Attachment_0034__TM_10-3930-638-10_-_4 000_lbs_Forklift.pdf

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T M 1 0 - 3 9 3 0 - 6 3 8 - 1 0

O P E R A T O R ’ S M A N U A L

T R U C K , F O R K L l F T , D E D , P N E U M A T I C T I R E , A R T I C U L A T E D

FRAME STEER, 4 ,000 LB. CAPACITY

R O U G H T E R R A I N , A R M Y M O D E L M H E 2 3 7

(J. I . CASE MODEL M4K)

(NSN 3930-01-076-4237)

H E A D Q U A R T E R S , D E P A R T M E N T O F T H E A R M Y

M A Y 1 9 8 0

TM 10-3930-638-10

Change 3 A

WARNING

FIRE HAZARD

Diesel fuel used in operation of this equipment is combustible

WARNING

HYDRAULIC OIL UNDER PRESSURE

2,500 PSI pressure is used in the operation of this equipment.

WARNING

ELECTRICAL SHOCK HAZARD

Always disconnect battery ground cable before working on electrical components of this equip-ment.

WARNING

TIRE INFLATION

Observe caution when inflating tires. Make sure tires are properly seated on rims before inflating.

Improperly seated tires can burst with explosive force sufficient to cause death.

WARNING

DANGEROUS CHEMICALS

Battery electrolyte is toxic and corrosive! Use protective goggles and gloves. Avoid contact with skin, eyes, clothes, and do not breathe vapors.

WARNING

EXHAUST GASES CAN BE DEADLY

Exhaust gases can produce symptoms of headache, dizziness, loss of muscular control, or coma.

Permanent brain damage or death can result from severe exposure. You can ensure your safety by following these rules:

DO NOT operate the heater or engine in an enclosed area unless it is properly ventilated.

DO NOT drive with any of the truck’s inspection plates, cover plates, or the hood off unless neces-sary for maintenance. If you notice exhaust odors or exposure symptoms, IMMEDIATELY VEN-

TILATE the area.

• If the symptoms persist, remove the affected people and treat them:

• Expose them to fresh air.

• If necessary, give artificial respiration.

• Keep them warm.

• DO NOT permit physical exercise.

Refer to FM 21-11, First Aid for Soldiers, for first aid treatment of injured personnel.

WARNING

NOISE HAZARD

Noise level exceeds 85 dB(A) at three feet in front, 15 feet at side, and 24 feet at rear of vehicle.

All personnel shall wear a hearing protection device when operating the vehicle.

B Change 3

WARNING

Be sure your seat belt is fastened before starting engine and operating the vehicle.

WARNING

Be sure that steering bypass valve is closed (fully clockwise) and that shipping lock pin is removed before operating vehicle. Failure to do so will cause loss of steering control, which may result in death or serious injury.

WARNING

Always operate vehicle at a safe speed. Avoid overloading and sudden stops. Caution is advised when operating on a slope with any load. Do not tilt load out beyond vertical position of mast when elevated unless load is over a stack.

WARNING

Starting fluid is toxic and highly flammable. Container is pressurized to act as an expellent. Do not heat container and do not discharge starting fluid in confined areas or near an open flame. Do not discard used container in an open flame.

WARNING

Dry cleaning solvent P-D-680 used to clean parts is potentially dangerous to personnel and prop-erty. Do not use near open flame or excessive heat. Flash point of solvent is 138 degrees F.

WARNING

NBC EXPOSURE

If NBC exposure is suspected, personnel wearing protective equipment must handle all air cleaner media. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.

Refer to FM 3-3, Chemical and Biological Contamination Avoidance, FM 3-5, NBC Decontamina-tion, FM 3-3-1, Nuclear Contamination Avoidance.

NBC contaminated filters must be handled using adequate precautions and must be disposed of by trained personnel.

To order this NBC decal use:

National Stock Number (NSN) - 7690-01-114-3702 Part Number (PN) - 12296626 Commercial and Government Entity Code (CAGEC) - 19207

WARNING

IF NBC EXPOSURE IS SUSPECTED ALL AIR

FILTER MEDIA WILL BE HANDLED BY PER-

SONNEL WEARING FULL NBC PROTEC-

TIVE EQUIPMENT. SEE OPERATOR/

MAINTENANCE MANUAL.

7690-01-114-3702

C3

Approved for public release; distribution is unlimited.

CHANGE HEADQUARTERS

NO. 3 DEPARTMENT OF THE ARMY

Washington D.C., 15 July 2008

OPERATOR’S MANUAL

TRUCK, FORKLIFT, DED, PNEUMATIC TIRE,

ARTICULATED FRAME STEER,

4,000-LB CAPACITY, ROUGH TERRAIN

ARMY MODEL MME 237

(J.I. CASE MODEL M4K)

(NSN 3930-01-076-4237)

TM 10-3930-638-10, dated 30 May 1980, is changed as follows:

1. Remove old pages and insert new pages.

2. New or changed material is indicated by a vertical bar in the margin of the page and by a vertical bar adja-cent to the art.

Remove Pages Insert Pages A and B A and B i and 1-0 i and 1-0

1-1 thru 1-6 1-1 thru 1-6 2-5 thru 2-8 2-5 thru 2-8

2-8.1 and 2-8.2 2-10.1/(2-10.2 blank) 2-10.1/(2-10.2 blank)

2-11 thru 2-14 2-11 thru 2-14 2-17 thru 2-20 2-17 thru 2-20

3-3 and 3-4 3-3 and 3-4 3-4.1 and 3-4.2

3-5 thru 3-12 3-5 thru 3-12 Index 1 and Index 2 Index 1 and Index 2

2028 Sample 2028 Sample 2028 2028 2028 2028 2028 2028

3. File this change sheet in front of the publication for reference purposes.

C3

By Order of the Secretary of the Army:

GEORGE W. CASEY, JR.

General, United States Army

Chief of Staff Official:

DISTRIBUTION: To be distributed in accordance with the initial distribution requirements for IDN: 252161, require-ments for TM 10-3930-638-10.

06323

C2

CHANGE

No. 2

HEADQUARTERS

DEPARTMENT OF THE ARMY

Washington D. C., 4 December 1990

OPERATOR’S MANUAL

TRUCK, FORKLIFT, DED, PNEUMATIC TIRE,

ARTICULATED FRAME STEER,

4,000-LB. CAPACITY, ROUGH TERRAIN

ARMY MODEL MHE 237

(NSN 3930-01-076-4237)

TM 10-3930-638-10, 30 May 1980, is changed as follows:

1. Remove old pages and insert new pages.

2. New or changed material is indicated by a vertical bar in the margin of the page and by a vertical bar adja-cent to the TA number.

Remove Pages Insert Pages

1-9 and 1-10 1-9 and 1-10 2-9 through 2-12 2-9 through 2-12

3. File this change sheet in front of the publication for reference purposes.

By Order of the Secretary of the Army:

CARL E. VUONO

General, United States Army

Chief of Staff

Official:

THOMAS F. SIKORA

Brigadier General, United States Army

The Adjutant General

Distribution:

TO be distributed in accordance with DA Form 12-25-E (Block 2161) Operator maintenance require-ments for TM10-3930-638-10.

A B i 1-0

1-1 1-2

1-7 1-10.2

2-9 2-12

2-17 2-18

A-1(A-2 blank)

C-1(C-2 blank)

D-1(D-2 blank)

Change 3 A/(B Blank)

LIST OF EFFECTIVE PAGES

Date of issue for original manual is:

Original . . . . . . . 30 May 1980 Change 1 . . . . . . 14 March 1990 Change 2 . . . . . . 4 December 1990 Change 3 . . . . . . 15 July 2008

Total number of pages for front and rear matter is 40and total number of pages is 418 consisting of the following:

Page No.

*Change No.

Page No.

*Change No.

Cover 0 Authentication Page 0 A and B 3 Back Cover 0 i 3 1-0 0 1-1 to 1-5 3 1-6 and 1-7 0 1-8 1 1-9 2 1-10 1 2-1 to 2-4 0 2-5 to 2-8 3 2-8.1 and 2-8.2 3 2-9 1 2-10 2 2-10.1/(2-10.2 Blank) 3 2-11 0 2-12 and 2-13 3 2-13.0/(2-13.1 Blank) 3 2-14 to 2-17 0 2-18 3 2-19 0 2-20 3 2-21 and 2-22 0 3-1 to 3-3 0 3-4 3 3-4.1/(3-4.2 Blank) 3 3-5 to 3-12 3 3-13 to 3-15/(3-16 Blank) 0 A-1/(A-2 Blank) 1 B-1 and B-2 0 C-1/(C-2 Blank) 1 D-1/(D-2 Blank) 1 Index-1 and Index-2 3

* Zero in this column indicates an original page or work package.

Change 3 i

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

Washington, D.C., 30 May 1980

OPERATOR’S MANUAL

TRUCK, FORKLIFT, DED, PNEUMATIC TIRE, ARTICULATED FRAME STEER,

4,000-LB. CAPACITY, ROUGH TERRAIN,

ARMY MODEL MHE 237

(J.I. CASE MODEL M4K)

(NSN 3930-01-076-4237)

CHAPTER 1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Section I General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

II Equipment Description and Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 III Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

CHAPTER 2 OPERATING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section I Description and Use of Operator’s Controls and Indicators . . . . . . . . . . . . . . . . . . 2-1

II Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . 2-9 III Operation Under Usual Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 IV Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

CHAPTER 3 DIRECT SUPPORT MAINTENANCE PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Chapter Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Section I Lubrication Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

II Operator / Crew Troubleshooting Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

APPENDIX A REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

APPENDIX B MAINTENANCE ALLOCATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

APPENDIX C LUBRICATION ORDER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

APPENDIX D EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST . . . . . . . . . . . . . . . . . . . D-1

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help im prove this publication. If you find any mistakes or if you know of a way to im prove the proce-dures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical Publica-tions), throug h th e Int ernet, o n the A rmy Electroni c Product Su pport (AEPS) w ebsite. The In ternet address is https://aeps.ria.army.mil. The D A Form 2028 is lo cated under the Publ ic Applications section in the A EPS Public Hom e Page. Fill ou t th e form and cli ck o n SUBMIT. Usin g t his form on t he A EPS wi ll en able us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or E-mail your letter or DA Form 2028 direct to: AMSTA-LC-LMPP/TECH PUBS, TACOM-RI, 1 Rock Island Arse-nal, Rock Island, IL 61299-7630. The E-mail address is ROCK-TACOM-TECH-PUBS@conus.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

1-0

MHE 237 forklift truck

Right Front View

Left Front View

Change 3 1-1

CHAPTER 1

INTRODUCTION

Index Section Title Page

I General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 II Equipment Description and Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 III Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Section I. GENERAL INFORMATION

Para

Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Maintenance Forms, Records and Reports. . . . . . . . . . . . . 1-2 Reporting Errors and Recommending Improvements . . . . 1-3

Para

Warranty Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Orientation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 List of Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6 Different Vehicle Configurations. . . . . . . . . . . . . . . . . . .1-6.1

a. Type of Manual. Operator’s Technical Manual, including operating and troubleshooting instructions.

NOTE

• On origi nal vehi cle, a waterproof clot h container is attached to the rear of the operator’s seat. This container has tw o compartments: one compartment contains the v ehicle log boo k and the ot her com-partment provi des st orage for th e opera-tor’s manual.

• On a replacement vehicle, the seat back is smooth w ithout a co ntainer for t he lo g book and manual.

b. Model Number and Equipment Name. MHE 237 Rough T errain 4,000 Po und Capacit y, Articul ated Fram e Steer, Pneumatic Tire, Diesel Engine Driven Forklift Truck.

c. Purpose of Equipment. Handle, tran sport, an d stack materials on various types of terrain, The forklift truck has a capacit y of 4,000 pou nds at 2 4-inch l oad cen ter an d can lift the load to a maximum height of 100-inches.

Department of t he Arm y fo rms and p rocedures u sed fo r equipment maintenance will be those prescribed by DA Pam 738-750, The Army Maintenance Management System.

You can help improve this publication. If you find any mis-takes or if you kno w o f a way t o i mprove the procedures, please l et u s know. Su bmit y our DA Form 202 8 (Recom -mended Changes to Equi pment Technical Publ ications), Through the Internet, on the Army Electronic Product Sup-port (A EPS) websit e. T he Internet address i s: ht tps:// aeps.ria.army.mil. The D A Form 2028 is locat ed under the Public Applications section in the AEPS Public Home Page.

Fill out the form and check on SUBMIT. Using this form on the AEPS w ill enab le us to respond q uicker to yo ur com-ments and better manage the DA Form 2028 program. You may also mail, fax o f E-mail your letter or DA Form 2028 direct to : T ACOM Life Cy cle Managem ent Co mmand, ATTN: AMST A-LC-LPIT / TE CH PUBS, 1 Rock I sland Arsenal, Rock Island, IL 61299-7630. The emai l address is ROCK-TACOM-TECH-PUBS@conus.arm.mil. T he fax number is DSN 793-0726 or Commercial (309) 782-0726.

CHAPTER OVERVIEW

The purpose of this chapter is to acquaint you with the maintenance forms, records, and reports that you must maintain for the fo rklift truck, to familiarize you with the purpose and capabilities of the forklift truck and to give you a brief descrip tion of the different systems and components of the forklift truck.

1-1. SCOPE 1-2. MAINTENANCE FORMS, RECORDS

AND REPORTS

1-3. REPORTING ERRORS AND RECOM-

MENDING IMPROVEMENTS

1-2 Change 3

The model MHE 237 forklift truck is warranted by J. I. Case for 15 m onths or 150 0 operatin g hou rs, whichever com es first. It starts on the date, found in block 23, DA Form 2408- 9 in the logbook. Report all defects in material or workman-ship to you r supervisor, who will take appropriate act ion through your organizational maintenance shop.

The lifting forks are mounted on the front of the vehicle and the eng ine faces th e rear. Con trols for operatin g th e l ifting forks (til ting, rotati ng, l owering, side shifting of t he l ifting forks) are l ocated to the rig ht wh en you are sitting in th e operator’s seat.

To support sustainment of the mod el MHE 237 forklift trucks, some components have been replaced with a different design. The most obvious of these replacements are the driver’s seat and the engine. The vehicle may have any com-bination of these configurations — or none. The most obvi-ous indication of which seat is in stalled i s that the original seat did not have retractable seat belts. The replacement seat does have retractable seat belts. The most obvious indication of which engine is installed is that on vehicles with the origi-nal eng ine in stalled, t he engin e exhaust pipe is on the to p RIGHT s ide of the vehicle. Vehicles that have the replace-ment engine in stalled have th e eng ine exhaust pi pe on the top LEFT side of the vehicle. The replacement engine required minor modi fication to the chassis and replacement of o ther suppo rting h ardware/components. T o replace the engine in a vehicle that has the original engine installed, you must order th e NSN for the Engine Mod ification K it. T o replace the engine in a vehi cle that has the replacement engine already installed, you must order the NSN for just the engine. Replacement components will be identified in greater detail in TM 10 -3930-638-24. For the engine, com-ponents will be identified by the engine model number. The original engine is model number G207D. The replacement engine is m odel n umber 4 -390. Various o ther com ponents that have been replaced will be identified as “original” or replacement”.

ABBREVIATION DEFINITION

B.O. Black out

C Centigrade

CCW Counterclockwise

CW Clockwise

DA Department of the Army

DED Diesel engine driven

D.C. District of Columbia

EA Each

EIR Equipment improvement recommendations

F Forward

F Fahrenheit

FWD Forward

Lg Long

MHE Material handling equipment

MI Michigan

MPH Miles per hour

MTOE Modified table of organization and equipment

N Neutral

NSN National stock number

OZ Ounce

Para Paragraph

1-4. WARRANTY INFORMATION

1-5. ORIENTATION

1-6. LIST OF ABBREVIATIONS

PMCS Preventive maintenance checks and services

PRESS Pressure

PSI Pounds per square inch

GAL Gallon

In. Inch

LB. Pound

ABBREVIATION DEFINITION

QT Quart

R Reverse

ROPS Roll Over Protective Structure

RPM Revolutions per minute

SAE Society of Automotive Engineers

SER Service

TEMP Temperature

TRANS Transmission

1-6.1. DIFFERENT VEHICLE

CONFIGURATIONS

Change 3 1-3

Section II. EQUIPMENT DESCRIPTION AND DATA

Para

Equipment Purpose, Capabilities, and Features. . . . . . . . . 1-7 Location and Description of Major Components . . . . . . . 1-8 Equipment Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9

a. Purpose of Forklift Truck. Handle, transport, and stack materials while operating over various types of ter-rain.

b. Capabilities and Features.

(1) 4,000 pounds load capacity.

(2) Operates over rough terrain.

(3) Three speed ranges in both forward and reverse.

(4) Declutch pedal to neutralize transmission.

(5) Axle disconnect.

(6) Diesel engine.

(7) Power steering.

(8) Power assisted brakes.

(9) Articulated frame s teering for operation within a 20 foot long by 8 foot wide by 8 foot high container.

(10) Forks can b e rotat ed and/or shifted l eft o r right.

(11) Mast can be tilted rearward or forward.

ENGINE. Four cylinder diesel.

FUEL SYSTEM. Consists of an electric or mechanical fuel pump, air cleane r, fuel tank, fuel filters, quick start kit , fuel injection pump, and fuel injectors.

EXHAUST SYSTEM. Consists of muffler and exhaust pipe;

muffler mounted on top of engine and is of the spark arrest-ing type.

COOLING SYSTEM. Includes rad iator mounted in rear of truck, thermostat and housi ng, engine dri ven water pum p, and fan.

ELECTRICAL SYSTEM. 24 Volt, n egative g round.

Includes engine d riven al ternator, starter motor, i nstrument panel, light system, and two 12 Volt batteries connected in series.

TRANSMISSION AND DRIVE SHAFTS. Three speeds in both forward and reverse, has declutch feature which permits neutralizing transm ission, eq uipped with axl e di sconnect.

Three drive shafts used to tr ansmit power to front and rear axles.

AXLES AND WHEELS. Single reduction type axles; pneu-matic tires.

BRAKES. Hydraulic operated service brak es and pow er assisted on all wheels; lever operated parking broke lo cated on transmission output shaft.

STEERING SYSTEM. Consists of steering wheel, steering gear, two steering cylinders, and hydraulic pump driven by transmission.

1-7. EQUIPMENT PURPOSE,

CAPABILITIES, AND FEATURES

1-8. LOCATION AND DESCRIPTION OF

MAJOR COMPONENTS

1-4 Change 3

HYDRAULIC LIFT SYSTEM. Includes control valve, mast column, hydraulic reservoir, and cylinders (tilt, rotation, side shift, and lift).

BODY AND T OWING A TTACHMENTS. T wo sectio n body consisting of front and rear chassis; towing attachments include pi ntle hook, to w bar an d tw o chain s al l locat ed at rear of truck.

The fol lowing dat a covers of the M4K on a case-by-case basis. Data unique to the replacement vehicle is in parenthe-ses.

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .J. I. Case

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .M4K

Dimensions and Weight

Length (overall, mast vertical) . . . . . . . . . . . . . 205 inches

Length (overall, forks removed) . . . . . . . . . . . . 165 inches

Height (overall, mast raised) . . . . . . . . . . . . . . 129.5 inches

Height (overall, mast lowered, no ROPS). . . . . . 78 inches

Maximum height for shipping. . . . . . . . . . . . . . . 80 inches

Height to top of exhaust . . . . . . . . . . . . . . . . . . . 71 inches

Height to top of ROPS . . . . . . . . . . . . . . . . . . . . 80 inches

Height to top of steering wheel . . . . . . . . . . . . . . 62 inches

Ground clearance at mast (loaded) . . . . . . . . . . . 10 inches

Ground clearance at center . . . . . . . . . . . . . . . .13.5 inches

Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 inches

Tire Tread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 inches

Width over tires . . . . . . . . . . . . . . . . . . . . . . . . . . 79 inches

Angle of approach (forks raised and mast tilted back) . . . . . . . . . . . . . . . . . . . . . . . 26 degrees

Angle of Departure . . . . . . . . . . . . . . . . . . . . . . 34 degrees

Pintle hook height (center) . . . . . . . . . . . . . . . .31.8 inches

Rear axle oscillation - total . . . . . . . . . . . . . . . . 25 degrees

Turning Radius (outside of tires) . . . . . . . 26 feet, 8 inches

Turning angle from center (left and right) . . . . 43 degrees Rear load retaining surface

(including load backrest) . . . . . . . . . . . .17.0 inches high x 36 inches wide

Weight No load weight, less operator, with full tank . . . . . . . . . . . . . . . . 9,725 (10,180) pounds Front axle load. . . . . . . . . . . . . . . 4,685 (4,985) pounds Rear axle load . . . . . . . . . . . . . . . 5,040 (5,195) pounds

Weight with 4000 pound load . . . . 13,725 (14,180) pounds Front axle load. . . . . . . . . . . . . 10,810 (11,010) pounds Rear axle load . . . . . . . . . . . . . . . 2,915 (3,170) pounds

Performance Speeds (MPH)

1st . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 2nd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2 3rd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20.2

Lift capacity rated (at 24 inch center) . . . . . . 4,000 pounds Maximum lift height (to bottom of forks; empty) . . . . . . . . . . . . . . . . . . . . . . . . . 100 inches Drop below ground (bottom of forks) . . . . . . . . . . 4 inches Minimum lateral fork adjustment (on centers) . . . 8 inches Maximum lateral fork adjustment . . . . . . . . . . . . 30 inches Rate of lift at rated load. . . . . . . . . . . . . . . . . . . . . 62 FPM Rate of lift empty. . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 FP Rate of drop at rated load . . . . . . . . . . . . . . . . . . . 80 FPM Rate of drop empty . . . . . . . . . . . . . . . . . . . . . . . . 68 FPM Reach from center line of drive wheels. . . . . . 31.75 inches Degrees tilt (mast centered)

Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 degrees Rearward . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 degrees

Mast sideshift (right or left from center) . . . . . . . 22 inches Rotation angle . . . . . . . . . . . . . . . . . . . . . . 22 degrees total

Capacities Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 gallons Cooling system . . . . . . . . . . . . . . . . . . . . . . . . 4 (5) gallons Hydraulic system. . . . . . . . . . . . . . . . . . . . . . . . . 65 quarts Transmission, torque converter . . . . . . . . . . . . . . 22 quarts Engine crankcase. . . . . . . . . . . . . . . . . . . . . . .7 (10) quarts Axles (each). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 quarts

1-8. LOCATION AND DESCRIPTION OF

MAJOR COMPONENTS (cont)

1-9. EQUIPMENT DATA

Change 3 1-5

Section III. PRINCIPLES OF OPERATION

Para

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10 Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11 Transmission Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14

Brake System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13 Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-15 Body, Towing Attachments, and Towing Controls . . . . . 1-12 Mast Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-16

FUEL GAGE. Electrically operated meter type; calibrated in six gallon increments. With ignition switch key turned to ON position, fu el gage ind icates quant ity of fuel remaining in fuel tank.

ACCELERATOR PE DAL. Depr essing pedal with foot increases fuel flow and engine speed; releasing pedal decreases fuel flow and engine speed. Pedal is spring loaded to return to low speed position when released.

FUEL T ANK. Holds approximately 27 gall ons of diesel fuel; constructed as part of rear chassis. Fuel filler neck and removable cap located at right rear of vehicle. A drain plug is located at the bottom of the tank.

ELECTRIC F UEL PUMP ( original vehicle). Pumps diesel fuel from tank to engine. With ignition switch key turned to

ON position, electric fuel pump will emit a slight buzz sound indicating proper operation.

MECHANICAL FUEL PUMP (replacement vehicle).

Pumps diesel fuel from fuel tank to fuel injection pump on engine. Has a bu ilt-in manually operated fuel p rimer pump to prime the fuel system when needed.

SHUT-OFF VALVE (original vehicle). Located in right side of engine compartment above fuel filler neck. W ith valve handle i n v ertical p osition, b locks passage of di esel fuel from fuel tank to electric fuel pump. Valve handle must be in horizontal position to start and operate engine.

AIR CLEANER. Removes dust and dirt from air before air is app lied t o eng ine. Metal sh ell houses replace able paper-type filter element.

1-10. FUEL SYSTEM

444-0001

1-6

QUICK START CO NTROL. Used to start engine in cold weather. When lever is pressed against valve, injects volatile starting fuel from steel cyli nder t o engine. Removable cli p attaches to lever to prevent accidental discharge.

AIR CLEA NER INDICATOR. Indi cates res triction of air flow throu gh air cleaner due to dirty or clogged filter ele-ment. Filter element service is required when red signal within indicator is in full view. After servicing filter element, indicator is reset by depressing button on top of indicator.

a. Vehicle Lights.

VEHICLE LI GHTS SWIT CH. Contains three separate switch s ections us ed t o co ntrol all vehicle lights. A lso has internal resistance to provide selection of dim illumination of gage lights. Ignition switch must be turned to extreme left or ON position for VEHICLE LIGHTS switch to operate.

FRONT FLOO D AN D REAR FLO OD SWITCH ES. Used to independently turn front and rear fl ood lights on and off.

VEHICLE LIGHTS main swit ch section mu st be in SER.

DRIVE position for these switches to operate.

BLACK OUT DRIVING LIGHTS. Mo unted at left side of roll over protective structure. Prov ides forward bl ack ou t illumination during tactical operations. Controlled by VEHI- CLE LIGHTS switch.

GAGE LIGHTS. Internal lights illuminate meter face and pointer of FUEL and OIL PRESS gages. Bright, dim and off settings controlled by VEHICLE LIGHTS switch.

FRONT FLOOD LIG HTS. Fou r sealed-beam type lamps mounted on rol l over protective structure and steel channel extension of in strument panel. Il luminate area in front of vehicle for driving forward and material handling. Turned on and off with FRONT FLOOD switch.

REAR FLOOD LIGHTS. T wo sealed-beam type lamps mounted on bottom of steel plates behind radiator grille. Illu-minate area behind vehicle for backi ng up, connecting tow bar, or co nnecting to wed l oad. T urned on an d of f wi th REAR FLOOD switch.

SERVICE ST OP AN D T AIL LIGHTS. Two light a ssem-blies mou nted on to p of st eel plat es behind rad iator grill e.

Assembly incl udes incandescent lamp and red plasti c lens.

Tail lights turned on and of f wit h VEHIC LE LIGH TS switch. Stop lights are normally off; turned on by depressing service brake pedal.

BLACK OUT ST OP AN D T AIL LIGHTS. Two light assemblies mounted in protective metal housings at rear of vehicle. Each assembly cont ains two in candescent lamps.

Provides stop light and tail light illumination during tactical operations. Tail li ghts tu rned on and of f wit h VEHIC LE LIGHTS switch. Stop lights are normally off; turned on by depressing service brake pedal.

1-10. FUEL SYSTEM (cont)

1-11. ELECTRICAL SYSTEM

b. Horn and Back-Up Alarm.

HORN. Electrically operated by depressing horn button BACK-UP ALARM. Electrically operated alarm module located on steering wheel. Located next to front flood located at rear of vehicle behind radiator grille. Sounds light, on right side extension of instrument panel. distinctive warning whenever transmission direction selector is in reverse (R) position. Ignition switch must be HORN BUTTON. Spring loaded button located at center turned to ON position before back-up alarm will sound.

of steering wheel. Horn sounds when button is depressed, and turns off when button is released. Horn and horn button operate at any position of the ignition switch, including OFF.

c. Switches and Warning Indicators.

IGNITION SWITCH. Four position key switch controls WARNING INDICATORS. Five light assemblies; each power to all vehicle electrical circuits except horn. contains incandescent lamp and red lens. With engine running, warning indicator illuminates to indicate START SWITCH. Spring loaded pushbutton switch. malfunction (see chapter 2).

When depressed, starter motor cranks to start engine.

Ignition switch must be in ON position before START switch will crank starter motor.

1-7

1.12.

SPEED SELECTOR. Selects one of three drive speed DECLUTCH PEDAL. Depressing pedal with foot applies ranges for forward or reverse travel. Rearmost position service brake and shifts transmission to neutral range provides greatest pulling power and lowest top speed; full (regardless of position of direction selector). Releasing forward position provides highest top speed. spring loaded pedal releases service brake and returns transmission to range (F, N, or R) selected by direction DIRECTION SELECTOR. Three position lever control selector control.

selects forward, neutral or reverse direction of travel.

Reverse position also sounds back-up alarm module.

1-13. BRAKE SYSTEM

SERVICE BRAKE PEDAL. Depressing pedal applies PARKING BRAKE LEVER. Located at right side of shoe and drum hydraulic brakes located at each wheel. operator’s seat. Pulling lever up applies drum-type Also illuminates service or blackout stop lights, as parking brake located at output shaft of transmission, determined by position of VEHICLE LIGHTS switch. which prevents axles and wheels from rotating. Pushing Releasing spring loaded pedal releases service brakes. lever down releases parking brake.

Brake system is power assisted for reduced brake pedal effort when engine is running.

1-8 Change 1

1-14. STEERING SYSTEM

PIVOT PINS. Heavy duty steel pins mounted in bushings, and located at top and bottom chassis connection points. Secure front chassis to rear chassis and allow front chassis to pivot and steer vehicle.

STEERING CYLINDERS. Two hydraulic cylinders, one mounted on each side of vehicle. Cylinder housings attached to front chassis, and cylinder rods attached to rear chassis. Cylinder rods extend or retract as steering wheel is turned, forcing front chassis to pivot about pivot pins and turn vehicle.

1-15. BODY, TOWING ATTACHMENTS,

AND TOWING CONTROLS

STEERING WHEEL. Connected to steering column and steering gear, which controls flow of hydraulic oil to and from steering cylinders. Power assist provided by hydraulic pump mounted on transmission for reduced steering wheel turning effort when engine is running.

SHIPPING LOCK PIN. Heavy duty steel pin, normally stored under operator’s seat. Installs in mating holes in front and rear chassis to prevent articulation when shipping or jacking vehicles. Shipping lock pin must be removed to allow normal steering. Do not install the shipping lock pin when towing the vehicle.

1-9

1-16.

1-15. BODY, TOWING ATTACHMENTS,

AND TOWING CONTROLS (cont)

ROLL OVER PROTECTIVE STRUCTURE. Constructed of heavy duty steel; bolted to front chassis. Protects operator from injury due to falling material and truck rolling over.

SIDE PANELS. Constructed of sheet metal; secured to rear chassis with latches. Provide access to engine compartment.

RADIATOR GRILLE. Welded steel construction;

protects engine radiator, transmission oil cooler, and vehicle lights from damage. Swings open for access to batteries and radiator overflow bottle.

WARNING

The tow bar is provided to tow the forklift ONLY.

TOW BAR. Constructed of heavy duty steel; normally stowed in vertical position with retaining pin. Pivots to horizontal position to connect forklift truck to towing vehicle.

PINTLE HOOK. Manually operated latch type rigid pintle. Opened by removing cotter pin, pulling latch handle rearward, and lifting top jaw. Accepts standard 3 inch by 1-5/8 inch lunette for connecting towed load to forklift truck.

CHAINS. Steel link construction with attachment hooks;

provide additional connection (safety) between forklift truck and towed load or towing vehicle.

STEERING BYPASS VALVE. Mounted on left side of operator’s seat; turning valve handle counterclockwise disables steering system and allows front chassis to pivot freely about rear chassis and steering cylinders. Valve must be open when towing forklift truck, and must be closed (turned fully clockwise) for normal steering and truck operation.

AXLE DISCONNECT LEVER. Used to disengage axles from transmission when towing forklift truck to new location. Pulling lever outward allows transmission output shaft to freewheel, and prevent transmission damage or wear while towing. Lever must be pushed inward for normal truck operation.

MAST. Raises and lowers carriage. Hydraulic lift cylinder, controlled by LIFT control lever, raises and lowers two lift chains attached to carriage. Two hydraulic tilt cylinders, activated by TILT control lever, tilt mast forward or rearward.

FORKS. Constructed of heavy duty steel; mounted on carriage. Locking notches on carriage and locking lugs on forks permit adjustment of width between forks.

CARRIAGE. Rotates and side shifts forks. Hydraulic rotation cylinder controlled by ROTATE control lever;

hydraulic side shift cylinder controlled by SHIFT control lever.

ROTATE CONTROL LEVER. Hold in forward position to rotate forks counterclockwise; hold in rearmost position to rotate forks clockwise.

LIFT CONTROL LEVER. Hold in forward position to lower carriage and forks; hold in rearmost position to raise carriage and forks.

SHIFT CONTROL LEVER. Hold in forward position to shift forks to left; hold in rearmost position to side shift forks to right.

TILT CONTROL LEVER. Hold in forward position to tilt mast and forks forward; hold in rearmost position to tilt mast and forks rearward.

1-10 Change 1

I I

Section I

III

IV

CHAPTER 2

OPERATING INSTRUCTIONS

CHAPTER OVERVIEW

The purpose of this chapter is to familiarize you with the equipment so that you can operate it safely, efficiently and effectively.

Index

Title Description and Use of Operator’s Controls and Indicators

Page . . . . . . . . . . . . . . 2-1

Preventive Maintenance Checks and Services (PMCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Operation Under Usual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Operation Under Unusual Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ... 2-21

Section I. DESCRIPTION AND USE

OPERATOR’S CONTROLS AND INDICATORS

Para Para Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Externally Mounted Controls Brake and Throttle Controls . . . . . . . . . . . . . . . . . . 2-2 and Indicators 2-4 Operator’s Compartment . . . . . . . . . . . . . . . . . . . . . 2-3

Other Operator’s Controls and Indicators . . . . . . . 2-5

2-1. INSTRUMENT PANEL

a. Gages.

2-1

2-2

2-1.

2-1. INSTRUMENT PANEL (cont)

c. VEHICLE LIGHTS Switch.

2-3

d. Flood Lights and Engine Switches.

2-4

Change 3 2-5

e. Transmission Control Levers.

f. Fork Lift Control Levers.

2-6 Change 3

2-2. BRAKE AND THROTTLE CONTROLS

2-3. OPERATOR’S COMPARTMENT

444-0002

Change 3 2-7

2-3. OPERATOR’S COMPARTMENT (cont)

444-0003

2-4. EXTERNALLY MOUNTED CONTROLS

AND INDICATORS

2-8 Change 3

2-5. OTHER OPERATOR’S CONTROLS

AND INDICATORS

444-0004

444-0005

Section Il. PREVENTIVE MAINTENANCE

2-6. MAINTENANCE FORMS AND

RECORDS

Every mission begins and ends with the paperwork. There isn’t much of it, but you have to keep it up. The forms and records you fill out have several uses. They are a permanent record of the services, repairs and modifications made on your vehicle. They are reports to organizational maintenance and to your Commander. And they are a checklist for you when you want to know what is wrong with the vehicle after its last use, and whether those faults have been fixed. For the information you need on forms and records, see DA Pam 738-750.

2-7. PREVENTIVE MAINTENANCE

CHECKS AND SERVICES

a. Do your before(B) PREVENTIVE MAINTENANCE just before you operate the vehicle. Pay attention to the CAUTIONS and WARNINGS.

b. DURING checks and services(D) of PREVENTIVE MAINTENANCE will be performed while the equipment and/or its component systems are in operation.

c. Do your after (A) PREVENTIVE MAINTENANCE right after operating the vehicle. Pay attention to the CAUTIONS and WARNINGS.

d. Do your weekly (W) PREVENTIVE MAINTENANCE weekly.

e. Do your monthly (M) PREVENTIVE MAINTENANCE once a month.

f. If something doesn’t work. troubleshoot it with the instructions in this manual or notify your supervisor.

g. Always do your PREVENTIVE MAINTENANCE in the same order so it gets to be a habit. Once you’ve had some practice, you’ll spot anything wrong in a hurry.

h. If anything looks wrong and you can’t fix it, write it on your DA Form 2404. If you find something seriously wrong. report it to organizational maintenance

RIGHT NOW.

i. When you do your PREVENTIVE MAINTENANCE, take along the tools you need to make all the checks. You always need a rag or two.

WARNING

Dry cleaning solvent, used to clean parts is potentially dangerous to personnel and property.

Do not use near open flame or excessive heat.

Flash point of solvent is 138 degrees F.

(1) Keep it clean: Dirt, grease, oil and debris only get in the way and may cover up a serious problem.

TM 10-3930-638-10

CHECKS AND SERVICES (PMCS)

Clean as you work and as needed. Use dry cleaning solvent (P-D-680) on all metal surfaces. Use soap and water when you clean rubber or plastic material.

(2) Bolts, nuts and screws: Check them all for obvious looseness, missing, bent or broken condition.

You can’t try them all with a tool, of course, but look for chipped paint, bare metal or rust around bolt heads. If you find one you think is loose, tighten it, or report it to organizational maintenance if you can’t tighten it.

(3) Welds: Look for loose or chipped paint, rust or gaps where parts are welded together. If you find a bad weld, report it to organizational maintenance.

(4) Electric wires and connectors: Look for cracked or broken insulation, bare wires and loose or broken connectors. Tighten loose connectors and make sure the wires are in good shape.

(5) Hoses and fluid lines: Look for wear, damage and leaks, and make sure clamps and fittings are tight.

Wet spots show leaks, of course, but a stain around a fitting or connector can mean a leak. If a leak comes from a loose fitting or connector, tighten it. If some-thing is broken or worn out, report it to organizational maintenance.

j. It is necessary for you to know how fluid leakage affects the status of your vehicle. The following are definitions of the types/classes of leakage you need to know to be able to determine the status of your vehicle.

Learn, then be familiar with them and REMEMBER-

WHEN IN DOUBT, NOTIFY YOUR SUPERVISOR!

Leakage Definitions for Crew/Operator PMCS

Class I Seepage of fluid (as indicated by wetness or discoloration) not great enough to form drops.

Class II Leakage of fluid great enough to form drops but not enough to cause drops to drip from item being checked/inspected.

Class III Leakage of fluid great enough to form drops that fall from the item being checked, inspected.

CAUTION

EQUIPMENT OPERATION IS ALLOWABLE

WITH MINOR LEAKAGES (CLASS I OR II).

OF COURSE, CONSIDERATION MUST BE

GIVEN TO THE FLUID CAPACITY IN THE

lTEM/SYSTEM BEING CHECKED/

INSPECTED. WHEN IN DOUBT, NOTIFY

YOUR SUPERVISOR.

CLASS Ill LEAKS SHOULD BE CORRECTED

IMMEDIATELY OR REPORTED TO YOUR

SUPERVISOR OR ORGANIZATIONAL

MAINTENANCE.

Change 1 2-9

Table 2-1. Operator PMCS

B — Before D — During A — After W — Weekly M — Monthly

Interval ITEM TO BE INSPECTED Item Procedure: Check For And Have Repaired, Filled Or Equipment is Not Ready/ No. B D A W M Adjusted As Needed Available If:

IMPORTANT: PERFORM WEEKLY AS WELL AS

BEFORE OPERATIONS PMCS IF:

1. YOU ARE THE ASSIGNED OPERATOR AND

HAVE NOT OPERATED THE VEHICLE SINCE THE

LAST WEEKLY.

2. YOU ARE OPERATING THE VEHICLE FOR THE

FIRST TIME.

NOTE

Have the following three operations performed by Organiza-tional and Direct Support Maintenance at 20 hours to comply with warranty also if engine is rebuilt or cylinder head is removed.

1. Replace engine oil and filter.

2. Torque cylinder head bolts.

3. Adjust valve tappet clearance.

EXTERIOR OF VEHICLE

1 ● a. Check for leaks or appearance of leaks. Class III leaks.

● b. Visually check Roll Over Protective Structure (ROPS) ROPS is bent, cracked or and Falling Object Protection Structure (Fops) for obvious damaged or missing damage. hardware.

● c. Visually check forks, carriage, side shifter frame for Forks, carriage, side shifter cracked, bent, or broken frame members. frame are cracked bent, or broken.

● d. Check lift and side shift chains for 1/2 inch deflection Broken or missing chains.

by depressing chain in center.

● e. Visually check wiring harness and connections for frayed or broken wires.

● f. Check towbar for any bends, cracks or cracked Towbar is bent, cracked, welds. or damaged in any way.

STEERING BYPASS VALVE

2 Check that s teering bypass valve is closed (fully-clockwise) and that shipping lockpin is removed.

ENGINE OIL LEVEL

3 Check level on dipstick and add oil as required to bring level up to full mark.

2-10

Change 3 2-10.1/(2-10.2 blank)

Table 2-1. Operator PMCS (cont) B — Before D — During A — After W — Weekly M — Monthly

Item No.

Interval ITEM TO BE INSPECTED Procedure: Check For And Have Repaired, Filled Or Adjusted

As Needed Equipment is Not Ready/

Available if:B D A W M

PRIMARY FUEL FILTERS

4 • a. Drain water from primary fuel filters.

• b. In fre ezing we ather, dra in w ater fro m fil ters aft er operating.

RADIATOR COOLANT RESERVOIR

5 • Check to ensure co olant is at c old mark lev el, ad d a s required

TIRES AND WHEELS

6 • Check tires fo r wear, nails and foreign objects, missing or loose lug nuts (240-260 lb. ft. torque), and correct pressure (45 psi).

Tire wi th less th an 1/4 inch tread or abrasions which would resul t in ti re fai lure during operation.

HYDRAULIC RESERVOIR

7 • With mast lowered, check reservoir oi l level. If n ecessary, add oil to bring up level to full mark on dipstick.

FIRE EXTINGUISHER

8 • Check availability of extingu isher (if au thorized locall y) and proper pressure (indicator in green).

SEAT BELT

9 • Check that belt is securely mounted, material is not frayed, and latch is operable.

Belt no t securel y mo unted, material is frayed, and latch is inoperable

444-0006

2-11

Table 2-1. Operator PMCS (cont) B — Before D — During A — After W — Weekly M — Monthly

Item No.

Interval ITEM TO BE INSPECTED Procedure: Check For And Have Repaired, Filled Or Adjusted

As Needed Equipment is Not Ready/

Available if:B D A W M

LIGHTS AND HORN

10 • Check that head, tail, flood, blackout lights and horn are working.

INDICATOR LIG HTS, OIL PR ESSURE GAUGE, AND

HOURMETER

11 • Check that alternator and oil pressure warning lamps are not lit. Check oil pressure gauge for normal reading of 50-70 psi, and hourmeter is working.

Alternator lam p or oil pressure lamp are lit. Oil pressure gaug e not wit hin normal range.

LAMP TEST

12 • With engine running, check that hydraulic filter by-pass, transmission te mperature, a nd en gine t emperature indicator lights function in test phase.

Engine or transmi ssion lamp does not fun ction or en gine temperature or transmission temperature indicator lamp comes on during operation.

NOTE

If HYDRAULIC FILTER light comes on during operation, finish shift and have filter replaced before further operation.

LIFT FORK CONTROLS

13 • Check that li ft, til t, side shift, and rot ation movement is smooth and immediate.

Any functi on fails to o perate or is erratic.

STEERING

14 • Check that truck steers freely and easily. Steering st icks, b inds, or i s hard to steer.

PARKING BRAKE

15 • Check that brake holds ve hicle. Turn kn ob clock wise to tighten.

ACCELERATOR

16 • Check that accelerator operates smoothly. Pedal sticks.

TRANSMISSION CONTROLS

17 • Check that transmiss ion shif t levers operate smoothly and correct gear and range are engaged.

Transmission d oes not operate.

BACK-UP ALARM

18 • Check that alarm sounds in reverse.

BRAKES

19 • Check that normal brake pressure stops truck. Service b rake w ill not stop truck.

2-12 Change 3

TRANSMISSION FLUID

20 • At operatin g temp erature, engin e idling check level on dipstick and add fluid as required to bring up level to full mark on dipstick.

AIR CLEANER

WARNING

• If NBC exposure is suspected, p ersonnel wearing protective equipment should handle all air cleaner media. Consult your NBC Officer or NBC NCO for appropriate handling or disposal procedures.

• NBC cont aminated fil ters must be handl ed using ade quate prec autions a nd must be disposed of by trained personnel

21 • Check contamination indicator . Have serv iced i f i ndicator shows red.

FAN AND DRIVE BELT

22 • a. Check belt for frayed or damaged condition.

• b. Check fan for bent or damaged blades.

BATTERIES

23 • Inspect for el ectrolyte lev el. Ad d d istilled water, if available, or clean water. In freezing w eather, run engine 15 minutes after addi ng water (reference TM 9-6140-200-14).

Check that cables are clean

Battery cracked or missing.

Table 2-1. Operator PMCS (cont) B — Before D — During A — After W — Weekly M — Monthly

Item No.

Interval ITEM TO BE INSPECTED Procedure: Check For And Have Repaired, Filled Or Adjusted

As Needed Equipment is Not Ready/

Available if:B D A W M

Change 3 2-13

Section III. OPERATION UNDER USUAL CONDITIONS Para

Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8 Operating Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Preparation for Movement . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Operating Instructions on Decals and Instructions Plates . . . . . . . . . . . . . . . . . . . . . . . 2-11

Refer to current Lubrication Order and lubricate forklift truck. Refer to paragraph 2-7 and perfo rm before operation

PMCS.

a. Starting the Engine.

WARNING

Noise le vel excee ds 85 dB(A) a t th ree feet in front, 15 feet at side and 24 feet at rear of vehicle. All personnel shall wear a hearing protection device when operat-ing the vehicle.

WARNING

Before starting engine, check and be sure that STEERING BYPASS valve is closed (full clockwise) and that shipping lock pin has be en rem oved. Fai lure to do so will cause loss of steering control which may result in serious in jury or death and dam-age to equipment.

(1) Remove shipping lock pin by slipping ring of klik pin down fro m b ody o f ship ping lock pi n t hen remo ving k lik pin . Remove shipping lock pin from chassis, in stall klik pin and store shipping lock pin under oper-ator’s seat.

CAUTION

When m ounting truck from curbside, avoid stepping on rod of steering cylinder.

A scratched cylinder rod wil l dam age hydraulic seal and cause leak.

(2) Mount truck and sit in operator’s seat.

(3) If necessary, adjust seat.

(4) Fasten seat belt.

2-8. INITIAL CHECKS

2-9. OPERATING PROCEDURES

444-0151

444-0007

444-0008

2-13.0/(2-13.1 blank) Change 3

a. Starting the Engine (cont).

(5) Pull parking brake lever towards you to set parking brake.

(6) Place trans mission DIRECTION SELEC- TOR in neutral (N) position.

(7) Insert key into ignition switch; turn key to first position clockwise (ON position).

444-0150

2-14

a. Starting the Engine (cont).

WARNING

Be s ure your seat belt is fastened before starting engine.

(8) Depress accelerator pedal 1/3 to 1/2 from normal position.

CAUTION

Do not operate starter motor for more than 30 seconds. W ait at leas t three minutes before cranking to allow batteries to recu-perate and starter motor to cool.

(9) Depress START pushbutton switch.

WARNING

Starting fluid is toxic and highly flamma-ble, Container is pressurized to act as an expellent. Do not heat container and do not discharge st arting flui d in confin ed areas or near open flame. Do not discard used container in an open flame.

(10) If tem perature i s bel ow 40 °F, use qu ick start aid. Remove clip, then engage starter while p ressing qu ick start lever and ho ld lever for one or two seconds.

CAUTION

If there is no oil pressure indi cation on OIL PRESS gage within ten to 15 seconds and if oil pressure lamp is li t, turn eng ine off and check cause.

(11) When engine starts, release START push-button switch immediately. Reinstall clip in quick start aid.

(12) Ten to 15 seconds after engine starts, check OIL PRESS gage for proper in dication. If proper indi cation is not ob tained on gag e, turn engine off and check cause if oil pres-sure lamp is lit.

a. Starting the Engine (cont).

(13) Check control panel indicators for proper indication:

(a)

(b)

If oil pressure indicator is lit and if OIL PRESS gage indication is abnormal, turn engine off if OIL PRESS gage indication is normal, continue operation and report indi-cator abnormal indication to organizational maintenance.

If alternator indicator is lit, turn engine off and…