TM TECHNICAL MANUAL

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1 TM DEPARTMENT OF THE ARMY TECHNICAL MANUAL TECHNICAL MANUAL DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL TRUCK, LIFT, FORK, POWER SHIFT G.E.D., 6,000 LB CAPACITY, 180 IN. LIFT (ALLIS CHALMERS MODEL F-60-24PS-180) (ARMY MODEL MHE 212) FSN HEADQUARTERS, DEPARTMENT OF THE ARMY MAY 1971

2 TM TECHNICAL MANUAL HEADQUARTERS, DEPARTMENT OF THE ARMY No WASHINGTON. D.C., 11 May 1971 DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE MANUAL TRUCK, LIFT, FORK, POWER SHIFT G.E.D., 6,000 LB CAPACITY, 180 IN. LIFT (ALLIS CHALMERS MODEL F-60-24PS-180) (ARMY MODEL MHE 212) F SN Paragraph 1. I INTRODUCTION General Description and data I II DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS Repair parts, special tools, and equipment Troubleshooting General maintenance Removal and installation of major components Chapter 3. I Ill. REPAIR OF ENGINE Repair of fuel system Repair of engine lubrication system Repair of the cooling system Repair of engine components 1 Chapter 4. I II V. V REPAIR OF TRANSMISSION, STEERING AND DRIVE COMPONENTS Repair of transmission Repair of front axle assembly Repair of rear axle Repair of service brakes Repair of wheel assembly Repair of steering system SECTION 5. I REPAIR OF ELECTRIC AND HYDRAULIC COMPONENTS Repair of electric components Repair of steering system I REPAIR OF THE BODY Repair of lift structures Repair of frame APPENDlX A REFERENCES i

3 Number LIST OF ILLUSTRATIONS Title Electrical schematic diagram Hydraulic diagram Transmission and torque converter hydraulic system diagram Hydraulic reservoir drain Hydraulic lines Shift linkage Throttle linkage Lifting studs Transmission removal Checking tang depth Checking converter alignment Front axle assembly Mounting pad Rear axle mounting Carburetor assembly Governor Governor, exploded view Oil pump. exploded view Positioning drive gear offset slot Oil pressure valve Cylinder head and valves Guide stud location and torquing sequence Rocker arm shaft support installation Checking gear backlash Flywheel and flywheel, exploded view Checking flywheel housing runout Checking flywheel runout Camshaft assembly Piston and connecting rod Checking ring-to-groove clearance Checking rod side play Crankshaft assembly Checking crankshaft end play Temporary locating dowel Torque converter and transmission Torque converter and pump assembly, exploded view Drum and disc assembly. exploded view Installing torque converter to drum and disc assembly Transmission gearcase assembly, exploded view Installing output gear and shaft Installiny idler gear and shaft Installing forward gear and shaft Checking pump and converter pressure Checking clutch pressure Regulating valve adjustment Transmission control valve, exploded view Front axle assembly. cutaway view Front axle and axle housing, exploded view Differential and carrier assembly, exploded view Differential tooth pattern Rear axle assembly, exploded view Pivot arm bearings Master cylinder, exploded view Wheel cylinder, exploded view Inching pedal mechanical adjustment Inching pedal hydraulic adjustment Wheel assembly, exploded view Spiral pin installation Tire replacement Steering Valve Steering wheel, column and valve, exploded view Steering cylinder, exploded view Alternator, exploded view Checking rotor for ground. shorts and opens Checking stator windings Checking the diodes ii

4 LIST OF ILLUSTRATIONS - Continued Title Number Alternator brush replacement Starting motor, exploded view Hydraulic pump Hydraulic pump, exploded view Control valve Control valve, exploded view Adjusting relief valves Control levers, exploded view Tilt cylinder, exploded view Primary lift cylinder, exploded view Secondary lift cylinder, exploded view Mast assembly, exploded view Carriage and backrest assembly Fork and locking mechanism, exploded view iii

5 1 INTRODUCTION GENERAL. Scope The instructions in this manual are for the use of personnel to whom the F60-24PS-180 Forklift Truck is issued. This manual contains procedures for Direct Support and General Support levels of maintenance for the equipment and its accessories Forms and Records Maintenance forms. records, and reports which are to be used by maintenance personnel at all maintenance levels are listed in, and prescribed by, TM Reporting of Errors Reporting of errors, omissions, and recommendations for improving this publication by the individual user is encouraged. Reports should be submitted on DA form 2028, Recommended Changes to Publications, and forwarded to Commanding General, U.S. Army Mobility Equipment Command, ATTN: AMSME-MPP Goodfellow Blvd., St. Louis. MO I DESCRIPTION AND DATA 1-4. Description A general description of the forklift truck and information pertaining to the identification plates are contained in TM A -more detailed description of specific components and assesmblies is contained in the applicable sections of this manual Tabulated Data a. Engine Allis-Chalmers part number MB-230 Gasoline Displacement 230 cubic inches Power 55 horsepower at 220 rpm Torque 153 ft lbs at 1200 rpm Number of cylinders 6-in line Bore 3 7/16 inches Stroke 4 1/3 inches Firing order Compression ratio 7.3 to 1 b. Carburetor. part number ModeI Zenith Carburetor Division J8 Up-draft, single barrel c. Alternator, Electrica Manufacter Delco-Remy part number DN 12 volt, negative ground Voltage output 12 volts Current output 22 amps Rotation Clockwise d. Starter, Electrical Delco-Remy part number volt, negative ground Amperage draw amps/10.3 volts at 6900 rpm Rotation Clockwise c. Transmission. Warner Gear part number T12 T y p e Single range Gear ratio: Forward 1.19:1 Reverse 1.19:1 Maximum input torque 350 ft lbs Maximum input speed 2200 rpm Pressure : Main psi Converter psi Lube psi f. Drive Axle. part number. Allis-Chalmers g. Cylinder. Master, Brake. part number. h. Wheel Cylinder. part number. Wagner Electric FE24728 Combination reservoir and cylinder Wagner Electric FD20945A Standard straight bore, double end

DEPARTMENT OF THE ARMY TECHNICAL MANUAL TECHNICAL MANUAL OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL TRUCK, LIFT, FORK, POWER SHIFT G.E.D.

TM 10-3930-624-12 DEPARTMENT OF THE ARMY TECHNICAL MANUAL TECHNICAL MANUAL OPERATOR AND ORGANIZATIONAL MAINTENANCE MANUAL TRUCK, LIFT, FORK, POWER SHIFT G.E.D., 6,000 LB CAPACITY, SRT. 180 IN. LIFT (ALLIS