4-69) from brake
b. Inspection. pedal
(1) Remove floor plate. (3) Remove mounting screws (1, Fig. 4-75),
(2) Inspect master cylinder and tubing for leaks lockwashers (2) and nuts (3). Remove master cylinder
and damage. (4) from truck.

4-82
 TM 10-3930-630-12

1 Screw
2 Lockwasher
3 Nut
4 Master cylinder
5 Clevis
6 Nut

Figure 4-75. Service brake master cylinder, removal and installation

(4) Remove (6) and clevis (5) from master brake with a cable.
cylinder (4). b. Adjustment. To compensate for brake lining
d. Installation. wear the parking brake lever can be adjusted. If the
(1) Install nut (6, Fig. 4-75) and clevis (5) on adjusting knob on the parking brake lever will no longer
master cylinder. provide correct brake adjustment and sufficient brake
(2) Install master cylinder on truck and secure lining is still available, further adjustment can be made
with screws (1), lockwashers (2) and nuts (3). Connect with the brake cable.
ground wire to rear master cylinder mounting screw. (1) Place brake lever in the fully released
position.
NOTE (2) Remove setscrew (Fig. 4-76) in brake lever
Internal-external tooth lockwashers (2) adjusting knob. Rotate knob (Fig. 4-76) one or two turns
must be installed with mounting screws for clockwise. Check adjustment by engaging brake.
radio suppression. (3) Repeat adjustment ((2) above) as
necessary to assure correct lining contact with drum.
(3) Connect clevis (Fig. 4-69) to brake pedal After adjustment is correct, install setscrew to secure
adjust pedal travel (par 4-87) as necessary. adjusting knob.
(4) Refer to paragraph 4-89 to fill master (4) If above steps do not provide proper
cylinder and bleed brake system. braking action, adjust cable.
(5) Refer to figure 4-77 and remove cotter pin,
4-91. Parking Brake Lever and Linkage washer and clevis pin securing clevis to cam lever.
a. General The parking brake lever mounted next
to the instrument panel is connected to the parking

4-83
 TM 10-3930-630-12

Figure 4-76. Parking brake lever, installed view.

(6) Loosen clevis locknut and turn clevis three (4) Remove cotter pin and washer and remove
or four turns clockwise to shorten the cable. Install cable pin and disconnect cable from lever.
clevis on cam lever and secure with clevis pin and cotter (5) Disconnect cable from brake cam lever (b
pin. (5) above), remove clamps and remove cable.
(7) Engage brake and check braking action.
Adjust cable above until action is correct. Tighten d. Installation.
locknut to secure adjustment. (1) Install cable (b (5) above) and connect
c. Removal cable to cam lever. Install clamps to secure cable to
(1) Place brake lever in released position frame.
(forward). (2) Install end of cable in parking brake lever
(2) Loosen setscrew securing adjusting knob (fig. 4-76) and secure cable with cable pin, washer and
and rotate knob counterclockwise to release tension on cotter pin.
cable. (3) Install mounting screws (Fig. 4-76),
(3) Remove two screws (Fig. 476), lockwashers and nuts and secure lever to frame.
lockwashers and nuts and disengage lever from frame. (4) Refer to b. above and adjust lever and
Remove spacers. cable.
4-84
 TM 10-3930-630-12

Figure 4-77. Parking brake cable, installed view.

4-85
 TM 10-3930-630-12

4-92. Parking Brake (2) Disconnect brake cable from parking brake
a. General. The parking brake is on the drive shaft (para 4-91).
to the rear of the drive axle. (3) Remove screws (1, Fig. 4-78) and
b. Removal lockwashers (2) and remove brake drum (3) from pinion
(1) Disconnect drive shaft (para 4-94) from flange (13).
parking brake.

1 Screw 8 Backing plate

2 Lockwasher 9 Screw
3 Brake drum 10 Lockwasher
4 Spring 11 Cotter pin
5 Brake shoe 12 Nut
8 Brake lever 13 Flange
7 Roller

Figure 4-78. Parking brake, exploded view.

(4) Remove cotter pin (11) and nut (12) from and remove backing plate from differential carrier.
pinion shaft and remove flange (13). c. Inspection.
(5) Remove brake lever (6) and rollers (7) from (1) Check backing plate for distortion, loose or
backing plate (8). sheared rivets and worn pawls.
(6) Remove return springs (4) and remove (2) Inspect brake lining for wear or grease
brake shoes (5). saturation.
(7) Remove screws (9) and lockwashers (10)

4-86
 TM 10-3930-630-12

(3) Check brake shoes for worn pawl holes, (GAA) to roller slots and lever wear points on brake
lever contact areas and worn pads. shoes.
(4) Check brake drum for cracks, wear and (3) Install lever (6) and rollers (7) on brake
damage. shoes.
(5) Inspect springs for broken ends, cracks and (4) Install flange (13) on pinion shaft and
fatigue. secure with nut (12) and cotter pin (11).
(6) Replace unserviceable parts. (5) Install brake drum (3) on flange and secure
d. Installation. with screws (1) and lockwashers (2).
(1) Install backing plate (8, Fig. 4-78) on (6) Refer to paragraph 4-94 and connect drive
differential carrier and secure with screws (9) and shaft.
lockwashers (10). Apply light coat of grease (GAA) to (7) Refer to paragraph 4-91 and connect cable
wear pads and pawls. to parking brake lever. Adjust brake as described in
(2) Install brake shoes (5) on backing plate and paragraph 4-91.
install return springs (4). Apply light coat of grease

Section XXI. DRIVE AXLE

4-93. General transmission to the parking brake and drive axle.

b. Removal.
The drive axle propels the front wheels and provides (1) Raise front of truck and block in position.
motive force for the truck. It is connected to the Block rear wheels.
transmission by a drive shaft. The service brakes are (2) Remove self-locking screws (1, Fig. 4-79)
attached to the drive axle. securing drive shaft to transmission flange and
parking brake.
4-94. Drive Shaft

a. General. The drive shaft connects the

1 Screw
2 Screw
3 Cross and bearing
4 Drive shaft

Figure 4-79. Drive shaft, exploded view.

(3) Slide transmission output shaft into bearings (3) from drive shaft (4).
transmission to allow drive shaft to clear parking brake. (5) Remove output shaft from transmission.
Remove drive shaft
(4) Remove screws (2) and remove cross and

4-87
 TM 10-3930-630-12

c. Installation. breather and clean in cleaning compound, solvent (Fed.

(1) Install cross assemblies (3, Fig. 4-79) on Spec. P-D-680) and dry thoroughly. Install breather
drive shaft (4) and secure with screws (2). Tighten and tighten securely.
screws to a torque of 25 to 30 pound-feet (338 to 40.6 c. Lubrication
N.m) dry or 20 to 24 pound-feet (27.1 to 32.5 N.m) (1) The differential level plug is located on the
lubricated. right front of the axle housing. Remove plug and check
(2) Install output shaft in transmission. level of oil. Oil should be to level of plug hole. Add
(3) Install drive shaft on transmission output lubricant as required. Refer to current Lubrication Order
shaft and parking brake and secure with screws (2). for correct lubricant. Install plug.
Tighten screws to a torque of 25 to 30 pound-feet (338 (2) The drain plug (Fig. 4-77) is located at the
to 40.6 N-m) dry or 20 to 24 pound-feet (27.1 to 32.5 N- bottom of the differential housing. To drain axle,
m) lubricated. remove level plug (Fig. 4-77). Place a suitable
(4) Remove blocks and lower truck to ground. container beneath axle, remove drain plug and drain
lubricant. Install drain plug and tighten securely. Refer
4-95. Differential to current Lubrication Order for correct lubricant and fill
housing through level plug hole. Install level plug.
a. General The differential provides a double (3) Lubrication of axle pinion and ring or bull
reduction internal gear drive. A pinion driven by the gear is accomplished by removing the front wheel Refer
drive shaft is meshed with a ring gear which drives the to paragraph 4-85 and remove the front wheel Clean
differential. The differential is splined to the axle shafts, pinion and ring gears with solvent and dry with
which drive pinions that are meshed with the ring or bull compressed air. Fill all spaces between ring or bull gear
gears in the wheels. teeth with grease (GAA) to approximately three-fourths
b. Service the height of the teeth (Fig. 4-80). Refer to paragraph 4-
(1) Axle Breather. The breather is located on 85 and install front wheels.
the right top of the differential housing. Remove

Figure 4-80. Ring or bull gear lubrication.

4-96. Axle Shafts cracked, broken, damaged or worn teeth.
a. General Drive from differential to the wheels is (3) Inspect axle pinion (Fig. 4-71) for cracked,
provided by the axle shafts. The inner end is splined to broken, damaged or worn teeth.
the differential and the outer end acts as a pinion riding c. Removal
in the ring or bull gear of the wheel. (1) Refer to paragraph 4-85 and remove front
b. Inspection wheels and dust shield.
(1) Refer to paragraph 485 and remove the (2) Remove two screws and lockwashers
front wheels 440 secur
(2) Inspect ring or bull gear in wheel for

4-88
 TM 10-3930-630-12

ing axle shaft cap (Fig. 4-81) to drive axle. Install

threaded puller into threaded end of axle shaft and
carefully remove axle shaft with axle cap and bearing
attached.

TA034857

Figure 4-82. Removing spindle.

(6) Inspect spindle bearing surfaces for

evidence of wear and damage. Replace unserviceable
spindles.
Figure 4-81. Removing axle shaft. b. Installation.
(1) Install spindle in drive axle housing and
(3) Inspect seal in axle shaft bore. If seal is secure with locknut. Tighten locknut until spindle
damaged or shows evidence of leaking, remove seal seats.
(4) Inspect seal in axle cap. If seal is (2) If seal was removed ((3) above) install new
damaged or shows evidence of leaking, notify oil seal in axle shaft bore.
organizational maintenance. (3) Slide axle shaft in position in drive housing.
(5) Remove locknut securing spindle at inside Aline splines on shaft with splines in differential. Aline
of drive axle housing (Fig. 4-82). Install a spindle puller holes in housing with holes in axle shaft cap. Use a soft
as shown in figure 4-82 and remove spindle. mallet and drive the shaft in place on axle. Secure axle
cap with screws and lockwashers.
(4) Refer to paragraph 4-85 and install front
wheels.

Section XXII. TRANSMISSION

4-97. General pump through the transmission control valve to the

clutches. The oil returns through the oil cooler and oil
The power shift transmission has one speed forward and filter to the transmission.
one speed in reverse. Direction of travel is controlled by b. Inspection.
a shift lever on the steering column. The transmission (1) Inspect transmission oil filter (Fig. 4-28) for
torque converter is directly coupled to the engine leaks and damage.
flywheel with two flex plates. (2) Inspect hoses for wear, leaks and
deterioration.
4-98. Transmission Oil Filter c. Removal.
a. General. The transmission oil filter is remotely (1) Open left side panel
mounted on the front left side of the engine (2) Remove transmission oil filter (Fig. 4-28)
compartment (Fig. 428). Oil flows from the converter by unscrewing filter from filter base (14, Fig. 4-83).

4-89
 TM 10-3930-630-12

1 Tywrap 11 Screw
2 Hose 12 Lockwasher
3 Elbow 13 Filter
4 Clamp 14 Base
5 Hoe 15 Screw
6 Elbow 16 Washer
7 Fitting 17 Lockwasher
8 Hose 18 Nut
9 Elbow 19 Bracket
10 Elbow

Figure 4-83. Transmission oil filter and hoses, exploded view.

(3) If hoses require replacement disconnect 4-99. Control Lever and Linkage
hoses, remove clamps or tywrap and remove elbows a. General The transmission is controlled through
and fittings as necessary. Plug hoses and openings to a linkage extending from the bottom of the control
prevent entrance of foreign material column. A lever at the end of the column is connected
d. Installation. to the transmission forward and reverse plunger with a
(1) If hoses were disconnected or fittings were shift rod and yoke. The inching pedal operates the
removed, remove plugs and install fittings and connect inching valve through a pin and screw attached to the
hoses. Secure hoses with tywrap or clamp as valve plunger.
necessary. b. Adjustment
(2) Apply a light coat of transmission oil to (1) Shift Rod.
rubber gasket on filter. Screw filter (13, Fig. 483) into (a) Remove floor and toe plates.
base by hand and hand tighten only. (b) With the engine off, place forward and
(3) Close left side panel. reverse control lever in N (neutral) position. Attempt to
(4) Refer to paragraph 4-12 and add oil to start truck engine.
transmission, if necessary.
4-90
 TM 10-3930-630-12

(c) If engine starts, transmission selector switch has not closed starting circuit.
valve is in neutral position. If engine does not start, (d) Remove cotter pin and pin and detach
selector valve is not in neutral position and neutral start yoke (Fig. 4-84) from transmission selector valve.

Figure 4-84. Transmission control adjustment.

CAUTION
(e) Move selector valve back and forth to
determine center, or neutral, position. Again at-tempt to Do not thread yoke to far on shift rod. End
start engine. If engine starts, transmission is in neutral of shift rod must not protrude through yoke
(f) Hold selector valve in this position and and come out on other side. If it does,
loosen nut on shift rod (Fig. 4-84) to move yoke on rod selector valve movement will be restricted.
to lengthen or shorten rod to aline with selector valve in
neutral position. Tighten nut to secure yoke. (g) Connect yoke to selector valve
plunger with pin and cotter pin.
(h) Operate truck and check adjustment.
4-91
 TM 10-3930-630-12

(i) Install floor and toe plates. (f) Disengage parking brake. Pressure
(2) Inching control. gage should indicate at least 95 psi at 2000 rpm with
(a) Remove floor and toe plates. transmission in R (reverse) position.
(b) Operate truck and check inching (g) Shut off engine. Remove gage and
control operation. Truck should come to a full stop install plug in transmission control valve.
when inching control pedal is completely depressed and (h) Install floor and toe plates.
should move forward smoothly with the pedal released.
(c) Check brake pedal to see that it is fully 4-100. Neutral Start Switch
retracted against brake stop (Fig. 4-84). a. General. A pressure switch, actuated by the
(d) Measure return spring (Fig. 4-84). transmission, prevents the truck starter from operating
Spring should measure 11.0 to 11.25 inches (279.4 to unless the transmission is in neutral. The switch is
285.7 mm) when inching pedal is retracted. If spring mounted on the right side of the transmission control
length requires adjustment, loosen nut on adjusting valve.
screw and adjust length of spring as required. b. Removal.
(e) With the return spring at proper length, (1) Place transmission in neutral and attempt
adjust inching pedal stop (Fig. 4-84) so that plunger to start truck. If starter does not operate, replace switch.
spring (Fig. 4-84) is compressed to a length of 0.062 to (2) Remove floor plate.
0.125 inches (1.57 to 3.17 mm). (3) Disconnect wires from neutral start switch
(f) With the brake pedal against brake (Fig. 3-4) and remove switch from control valve. Plug
stop (Fig. 4-84) set adjustment setscrew to allow a gap openings in valve to prevent entrance of foreign
of 0.25 inch (6.35 mm) between brake pedal lug and material.
inching pedal setscrew. Lock setscrew with locknut. c. Installation.
(g) To check adjustments, raise front (1) Remove plug from control valve.
wheels from floor and block truck in raised position. (2) Install neutral start switch (Fig. 3-4)
Block rear wheels. Operate truck and shift in F securely in control valve. Connect wires to switch.
(forward) or R (reverse). With engine at high idle, (3) Start truck engine to check operation. Shut
inching pedal should not move forward. If it does, off engine.
repeat adjustments above. Shift lever to N (neutral), (4) Install floor plate.
stop engine and lower truck to floor.
(h) To check transmission output, operate 4-101. Transmission Service
truck and set parking brake. Return engine to low idle a. General. The transmission should be drained
and shift into forward or reverse. Engine should and refilled at specified intervals. Refer to current
approach a stall condition. Stop engine. lubrication order for intervals and lubricant.
(3) Pressure Check b. Service.
(a) Install a zero to 300 psi gage in (1) Remove transmission filler cap and level
reverse clutch pressure port (Fig. 4-84). gage (Fig. 3-4).
(b) Raise front of truck and block in (2) Place a suitable container under
position. transmission drain plug (Fig. 4-77). Remove plug and
(c) Engage parking brake. Depress brake allow oil to drain.
pedal until shoes contact drums. This will occur when (3) Remove transmission screen through oil
resistance to pedal movement is felt. Wedge a block of drain plug hole. Clean screen in cleaning compound,
wood between brake pedal stop (Fig. 4-84) and pedal to solvent (Fed. Spec. P-D-680) and blow dry with
hold brakes in applied position. compressed air.
(d) Start engine. With engine at low idle (4) Install screen in drain plug hole and install
(500 to drain plug.
600 rpm) place transmission control lever in R (reverse). (5) Service transmission filter (para 4-98).
Depress inching pedal until gage reads 6 to 10 psi. (6) Refer to current lubrication order and fill
(e) Adjust inching pedal setscrew (Fig. 4- transmission with correct grade of oil. Install
84) to engage brake pedal lug at this point. Lock transmission filler cap and level gage (Fig. 3-4).
setscrew with lock nut.

4-92
 TM 10-3930-630-12

APPENDIX A
REFERENCES

A-1 Fire Protection

TB 54200-20-10 Hand Portable Fire Extinguishers approved for Army Users

A-2 Lubrication
C9100IL Fuels, Lubricants, Oils and Waxes
LO10-3930-630-12 Lubrication Order for: Truck, Lift, Fork, Gasoline, Solid Rubber Tired Wheels,
400 Lb Capacity, 100 and 180 Inch Lift, Allis-Chalmers Models
ACC40-24PS100 and ACC40-24PS180

A-3 Painting
AR746-1 Color, marking and preparation of equipment for shipment
TM 43-0139 Painting Instructions for Field Use
TB 746-93-1 Color and Marking of Military Vehicles, Construction Equipment and Materiels
Handling Equipment

A-4 Radio Interference

Suppression
TM 11-483 Radio Interference Suppression

A-5 Maintenance
TB 750-651 Use of Antifreeze Solutions and Cleaning Compounds in Engine Cooling
Systems
TM 9-6140-200-12 Operator's and Organizational Maintenance Manual for Lead-Acid Storage
Batteries
TM 10-3930-630-12 Operator and Organizational Maintenance Manual for: Truck, Lift, Fork,
Gasoline, Solid Rubber Tired Wheels, 4000 Lb Capacity, 100 and 180 Inch
Lift,
Army Model MHE-231, Allis-Chalmers Models ACC40-24PS100 and
ACC40-24PS180
TM 10-3930-630-20P Organizational Maintenance Repair Parts and Special Tools List for: Truck,
Lift, Fork, Gasoline, Solid Rubber Tired Wheels, 4000 Lb Capacity, 100 and
180 Inch Lift, Army Model MHE-231, Allis Chalmers Models ACC40-
24PS100 and ACC40-24PS180
TM 38-750 The Army Maintenance Management System (TAMMS)

A-6 Destruction to Prevent

Enemy Use
TM 750-244-3 Procedures for Destruction of Equipment to Prevent Enemy Use (Mobility
Equipment Command)

A-7 Shipment and Storage

TB 740-97-2 Preservation of USAMECOM Mechanical Equipment for Shipment and
Storage
TM 740-90-1 Administrative Storage of Equipment

A-1
 TM 10-3930-630-12
APPENDIX B
MAINTENANCE ALLOCATION CHART

Section I. INTRODUCTION

B-1 General
a. This section provides a general explanation c. Service. Operations required periodically
of all maintenance and repair functions authorized at to keep an item in proper operating condition, i.e., to
various maintenance levels. clean, to preserve, to drain, to paint, or to replenish fuel,
b. Section II designates overall responsibility lubricants, hydraulic fluids, or compressed air supplies.
for the performance of maintenance functions on the d. Adjust. To maintain within prescribed
identified end item or component and the work limits, by bringing into proper exact position, or by
measurement time required to perform the functions by setting the operating characteristics to specified
the designated maintenance level The implementation parameters.
of the maintenance functions upon the end item or e. Align. To adjust specified variable
component will be consistent with the assigned elements of an item to bring about optimum or desired
maintenance functions. performance.
c. Section III lists the special tools and test f. Calibrate. To determine and cause
equipment required for each maintenance function. corrections to be made or to be adjusted on instruments
d. Section IV contains supplementary or test measuring and diagnostic equipment used in
instructions or explanatory notes for a particular precision measurement. Consists of comparison of two
maintenance function. instruments, one of which is a certified standard of
known accuracy, to detect and adjust any discrepancy in
B.2. Explanation of Columns In Section II the accuracy of the instrument being compared.
a. Column 1. Group Number. Column 1 lists g. Install. The act of emplacing, seating, or
a group of numbers to identify related components, fixing into position an item, part, or module (component
assemblies, subassemblies, and modules with their next or assembly) in a manner to allow the proper functioning
higher assembly. The applicable groups are listed in the of an equipment or system.
MAC in disassembly sequence beginning with the first h. Replace. The act of substituting a
group removed. serviceable like type part, sub-assembly, or module
b. Column 2. Functional Group. This column (component or assembly) for an unserviceable
contains a brief description of the components of each counterpart.
numerical group. i. Repair. The application of maintenance
c. Column 3. Maintenance Functions. This services (inspect, test, service, adjust, align, calibrate,
column lists the various maintenance functions (A or replace) or other maintenance actions (welding,
through K). The lowest maintenance level authorized to grinding, reveting, straightening, facing, remachining or
perform these functions is indicated by a symbol in the resurfacing) to restore serviceability to an item by
appropriate column. Work measurement time standards correcting specific damage, fault, malfunction, or failure
(the active repair time required to perform the in a part, subassembly, modure (component or
maintenance function) are shown directly below the assembly), end item, or system.
symbol identifying the maintenance level The symbol j. Overhaul. That maintenance effort
designations for the various maintenance levels are as (service/ action) necessary to restore an item to a
follows: completely serviceable/operational condition as
C - Operator or crew prescribed by maintenance standards (i.e., DMWR) in
0 -- Organization maintenance appropriate technical publication. Overhaul is normally
F - Direct support maintenance the highest degree of maintenance performed by the
H - General support maintenance Army. Overhaul does not normally return an item to like
D - Depot maintenance new condition.
The maintenance functions are defined as follows: k. Rebuild. Consists of those services/actions
a. Inspect. To determine serviceability of an necessary for the restoration of unserviceable
item by comparing its physical, mechanical, and equipment to a like new condition in accordance with
electrical characteristics with established standards original manufacturing standards. Rebuild is the highest
through examination. degree of material maintenance applied to Army
b. Test. To verify serviceability and detect equipment. The rebuild operation includes the act of
incipient failure by measuring the mechanical or returning to zero those age measurements (hours/miles,
electrical characteristics of an item and comparing those etc.) considered in classifying Army
characteristics with prescribed standards. equipment/components.

B-1
 TM 10-3930-630-12
d. Column 4. Tools and Equipment. This column is lowest level of maintenance authorized to use the
provided for referencing by code the special tools and special tools or test equipment.
test equipment. (section III) required to perform the c. Nomenclature. This column lists the name or
maintenance functions (section II). identification of the tools or test equipment.
e. Column 5. Remarks. This column is provided for d. Tool Number. This column lists the
referencing by code the remarks (section IV) pertinent to manufacturer's code and part number, or national stock
the maintenance functions. number of tools and test equipment.
B-3. Explanation of Columns in Section III B-4. Explanation of Columns in Section IV
a. Reference Code. This column consists of a a. Reference Code. This column consists of two
number and a letter separated by a dash entered from letters separated by a dash, entered from column 5,
column 4 on the MAC. The number references the section II. The first letter references the remark and the
special tools and test equipment requirements and the second letter references a maintenance function,
letter represents the specific maintenance function the column 3, A through K, to which the remark applies.
item is to be used with. The letter is representative of b. Remarks. This column lists information perti-
columns A through K on the MAC. nent to the maintenance function being performed,
b. Maintenance Level. This column shows the as indicated on the MAC. section II.

Section II. MAINTENANCE ALLOCATION CHART

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

Assembly Group Maintenance functions Tools and Remarks
equipment
A B C D E F G H I J K

01 OVERHEAD GUARD AND O O

PANEL 0.2 1.0
02 OPERATORS SEAT O O
0.1 0.5
0.2 0.5
03 BODY PANEL AND HOODS O O O
0.2 0.5 1.0
04 INSTRUMENT PANEL AND C D O
INSTRUMENTS 0.2 0.3 1.0
05 MAST ASSEMBLY O O O O O F
0.2 0.4 0.2 0.5 0.5 1.0
06 HYDRAULIC LIFT
COMPONENTS:
Lines and Fittings O O O
0.3 0.4 0.5
Lift Chains O O O
0.1 0.4 0.5
Lift Cylinder O O F
0.4 0.5 1.0
Tilt Cylinder O O F
0.4 0.5 1.0
Control Valve F F
1.0 2.0
Hydraulic Tank and Oil O O F
Filter 0.2 1.0 1.0
Hydraulic Pump F F F F
0.2 0.5 1.0 2.5
07 ELECTRICAL SYSTEM:
Batteries and Cables O O O
02 0.5 0.4 0.5
Lights, Horn and Wiring O O O
0.4 0.5 0.5
Alternator O O O F
0.5 0.5 2.0
Starting Motor O O F
0.5 0.5 4.0
Distributor O O O O
0.5 0.5 0.5 1.0
Spark Plugs O O O
0.5 0.2 0.5
B-2
 TM 10-3930-630-12

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

Assembly Group Maintenance functions Tools and Remarks
equipment
A B C D E F G H I J K

08 FUEL SYSTEM:
Air Cleaner C O O
0.1 0.2 0.5
Carburetor O O F
0.5 0.5 1.5
Fuel Pump O O
0.2 0.5
Fuel Filter O O
0.2 0.5
PCV Valve O O
0.2 0.5
Governor O O
0.4 0.5
Fuel Tank Filler Cap O O O F
and Screen 0.2 0.2 0.2 0.5
Fuel Lines C C C
0.2 0.5 1.0
09 COOLING SYSTEM:
Belts O O O
0.2 0.2 0.5
Fan and Water Pump O O
0.2 0.5
Radiator O O C O H
Hoses and 0.2 1.0 0.2 1.0 2.0
Thermostat O O
0.5 0.5
10 EXHAUST SYSTEM:
Muffler and Pipes C O
0.2 0.5
11 STEERING SYSTEM:
Drag Links O O O
0.5 0.5 1.0
Tie Rod O O O
0.5 0.5 1.5
Steering Gear Assembly F F H
1.0 2.0 4.2
Steering Cylinder O O F
0.3 1.2 2.0
12 ENGINE:
Engine Assembly O O C F F H D A-B
0.3 1.0 0.4 1.5 8.0 6.0 16.0
Oil Filter O O
0.2 0.5
Manifolds O O
0.2 0.5
Cylinder Head O O
0.2 2.0
Engine Valves O F F C-1
1.5 3.0 5.0
Connecting Rod and Piston F H
Assembly 4.0 8.0
Oil Pump F F
2.0 4.0
Timing Gears F F
2.0 4.0
Camshaft Assembly F F
2.0 8.0
Flywheel Assembly F F
4.0 8.0

B-3
 TM 10-3930-630-12

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

Assembly Group Maintenance functions Tools and Remarks
equipment
A B C D E F G H I J K

ENGINE- CONTINUED
Crankshaft H D B-1
6.0 8.0
Cylinder Block H H D B-1
1.0 8.016.0
Wheel Assembly C H
0.4 1.5
Tires C H
0.2 1.7
Wheel Bearings and Seals O O
0.9 1.5
13 WHEELS:
Service Brake Shoes O O F
0.9 0.5 0.9
Parking Brake Shoes O O F
0.9 0.5 1.0
Wheel Cylinder O F F
0.4 1.8 2.0
Brake Pedal and Linkage O O
0.5 1.0
Parking Brake Lever and O O
Linkage 0.5 1.5
Parking Brake O
2.0
15 FRONT AXLE (DRIVE):
Propeller Shaft O O F
0.2 1.0 2.5
Drive Axle Ends O O O
0.5 1.0 2.0
Differential O F H
0.5 5.0 7.0
16 REAR AXLE (STEERING): 0.5 5.0 7.0
Rear Axle Assembly O F F F D-D
0.4 1.0 3.5 5.0
17 TRANSMISSION:
Oil Filter O O
0.2 0.5
Control Lever and Linkage O F
0.5 1.5
Filter Screen F F
0.2 0.2
Control Valve F F F
0.5 1.0 3.0
Transmission Assembly F C F H D E-B
1.0 0.2 3.0 8.0 16.0
Torque Converter F F
0.2 3.0

Section III. SPECIAL TOOLS AND TEST EQUIPMENT

No special tool or test equipment is authorized.

B-4
 TM 10-3930-630-12

Section IV. SUPPLEMENTARY INSTRUCTIONS

Reference
code Remarks
Estimated sine unit manhour repair or replacement
A-B Test includes engine operation and compression
B-1 Align and resize
C-1 Reface
D-D Adjust toe-in
E-B Test hydraulic control pressure

B-5
 TM 10-393-630-12
APPENDIX C
BASIC ISSUE ITEMS LIST, ITEMS TROOP
INSTALLED OR AUTHORIZED LIST

Section I. INTRODUCTION

C-1. Scope Code Explanation

This appendix lists basic issue items and items troop X2 - Repair parts which are not stocked and have no
installed or authorized required by crew/operator for foreseen mortality. The indicated maintenance
operation and required for the performance of category requiring such repair parts will attempt to
organizational maintenance of the fork lift truck. obtain the parts through cannibalization or
salvage. The item may be requisitioned, with
exception data, from the end item manager for
C-2. General immediate use.
This Basic Issue Items, Items Troop Installed or G - Major assemblies that are procured with PEMA funds
Authorized List is divided into the following sections: for initial issue only as exchange assemblies at DS
a. Basic Issue Items List-Section II. A list, in and GS level These assemblies will not be stocked
alphabetical sequence, of items which are furnished above DS and GS level or returned to depot supply
with, and which must be turned in with, the end item. level
b. Items Troop Installed Or Authorized List-Section NOTE
III. A list, in alphabetical sequence, of items which, at Cannibalization or salvage may be used
the discretion of the unit commander, may accompany as a source of supply for any items source
the end item, but are not subject to be turned in with the coded above except those coded X1.
end item. (2) Maintenance code. Indicates the lowest
category of maintenance authorized to install the listed
C-3. Explanation of Columns item. Capabilities of higher maintenance categories are
The following provides an explanation of columns considered equal or better. Maintenance codes are:
found in the tabular listings. Code Explanation
a. Source, Maintenance, and Recoverability Codes C Crew/Operator
(SMR). 0 Organizational maintenance
(1) Source code. Indicates the source for the (3) Recoverability code. Indicates whether
listed items. Source codes are: unserviceable items should be returned for recovery or
Code Explanation salvage. Items not coded are nonrecoverable.
P- Repair parts, supplied from the GSA/DSA or Army Recoverability codes are:
supply system and authorized for use at indicated Code Explanation
maintenance categories. R Repair parts (assemblies and components) which are
P2 - Repair parts which are procured and stocked for considered economically reparable at direct and
insurance purposes because the combat or military general support maintenance levels When the item
essentiality of the end item dictates that a
is no longer economically reparable, it is normally
minimum quantity be available in the supply
system. disposed of at the GS level When supply
P9 - Assigned to items which are NSA design controlled: considerations dictate, some of these repair parts
unique repair parts, which are stocked and may be listed for automatic return to supply for
supplied by the Army COMSEC Logistic System depot level repair as set forth in AR 710-50. When
and which are not subject to the provisions of AR so listed, they will be replaced by supply on an
380.4L exchange basis.
M- Repair parts which are not procured or stocked as S Repair parts and assemblies which are economically
such in the supply system but are to be reparable at DS and GS activities and which
manufactured at indicated maintenance levels. normally are furnished by supply on an exchange
A- Assemblies which are not procured or stocked as
basis. When items are determined by a GSU to be
such but are made up of two or more units. Such
component units carry individual stock numbers uneconomically reparable, they will be evacuated
and descriptions, are procured and stocked to a depot for evaluation and analysis before final
separately, and can be assembled to form the disposition.
required assembly at indicated maintenance T High dollar value recoverable repair parts which are
categories subject to special handling and are issued on an
X- Parts and assemblies that are not procured or exchange basis Such items will be repaired or
stocked because the failure rate is normally below overhauled at depot maintenance activities
that of the applicable end item or component. The U Repair parts specifically selected for salvage by
failure of such part or assembly should result in reclamation units because of precious metal
retirement of the end item from the supply system. content, critical materials, high dollar value, or
X1- Repair parts which are not procured or stocked The
reusable casings or castings.
requirement for such items will be filled by the next
higher assembly or component.
C-1
 TM 10-3930-630-12

b. National Stock Number. Indicates the National e. Quantity Furnished with Equipment (Basic Issue
stock number assigned to the item and will be used for Items Only). Indicates the quantity of the item furnished
requisitioning purposes. with the equipment.
c. Description. Indicates the Federal item name f. Quantity Authorized (Items Troop Installed or
and a minimum description required to identify the item. Authorized Only). Indicates the quantity of the item
d. Unit of Measure (U/M). Indicates the standard authorized to be used with the equipment.
or basic quantity by which the listed item is used in g. Illustration. This column is divided as follows:
performing the actual maintenance function. This (1) Figure number. Indicates the figure
measure is expressed by a two-character alphabetical number of the illustration on which the item is shown.
abbreviation, e.g., ea, in, pr, etc. (2) Item number. Indicates the callout number
used to reference the item on the illustration.

Section II. BASIC ISSUE ITEMS LIST

No basic issue items are authorized.

Section III. ITEMS TROOP INSTALLED OR AUTHORIZED LIST

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

National Unit of meas.
stock Description Qty
number auth
7510-00-889-3494 Binder, loose leaf Ea 1
7520-00-559-9618 Case operation and
maintenance manual Ea 1
4210-00-889-2221 Extinguisher, fire Ea 1

C-2
 TM 10-3930-630-12
INDEX

Paragraph Page
Abbreviations................................................................................................................................ 1-10 1-5
Accelerator .................................................................................................................................. 4-63 4-59
Adjustments:
Accelerator...................................................................................................................... 4-63 4-44
Alternator belt.................................................................................................................. 4-51 4-55
Carburetor....................................................................................................................... 4-58 4-22
Carriage .......................................................................................................................... 4-36 4-20
Chain .............................................................................................................................. 4-35 4-57
Governor......................................................................................................................... 4-59 4-83
Parking brake.................................................................................................................. 4-91 4-78
Service brake .................................................................................................................. 4-87 4-52
Spark plug....................................................................................................................... 4-54 4-66
Steering .......................................................................................................................... 4-74 4-25
Tilt cylinder ..................................................................................................................... 4-37 4-25
Transmission control ....................................................................................................... 4-99 4-90
Transmission shift rod ..................................................................................................... 4-99 4-90
Valves, engine................................................................................................................. 4-83 4-71
Air cleaner and indicator ............................................................................................................... 4-10 4-4
Air cleaner .................................................................................................................................... 4-57 4-53
Alternator...................................................................................................................................... 4-51 4-44
Axle, drive..................................................................................................................................... 4-11 4-4
Axle, steering ................................................................................................................................ 4-78 4-69
Axle shafts .................................................................................................................................... 4-96 4-88
Battery and cables ........................................................................................................................ 4-46 4-38
Belt, drive ..................................................................................................................................... 4-67 4-61
Bleeding brakes ............................................................................................................................ 4-89 4-81
Brake master cylinder ................................................................................................................... 4-10 4-4
Brake, parking .............................................................................................................................. 4-92 4-86
Breathers:
Axle................................................................................................................................. 4-95 4-88
Hydraulic reservoir .......................................................................................................... 3-18 3-9
Carburetor .................................................................................................................................... 4-58 4-55
Carriage, backrest and forks ......................................................................................................... 4-36 4-22
Coil, ignition.................................................................................................................................. 4-55 4-52
Controls and instruments .............................................................................................................. 2-2 2-1
Cowls ....................................................................................................................................... 4-25 4-12
Cluster cylinder ............................................................................................................................. 4-38 4-27
Crankcase ventilation.................................................................................................................... 4-62 4-58
Cylinder head................................................................................................................................ 4-82 4-71
Cylinder, cluster ............................................................................................................................ 4-38 4-27
Cylinder, lift .................................................................................................................................. 4-39 4-30
Cylinder, steering .......................................................................................................................... 4-76 4-69
Cylinder, tilt .................................................................................................................................. 4-37 4-25
Depositing a load .......................................................................................................................... 2-9 2-7
Description ................................................................................................................................... 1-8 1-1
Differences in models.................................................................................................................... 1-10 1-5
Differential .................................................................................................................................... 4-95 4-88
Dismantling for movement ............................................................................................................ 4-3 4-4
Distributor..................................................................................................................................... 4-53 4-47
Drag link ....................................................................................................................................... 4-75 4-67
Drive axle...................................................................................................................................... 4-11 4-4
Drive belt ...................................................................................................................................... 4-67 4-61
Drive shaft .................................................................................................................................... 4-94 4-87
Engine assembly .......................................................................................................................... 3-14 3-7
Engine crankcase ......................................................................................................................... 4-14 4-5
Engine oil filter .............................................................................................................................. 4-13 4-4
Fan ....................................................................................................................................... 4-68 4-61
Filters:
Engine oil ........................................................................................................................ 4-13 4-4
Fuel ................................................................................................................................ 4-61 4-58
Hydraulic oil .................................................................................................................... 4-43 4-33
Transmission oil.............................................................................................................. 4-98 4-89
INDEX-1
 TM 10-3930-630-12

Paragraph Page
Floor and toe plates ......................................................... ............................................................ 4-27 4-4
Front wheel .................................................................................................................................. 4-85 4-76
Maintenance ................................................................................................................... 4-64 4-60
Service ........................................................................................................................... 3-11 3-6
Fuel tank....................................................................................................................................... 4-65 4-60

Governor ...................................................................................................................................... 4-59 4-57

Grille and screen .......................................................................................................................... 4-28 4-14

Headlight ...................................................................................................................................... 4-47 4-39

Horn ....................................................................................................................................... 4-48 4-41
Hydraulic filter and reservoir.......................................................................................................... 4-9 4-4
Hydraulic filter element indicator ................................................................................................... 3-17 3-8
Hydraulic lines and fittings ............................................................................................................ 4-34 4-20
Hydraulic reservoir:
Removal ......................................................................................................................... 4-44 4-35
Service............................................................................................................................ 3-18 3-9
Indicators:
Air cleaner....................................................................................................................... 3-10 3-5
Hydraulic filter ................................................................................................................. 3-17 3-8
Ignition timing ............................................................................................................................... 4-53 4-47
Indicator, hydraulic filter................................................................................................................ 4-42 4-31
Inspecting and servicing the equipment......................................................................................... 4-1 4-1
Installation of separately packed components ............................................................................... 4-2 4-2
Instrument panel:
Maintenance.................................................................................................................... 4-32 4-15
Service............................................................................................................................ 3-9 3-5
Interference suppression components ........................................................................................... 4-20 4-10
Lamps:
Headlight......................................................................................................................... 4-47 4-39
Rear light ........................................................................................................................ 4-47 4-39
Lift chains ..................................................................................................................................... 4-35 4-20
Lifting and transporting a load....................................................................................................... 2-8 2-5
Linkage, accelerator...................................................................................................................... 4-63 4-59
Linkage, parking brake.................................................................................................................. 4-91 4-83
Lubrication instructions, operator:
Detailed........................................................................................................................... 3-2 3-1
General ........................................................................................................................... 3-1 3-1
Lubrication instructions, organizational.......................................................................................... 4-8 4-4
Manifolds ...................................................................................................................................... 4-81 4-71
Maintenance repair parts............................................................................................................... 4-7 4-4
Mast assembly.............................................................................................................................. 4-40 4-30
Master cylinder ............................................................................................................................. 4-90 4-82
Moving the truck ........................................................................................................................... 2-7 2-1
Muffler:
Maintenance.................................................................................................................... 4-72 4-65
Service............................................................................................................................ 3-13 3-6
Oil filter, transmission ................................................................................................................... 4-98 4-89
Operator ....................................................................................................................................... 2-3 2-1
Operation in:
Extreme heat................................................................................................................... 2-11 2-8
Extreme cold ................................................................................................................... 2-12 2-8
Sandy or dusty areas ...................................................................................................... 2-14 2-8
Damp tropical areas ........................................................................................................ 2-14 2-8
Orientation.................................................................................................................................... 1-9 1-5
Overhead guard ............................................................................................................................ 4-23 4-10

Parking brake ............................................................................................................................... 4-92 4-86

Parking brake lever ....................................................................................................................... 4-91 4-83
Parking brake linkage.................................................................................................................... 4-91 4-83
Pedal, accelerator ......................................................................................................................... 4-63 4-59
Pedal, brake ................................................................................................................................. 4-87 4-78
Pipes, muffler ............................................................................................................................... 4-72 4-65

INDEX-2
 TM 10-3930-630-12

Paragraph Page

Preventive maintenance:
Operator's ...................................................................................................................... 3-4 3-1
Organizational................................................................................................................. 4-16 4-5
Pump, fuel .................................................................................................................................... 4-60 4-57
Pump, water ................................................................................................................................. 4-68 4-61
Radiator:
Maintenance.................................................................................................................... 4-69 4-62
Service............................................................................................................................ 3-12 3-6
Rear light ...................................................................................................................................... 4-47 4-39
Rear wheel.................................................................................................................................... 4-85 4-76
Records ....................................................................................................................................... 1-2 1-1
Reinstallation after movement....................................................................................................... 4-4 4-4
Reservoir, hydraulic ...................................................................................................................... 4-44 4-35
Scope ....................................................................................................................................... 1-1 1-1
Seat assembly .............................................................................................................................. 4-30 4-14
Sending units................................................................................................................................ 4-50 4-43
Service brake pedal ...................................................................................................................... 4-4-87 4-78
Service brake linkage .................................................................................................................... 4-87 4-78
Service brakes .............................................................................................................................. 4-88 4-78
Service transmission..................................................................................................................... 4-101 4-92
Shafts, axle................................................................................................................................... 4-96 4-88
Shaft, drive ................................................................................................................................... 4-94 4-87
Side panels................................................................................................................................... 4-26 4-13
Single lift cylinder.......................................................................................................................... 4-39 4-30
Spark plugs .................................................................................................................................. 4-54 4-52
Special tools and equipment ......................................................................................................... 4-6 4-4
Starter ....................................................................................................................................... 4-52 4-46
Starting ....................................................................................................................................... 2-4 2-1
Stopping ....................................................................................................................................... 2-5 2-1
Switch, neutral start ...................................................................................................................... 4-100 4-92
Switch, stoplight............................................................................................................................ 4-47 4-39
Tabulated data.............................................................................................................................. 1-9 1-5
Tank, fuel...................................................................................................................................... 4-65 4-60
Tie rods ....................................................................................................................................... 4-75 4-67
Tilt cylinders ................................................................................................................................. 4-37 4-25
Tuning, ignition ............................................................................................................................. 4-53 4-47
Tools and equipment .................................................................................................................... 4-5 4-4
Transmission ................................................................................................................................ 3-16 3-8
Transmission control lever ............................................................................................................ 4-99 4-90
Transmission linkage .................................................................................................................... 4-99 4-90
Transmission service .................................................................................................................... 4-101 4-92
Troubleshooting:
Operator's ....................................................................................................................... 3-6 3-2
Organizational................................................................................................................. 4-18 4-7
Valve, control................................................................................................................................ 4-52 4-46
Valves, engine .............................................................................................................................. 4-83 4-74

Water pump.................................................................................................................................. 4-68 4-61

Wheel cylinder, brake ................................................................................................................... 4-89 4-81
Wheel, steering............................................................................................................................. 4-77 4-69
Wheels:
Drive ............................................................................................................................... 4-85 4-76
Steer ............................................................................................................................... 4-85 4-76
Wiring ....................................................................................................................................... 4-49 4-43

INDEX 3
By Order of the Secretary of the Army:

FRED C. WEYAND
General, United States Army
Official: Chief of Staff

PAUL T. SMITH
Major General, United States Army
The Adjutant General

Distribution:
To be distributed in accordance with DA Form 1225A, Operator maintenance requirements for Warehouse, Equipments.

*U.S. GOVERNMENT PRINTING OFFICE: 1993-342-421/62289

PIN: 015452-000