TRUCK, FORKLIFT; 6,000 LB. VARIABLE REACH, ROUGH TERRAIN NSN

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1 TECHNICAL MANUAL UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST (INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST) FOR TRUCK, FORKLIFT; 6,000 LB. VARIABLE REACH, ROUGH TERRAIN NSN This manual supersedes TM P dated 14 Oct 89. Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY MARCH 1993

2 * TM P TECHNICAL MANUAL P HEADQUARTERS DEPARTMENT OF THE ARMY Washington D. C., 30 March 1993 UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST (INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST) FOR TRUCK,FORKLIFT; 6,000LB. VARIABLE REACH,ROUGH TERRAIN NSN REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes or if you know of any way to improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form located in back Of this manual direct to: Commander, US Army Tank-Automotive Command, ATTN: AMSTA-MP, Warren, MI A reply will be furnished to YOU. Current as of: 24 NOV 92 TABLE OF CONTENTS Section I. INTRODUCTION Fig. vii Section II. REPAIR PARTS LIST Group Engine Assembly Engine, Mounting and Lifting Brackets Cylinder Block Block, Service Short Cylinder Head Crankshaft, Bearings and Vibration Damper O3 Flywheel and Flywheel Housing Flywheel Coupling and Housing Cover Piston, Rings and Connecting Rod Front Housing and Cover Camshaft and Valve Tappet Rocker Arm Assembly Push Rod Cover Rocker Arm Covers Tachometer Drive and Accessory Cover il Pan and Oil Level Gauge Oil Pump, Engine il Sampling Valve, Engine il Cooler and Filter, Engine l * This manual supersedes TM P dated 14 Oct 89. i

3 TABLE OF CONTENTS - CONT'D Group Group Oil Filler Tube, Side, Engine Exhaust Manifold and Intake Manifold Cover Fuel Injector * Fuel Injection Pump and Coupling Fuel Injection Pump Assembly Fuel Transfer Pump Air Cleaner Assembly Turbocharger and Piping Turbocharger Assembly Fuel/Hydraulic Tank Assembly Fuel Lines, Fittings and Water Separator Fuel Lines and Fittings, Engine Engine STE/ICE Assembly Fuel Filter Assemblies Engine Starting Aid Accelerator Pedal and Cable Accelerator Pedal Assembly Exhaust System , Group /0502 Radiator and Overflow Radiator Shroud Mounting Bracket Thermostat and Radiator Hoses Connection, Water Inlet , Water Pump, Engine Fan and Fan Guard, Engine Engine Fan Drive and Spacer Drive Belt and Belt Tensioner Group Alternator and Mounting Alternator Assembly Starter Relay and Starter Wiring Starting Motor Starting Motor Assembly Cab Instrument Panel Circuit Breakers Cab Instrument Panel, Cover Plates Switches for Engine and Heater Blackout Light Switch Engine Water Temperature and Oil Pressure Switches Boom, Electric Controller Joystick Boom, Electric Box Assembly Switch, Fork Auto Leveler Front and Rear Light Assemblies Work Light, Adjustable Engine Water Temperature and Oil Pressure Senders Transmission Temperature Switch and Sender Fuel Level Sender ii

4 .TM P TABLE OF CONTENTS - CONT ' D 0611 Back-up Alarm Back-up Switch Horn Assembly Batteries and Battery Cables Battery Box Cab Wiring Harness Assembly Cab Wiring Harness Main Wiring Assembly Main Wiring Harness STE/ICE Harness Electric Joystick Harness Slave Receptacle Group Transmission Shifter and Cables Transmission Shifter Assembly Transmission Disconnect Foot Control Torque Converter Assembly Transmission and Mounting Main Case and Covers, Transmission utput Yoke, Transmission Output Shaft, Transmission Front Housing, Transmission Front Cover Group, Transmission Front Cover Assembly, Transmission Input Shaft,Transmissiono Clutch Pack, First Stage Clutch Pack, Second Stage Clutch Pack, Third Stage Control Valve, Transmission Control Valve Assembly Oil Pump, Transmission Oil Pump Assembly Pump Drive Adapter, Hydraulic Piston Pump Drive Adapter Assembly Pump Drive, Hydraulic Gear il Filter, Transmission Oil Sampling Valve, Transmission Group Propeller Shafts Propeller Shaft, Front Differential Propeller Shaft, Rear Differential Propeller Shaft, Transmission Group Front Axle Assembly Housing Assembly, Front Axle Differential Assembly, Front Axle Planetary Wheel End, Front Axle Group Rear Axle Assembly Housing Assembly, Rear Axle iii

5 TABLE OF CONTENTS - CONT D 1102 Differential Assembly, Rear Axle Planetary Wheel End, Rear Axle Group Parking Brake Assembly Parking Brake Lever and Cable Disc Brake Caliper Assembly Mounting Hardware - Hydraulic Accumulator and Hydraulic Brake Control Valve Hydraulic Brake Control Valve Assembly Hydraulic Brake Accumulator Hydraulic Brake Lines and Axle Breather Hose, Front Axle Hydraulic Brake Lines and Axle Breather Hose, Rear Axle Hydraulic Brake Foot Control Group Wheel Assembly Tire Group Steering Wheel Assembly Steering Column and Control Valve Steering Knuckle, Tie Rod, Universal Joint and Spindle l Emergency Steering Pump and Motor Hydraulic Steering Lines and Fittings, Front Axle Hydraulic Steering Lines and Fittings, Rear Axle Steering Cylinders l l Steering Select Valve Group Frame Assembly and Pivot Pins Counterweight Assembly Pintle Hook l Group Miscellaneous Frame Covers Cab Assembly l Cab Mounting Hardware Cab Door Assembly Cab Interior Cover Plates and Floor Mat Cab Skylight Guard Cab Sound Suppression Panels Cab Windows and Skylight Cab Door Window Fender Assemblies Cab Floor Plate Seat Assembly Group Front Wiper Assembly Rear Wiper Assembly Wiper/Washer Assembly Mirror Assembly iv

6 TABLE OF CONTENTS - CONT D 2202 Defroster Fans Heater Assembly Heater Control Cable Heater Hoses, Lines and Fittings Data Plates, Decals and Stencils Group Hydraulic Tandem Gear Pump Piston Pump Main Control Valve Assembly B Relief Valve Assembly B Relief Valve Assembly MLRS Attachment Control Valve MLRS Attachment Control Valve Assembly B Relief Valve Assembly OC Relief Valve Assembly Priority Valve Relief Valve, Frame Tilt/Brakes Hydraulic Control Joystick and Frame Tilt Control Valve l Frame Tilt Valve Shuttle Valve Frame Tilt Cylinder Mounting Frame Tilt Cylinder Assembly Carriage Tilt Cylinder Assembly MLRS Attachment Assembly MLRS Carriage Assembly Boom Assembly Hydraulic Lines, Transmission Oil Filter Hydraulic Lines, Transmission Oil Cooler Hydraulic Lines, Transmission Disconnect Hydraulic Lines, Hydraulic Oil Reservoir Hydraulic Lines, Main Control Valve Hydraulic Lines, Dual Gear Pump Hydraulic Lines, Piston Pump Hydraulic Lines, Oil Filter Hydraulic Lines, Brake Valve Accumulator Hydraulic Lines, Priority Valve Hydraulic Lines, Relief Valve Hydraulic Lines, Frame Tilt Valve Hydraulic Lines, Steering Valve Hydraulic Lines, Steering Select Valve Hydraulic Lines, Emergency Steering Pump and Shuttle Valve Hydraulic Lines, Tow Line Hydraulic Lines, Boom Extend Cylinder Hydraulic Lines to Boom Hydraulic Lines, Boom V

7 TABLE OF CONTENTS - CONT D 2406 Hydraulic Lines, Boom Lines to Attachment Control Valve Hydraulic Lines, Fork Tilt Cylinders to Attachment Control Valve Hydraulic Lines, Attachment Cylinder Hydraulic Lines, Fork Sideshift Cylinders Boom Extend Cylinder Boom Hoist Cylinder Fork Sideshift Cylinder MLRS Attachment Cylinder Assembly Group Emergency Boom Lift/Retract Kit MLRS Hook Attachment Stabilizer Hooks L.H. and R.H Group Air Cleaner Restriction Indicator Hydraulic Oil Level Sight Gauge Section III. SPECIAL TOOLS LIST Group Special Tools, Transmission Kit Special Tools, Wrench Kit vi

8 UNIT (ORGANIZATIONAL), INTERMEDIATE (DIRECT SUPPORT AND GENERAL SUPPORT) INCLUDING DEPOT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LIST SECTION I. INTRODUCTION 1. Scope This RPSTL lists and authorizes spares and repair parts; special tools; and other equipment required for performance of organizational, direct support and general support maintenance of the forklift truck. It authorizes the requisitioning, issue and disposition of spares, repair parts and special tools as indicated by the source, maintenance and recoverability (SMR) codes. 2. General. In addition to Section I, Introduction, this Repair Parts and Special Teds List is divided into the following sections: a. Section II. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use in the performance of maintenance. The list also includes parts which must be removed for replacement of the authorized parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and item number sequence. Bulk materials are listed in item name sequence. Repair parts kits are listed separately in their own functional group within Section II. Repair parts for repairable special tools are also listed in this section. Items listed are shown on the associated illustration(s)/figure (s). b. Section III. Special Tools List. A list of special tools and other special support equipment authorized by this RPSTL (as indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE column) for the performance of maintenance. c* Section IV. Cross-reference Index. A list, in National Stock item identification number (NIIN) sequence, of all National stock numbered items appearing in the listing, followed by a list in alphanumeric sequence of all part numbers appearing in the listings. National stock numbers and part numbers are cross- -referenced to each illustration figure and item number appearance. The figure and item number index lists figure and item numbers in alphanumeric sequence and cross- -references NSN, CAGE and part numbers. 1

9 3. Explanation of Columns (Sections II and III). a. ITEM NO. (Column (l)). is a 5-position code containing category authorization criteria following breakout: The Source, Maintenance and Recoverability (SMR) code supply/requisitioning information, maintenance and disposition instruction, as shown in the How you get an item 3rd position 4th position Who determined Who can install, Who can do disposition replace or use complete repair* action on an the item on the item unserviceable itern *complete Repair: Maintenance capacity, capability and authority to perform all corrective maintenance tasks of the Repair function in a use/user environment in order to restore serviceability to a failed item. (1) Source Code. The source code tells you how to get an item needed for maintenance, repair, or overhaul of an end item/equipment. Explanations of source codes follows: Code Explanation Stocked items; use the applicable NSN to request/ requisition items with these source codes. They are authorized to the category indicated by the code entered in the 3rd position of the SMR code. **NOTE: Items coded PC are subject to deterioration. Items with these codes are not to be requested/requisitioned individually. They are part of a kit which is authorized to maintenance category indicated in the 3rd position of the SMR code. The complete kit must be requisitioned and applied. Items with these codes are not to be requested/requisitioned individually. They must be made from bulk material which is Identified by the part number in the DESCRIPTION AND USABLE CN CODE (UOC) column and listed in the Bulk Material group of the repair parts list in this RPSTL. If the item is authorized to you by the 3rd position code of the SMR code~ but the source code indicates it is made at a higher level, order the item from the higher level of maintenance. 2