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

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 3930-01-158-0849 This manual supersedes TM 10 3930-660-24P dated 14 Oct 89. Approved for public release; distribution is unlimited. HEADQUARTERS, DEPARTMENT OF THE ARMY MARCH 1993

* TM 10-3930-660-24P TECHNICAL MANUAL 10-3930-660-24P 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 3930-01-158-0849 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 2028-2 located in back Of this manual direct to: Commander, US Army Tank-Automotive Command, ATTN: AMSTA-MP, Warren, MI 48397-5000. 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 01 0100 Engine Assembly.................................. 1 0100 Engine, Mounting and Lifting Brackets............ 2 0101 Cylinder Block............................ 3 0101 Block, Service Short............................. 4 0101 Cylinder Head.................................... 5 0102 Crankshaft, Bearings and Vibration Damper........ 6 01O3 Flywheel and Flywheel Housing.................... 7 0103 Flywheel Coupling and Housing Cover.............. 8 0104 Piston, Rings and Connecting Rod................. 9 0105 Front Housing and Cover.......................... 10 0105 Camshaft and Valve Tappet........................ 11 0105 Rocker Arm Assembly................. 12 0105 Push Rod Cover..................... 13 0105 Rocker Arm Covers................................ 14 0105 Tachometer Drive and Accessory Cover............. 15 0106 0il Pan and Oil Level Gauge...................... 16 0106 Oil Pump, Engine................................. 17 0106 0il Sampling Valve, Engine....................... 18 0106 0il Cooler and Filter, Engine.................... 19 1-1 2-1 3-1 4-1 5-1 6-1 7-1 8-1 9-1 10-1 11-1 12-1 13-1 14-1 15-1 16-1 17-1 l8-1 19-1 * This manual supersedes TM 10-3930-660-24P dated 14 Oct 89. i

TABLE OF CONTENTS - CONT'D 0106 0108 Group 03 0301 0302 0302 0302 0304 0305 0305 0306 0306 0306 0306 0309 0311 0312 0312 Group 04 0401 Oil Filler Tube, Side, Engine.................... 20 Exhaust Manifold and Intake Manifold Cover....... 21 Fuel Injector.........................*...... 22 Fuel Injection Pump and Coupling................. 23 Fuel Injection Pump Assembly..................... 24 Fuel Transfer Pump............................. 25 Air Cleaner Assembly............................. 26 Turbocharger and Piping.......................... 27 Turbocharger Assembly............................ 28 Fuel/Hydraulic Tank Assembly............... 29 Fuel Lines, Fittings and Water Separator......... 30 Fuel Lines and Fittings, Engine.................. 31 Engine STE/ICE Assembly.......................... 32 Fuel Filter Assemblies.................... 33 Engine Starting Aid............................. 34 Accelerator Pedal and Cable.............. 35 Accelerator Pedal Assembly....................... 36 Exhaust System..........,.............. 37 Group 05 0501/0502 Radiator and Overflow....................... 38 0502 Radiator Shroud Mounting Bracket.............. 39 0503 Thermostat and Radiator Hoses.................... 40 0503 Connection, Water Inlet.............,. 41 0504 Water Pump, Engine............................... 42 0505 Fan and Fan Guard, Engine................ 0 43 0505 Engine Fan Drive and Spacer...................... 44 0505 Drive Belt and Belt Tensioner............ 45 20-1 21-1 22-1 23-1 24-1 25-1 26-1 27-1 28-1 29-1 30-1 31-1 32-1 33-1 34-1 35-1 36-1 37-1 38-1 39-1 40-1 41-1 42-1 43-1 44-1 45-1 Group 06 0601 0601 0603 0603 0603 0607 0607 0607 0607 0609 0609 0610 0610 0610 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........0.............. Engine Water Temperature and Oil Pressure Senders Transmission Temperature Switch and Sender....... Fuel Level Sender........................ 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 46-1 47-1 48-1 49-1 50-1 51-1 52-1 53-1 54-1 55-1 56-1 57-1 58-1 59-1 60-1 61-1 62-1 63-1 64-1 ii

.TM 10 3930-660-24P TABLE OF CONTENTS - CONT ' D 0611 Back-up Alarm.................................... 65 0611 Back-up Switch................................... 66 0611 Horn Assembly.................................... 67 0612 Batteries and Battery Cables..................... 68 0612 Battery Box...................................... 69 0613 Cab Wiring Harness Assembly...................... 70 0613 Cab Wiring Harness............................... 71 0613 Main Wiring Assembly.................... 72 0613 Main Wiring Harness.............................. 73 0613 STE/ICE Harness.............................. 74 0613 Electric Joystick Harness........................ 75 0613 Slave Receptacle................................. 76 Group 07 0705 Transmission Shifter and Cables.................. 77 0705 Transmission Shifter Assembly................. 78 0705 Transmission Disconnect Foot Control............. 79 0708 Torque Converter Assembly........................ 80 0710 Transmission and Mounting........................ 81 0710 Main Case and Covers, Transmission............... 82 0710 0utput Yoke, Transmission........................ 83 0710 Output Shaft, Transmission....................... 84 0710 Front Housing, Transmission...................... 85 0710 Front Cover Group, Transmission.................. 86 0710 Front Cover Assembly, Transmission............... 87 0710 Input Shaft,Transmissiono..................... 88 0710 Clutch Pack, First Stage......................... 89 0710 Clutch Pack, Second Stage........................ 90 0710 Clutch Pack, Third Stage......................... 91 0714 Control Valve, Transmission...................... 92 0714 Control Valve Assembly...................... 93 0721 Oil Pump, Transmission.......................94 0721 Oil Pump Assembly.........................95 0721 Pump Drive Adapter, Hydraulic Piston............. 96 0721 Pump Drive Adapter Assembly...................... 97 0721 Pump Drive, Hydraulic Gear....................... 98 0721 0il Filter, Transmission......................... 99 0721 Oil Sampling Valve, Transmission................. 100 Group 09 0900 Propeller Shafts................................. 101 0900 Propeller Shaft, Front Differential.............. 102 0900 Propeller Shaft, Rear Differential............... 103 0900 Propeller Shaft, Transmission.................... 104 Group 10 1000 Front Axle Assembly.............................. 105 1000 Housing Assembly, Front Axle..................... 106 1002 Differential Assembly, Front Axle................ 107 1003 Planetary Wheel End, Front Axle.................. 108 Group 11 1100 Rear Axle Assembly............................... 109 1100 Housing Assembly, Rear Axle...................... 110 65-1 66-1 67-1 68-1 69-1 70-1 71-1 72-1 73-1 74-1 75-1 76-1 77-1 78-1 79-1 80-1 81-1 82-2 83-1 84-1 85-1 86-1 87-1 88-1 89-1 90-1 91-1 92-1 93-1 94-1 95-1 96-1 97-1 98-1 99-1 100-1 101-1 102-1 103-1 104-1 105-1 106-1 107-1 108-1 109-1 110-1 iii

TABLE OF CONTENTS - CONT D 1102 Differential Assembly, Rear Axle................. 111 1103 Planetary Wheel End, Rear Axle................... 112 Group 12 1201 Parking Brake Assembly........................... 113 1201 Parking Brake Lever and Cable................... 114 1202 Disc Brake Caliper Assembly...................... 115 1204 Mounting Hardware - Hydraulic Accumulator and Hydraulic Brake Control Valve.............. 116 1204 Hydraulic Brake Control Valve Assembly........... 117 1204 Hydraulic Brake Accumulator...................... 118 1204 Hydraulic Brake Lines and Axle Breather Hose, Front Axle.................... 119 1204 Hydraulic Brake Lines and Axle Breather Hose, Rear Axle.................................. 120 1206 Hydraulic Brake Foot Control..................... 121 Group 13 1311 Wheel Assembly............................. 122 1313 Tire...................................... 123 Group 14 1401 Steering Wheel Assembly.......................... 124 1401 Steering Column and Control Valve................ 125 1401 Steering Knuckle, Tie Rod, Universal Joint and Spindle.........................l........ 126 1410 Emergency Steering Pump and Motor................ 127 1411 Hydraulic Steering Lines and Fittings, Front Axle 128 1411 Hydraulic Steering Lines and Fittings, Rear Axle. 129 1412 Steering Cylinders.............l...........l... 130 1414 Steering Select Valve............................ 131 Group 15 1501 Frame Assembly and Pivot Pins.................... 132 1502 Counterweight Assembly.................... 133 1503 Pintle Hook........l...................... 134 Group 18 1801 Miscellaneous Frame Covers....................... 135 1801 Cab Assembly.......................l........... 136 1801 Cab Mounting Hardware............................ 137 1801 Cab Door Assembly................................ 138 1801 Cab Interior Cover Plates and Floor Mat.......... 139 1801 Cab Skylight Guard.................140 1801 Cab Sound Suppression Panels..................... 141 1802 Cab Windows and Skylight.........................142 1802 Cab Door Window.................................. 143 1802 Fender Assemblies....................144 1805 Cab Floor Plate.................................. 145 1806 Seat Assembly............................. 146 Group 22 2202 Front Wiper Assembly............................. 147 2202 Rear Wiper Assembly...........................148 2202 Wiper/Washer Assembly................ 149 2202 Mirror Assembly.................. 150 111-1 112-1 113-1 114-1 115-1 116-1 117-1 118-1 119-1 120-1 121-1 122-1 123-1 124-1 125-1 126-1 127-1 128-1 129-1 130-1 131-1 132-1 133-1 134-1 135-1 136-1 137-1 138-1 139-1 140-1 141-1 142-1 143-1 144-1 145-1 146-1 147-1 148-1 149-1 150-1 iv

TABLE OF CONTENTS - CONT D 2202 Defroster Fans..................... 151 2207 Heater Assembly.................................. 152 2207 Heater Control Cable................. 153 2207 Heater Hoses, Lines and Fittings................. 154 2210 Data Plates, Decals and Stencils................. 155 Group 24 2401 Hydraulic Tandem Gear Pump....................... 156 2401 Piston Pump................................... 157 2402 Main Control Valve Assembly...................... 158 2402 5060B Relief Valve Assembly...................... 159 2402 4545B Relief Valve Assembly..............160 2402 MLRS Attachment Control Valve.................... 161 2402 MLRS Attachment Control Valve Assembly........... 162 2402 5060B Relief Valve Assembly...................... 163 2402 5271OC Relief Valve Assembly..................... 164 2402 Priority Valve................................... 165 2402 Relief Valve, Frame Tilt/Brakes.................. 166 2402 Hydraulic Control Joystick and Frame Tilt Control Valve........................l..... 167 2402 Frame Tilt Valve................................. 168 2402 Shuttle Valve......................... 169 2404 Frame Tilt Cylinder Mounting..................... 170 2404 Frame Tilt Cylinder Assembly..................... 171 2404 Carriage Tilt Cylinder Assembly.................. 172 2405 MLRS Attachment Assembly......................... 173 2405 MLRS Carriage Assembly........................... 174 2405 Boom Assembly............................ 175 2406 Hydraulic Lines, Transmission Oil Filter......... 176 2406 Hydraulic Lines, Transmission Oil Cooler......... 177 2406 Hydraulic Lines, Transmission Disconnect......... 178 2406 Hydraulic Lines, Hydraulic Oil Reservoir......... 179 2406 Hydraulic Lines, Main Control Valve.............. 180 2406 Hydraulic Lines, Dual Gear Pump.................. 181 2406 Hydraulic Lines, Piston Pump..................... 182 2406 Hydraulic Lines, Oil Filter...................... 183 2406 Hydraulic Lines, Brake Valve Accumulator......... 184 2406 Hydraulic Lines, Priority Valve.................. 185 2406 Hydraulic Lines, Relief Valve.................... 186 2406 Hydraulic Lines, Frame Tilt Valve................ 187 2406 Hydraulic Lines, Steering Valve.................. 188 2406 Hydraulic Lines, Steering Select Valve........... 189 2406 Hydraulic Lines, Emergency Steering Pump and Shuttle Valve..............................190 2406 Hydraulic Lines, Tow Line........................ 191 2406 Hydraulic Lines, Boom Extend Cylinder............ 192 2406 Hydraulic Lines to Boom.......................... 193 2406 Hydraulic Lines, Boom............................194 151-1 152-1 153-1 154-1 155-1 156-1 157-1 158-1 159-1 160-1 161-1 162-1 163-1 164-1 165-1 166-1 167-1 168-1 169-1 170-1 171-1 172-1 173-1 174-1 175-1 176-1 177-1 178-1 179-1 180-1 181-1 182-1 183-1 184-1 185-1 186-1 187-1 188-1 189-1 190-1 191-1 192-1 193-1 194-1 V

TABLE OF CONTENTS - CONT D 2406 Hydraulic Lines, Boom Lines to Attachment Control Valve..............195 2406 Hydraulic Lines, Fork Tilt Cylinders to Attachment Control Valve..................... 196 2406 Hydraulic Lines, Attachment Cylinder............. 197 2406 Hydraulic Lines, Fork Sideshift Cylinders........ 198 2407 Boom Extend Cylinder............................. 199 2407 Boom Hoist Cylinder.............................. 200 2407 Fork Sideshift Cylinder.......................... 201 2407 MLRS Attachment Cylinder Assembly................ 202 Group 31 3100 Emergency Boom Lift/Retract Kit.................. 203 3100 MLRS Hook Attachment....................... 204 3100 Stabilizer Hooks L.H. and R.H.................... 205 Group 47 4702 Air Cleaner Restriction Indicator................ 206 4702 Hydraulic Oil Level Sight Gauge.................. 207 195-1 196-1 197-1 198-1 199-1 200-1 201-1 202-1 203-1 204-1 205-1 206-1 207-1 Section III. SPECIAL TOOLS LIST Group 26 2604 Special Tools, Transmission Kit.................. 208 2604 Special Tools, Wrench Kit........................ 209 208-1 209-1 vi

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

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