Yard Machines Y60 Operations Instructions Page 1

TM 10-3930-647-14&PTECHNICAL MANUALOPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORT ANDGENERAL SUPPORTMAINTENANCE MANUAL(INCLUDING REPAIRPARTS INFORMATI

By Order of the Secretary of the Army:Distribution:To be distributed in accordance with DA Form 12-25F (BlockNos, 2152, 2153, 2154), Operator, Unit, a

4-44

3.Now...check the torque of the steeringgear mounting bolts (refer to ‘Plate 9856):Steer gear to frame bolts (A); 40-50 Ibs./ft.Outboard bearing bolts

NOTEIn some cases the pitman arm may barely contactthe stops when the hand wheel is fully turnedright or left.In such cases it i s not necessaryto rep

16.Now check for free play caused by looseor misadjusted linkage. TO do this...first,torque the cylinder valve control ball stud nut(L) to 90 to 110 p

4-48

#9852.Typical Drive Wheel LugNuts Torque26.Now...torque all drive wheel lug nutsto the correct torque:STD & TTU, 290-390 lbs.ft.and wide drive, 19

Figure 4-73. Hydraulic System Pressure CheckFigure 4-72. Fuses and Underdash Wiring4-63. ELECTRICAL WIRING, SWITCHES,AND FUSES.a. The wiring system on

FIGURE 4-75.TRANSMISSION LINKAGE ADJUSTMENT4-50A/(4-50B blank)

b.Applying parking brake. Startengine and operate at governed RPM.Hold tilt lever back while graduallyclosing the load valve until pres-sure reaches 1

TM 10-3930-647-14&PTECHNICAL MANUALHEADQUARTERSNO. 10-3930-647-14&P DEPARTMENT OF THE ARMYWashington, D.C., 30 October 1981OPERATOR’S, ORGANIZ

1 -SPEED AND 2-SPEED HYDRATORK TRANSMISSION CHECKSTRANSMISSION STALL AND PRESSURE CHECKSMinimum Tools Required1 - Pressure Gauge, 0 - 250 PSI1 - Tacho

5.With a tachomter, check engine forgoverned speed at full throttle. The unloadedengine RPM should be set at 2350.6. Check governed engine speed with

9.Low engine stall RPM is 850 to 1050. . . . . . . . .converter malfunction is indicated.IO.High engine stall RPM is anythingabove 1600... either sl

Plate 9863.Forward and Reverse Pressure Check...Oil Temperature should be 200 degrees F. prior tomaking the above checks.4-52C

Plate 9864Converter Pressure Check...Oil Temperature should be 2OO degrees F. prior tomaking the above checks.4-52 D

Plate 9865.Oil Flow To Control Cover...Oil Temperature should be 200 degrees F. prior tomaking the above checks.4-52 E

Plate 9866. High and Low Pressure Check...Oil Temperature should be 200 degrees F. prim tomaking the above checks.4-52F

TROUBLE SHOWING GUIDETRANSMISSIONFLUID AERATION CHECKA fluid level that is too high will causethe fluid to become aerated. Aerated fluid willcause low

CUSTOMER SERVICES ENGINEERING DEPARTMENT, BATTLE CREEKTO ADJUST - USE ,010" SHIM GAUGE AND MINIMUM THICKNESS OFSHIMS UNDER THE SWITCH TO CLOSE WH

RIM AND WHEEL MAINTENANCE:NOTE“In order to maintain and insuremaximum service, a continuous main-tenance program is advisable...maintenance procedures

SectionPageI INTRODUCTION ANDDESCRIPTION. . . . . . . . . 1-11-32.Air Cleaner . . . . . 1-91-39.Alternator. . . . . .1-191-48.Body and Seat . . . .1-2

TIRE MAINTENANCE (CONTINUED) :wedging into it. Tires with cuts treated inthis manner may be continued in service withoutdanger of further growth of th

LUBRICATION AND PREVENTIVE MAINTENANCEPlate 9702. Typical Tire Inflation ProcedureTorque wheel stud nuts or wheel bolts to thevalues listed in specif

LUBRICATION AND PREVENTIVE MAINTENANCEPlate 7613.Typical Split Wheelseated prior to inflation.An inflated tirecontains potentially explosive energy th

LUBRICATION AND PREVENTIVE MAINTENANCEDIRECTIONAL TREAD TIRESAil directional tread tires are to bemounted in the correct position withrespect to the a

SAFETY TIPS1.NEVER WELD ON A RIM. REPLACE ANY PARTTHAT IS DISTORTED, CRACKED OR DAMAGED.2.ALWAYS EXHAUST ALL AIR FROM A SINGLE TIREAND FROM BOTH TIRES

- continued -10.NEVER RUN A VEHICLE ON ONE TIRE OF A DUALASSEMBLY. THE CARRYING CAPACITY OF THE SINGLETIRE AND RIM IS DANAGEROUSLY EXCEEDED, ANDOPERAT

4-72.WHEELS AND WHEEL BEARINGS.4-73.CLEAN, REPACK AND ADJUST STEERINGWHEEL BEARINGS. (See Figure 4-75.)a.Every 1000 operating hours or every sixmonths

Figure 476. Bearing Detailsb. Raise the rear of the machine far enough toclear the floor and place heavy blocking underthe machine frame, not under th

Figure 477. Wheel Removedsoap thickner containing anti-wear, anti-rust andanti-oxidants with EP additives. To meet or exceedClark Specifications MS-10

T A B L E 0 F C 0 N T E N T S (continued)SectionIV 4-32.4-33.4-25.4-19.4-21.4-18.4-17.4-20.4-16.4-13.4-12.4-47.4-46.4-45.4-44.4-48.4-49.4-75.4-31.4-

1. Axle end assembly, R.H., or L.H.2. Hub cap bolt and lockwasher3. Hub cap4. Spindle support5. Spindle support seal7. Axle shaft, bearing and sleeve1

Figure 4-80. Repack Axle End Bearingsd. Remove bearings and clean in a Stoddard typecleaning solvent. Slosh bearings up and down insolvent. Remove and

Figure 4-82. Lift Chain Adjustmentb. Elevate carriage to about 4 feet.c. Smear grease on the inner-slide channel asshown in figure 4-81.d. Pick up a c

Figure 4-84. Supporting Carriage4-83. UPRIGHT ROLLER ADJUSTMENT. Ifupright is binding or sticking during operation, anadjustment of the upright rolle

Figure 4-86. Upper and Lower Upright Rollers ExposedFigure 487. Inside Spanning Tool4-60

Figure 4-88. Outside Spanning Tool(see figure 4-85). Some clearance must he evidentbut not to exceed 1/32 inch. Record actualclearances measured and d

Figure 4-89. Checking Roller Angleare in place, raise inner rail enough to install thestop block behind the inner rail.4-84. CARRIAGE ROLLER ADJUSTMEN

Figure 4-91. Roller Centering MeasurementFigure 4-92. Checking Rollers for Squarenesssquare in place with hand and ankle as shown.b. Hold square tight

TABLE 4. TROUBLESHOOTING GUIDETROUBLEPROBABLE CAUSEREMEDY1. ENGINEStarting motor willBattery dischargedRecharge or replace battery.not crank engineBat

T A B L E 0 F C 0 N T E N T S (continued)SectionIV 4-57.4-14.4-67.4-70.4-71.4-9.4-69.4-67.4-68.4-15.V REPAIR.5-63.5-66.5-68.5-66.5-66.5-67.5-66.5-62

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSE1. ENGINE (Continued)REMEDYEngine will not start.Ammeter showing ab-normal discharge wi

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY1. ENGINE (Continued)Engine will not start.Fuel line pinchedRepair or replace lin

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY1. ENGINE (Continued)Engine operates, butHeat control valve not operatingFree-up,

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY1. ENGINE (Continued)Engine misfires on oneCracked spark plug porcelainReplace sp

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY1. ENGINE (Continued)Engine misses at highspeeds (continued)Fuel pump defective,

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY1. ENGINE (Continued)Engine lacks powerInsufficient oil, or improper gradeLubrica

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSE1. ENGINE (Continued)REMEDYEngine overheats(continued)Ignition timing incorrectDamaged

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSE1. ENGINE (Continued)REMEDYHigh fuel consumption(Continued)Spark advance stuckLeaking f

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY1. ENGINE (Continued)Low oil pressureImproper grade of oil, orChange oil, inspect

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY2. FUEL SYSTEMFuel does not reachcarburetorNo fuel in fuel tankFuel pump inoperat

TABLE OF CONTENTS (continued)SectionV 5-7.5-4.5-3.5-5.5-2.5-6.5-174.5-122.5-129.5-70.5-22.5-21.5-178.5-147.5-102.5-93.5-94.5-14.5-19.5-158.5-8.5-15.5-

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY2. FUEL SYSTEM (Continued)Engine idles too fast(continued)Control return spring

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY3. IGNITION SYSTEM (Continued)Distributor troubles(continued)Distributor automati

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDYStarting motor does notcrank engine(continued)Battery dischargedBattery (other tr

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY5. BATTERY, LIGHTS AND HORNLight switchDefective switchReplace switch.[continued)

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY6. TRANSMISSION, CONVERTER AND AXLE ADAPTOR (HYDRATORK DRIVE)Machine will not mov

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY6. TRANSMISSION, CONVERTER & AXLE ADAPTER (Hydratork Drive) (Continued)Transm

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY7. DRIVE AXLE (Continued)Excessive backlash inaxle driving(continued)Complete fai

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEREMEDY9. STEERING (Continued)Wander or weaving(continued)Steering gear worn ormaladjust

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEIREMEDY10. BRAKES (Continued)Brakes dragDirt imbedded in liningClean lining with wire b

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSEI10. BRAKES (Continued)REMEDYExcessive pedal pressure(continued)Wheel troublesShoes imp

SPECIFICATIONENGINE:MANUFACTURER...WAUKESHAMODEL...D176GTYPE...OVERHEAD VALVESERIES...

TABLE 4. TROUBLESHOOTING GUIDE (Continued)TROUBLEPROBABLE CAUSE11. HYDRAULIC SYSTEM (Continued)REMEDYPump not developingpressure (continued)Leak in hy

SECTION VREPAIR5-1. GENERAL. Instructions within this sectionprovide for removal and repair of all majorcomponents and assemblies of the vehicle. It i

c. Prior to disassembly of the vehicle, theexterior parts of the equipment should bethoroughly cleaned to remove accumulated mud,tar, and grease. This

b. Inspection consists of checking for defectssuch as physical distortion, wear, cracks, andpitting, and checking dimensions of parts forcompliance wi

e. Prior to resurfacing, scrape off loose andblistered paint from damaged areas. Clean area tobe painted by sanding or buffing. Remove residuecleaning

the assembly by applying force to the shaft. Whenmounting bearings on shafts, always apply force tothe inner races.f. Lubricate all preformed packings

c. The use of magnetic particle and/or dyepenetrant techniques of nondestructive testing forthis inspection are highly recommended.5-15. SAFETY.a. Pro

Figure 5-1. Welding Repair of Carriage5-7

Figure 5-2. Welding Repair of Fork Assemblyin hermetically sealed containers, and must havestorage care normal to their type. If containershave been o

Figure 5-3. Welding Repair of Outer Rail Trunniongroove-ground the entire length of the crack, andthe entire crack removed. Any weld repair must bemad

Figure1-1. ForkliftTruck,C500-Y45vii

Figure 5-4. Welding Repair of Outer Rail Assemblyrequired, a disc grinder with #80 grit abrasive isrecommended.5-20. WELDING.a. Welding should be perf

Figure 5-5. Welding Repair of Inner Rail Assemblyjoints. It will be obvious that the selection ofelectrode sizes under 5/32” is unwise for thisapplica

1.Gasket2.Well3.Bolt, lockwasher4.Hood5.Hood6. Bracket7.Bolt, washer,lockwasher, spacer8.Bracket9.Bracket10.Bolt, washer,lockwasher, nut11.Hood12.Bolt

1.Bracket5.Washer8.Bolt, washer,11.Mount2.Stud, nut,washer6.Bracketnut 12.Mount3.Bolt, nut7.Stud, nut,9.Mount13. Washer4.Mountwasher 10.Washer14.Washe

TABLE 5. ENGINE WEAR LIMITS AND SERVICE SPECIFICATIONS1. GENERAL.5. RING GAP/MAX. WEAR LIMIT.Model . . . . . . . . . . . . . . . .Clark D176GDisplacem

1. Cylinder sleeve bore wear2.Cylinder sleeve bore - maximumtaper (after ridge removal and honing)3. Piston diameter wear4. Piston pin diameter wearWE

TABLE 5. ENGINE WEAR LIMITS AND SERVICE SPECIFICATIONS (Continued)10. CAMSHAFTReam Cam Bushingin place ... . ... . ... . ...1.7515-1.752 in.Ca

hood and seat support, floor plate and side doorhoods. These parts are shown in figure 5-6.a. After removal of sheet metal parts, tag anddisconnect al

Figure 5-12. Rocker Arm Removalc. Remove P.C.V. system from rockerarm cover.d. Carefully inspect rocker arm assembly forbroken springs or rocker arms,

EngineeringDATA SHEET 36StandardsPAGE 1 OF 2TIGHTENING TORQUE VALUES FOR STEEL THREADED FASTENERSThe following torque values are for use in general ap

LEGEND FIGURE 5-15Figure 5-14. Cylinder Head Removalassembly5-28.REMOVALa. Remove water outlet assembly beforeloosening cylinder head bolts. This pre-

Figure 5-15. Cylinder Head and Camshaft5-19

Figure 5-16. Valve Removal5-30. REPAIR.a. Test valve spring pressure and length, usingspring tester as shown in figure 5-18. If springs donot meet spe

Figure 5-19. Checking Valve Face RunoutFigure 5-18. Testing Valve Springf. Check cylinder head for flatness by placing astraightedge across cylinder h

Figure 5-21. Checking Cylinder Head FlatnessFigure 5-22. Cleaning Valve GuidesFigure 5-23. Installing Valve Guide5-22

Figure 5-24. Reaming Valve Guidese. Do not over-ream valve guides. Use ream nolarger than original guide size (see Table 5).5-32. VALVE SEAT REFACINGA

Figure 5-26. Scrap Valve Welded In PlaceFigure 5-27. Driving Out SeatWARNINGDry ice is a solid with an extreme lowtemperature. Contact with the skin w

Figure 5-29. Rocker Arm Retainerb. Be sure that the refacer grinding wheels areproperly dressed and are the proper wheels for thevalve material (exhau

e.Install rocker arm assembly and makecertain that push rods engage with rock-er arms.Torque bolts to specificationsshown in Table 5.f. Perform a valv

b. Remove the pump cover which is securedto the pump body with flat head screws.c. Remove and discard the shaft retainer.Place the pump (hub end down)

EngineeringStandardsDATA SHEET 36PAGE 22. All torque values shown in customary (LB.FT) units represent values as described in NOTE 1 rounded to thenea

Figure 5-34. Removing Crankshaft PulIey NutFigure 5-35. Pulley RemovalLEGEND FOR FIGURE 5-361. Seal2. Oil Lube3. Fitting4. Fitting5. Bolt6.Bolt, L.W.7

Figure 5-36. Timing Gear Cover Parts5-29

Figure 5-39. Idler Gear RemovalFigure 5-40. Camshaft RemovalFigure 5-38. Camshaft Thrust Plunger Removal5-30Figure 5-41. Backing Plate Removal

oil seal. If the seal running surface ofn. Pull the camshaft forward, outthe wear sleeve is grooved or damaged,of the crankcase,very carefully tothe w

Figure 5-43. Gear Timingg. Install thrust washer on shaft with oilgrooves facing away from engine.h. Install idler gear assembly on shaft withlongest

Figure 5-44. Oil Pan5-42. PISTONS, CONNECTING RODSAND CRANKSHAFT REMOVAL.a. Drain the oil pan and remove cylinder head,water pump, timing gears and ca

Figure 5-47. Crankshaft Gear RemovalFigure 5-48. Flywheel Removali. In those instances where replacement of thecrankshaft gear is necessary and a pull

Figure 5-48ABefore removing the ring gear inspectit for worn or broken teeth as shownby the arrow in Figure 5-48A.Whengear teeth are worn to the point

5-42C.INSTALLATIONa.Remove the flywheel from the viseand place it on a flat surface with theside the ring gear slips over face up(refer to Figure 5-48

Figure 5-51. Piston RemovalFigure 5-52. Forcing Cylinder Sleeve Upn. Remove connecting rod bearings and caps.Make sure the rods and caps are marked fo

Figure 5-55. Crankshaft Removals. The cylinder sleeve may be removed by placingd wooden block between the crankshaft and thebottom of the cylinder sle

Figure 5-58. Filing Ring GapFigure 5-59. Checking Ring Side Clearance5-43. FITTING NEW PISTON RINGS.a. Select the proper ring set (standard, oversize,

Figure 5-62. Flywheel Housing InstallationFigure 5-61. Checking Rod Alignment5-44. CONNECTING ROD BEARINGREPLACEMENT.a. Connecting rod bearings must b

Figure 5-63. Crankshaft End Play CheckFigure 5-65. Connecting Rod OrientationFigure 5-64. Flywheel Runout Checki. Coat the rear seal assembly with a l

1.Balancer assembly 6.Spindle11. Gear 16.Retainer2.Oil tube seal 7.Weight 12.screw17.Thrust washer3.Dowel pin8.Key13. Washer 18. Bearing4.Frame9.Shim

b. Turn the flywheel, making sure thatit is fully forward or rearward, so thatcrankshaft end play will not be indicatedas flywheel runout.c. If the cl

1.Oil assemblypump4.Body7.Vane 10.Bolt2.Drive gear5.Bolt,washer8.Spring 11.Bolt3.Pin6. Drive shaft9.Cover 12. StrainerFigure 5-67. Oil Pump Assemblyd.

Figure 5-68. Timing Oil Pump and Distributor5-43

Figure 5-89. Starter Removal5-52. OIL PAN INSTALLATIONa.Inspect oil pan carefully aftercleaning with Stoddard solvent.b.Check for cracks, particularly

d. Remove the commutator end frame(Item 28) and field frame assembly(Item 3).It may be necessary to tapthe end frames with a fibre hammer toremove the

1-1.INTRODUCTION1-11.DETAILED DESCRIPTION1-2. This manual provides operation, main-tenance, and repair instructions for theModel C500-Y45 Fork, Lift T

1.Starting motor8.Spring15.Motordrive assembly22.Grommet29. Bolt2.Bearing9.Switch16.3.Stud,nut, washer23.Screw, washer30. WasherHousing (pinion)10.Scr

Figure 6-73. Undercutting MicaMeter needle will jump wildly; precautionsshould be taken to avoid damage toinstrument.STEP 4. To test armature for grou

5-59.BRUSH REPLACEMENT.Brushes canbe replaced without removing motor fromtruck.a.Disconnect battery cable.b.Remove brush covers (band orplates).c.Remo

Figure 5-79.Alternator Assembly1. Nut 12.Rotor Assembly 23. Rectifier Assembly2. Washer 13.Lockwasher 24. Screw3. Pulley 14.Nut 25. Bearing4.Fan15.boc

TROUBLE SHOOTING(DELCOTRON GENERATORS WITH BUILT-IN VOLTAGE REGULATORS)5-62 TROUBLE SHOOTING PROCEDURESClose adherence to the following proceduresin t

5.If previous Steps 1 thru 5check satisfactorily, check Delcotronalternator as follow:a.Disconnect Energizer groundcable.b.Connect an ammeter in theci

c. If both readings are zero, eitherthe brush lead clip is grounded orregulator is defective.d.A grounded brush lead clip canresult from omission of i

Typical 10-SI Series Generator5-63.INTRODUCTION:The DELCOTRON Generator illustrated onthis page features a solid state voltageregulator that is mounte

IMPORTANT: Read the introductory paragraphs on 5-50Bbefore proceeding with either one of these sections.UNDERCHARGED ENERGIZEROVERCHARGED ENERGIZERThi

TABLE 1.GENERAL :Vehicle Model...C500-Y45Machine Weights:Drive:Empty...4218 LBS.Loaded...10

end frame bearing to prevent entry of dirtand other foreign material; also place apiece of tape over the shaft on the slipring end.CAUTIONUSE PRESSURE

or damaged insulating sleeve.Remove screwnspect sleeve.NOTEIf screw assembly is correct, and bothohmmeter readings are the same, replacethe regulator.

b. Then reverse the lead connections to thegrounded heat sink and same terminal (orconnector).If both readings are the same,replace the rectifier brid

Slip rings which are rough or out of roundshould be trued in a lathe to .002 inch maximumindicator reading.Remove only enough materialto make the ring

Plate 12344. Connections for Bench CheckeraterSTEP 1(Negative Ground Generator Shown.)ofMake connections as shown in plate 12344,Gen-except leave the

5-69.INSTALLATION.a. When reassembly is complete,install the alternator onto the mount-ing brackets on the engine and securewith the mounting and adju

1.Cap2.Rotor3.Cover4. Screw5. Condenser6. Screw7. Point Set8.Lock9. Plate10. Retainer11.Cam12. Bearing13.Weight14.Spring15.Mainshaft16. Primary Lead17

and disassemble the distributor as follows:upon viscosity. Under no circumstances mustgrease be used in the oil reservoir.e. Unsnap cap springs, take

Table 5. The point opening of new points can bechecked with a wire feeler gauge, or a Dwell AngleMeter. A meter of this type indicates the cam orconta

WHEELSTorque Specifications:Drive Wheel..290-300 ft/1bs (dry thread)Steer Wheel.. 115-125 ft/1bs (dry thread)Steering gear pitman arm . . . . . . . .

LEGEND FOR FIGURE 5-811.Carbutor12.2.Repair kit13.3. Gasket kit14.4. Screw15.5.Spring6.16.7.Screw 17.Screw 18.8.Screw19.9.Float20.10. Jet 21.11. Plu

Figure 5-81. Carburetor Assembly5-55

bottom of fuel bowl, using a 7/16 inch open endwrench.Noteo. Remove discharge jet and fibre washer.p. Remove well vent jet from center of largeopening

Figure 5-82. Float Level Check5-81. REASSEMBLY. (See figure 5-81.)Fuel Bowl Body.a. Install the choke shaft hole plug, packing andretainer in fuel bow

LEGEND FOR FIGURE 5-831. Fuel pump2. Stud3. Gasket4. Repair kit5. Diaphragmkit7. Lockwasher13.Arm8.9.Capscrew 14. RetainerLockwasher10. Screw15. Cover

Figure 5-83. Fuel Pump5-59

b. Connect fuel pump to carburetor hose, andair filter hose.c. Connect accelerator and governor linkage andperform adjustments as outlined in Section

1.Axle end assembly14. Bearing24.Bearing cup, outer35.Brake assembly2.Hub cap bolt15.Retainer bolt26.Wheel mounting bolt36.Spindle3.Hubcap16.Seal27.Hu

Figure 5-87. Outer Bearing RemovalFigure 5-86. Removing Outer Bearing NutFigure 5-88. Drive Hub Removalh. Remove drive axle spindle fasteners and driv

Figure 5-89. Drive Axle Spindle RemovalFigure 5-90. Drive Axle Shaft Removalh. Carefully install drive hub assembly on axlespindle, making sure inner

1-17.The torque converter has three basiccomponents; they are the impeller, turbine,and housing or stator. Under normal operat-ing conditions, the act

2.Differential housing9. Dipstick3.Drain plug17.Differential10.Bearing carrier shimhousingshim4.Inspection cover18. Seal11. Differential bearing cone5

Figure 5-92. Tooth Contact Patterns5-65

LEGEND FOR FIGURE 5-931.32. Control cover studTransmission assembly2. Auxiliary shaft bearing3.Auxiliary shaft4. Drivengear6. Auxiliary shaft bearing6

06.20005.00005.03305.03405.05705.06705.06805.09005.09105.09205.13005.13205.13305.13405.15205.15306.20606.23306.23406.23506.37706.39306.55506.55606.557

06.20006.20206.27806.27906.28006.28706.28806.40006.40706.40806.42406.49006.50406.50806.52206.55006.55106.55406.56006.56106.57206.58406.59206.59706.598

2 SPEED FORWARD AND REVERSE HYDRATORK TRANSMISSION(MODELS H-200 THROUGH H-211)Whenever the Hydratork transmission is dis-assembled, the following step

STEP 3.Remove the axle adaptor adjustmentshim/s and “O” ring seal.Step 3. Plate 10223STEP 4.Remove from the transmission assemblythe converter pump.ST

STEP 6.Using the control cover capscrews,Install into the threaded oil sleeves. Afterthe capscrews are in place pry up on thecapscrews while holding t

STEP 9.Remove the speed selector oil distributorretainer ring.STEP 10.Remove the speed selector oil distri-butor by pulling straight out from transmis

STEP 12.Remove the output shaft retainer.STEP 13.Drive the output shaft from theconverter end toward axle adaptor end using asoft brass bar.Step 13. P

Figure 1-2. Cooling System Diagram1-25. ENGINE FUEL SYSTEM.The enginesystem is powered by a gear-type hydrau-fuel system consists of the fuel tanklic

Plate 10244Output Shaft Assembly5-74

STEP 15. Remove the transmissionInputcap on axle adaptor end of transmission.shaftStep 15. Plate 10229STEP 16.Check the input shaft cap for ringwear a

STEP 18.Remove the stator support assembly.Step 18. Plate 10231STEP 19.Using a soft brass bar drive Inputshaft from axle adaptor end toward converter

Plate 10243Input Shaft AssemblyLocated at the small gear end of the inputshaft is a 1/4 In. thrust washer.Care mustbe used when reassembling transmiss

STEP 21.Insert a long brass rod from axleadaptor end and drive the oil distributor fromthe transmission.Step 21. Plate 10233STEP 22.Check the oil dist

STEP 23.Remove the thrust washers, small gearand inner bearing race from the clutch pack.Step 23. Plate 10337STEP 24. Remove the thrust washers, large

STEP 25.Remove the clutch end plate and discretainer ring and remove the clutch plates.STEP 26.Install the clutch pack disassemblytool and remove the

STEP 28.The clutch drum assembly containsbleedoff orifices and must be cleaned with afine wire to remove all foreign material andobstructions.STEP 29.

Plate 8039Clutch Pack Assembly5-80B

Step 31. Plate 10098STEP 31.Remove the intermediate shaft retainerring on the axle adaptor end of transmission.Step 32. Plate 10240STEP 32.Remove the

1-28.SERVICE BRAKE AND INCHINGCONTROL SYSTEM.Examing the inching and brake circuitsyou will note that we have two mastercylinders - the left one for l

Plate 10242Intermediate Shaft Assembly5-80D

STEP 34A.Remove reverse idler gearfasteners and gear.STEP 35.fastener.Remove the converter pump idler gearSTEP 36.Remove the thrust washer and idlerge

Plate 10103The parking brake will not have to be removedexcept in the event of replacement of bearings,gears or seals.STEP 7.Remove auxiliary gear and

5-95TRANSMISSION REASSEMBLYSTEP 1.Install reverse idler gearand fasteners.STEP 1A. Install the idler gear thrust washermaking sure the locking tang is

Plate 10242Intermediate Shaft Assembly5-80H

STEP 4.Insert the intermediate shaft from theconverter end of the transmission with bearinginstalled on shaft,STEP 5.Install on the shaft, the shaft s

Plate 8039CLUTCH PACK HUB AND DRUM, PISTON AND DISC ASSEMBLY.5-80K

STEP 8.Check the clutch hub ring seal sideclearance.A MAXIMUM wear of .008 and abovewill require ring replacement.Step 8. Plate 10331STEP 9.Check the

STEP 11.Install the clutch piston into drumand over hub.STEP 12.Install the clutch springs, springretainer, and locking ring.Now install thespring com

STEP 13.Install a steel disc plate, then abronze disc plate alternate In this manner untilthe appropriate number of plates have beeninstalled.STEP 14.

This detail of the selector valve showsthe flow through it when the right mastercylinder is applied. (Refer to Fig. 1-3)When the left foot inching ped

STEP 18.Install the gear, turning it back andforth until all of the bronze discs are engaged.Step 18. Plate 10349STEP 19.Insert the bearing race, reme

STEP 21.Parts location of small gear end ofclutch pack.Step 21. Plate 8038STEP 22.Parts location of large gear end ofclutch pack.Step 22. Plate 103375

STEP 23. Turn the gear and watch the inner discsto determine if they are engaged. When the gearhas completely entered the discs it should be1/4 inch b

Plate 10243INPUT SHAFT ASSEMBLYLocated at the small gear end of the inputshaft is a 1/4 in. thrust washer. Caremust be used when reassembling transmis

STEP 25.Check the sealing rings on the inputshaft.Rings must be replaced if a MAXIMUM of.008 wear and above exists.STEP 26.Install the sealing rings b

STEP 28.Check the oil distributor sleeve sealswith a flat type feeler gauge as Illustrated.All three seals must not have more than aMAXIMUM of .004 si

STEP 31.Replace the old oil distributor "0" ringseals with new seal s.Step 31. Plate 8046STEP 32.Place the transmission on the axleadaptor e

STEP 34. The beveled end of the distributorsleeve must face the input shaft bearing.STEP 35.Insert the input shaft from the con-verter end, making sur

STEP 38.Place the transmission on the con-verter end of assembly.STEP 39.Install the inputshaft retainer ring.Step 38. Plate 10359STEP 40.Carefully in

STEP 41.Install new input shaft cap seal.Step 41. Plate 10229STEP 42.Assemble cap to transmission overend of input shaft and Install retainers.Tighten

When the inching pedal is pushed down to apoint where the transmission is partiallydisengaged,the brake piston is applied.Fluid, trapped between the b

Plate 10244Output Shaft AssemblyThe clutch installation tool can beeasily made in your shop and itsdimensions are shown in this drawing.5-80AA

Step 43. Plate 10361STEP 43.Measure the output shaft oil distri-butor sleeve seals.Seals must be replaced if a MAXIMUM of .008"and above measurem

Step 47. Plate 10365STEP 47.Assemble output shaft into transmissionhousing making sure index splines are in align-ment with splines in clutch pack.Ste

STEP 51.Install the output shaft fastener andtorque to specifications.Step 51. Plate 10369STEP 52.Using an inch pound torque wrenchinstall on outputsh

STEP 54.Install new "0" ring seals into thehigh and low oil distributor making sure theyare well seated.Step 54. Plate 10371STEP 55.Assemble

STEP 57.Install forward and reverse oil tubesinto oil distributor.Be careful not to damagethe seals in the distributor when installingtubes.Step 57. P

Step 60. Plate 10225Step 61. Plate 10373STEP 60.Install new “0” rings into positionon control cover.STEP 61.Install control cover to transmissionassem

STEP 64.Install the axle adaptor assembly tothe transmission assembly.5-96 INSTALLATIONa.Install transmission assembly intothe machine, follow the rev

2 SPEED FORWARD AND REVERSE HYDRATORK TRANSMISSION(MODELS H-200 THROUGH H-211)Converter pump idler gear shaft70-85 LB.FT.FLUID SEAL(S). SPECIFICATIONS

SECTION 5-97 DISASSEMBLY OF CONTROL VALVEStep 1 Plate 8003Remove the capscrews retaining the controlcover plate and baffle.Step 2 Plate 8004.Remove th

1-29.HYDRAULIC SYSTEM. In the vehiclelift and tilt hydraulic system, oil isdrawn from the reservoir by the pumpwhich is mounted to the engine gear cas

Step 5 Plate 8007.Remove roll pins from cover with sidecutters. When removing the roll pins fromthe convertor regulator and pressure reg-ulator bores,

CLEANING AND INSPECTIONStep 9 Plate 8071.Remove inching valve and components shownabove.CLEANING:Clean all metal parts thoroughlyusing a Stoddard Type

SECTION 5-97APlate 8002.Disassembled View of Control CoverREASSEMBLY OF CONTROL COVERCoat the outside diameter of the selectoroil seals with a light c

Step 1 Plate 8072.Exercise catuion to avoid damaging thelip of the oil seal during installationof the selector spool. Place a new “0”ring on the stop

Install the convertor pressure regulatingvalve, spring and stop. Replace theretaining roll pin.Step 5 Plate 8009.Step 6 Plate 8008.Install the pressur

Step 9 Plate 8006.Press a new oil seal in the inchingpiston seal housing. Install a new “0”ring and with finger pressure, push thehousing into its sea

FIGURE 5-1315-98.BRAKE REPAIRS5-99REMOVAL AND DISASSEMBLY -WHEEL BRAKEa.Brake removal is outlined underparagraph 5-86.Refer to figure 5-131for parts i

THERE IS A SHOE ANCHOR KEY ON EACH SIDEOF THE ANCHOR BLOCK.THESE ARE LOOSEPIECES AND CARE SHOULD BE TAKEN SO THEYARE NOT LOST.c.If you should turn the

Occasionallygreaseretainersbecomeworn,allowing lubricant from wheel bearings to leakthrough in the brake drum. When grease comesinto contact with the

WARNINGIt is not recommended that tires with breaks be used again.WARNINGIn all cases, when removing tires with split rims from the machine forrepair

1-35 CARBURETORPR I NC I PLE OF OPERAT I ON :Marve1-Schebler Carburetors are used onthousands of tractor and industrialengines and have been designed

5-104. CLEANING AND INSPECTION.tetrachloride, acetone, paint thinner, etc.a. Clean master cylinder assembly with stoddard typeThese solvents deteriora

5-105.INSTALLATION.a.Fill the master cylinder reservoirwith fluid,then force the piston throughone full stroke.Repeat piston strokinguntil fluid is fo

e.To remove side cover from sectorshaft,turn adjustor screw in end ofsector shaft down through cover.f.Remove screws and take out endcover with worm b

FIG 5-1332.NUT3.BOLT4.LOCKWASHER5.BUSHING6.BUSHING7.GASKET8.NUT9.LOCKWASHER10.SUPPORT11.BUSHING12.GEAR13.SHIM14.ADJUSTER15.LOCKNUT16.ADJUSTER17.CUP18.

1.Install horn contact brush assemblyb.(Item 40) and retaining plate (Item 47)Screw the rod end sub-assemblyonto the end of the cylinder rod.and faste

Figure 5-134. Steering Cylinder Seals5-113. STEERING VALVE. (See figure 5-135.)5-114. DISASSEMBLYa. Hold control ball stud housing and valveassembly i

Figure 5-135. Steering Valve Assemblyb. Wash all parts in a Stoddard type cleaningsolvent.c. Inspect all fluid passages in valve body to becertain the

1.Pump assembly2.Shaft seal3. Cover bolt, washer4. Cover bolt, washer5.Cover6.Dowel7.v-seal8.Gasket9. Heat shield17. Idler gear assembly10. Wear plate

f.Install new O-ring on check valveand place ball and check valve in valvebody recesses and hold valve against itsport end mating surface, making sure

In order to understand the function andoperation of the Marve1-ScheblerWhen the fuel bowl (1) is empty theTractor and Industrial Carburetors itfloat a

Rotation causes the volume at the gearSTEP 3.mesh to increase on the inlet side anddecrease on the pressure 'side.ThisSTEP 4.creates a suction at

STEP 12. Remove and discard the twoO-Rings (Item 11) betweenend covers and pump centersections.STEP 13.DO NOT REMOVE drive shaftseal (Item 2) in the f

NOTEThe front cover must be lockedby a smooth clean surface dur-ing this operation to preventdamaging or scoring its face.CAUTIONDO NOT BEND THE STEEL

STEP 13.STEP 14.STEP 15.STEP 16.STEP 17.STEP 18.Add a generous amount of cleanoil in both the inlet and out-let ports.Install pump drive gear, washera

Fig. 13344NOTENOTEUse caution to avoid "cocking" ofthe dowel pins (Item 7).STEP 8. Remove wear plate (Item 10) andthe thrust plate (Item 22)

STEP 11.Remove and discard the twoO-rings (Item 11) betweenend covers and pump centersection.STEP 12.Do Not Remove drive shaftseal (Item 1) in the fro

CAUTIONDO NOT BEND THE SEAL RETAINER OR SCORE THEHOUSING SEAL BORE.STEP 3.Install the rubber seal (Item 61,the gasket (Item 8) and the heatshield into

STEP 14. Install the pump drive gear, thetwo washers and the nut onto thepump drive gear shaft.Tightenthe nut snug and align slot inthe nut with the h

TROUBLE1.Noisy Pump2.Foaming Oil3.Pump or oil overheating4.Low Flow5.Failure to buildpressurePROBABLE CAUSEa. Low oil supplyb. Oil too heavy,(i.e. vis

TROUBLE SHOOTINGTROUBLEPROBABLE CAUSEPOSSIBLE REMEDY1 External leakage throughvalve cap vent hole.2 Failure to tilt forward.1 Ruptured"0" ri

As can readily be seen the float systemunder the most favorable of operatingconditions is subjected to a certainamount of wear. Under severeconditions

5-127DISASSEMBLY AND INSPECT IONW A R N I N GTHE TILT LOCK VALVE SERVES AS A SAFETYDEVICE ON THE MACHINE. ANY TAMPERINGWITH THE VALVE BY UNQUALIFIED P

5-128REASSEMBLY:CAUTIONSTEP 1.Install spool check ball, Spring, plugand internalnecessary to press or drive plug intosnap ring.It may beposition SO th

LEGEND FOR FIGURE 5-1381. Valve assembly2. Inlet section3. Inlet body4. Screw5. Sleeve retainer cover6. Sleeve7. Spring cover seal8. Lower spool seal9

Figure 5-138. Hydraulic Valve Assembly5-95

1.Tilt Cyl. Assy. 9.Bushing2.Barrel10.Packing Set3.u-cup11.Shim4.Wear Ring12.Retainer5.Spacer13.Lockwasher6.O-Ring14. Capscrew7.Back-up Ring15. Wiper

FIG. 5-1605-97

Figure 5-162.Gland Detailse. Remove segment rings (G), This will allowthe gland assembly to be pulled from cylinderand piston rod.f.Refer to figure 5-

C A U T I O N (CONTINUED)SEALING AREAS ARE FREE OF NICKS, BURRS ORSHARP EDGES THAT MIGHT DAMAGE SEALS.LUBRICATEEACH COMPONENT WITH CLEAN HYDRAULIC FLU

Figure 5-141. Blocking CarriageFigure 5-142. Fork and Carriage BlockingCARRIAGE ASSEMBLY.5-139. REMOVAL.a. Set parking brake and block drive wheelssec

As this rich mixture of fuel and airemerges from the primary idle orifice(7) it is reduced to correct proportionsby the air which passes around thethr

Figure 5-143. Securing Chainstime, and replace each pin with a 3/8 inch diameterx 2 inch long bolt.d. Raise the carriage off the upright beam. Placeth

b. Refer to the welding instructions at the frontof this section before attempting any welding onthe carriage.c. Perform carriage roller adjustments a

LEGEND FOR FIGURE 5-1451. Upright & Lift Cylinder Assembly10. Inner Rail2. Outer Rail11. Lever3. Bolt12. Support4. Roller13. Capscrew5. Shim14. Re

Figure 5-145. Upright Assembly5-103

LEGEND FOR FIGURE 5-1461. Lift cylinder assembly10. Sheave carrierrod 19.Back-upring 28.Inter rod20.Inner rail rod29. Retainer2. Barrel-3.4. SealPacki

Figure 5-146. Lift Cylinder5-105

Figure 5-148. “V” Packings5-106

Figure 5-149.“V” Packing RemovalFigure 5-150. Stationary Piston End Cap5-107

Figure 5-151. End Cap RemovalFigure 5-152. Flow Tube Removalalternate one rubber and one plastic ring, alwaysstarting with the rubber ring, and build

Figure 5-153. Primary Piston RemovalFigure 5-154. Primary Piston Installationd. Complete installation of primary piston bycompressing piston ring with

c. POWER FUEL FEED SYSTEM:With the throttle valve (6) in slow orjust off slow idle position, fuel risesup through the nozzle (14) and out thenozzle ai

Figure 5-155. Stationary Piston InstallationFigure 5-156.“V” Packing Arrangementend of secondary piston into stationary piston.f. Assemble O-ring and

Figure 5-157.“V” Packing Toolg. Install brass stop ring over stationary piston.Install end cap on stationary piston using a spannerwrench and piece of

LEGEND FOR FIGURE 5-1601.Tilt cylinder assy.2.Barrel assembly3. Rod, piston assembly5.u-cup6.Gland bushing retainer7.Bolt8.Wear ring9. Segment ring10.

SECTION 5-154FULL FREE LIFT TRIPLE STAGE UPRIGHTS EQUIPPEDWITH 6-ROLLER CARRIAGESOperational Checks & Adjustments...Page 5-114Latch Operation

The following procedures cover FULL FREE LIFT TRIPLE STAGEUPRIGHTS equipped with six-roller carriages used on trucksrated from 2,000 through 12,000 po

Maintenance procedures should be followed carefully.WORK SAFELY Keep hands and feet out from between movingparts unless parts are secured to prevent m

Here the carriage has just passed maximum full free-liftposition.Notice that at this point the top carriage rollersare visible.When the carriage reach

. . .pass around shives on the intermediate rail tie bar ...Fig. 16163. . .and anchor near the top of the outer rails.Inspectchains for wear and for e

. . .when the upright is fully extended . . .. . . like this . . ...but not so much that it jams against its retaining bolts.Either lack of free move

They should be shortened by means of their adjusting nuts onthe anchor plate that’s attached to the lift cylinder.Fig. 16170If these nuts are removed,

Because the size of the power jet(20) and the position of thepower adjusting needle (18)restrict the amount of fuel whichcan enter the nozzle (14), th

. . .and anchor to the same plate as the Intermediate railchains, but enter the anchor plate from above.Fig. 16174Carriage chains should be adjusted s

. . .applying a light coat of spray paint or a thin layer ofgrease to the roller contact area and then operating theupright several times with a load.

. . .secondary piston rod . . .Fig. 16182. . .and feed tube assembly should be checked. Cylinder rodsshould be free of grit, chemical residues, paint

If you observe no racking,check to see that keys are inplace and locking bolts are tight.This completes the operational checks of the upright. Beforec

. . .placing a capacity load on the forks and securing it tothe carriage.Tilt the upright back slightly.Raise the upright to maximum extension several

Fig. 16192Fig. 16193Fig. 16194Fig. 16195Then four inches off center in the other direction . . .. . .and again raised to full extension.The offset has

Providing the upright works smoothly with a capacity load,the service man should considerthe application for which the truck is used in making a decis

The TEST LOAD must have stability on the pallet. Thematerial used to make up the TEST LOAD must be put onthe pallet so that it has stability. The TEST

Figures 16198 through 16202 and corresponding text arerescinded.When performing tests and services on a truck . . . never walkunder raised forks . . .

. . .set the parking brake and . . ...block the steer wheels to prevent the truck from movingforward or backward.With the transmission in neutral, st

Through regulations of the air pressurein the fuel bowl chamber the fuel flowthrough carburetor can be controlledto provide proper mixture proportions

Working from behind the upright, remove the cotter keysfrom the carriage anchor pins.Then one at a time,hold the carriage chains with one handand remo

When both carriage anchor pins have been replaced with bolts,stand away from the carriage, start the truck, and raise thelift cylinder until the carri

Push the carriage chains up around their shives on the pistonhead so that they will be out of the way of the carriage.Remove chocks from the steer tir

Lower the lift cylinder until the upright rails are down . . .. . .but not enough to lower the piston head. Shut off thetruck and set parking brake.Ti

ADJUSTING CARRIAGE ROLLERSThese are special calipers designed for making carriageadjustments.The top caliper is an inside caliper . . . thelower one,

...add a 1/32nd inch thick shim . . .. . .between the contact point of the caliper and the innerrail. Then re-tighten the caliper and re-check the ins

Now move to the back side of the carriage.Inspect the side thrust rollers on the back side of theupper fork bar.Check the rollers for damage to contac

If the thrust rollers are in good condition, place the out-side caliper across the second set of carriage rollers.Place the caliper on the side of the

Do this on both sides of the carriage. To obtain equal dis-tance between side thrust and main carriage rollers on bothsides, we find that two shims ne

... inspect the roller for damage or excessive wear ... replaceit if necessary ... and ...re-install by tapping it on with a heavy plastic or aleat

e. CHOKE SYSTEM:The choke system is used during coldstarting and the warm-up period. Underthese cold conditions it is necessaryto supply an additional

... a re-check with the rule shows that both thrust rollers ... are the same distance from the carriage rollers.With the same caliper position, spa

. . .the calipers need to be placed on the side of theroller closest to you.The bottom rollers must be directly below the center carriagerollers.To ge

Use your steel rule to get one leg of the carpenter’s squareparallel to the upper fork bar.Move the rule back and forth across the upper fork bar whil

. . . and shims added.A check with the square on the opposite side indicates noshims are needed.A re-check with the caliper shows zero clearance betwe

Place a square directly through the centers of the lowerand center rollers.The top rollers nest be adjusted so that a 1/32nd inch insetis obtained . .

. . .and re-check for the 1/32nd inch inset.The inset should be achieved on both sides.The last step in adjusting the carriage rollers Is toadjust the

. . . the face of the thrust roller should overlap the edge ofthe rule by 1/64th of an inch on both thrust rollers.The side thrust rollers should also

After both thrust rollers have been adjusted, their greasefitting should be lubricated.This completes the procedure for adjusting the six-rollercarria

Then prop the lift cylinder control . . .CONTROLS VARY WITH DIFFERENT TRUCK MODELS.REFER TO THE OPERATORS INSTRUCTION MANUALCOVERING THE PARTICULAR MO

Then start the truck ... . .and raise the lift cylinder until the pallet and the4 x 4 can be removed.Continue to raise the carriage until the 4 x 4 c

When the engine has obtained normaloperating temperature the choke valve(25) must be fully opened to assuremaximum power and economy. In addi-tion,ext

Turn off the truck. Exchange the machine bolts . . .. . .for the carriage anchor pins.Use new cotter keys to secure the anchor pins.Then start the tru

. . .then lower the carriage. Remove the safety blocks atthe steer wheels.Operate the upright several times to be sure it is operatingproperly.Make op

Fig 13010Fig. 13011. OUTSIDE SPANNING TOOL5-152

5-153

FULL FREE LIFT TRIPLE STAGE UPRIGHTS EQUIPPEDWITH 6-ROLLER CARRIAGESUpright Rails and Rollers. . . . . . . . . . . . . . . . . .Page 5-155Measuring Ra

The following procedures cover Full Free Lift Triple StageUprights equipped with six-roller carriages used on trucksrated from 2,000 through 12,000 po

. . . outer rails . . .. . . intermediate rails . . .. . . and inner rails.When the lift cylinder is raised, the fork carriage extendsthrough what is

As the maximum free lift position is reached, the primarycylinder piston head trips a latch that permits the inner andintermediate rails to rise to ma

. . . and four rollers that work between the intermediate railsand inner rails.Sharp fork truck mechanics know that with age and wear, the. . .. . .cl

. . .a second set at the bottom of the intermediate rails . . .. . .a third set at the top inside of the intermediate rails,and . . .. . .a fourth set

Cross-Section View of Typical Delcotronwith Built-in Solid State VoltageRegulator in Frame.With the alternatoroperating, a.c. volt-ages are generated

By prying the rails to the right, we move all clearance tothe left side . . .. . .by prying rails left, we have all clearance at the right.In this way

TOOLSTo check and adjust rail-to-roller clearance, you will needthe following materials in addition to common hand tools.About four or five 4 x 4 hard

. . .and a marking block equipped with a steel scriber or asharply pointed pencil.The block needs to have smooth square edges, and a lockingbolt to ho

Set the parking brake . . .. . .and block the steer wheels to prevent the truck frommoving forward or backward.If the truck is gasoline, diesel, or LP

Begin by measuring the clearance between the top roller set ofthe outer rails and the intermediate rails.With the upright down, insert the pry bar bet

Then measure the distance between the two marks.With pencil or a marking pen, record this below the scribemarks.In this case it is 7/32nds of an inch.

. . .and then pry the intermediate and Inner rails left, andmake a parallel mark.Measure the distance between the marks with a rule end recordthe dist

Four shims will be added to the pair of rollers at the topof the outer rails.Next, determine clearance between the roller set at thebottom of the inte

. . . then left and record the clearance.Repeat the same operation at full upright extension with thekey off. Pry to the right, make a mark... . .pr

Now we will measure clearance between the rollers set atthe top of the intermediate rails with the inner rails.With upright fully down, pry the inner

WARNINGDo not smoke, weld,or employ any open flame near the battery, as anexplosive gas is produced by the battery during its operation.WARNINGNever d

Figure 1-8.Serial Number LocationFigure 1-9.Upright Deck NumberLocationThe first stage uses chains which haveone end attached to the lift cylinderchai

Repeat the same procedures at one-half and . . .. . .at full upright extension. The key should be offwhen making each measurement.Notice that you must

The last set of rollers that we must determine clearance forare those at the bottom of the inner rails.With the key off and rails slightly extended, p

Repeat with therails at one half... and full uprightextension ...Here, clearance between the roller set at inner rails andintermediate rails is fou

ADJUSTING RAIL-TO-ROLLER CLEARANCERemember,the parking brake is set ... . .drive wheels are on 2” thick boards, and steertires chocked.The piston hea

We’re ready to disassemble the upright.Always block the inner and intermediate rails when working onthe upright.Don’t put your hands or feet between p

Remove the two-piece latch from the back of the innerrail tie bar.Fig. 16369This is done by removing an allen head set screw andpulling the two pieces

. . .and then separating the halves of the latch.Then remove the Iifting bracket or “moose horn” from theintermediate rail lower tie bar. This is done

. . .and then push it down.CAUTIONPUSH THE LIFTING BRACKET DOWN ALL THEWAY . . .IF IT ISN’T ALL THE WAY, HY-DRAULIC PRESSURE WILL PUSH IT DOWNFORCEFUL

Continue to lower the lift cylinder until the lift cylinderis completely down.The inner rails will not lower further.Turn off the truck.Rollers at the

Here on your right we’re adding two shims . . .. . .and removing the left roller for another two,It’s important to keep track of the number of existin

1-47.COUNTERWEIGHT. The counterweightat the rear of the truck counter balancesthe truck when capacity loads are handledor carried. The drive axle then

. . .our measurements Indicated a minimum clearance of 2/32ndsof an inch.In removing the top intermediate rail rollers, wefind two shims on the left a

This completes the rail-to-roller adjustment of the innerrail/intermediate rail set,We will now adjust the four rollers that work between outerand int

Working from a secureladder or maintenancestand . . .remove theintermediate rail stopblock by removing twobolts.Fig. 16396Then drape a service chain b

Fig. 16401Fig. 16402Some uprights have their anchor plates welded onto the outerrails. To remove the chains on these models, cotter pinsare removed fr

. . .lift cylinder until the posts can be removed.Fig. 16406Lower the lift cylinder until the intermdiate ralis reston the floor.Then place a 4 x 4 be

. . .at the top of the outer rails, are not exposed forshimming.Fig. 16410Remove the top rollers on the outer rails first. We findtwo shims behind eac

Moving to the lower set of rollers, we find no shims on theleft side and one on the right side. Since our clearance was3/32nds, we want to add three s

. . .lift cylinder is raised until the block beneath theinner rail can be removed.Fig. 16419The longer blocks that were used earlier are placed againb

. . .and then the chain retainers are replaced.The service chain is removed.The Intermediate rail stop block is replaced . . .. . . and the latch on t

And the halves of the older style latch are beingassembled.With the long blocks still in place, we’ll re-position thelifting bracket.To do this we mus

We can now pry the bracket up . . .. . . and turn it around.Fig. 16431Fig. 16432Fig. 16433. . . start the truck and raise the lift cylinder.Removethe

. . .position shorter blocks beneath the inner and intermediaterails.Fig. 16435Lower the cylinder until the bolt holes for the bracket arein line,Shut

Start the truck and raise the cylinder and remove the postsbeneath the rails . . .. . .and the lifting bracket.Lower the lift cylinder completely.Remo

Replace the carriage by the procedure given in Section 10in this manual.Fig. 16443When the carriage has been replaced, operate the upright andnote unu

5-155. COUNTERWEIGHT. (See figure 6-6.)5-156. REMOVAL.a. Install a suitable chain hoist or other liftingdevice to a looped cable or to lifting eyes in

FIGURE 6-7 RADIATOR REMOVAL1. Drain Cock2. Radiator Cap3. Hose Clamp4. Upper Radiator Hose5. Lower Radiator Hose6. Radiator5-158 RADIATOR5-159 REMOVAL

d. Drain the radiator by opening thedrain cock (Item 1 in fig. 6-7) andremoving the radiator cap (Item 2 infig. 6-7).e. Loosen the clamps (Items 3 inf

Trouble-shootingHook Type Sideshift CarriagePROBLEMPROBABLE CAUSECORRECTIVE ACTIONCarriage fails tomove when controllever is opened.Insufficient hydra

5-161 SIDE SHIFT CYLINDER5-162 REMOVALg.Remove the"O"-Ring and back-upring from the Gland and Piston (Items3 and 4 in fig. 6-9).a. Release t

FIGURE 6-8SIDE SHIFT CYLINDER REMOVAL1. Tie2.strapHydraulicline5. Nut3.Fitting6.Cotterpin4."O"-Ring7.Pin8. Side Shift Cylinder5-199

SECTION IIPREPARATION FOR USE2-1. GENERAL.2-2. When a new or reconditioned truck is firstreceived by the using organization, it is necessaryto determi

5-200

TROUBLEPROBABLE CAUSEOil leaks at eitherDefective “0” rings in valveend of spool.body.REMEDYReplace"0" rings.Spring-centeredspools do not re

5-165 INSPECTION AND MAINTENANCEPeriodic inspection of spool opera-tion,oil condition and pressureconnections saves time consumingbreakdowns and unnec

d.Check the relief valve forsmooth movement in its bore.TheRelief Valve should move by itsown weight.5-169 ASSEMBLYNOTECoat all parts with clean hydra

5-204

5-170.EXHAUST SYSTEM5-173.INSTALLATION5-171.REMOVAL (Refer to Figure 6-11)a.Raise seat deck and open side hoods.b. Remove the two nuts (Item 1) thatmo

1.NUT7.CAPSCREW,LOCKWASHER,WASHER2.CLAMP8.CAPSCREW,LOCKWASHER,WASHER3.EXHAUSTPIPE(MANIFOLD END)9.CLAMP4.EXHAUSTPIPE(MUFFLER END)10.CLAMP5.CLAMP11.TAIL

5-207

Legend for Figure 6-121. Lower DashPanel4. Nut7.Nut2. Capscrew5. Lockwasher8.Lockwasher3. Lockwasher6. Bracket9. Gauge5-178. GAUGE REMOVAL (Refer to F

d.Adjust seat all the way to the rear.Insert 2 front seat mounting bolts (Items2 & 3) through the front mounting holes inthe adjustors -longer bol

Figure 2-2.Checking Engine Oil Levelg. Battery Water Level and State of Charge —Remove filler caps on the battery and checkwater level,which must cov

5-183.STEER AXLE5-184.REMOVAL & INSPECTION.a.Remove the counterweight (Refer topage 5-194.Section 5-155)b.using a 12 ton hydraulic jack andadaptor

B. SpiderB.SpiderStep 1.Remove snap ring fromStep 1. Install new bearingstop of spider and remove shim(s)and seals into the spider andthen pull spider

e.Install the four capscrews thatfasten the steer axle to the silentblock and torque to 140 ft. lbs.f.Remove the floor jack and installthe drag link o

SECTION 7-1 ILLUSTRATED PARTS BREAKDOWN INDEXTHIS SECTION INCLUDES THE FOLLOWING PAGESPARTPAGEAccelerator Pedal and Linkage.. .7-29Adjustable Headlamp

SECTION 7-1 ILLUSTRATED PARTS BREAKDOWN INDEXTHIS SECTION INCLUDES THE FOLLOWING PAGESPART PAGE PARTPAGEStarter Motor ...7-48Transmission Cont

7-3

7-4

7-5

GASKETS SETS FOR D176 WAUKESHA ENGINEWAUKESHA NUMBERCLARK PART NUMBERENGINE GASKET SETWASHERWASHERCOPPER GASKETVALVE STEM SEALCYL. HEAD GASKETOIL PAN

7-7

3-1.GENERAL3-2. This section provides informationand instructions concerning the theoryof operation and proper use of the truck.Operating and maintena

2351514 ENGINEASSEMBLY00.012-999279 1 SHORT BLOCK ASSEMBLY00.100-994724 1 ENGINE GASKET SET00.101-9947251VALVE GRIND GASKET SET01.085-890883 1 0IL PAN

7-9

7-10

7-11

7-12

7-13

7-14

7-15

7-16

7-17

direction of impeller rotation because ofa sprag clutch built into the stator; anda turbine which is driven by the fluidthrown from the impeller. Each

7-18

7-19

7-20

7-21

7-22

7-23

7-24

7-25

7-26

7-27

3-17. When low speed is selected, withthe transmission in forward gear, theforward and low packs are engaged.Power flow goes from the forward gear,thr

7-28

7-29

7-30

7-31

THE COMPONENTS OF THIS CONVERTER CHARGINGPUMP ARE NOT SERVICEABLE, REPLACE WITH ANEW PUMP,START -1-4560END -AND ABOVECONVERTER PUMP450263 CONVERTER PU

7-33

7-34

7-35

7-36

7-38

7-39

06-418 DIRECTIONAL CONTROL LINKAGE05.179-130039605.180-130039605.181-13009605.182-130039606.006-71366806.007-131825606.008-4F610606.008-1F31206.009-2J

7-41

7-42

7-43

START - 1-4560END -AND ABOVETRANSMISSION MOUNTING PARTS7-44

7-45

7-46

7-47

3-20. DRIVE AXLE. The drive axle is mounteddirectly to the transmission and is driven by thespiral bevel pinion on the ‘transmission outputshaft. The

7-48

7-49

7-50

7-51

7-52

7-53

7-54

7-55

7-56Change 1

7-57

WARRANTYAny defects in material or workmanship,under normal use and service for aperiod of 15 months from date of acceptance or 1500 vehicle operating

LEGEND FOR FIGURE 3-2INDEX NO.NOMENCLATURENORMAL USE OR READ I NC1.Ignition SwitchWhen turned fully clockwise, actuates enginestarter — when released,

7-58

7-59

Page 7-60 is rescinded.Change 17-61

7-62

Page 7-63 is rescinded.7-64Change 1

23-696 HYDRAULIC BRAKE LINES23.142-16F21PLUG23.436-1309676123.146-13096761FITTING23.437-8922502FITTINGBLEEDER23.173-859727 1FITTING23.438-2352547LINE2

23-772 BRAKE PEDAL AND LINKAGE22.027-8D71122.040-8D71122.055-13028131123.084-1C6141123.085-1C6141123.100-23482811223.114-1618250123.876-1C628 423.118-

7-67

Figure 3-2.Operators Controls and Instruments3-27.DRIVING THE TRUCK,a. Accelerate the engine slightly and move thelift control lover gradually to the

7-68Change 1

7-69

7-70Change 1

1618298 STEERING GEAR ASSEMBLY25.032-99173525.033-85006325.034-1C71625.034-23E725.039-40K825.040-89845725.041-89845825.042-89845925.043-1C61225.043-23

25-177 SLEERING LINKAGE25.031-169786025.031-23E1425.047-130595925.047-7D825.051-171918725.054-12H1525.055-1F53025.056-89435525.063-163642625.064-2C836

894355 BALL SOCKET ASSEMBLY25.056-8943551BALL SOCKET ASSEMBLY25.057-4292241SPRING GUIDE25.058-4292251SPRING25.059-4292262PRESSURE CUP25.060-8863311PLU

180040 POWER STEERING CYLINDER ASSEMBLY26.000-1800401126.001-1351011126.002-755855126.003-136882126.004-1368611126.005-134455126.006-10J6126.007-13505

193348 STEERING AXLE ASSEMBLY (CONTINUED)26.100-1933481STRG AXLE ASSEMBLY226.121-13G732CCUP2SCREW26.135-65416726.136-1223542HUB & CUP26.122-10879

193348 STEERING AXLE ASSEMBLY (CONTINUED)26.100-1933481126.101-1071362126.102-1034044226.103-2C7304126.104-12H152126.105-10H252126.106-1115634226.107-

START -1-4560END - AND ABOVEPOWER STEERING LINES26-116 POWER STEERING LINES28.258-91F7128.290-667289129.090-1765756131.098-42H10231.099-130705926"

When driving the truck, never "ride"the inching brake pedal as this willdamage the transmission.3-28. PICKING UP THE LOAD.NoteAt least once

2316008 POWER STEERING PUMP ASSEMBLY29.200-2316008129.202-993346129.203-991988129.208-1C548J229.208-784057229.214-6J605129.217-992214229.228-993347129

26-404 STEERING PUMP DRIVE29.200-231600829.212-4D829.269-1C62429.270.61805329.271-168657790.891-23E692.194-1F32092.195-8746061STEERING PUMP ASSEMBLY1N

29-052 HYDRAULIC PUMP DRIVE29.100-23349541HYDRAULICPUMPASSEMBLY29.106-2C8282 CAPSCREW29.114-4D101NUT29.143-25E291WASHER29.149-23515121GEAR29.150-23515

START -1-4560END - AND ABOVEHYDRAULIC SUMP FILTER1799525 HYDRAULIC SUMP FILTER ASSEMBLY29.738-179952529.728-177901129.740-181043729.742-179801229.754-

2334954 HYDRAULIC PUMP ASSEMBLY29.100-2334954 129.119-11G652J4HYDRAULIC PUMP ASSEMBLY29.119-994580BOLT429.140-6J808WASHER129.146-9944721KEY29.171-9959

3734222 HYDRAULIC VALVE ASSEMBLY (CONTINUED)30.000-373422230.100-90534230.001-89292330.002-89292430.002-89292530.006-88807430.018-24K630.020-88814030.

3734222 HYDRAULIC VALVE ASSEMBLY (CONTINUED)30.108-99022330.033-1C63230.039-89292430.039-89292530.040-89292330.064- NOT USED30.107-1C68830.107-61D630.

30-095 VALVE CONTROL LINKAGE30.085-1685098 2130.089-2348889 1130.090-1685092 1130.092-4F6106 1130.092-1F310 1130.094-2314196 1130.097-2314196 1130.099

1692517 AUXILIARY VALVE ASSEMBLY30.200-1692517 130.260-9Jl0 130.261-990078 130.262-990079 130.264-990080 130.268-99008130.269-990082130.270-990083 130

233471 TILT LOCK VALVE ASSEMBLY31.500-23347128.461-91F331.501-47K731.503-91F731.504-13501331.505-23346731.506-47K331.508-1C64031.508-23E631.512-135049

Figure 3-4. Fork Latch Disengagedc. Drive the truck forward until the load is aboveits resting place. To slowly maneuver the truckforward while high e

31-530HYDRAULIC TILT LINES31.061-130342931.062-17K631.065-91F631.070-130200031.071-130200031.072-172394931.073-172394931.075-17K531.077-17K531.081-742

31-819 MAIN HYDRAULIC AND LIFT LINES28.335-130106015"31.006-130903710''31.007-42H322231.008-2332872131.010-25K401161131.011-19J202231.0

31-955 HYDRAULIC VALVE MOUNTING30.000-3734222 130.033-1C632130.061-24K7130.195-1C724231.038-25K40028190.573-25E19290.574-25E18190.575-23E6190.576-61D6

START -1-4560END - AND ABOVETILT CYLINDER1791918 TILT CYLINDER ASSEMBLY32.000-17919181132.001-17919181132.002-1002391132.005-7438102132.008-7577571132

START -1-4560END - AND ABOVETILT CYLINDER MOUNTING32-058 TILT CYLINDER MOUNTING32.027-174852732.029-1C104432.030-175822532.031-1F74832.032-10H2532.033

M0772 UPRIGHT ASSEMBLY34.000-M077234.001-234055934.002-2C61434.013-34295734.014-66265534.036-130184834.042-130709234.043-173024134.044-93G102434.050-2

START -1-4560END - AND ABOVE7-94

2355448 LIFT CYLINDER ASSEMBLY34.400-235544834.401-2355201134.402-181116434.465-16G40634.475-174125934.477-178036034.478-235702034.479-165708834.490-2

34.400LIFTCYLINDERMFH ASSEMBLY149 235544834.401 34.475 34.49134.515 34.526SHEAVEINNERINTERMEDIATEFEEDCARRIERRAILRAILBARRELTUBEROD RODRODMFH2355201 174

START -1-4560END - AND ABOVELIFT CYLINDER PIPINGM0772 UPRIGHT ASSEMBLY (CONTINUED)34.444-23306561FLOW CONTROL VALVE34.543-94G4284CAPSCREW34.547-25K200

f. Turn the starter and ignition switch to OFFposition to stop the engine.If the engine has been operating at, or near,full load, it should be allowed

2355320 CARRIAGE ASSEMBLY34.301-666354AR34.307-130017734.308-39845334.310-74G62434.310-8E634.316-34295734.320-172951434.323-76332134.324-61903834.325-

START 1-4560END - AND ABOVEUPRIGHT SUPPORT34-712 UPRIGHT SUPPORT34.036-13018484BUSHING34.040-13017982BUSHING34.600-3363472SUPPORT SHAFT34.604.7948292L

34-748 LOAD SAFETY RACK34.998-93G632 4BOLT34.999-2344665 1LOAD SAFETY RACK92.226-23421294 NUT7-100

M0772 UPRIGHT ASSEMBLY (CONTINUED)34.080-659065234.100-2306721134.101-1703719234.102-156606134.103-1697965234.104-1F212234.107-1703720234.108-17721712

38-022 FRAME AND COUNTERWEIGHT38.020-232809102.022-77456329.732-774563138.093-175819038.100-1C61038.488-34967938.851-1C820138.852-163649838.853-235214

START -1-4560END - AND ABOVEINSTRUMENT PANEL39-086 INSTRUMENT PANEL13.023-17438261113.024-6485561113.028-9472571113.029-15341361413.030-12D6 113.032-1

START - 1-4560END - AND ABOVESEAT ASSEMBLYSEAT ASSEMBLY39.719-995189137.204-995305137.205-995286137.206-995287139.720-995190139.721-995191139.722-9953

START -1-4560AND - AND ABOVESEAT MOUNTING39-173 SEAT MOUNTING39.726-1649241 1SEAT ADJUSTOR (LH)39.727-995223 1SEAT ADJUSTOR (RH)39.728-43G516 4CAPSCRE

START -1-4560END AND ABOVEOVERHEAD GUARD39-204 OVERHEAD GUARD39.932-23539371OVERHEADGUARD39.933-93G8202 CAPSCREW39.934-1C8242 CAPSCREW90.962-23E82LOCK

START -1-4560END - AND ABOVESHEET METAL AND TRIM39-493 SHEET METAL AND TRIM37.014-173953437.308-61902139.535-1719070BRACKET (LH)239.536-1719069BRACKET

Preventive Maintenance Instructions given in thismanual.o. Avoid overloading the truck - this is ahazardous practice, for the operator as well as thee

39-494 SHEET METAL AND TRIM37.022-1725216137.161-17J224137.210-1784637139.475-2353138139.479-1C620239.484-1C610239.540-1797793139.541-1307834639.544-1

40-090 DATA PLATES AND DECALS40.000-231570940.001-175192440.006-174770640.008-233878040.010-234890440.011-234890440.019-235003340.024-178166040.025-17

2354694 HOSE ADAPTATION KITHOSE ADAPTATIONSTART - 1-4560END - AND ABOVEFOR DEVICE7-11075.031-235469434.103-178228250.006-234645950.007-234509050.200-1

2354694 HOSE ADAPTATION50.565-1C51250.566-lC51250.814-86F650.819-234063950.837-131600890.285-23ES90.286-61D590.287-61D490.289-23E590.292-23E590.293-7D

2329090 SIDE SHIFTER CYLINDER53.020-232909053.102-232880353.105-232906253.106-25K40200053.107-73096553.108-232461953.109-232897253.112-165708453.113-2

2355779 SIDE SHIFTER PACKAGE53.099-235577940.054-174772851.531-9K151.699-9K152.148-80F552.149-80F553.003-235578553.020-232909053.022-70D2053.023-23176

2343853 CRANKCASE VENTILATION KIT75.411-234385300.123-99186800.127-66686400.134-177962900.135-65624700.141-66683900.146-42H1000.165-lC41200.165-23E402

2339254 LIGHT INSTALLATION75.200-233925413.062-70768813.063-31648413.214-85237213.216-179698013.221-175253113.223-62031313.241-33657013.270-172177714.

2362319 AUXILIARY VALVE INSTALLATION KIT75.021-236231928.483-1F31030.061-16F630.200-169251730.278-1C53230.582-1C54030.817-168975830.843-176330730.845-

NUMBERICAL INDEX73370MFGR.VENDORMFGR.VENDORNO.VENDOR NO.CODENO. VENDOR NO.CODE01100200103405L-18-SV-5000-Z1192867103406L-18-SV-148-A-95HM-894115987560

b. Fill fuel tank at the end of the day to expelmoisture.3-48. DUSTY CONDITIONS.3-46. HUMID CLIMATES.3-47. In tropical areas, if paint is chipped, ors

NUMBERICAL INDEXMFGR.VENDORMFRG.VENDORNOVENDOR NO.NO.NO. VENDOR NO.NO.65899865906566016066040866155666326466878871251271283971315573362373008673363374

NUMBERICAL INDEXMFGR.VENDORMFGR.VENDORNO.VENDOR NO.CODENO.VENDOR NO.CODE892294892925893051893513894355895388895389895390895887895888896125896126896605

NUMBERICAL INDEXMFGR.VENDORMFGR.VENDORNO.VENDOR NO.CODENO.VENDOR NO.CODE990078 32078662983 993154 A-22014464104990079 32097362983 993346 7152674568199

NUMBERICAL INDEX99591499593199593299595399595499646599646699683099683199757599860099860199860299871299871399892099892299892599917099917299917399925399

TM 10-3930-647-14&PSUPPLEMENTAL OPERATING, MAINTENANCEAND REPAIR PARTS INSTRUCTIONSFORTRUCK, LIFT, FORK, PNEUMATIC TIREGASOLINE ENGINE DRIVEN, 4,0

TM 10-3930-647-148 PE.MAINTENANCE AND OPERATING SUPPLY LIST...F.PREVENTIVE MAINTENANCE CHECKS AND SERVICES. . . . . . . . . .

TM 10-3930-647-14&PTHIS PAGE INTENTIONALLY LEFT BLANK3

TM 10-3930-647-14&P4

TM 10-3930-647-148 PSECTION IGENERAL1-1. Purpose.To provide the user and support personnel sup-plemental maintenance and repair parts in-structions (S

SECTION IVPERIODIC INSPECTION, MAINTENANCEAND LUBRICATION4-1. SPECIAL TOOLS.4-2. Special tools required for the performance ofinspection, maintenance

7530-01-065-0166TM 10-3930-647-14&PSECTION IIMAINTENANCE2-1. Maintenance Concept.a Maintenance operations. The 4,000-Lb. Clarkmodel C500Y45 will n

TM 10-3930-647-14&P2.9 Special Tools and Equipment.Special tools and equipment are not required for the4,000-lb. Clark model C500Y45.2.10 Maintena

TM 10-3930-647-14&PSECTION IIIREPAIR PARTS SUPPLY3.1 General.a. The basic policies and procedures in AR 710-2and AR 725-50 are generally applicabl

TM 10-3930-647-14&Pwill be forwarded through DAAS to the DefenseConstruction Supply Center (DCSC) (app. J). Sam-ple formats for requisitioning are

TM 10-3930-647-14&PAPPENDIX ASPECIAL NOTES AND CORRECTIONThe package guard (backrest) should be removed prior to the loading or unloading of mil-v

TM 10-3930-647-14&PAPPENDIX BWARRANTY GUIDELINES1. The warranty period is 15 months from date ofacceptance or 1500 hours of operation, whichever o

TM 10-3930-647-14&PAPPENDIX CMAINTENANCE ALLOCATION CHARTFORTRUCK, FORKLIFT, GED, SRT, 4,000-LB.CAPACITY, CLARK MODEL C500Y45Section I. INTRODUCTI

TABLE 3. PREVENTIVE MAINTENANCE INSPECTIONAXLESCheck and tighten wheel driving flange bolts.Check security of axle mounting to frame.Check differentia

TM 10-3930-647-14&Pitem listed in column 2.d. Column 4-Maintenance Category. ColumnFour (4) specifies, by the listing of a “work time”figure in th

TM 10-3930-647-14&PSection II. MAINTENANCE ALLOCATION CHART(1)Groupnumber010100(2)ComponentassemblyEngineEngine Assembly0101Block, Short AssemblyC

TM 10-3930-647-14&P(1)Groupnumber(6)Remarks0603Starter Motor0.31.00605Switch, Starter IgnitionDistributor Assembly0607Ignition CoilwiringSpark Plu

TM 10-3930-647-14&P(1)Groupnumber(4)Maintenance level121201BrakesHand Brakes, Lever & LinkageParking Brake1202Service Brake1.51.52.54.05.02.01

TM 10-3930-647-14&P(1)Groupnumber2405(2)ComponentassemblyLift CylinderMast&Carriage Assembly2406Hydraulic Lines & Fittings2407Side Shift C

TM 10-3930-647-14&PTool or testequipmentreferencecode12MaintenanceNational/NATOcategoryNomenclature stock numberUNLESS OTHERWIDE NOTED. ALL MAINTE

TM 10-3930-647-14& PSection IV. REMARKSReferencecodesRemarksNONE NONEC-9

tm10-3930-647-14&pD-1/(D-2 blank)NSN3830-01-085-3767APPENDIX DMAINTENANCE EXPENDITURE LIMITSItem identificationTruck, Lift, Fork, Gasoline Engine

TABLE 3. PREVENTIVE MAINTENANCE INSPECTION (Continued)ENGINECheck cylinder head nuts.Check manifold nuts and gasket.Check tappet clearance and oil sup

E-1TM 10-3930-647-14&PAPPENDIX EMAINTENANCE AND OPERATING SUPPLY LISTNomenclature:MFR part No.:Make:Truck. Lift, Fork, 4K. GED, PT 144” LiftClarkN

E-2TM 10-3930-647-14&PNOTES:1. For Operation of Equipment in Protected ColdTemperatures Below -10F. Remove lubricantsprescribed in the key for tem

APPENDIX FTM 10-3930-647-14&PPREVENTIVE MAINTENANCE CHECKS AND SERVICESSection I. OPERATOR/CREW PMCS1. Do your before (B) PREVENTIVE MAIN-TENANCE

TM 10-3930-647-14&PIntervalItemNo.123456789101112131415Operator Crew Preventive Maintenance Checks and ServicesB-Before D-DuringA-AfterW-WeeklyM-M

TM 10-3930-647-14&POperator/Crew Preventive Maintenance Checks and Services-ContinuedB-BeforeD-DuringA-AfterW-Weekly M-MonthlyIntervalItem to be i

TM 10-3930-647-14&PSection II. ORGANIZATIONAL PMCS1. Do your (Q) PREVENTIVE MAINTENANCEonce each 3 months.2. Do your (S) PREVENTIVE MAINTENANCEonc

TM 10-3930-647-14&P)Item No.1234567891011200200200200400400500500500500500121314151617F-6Organizational Preventive Maintenance Checks and Services

Item No.TM 10-3930-647-14&POrganizational Preventive Maintenance Checks and Services-ContinuedQ-QuarterlyS-Semiannually A- Annually B-BienniallyH-

TABLE 3. PREVENTIVE MAINTENANCE INSPECTION (Continued)INSPECTION INVERVALHYDRAULIC SYSTEMReplace filter, inspect for proper operationand leaks.Check p

G-1TM 10-3930-647-14&PAPPENDIX GPRESCRIBED LOAD LIST/AUTHORIZED STOCKAGE LISTItem: Truck, Forklift, 4,000 Lb., GED, PTContract No.: DAAE07-79-C-58

TM 10-3930-647-14&PAPPENDIX HDISTRIBUTION CODES1. Card Columns 55 and 56Leave blank.2. Card ColumnCONUS customers will use “F” in column 54.OCONUS

APPENDIX ITM 10-3930-647-14&PFLOW OF REQUISITIONS AND MATERIELCHE PARTS (NSN)TA 126332I-1/(1-2 blank)

TM 10-3930-647-14&PAPPENDIX JFLOW OF REQUISITIONS AND MATERIELCHE PARTS (NON-NSN)TA 126333J-1/(J-2 blank)

TM 10-3930-647-14&PAPPENDIX KSAMPLE FORMAT - MILSTRIP REQUISITION FOR CHE (NSN)CARDDESCRIPTIONMANDATORY ENTRYCOLUMNOF DATAFOR CCE1-34-678-2223-242

Figure 4-1. Lubrication Chart (Sheet 1 of 2)4-5

TM 10-3930-647-14&PCardColumn67-697071-80Descriptionof DataBlankIdentification CodeApplicable to Entryin cc 71-80A -Technical Orderor TechnicalMan

TM 10-3930-647-14&PSAMPLE FORMAT - MILSTRIP REQUISITION FOR CHE (NON-NSN)CARDDESCRIPTIONMANDATORYENTRYCOLUMNOF DATA FOR CCE1-34-678-2223-2425-2930

TM 10-3930-647-14&PCardColumn67-697071-80Descriptionof DataBlankIdentification CodeApplicable to Entryin cc 71-80A - Technical Orderor TechnicalMa

TM 10-3930-647-14&PSAMPLE FORMAT - MILSTRIP REQUISITIONFORMHE/CCE (NON-NSN) (MANUAL)TA 126336K-5

TM 10-3930-647-14&PINSTRUCTIONSThis form will only be used in those cases where the manufacturer's codeand part number exceed the spaces allo

TM 10-3930-647-14&PBy Order of the Secretary of the Army:Official :E. C. MEYERGeneral, United States ArmyChief of StaffROBERT M. JOYCEBrigadier Ge

4-6Change 1Figure 4-1. Lubrication Chart (Sheet 2 of 2)

PIN:049900-002

Figure 4-2. Opening Side Panel4-7. AIR CLEANER (cont.)a. Refer to figure 4-3 and remove wing nut (1)from center stud (2) and remove element case (3).W

This fine document...Was brought to you by me: Liberated Manuals -- free army and government manualsWhy do I do it? I am tired of sleazy CD-ROM sell

1.Wingnut 4.Hydraulicsump breather7.Master cylinder2. Center stud5. Sump filter cover platefiller cap3.Element case6.PCV valve8.Filter cartridgeFigure

Figure 4-4. Element and Case Figure 4-5. Air Cleaner Hose Connectionsd. Refer to figure 4-2 and remove filter cartridge(8) by unscrewing from base. If

Figure 4-7. Checking Oil LevelFigure 4-8. Transmission Drain Plugb. Clean drain plugs of all foreign material, usingsolvent,SpecificationP-D-680, and

Figure 4-10. Sump Screen Removaltransmission/steering filter cartridge by unscrewingfrom the filter base.g. Clean off the filter base, and install a n

1.Fuel tank filler5.Distributor2.Trammission/steeringfluidfilter 6.Crankcase dipstick3. Inching master cylinder4.Ignition coil8.Fuel filterFigure 4-11

Figure 412. Transmission Refill ProcedureFigure 4-13. Draining Hydraulic System fromMain Control ValveFigure 4-14. Draining Sump TankFigure 4-15. Remo

CHANGENO. 2TM 10-3930-647-14&PC2HEADQUARTERSDEPARTMENT OF THE ARM-YWashington D.C., 18 March 1991OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORTAND GEN

Figure 4-16. Sump Filter Assembly4-14

Figure 4-19. Sump Tank Refi ProcedureFigure 4-17. Element Retainer NutsFigure 4-18. Filter Disassembledk. Remove the three filter element retainer nut

Figure 4-21. Fuel Filler Cap and Filter Screen4-11. FUEL SYSTEM SERVICE. The fuel systemshould be checked periodically for leakage at tubefittings and

d. Check radiator dd water pump gasketsurfaces and hose connections for leakage.e. Blow out debris and foreign material fromradiator core by directing

Figure 4-24. Radiator Cap Sealing Surfacea weighted vacuum valve which hangs open untilforced closed by a surge of vapor or coolant. Checkto be sure c

Figure 4-17.Thermostat Testf. If thermostat starts to openbefore 175 F. or doesn't open until185° F.,it is defective and must bereplaced.open at

9.If on the other hand it is obviousthat the viscous fan clutch did not engageand increase the fan speed, the clutch canbe considered defective due to

Figure 4-30. Pedal Adjustmentse.Pedal up-height must conform tob.Check the master cylinder fillerthe dimensions shown in figure 4-30.cap vent hole.Thi

Figure 4-31. Master Cylinder Cross Section4-19. BLEEDING BRAKE SYSTEM. Wheneverthe brake system is opened for any reason, such asrepairs to master cyl

Figure 4-32. Brake System Bleed Pointsd. Place a flat pan under the axle adapter tocatch brake fluid spillage, and connect the pressurebleeder line to

Figure 4-33. Pressure Bleeder Hook-uph. When air bubbles stop coming into thecontainer, close the bleeder fitting and remove thetube. Close bleeder ta

Figure 4-34. Axle Adapter Bleed PointsFigure 4-35. Bleeder JarFigure 4-36. Inching Valve Bleed Point4-25

may be performed when pressure bleedingequipment is unavailable. Manual bleeding willrequire two men, one to depress and hold thebrake pedal while the

Figure 4-37. Parking Brake and Linkagec. Refer to figure 4-37 and locate the adjusternut. Turn this nut clockwise until all slack isremoved from the b

Figure 4-38. Checking Battery Specific GravityNever allow sparks or open flame in thearea when checking the battery. Storagebatteries produce hydrogen

Figure 4-39. Battery Test Hook-upand the difference between highest and lowest cellis less than 0.05 volt, battery is good but requirescharging.f. If

an immovable object, or by applying a correctlyadjusted parking brake equipped with good brakelinings. Place the machine in gear and accelerateengine

Figure 4-41. Valve ArrangementFigure 4-42. Setting Valve Lash4-39. VALVECLEARANCE (LASH)ADJUSTMENT. Maintaining the proper valve lashsetting is one of

Figure 4-43. Compression Check4-40. COMPRESSION CHECK.A cylindercompression test aids in determining the conditionof the valves, rings and head gasket

Figure 4-44. Spark Plug Inspection Chart4-33

TM 10-3930-647-14&PC1CHANGENo. 1HEADQUARTERSDEPARTMENT OF THE ARMYWashington, D.C., 22 December 1989OPERATOR’S, ORGANIZATIONAL, DIRECT SUPPORTAND

e. After cleaning, examine the plug carefully forcracked or broken insulator, badly erodedelectrodes and other signs of failure. Replace asrequired.f.

Figure 4-45. Breaker Point InspectionFigure 4-46. Breaker Point Metal Transferd. After an adjustment has been made to onespring, check the minimum adv

Figure 4-47. Filing Contact Pointscrater will form in the negative contact. See figure4-46.e. For a temporary repair, dress the contactpoints with a f

f. Insert a screwdriver blade into the adjustmentslot in point set and breaker plate as shown infigure 4-49.g. Rotate screwdriver blade until only a v

Figure 4-51. Checking Timing with Timing Lightc. Connect plug wire to spark plug adapter.d. Clamp timing light spark plug lead to the sparkplug adapte

Figure 4-53. Intake Manifold Vacuum Test(2150 RPM) which should be 14-16 inches.f. With operator on seat and engine atfull throttle, hold tilt lever a

Figure 4-54. Idle Mixture Adjustmentdamaged it must be replaced before a satisfactoryfuel mixture can be obtained.4-54. INITIAL IDLE SPEED ADJUSTMENT

Figure 4-56. Pedal and Linkage Adjustmenth. Check the engine idle (hot engine) speed andadjust it to specifications, if necessary. See figure4-55 for

Figure 4-57. Governor and Linkage Adjustmentwarmed to normal operating temperature.a. Start the engine and run at idle until it hasindicated by an aud

#10978 Typical Frame-To-AxleAdapter BoltsSTEERING SYSTEM ADJUSTMENT:NOTEIn making power steering adjustments, we areout to acomplish these basic thing