Maintenance Repair Parts And Special Tools Lists Truck, Forklift .

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TM 10-3930-622-24P TECHNICAL MANUAL UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS TRUCK, FORKLIFT: GASOLINE ENGINE, PNEUMATIC TIRES, 6000 LB CAPACITY, 173 IN. LIFT BAKER MODEL FJF-060 (NSN 3930-00-235-4674) ARMY MODEL MHE210 This manual supersedes TM 10-3930-622-20P, dated 10 March 1971 and TM 10-3930-622-35P, 10 March 1971, and all changes. Approved for public release, distribution is unlimited HEADQUARTERS, DEPARTMENT OF THE ARMY AUGUST 1992

TM 10-3930-622-24P C1 CHANGE HEADQUARTERS DEPARTMENT OF THE ARMY Washington D.C., 24 May 1993 NO. 1 UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS TRUCK, FORKLIFT. GASOLINE ENGINE, PNEUMATIC TIRES, 6000 LB CAPACITY, 173 IN. LIFT BAKER MODEL FJF-060 (NSN 3930-00-235-4674) ARMY MODEL MHE210 Current as of 12 March 1993 TM 10-3930-622-24P, dated 26 August 1992, is changed as follows: 1. Remove old pages and insert new pages. 2. New or changed material is indicated by an asterisk or by a vertical bar in the margin of the page. Remove Pages Insert Pages 1-1 through Figure 3 4-1 through Figure 7 8-1 and Figure 9 14-1 and Figure 15 17-1 and Figure 18 22-1 through Figure 24 26-1 and Figure 27 28-1 through Figure 31 32-1 and Figure 33 34-1 through Figure 36 37-1 and Figure 38 39-1 through 40-2 41-1 through Figure 44 45-1 and 45-2 46-1 and 46-2 47-1 through Figure 50 Figure 52 54-1 through 57-2 58-1 through 592 62-1 through 65-2 68-1 through 692 Kits- 1 and Kits-2 I-1 through 1-61 1-1 through Figure 3 4-1 through Figure 7 8-1 and Figure 9 14-1 and Figure 15 17-1 and Figure 18 22-1 through Figure 24 26-1 and Figure 27 28-1 through Figure 31 32-1 and Figure 33 34-1 through Figure 36 37-1 and Figure 38 39-1 through 40-2 41-1 through Figure 44 45-1 and 45-2 46-1 and 46-2 47-1 through Figure 50 Figure 52 54-1 through 57-2 58-1 through 59-2 62-1 through 65-2 68-1 through 69-2 Kits- 1 and Kits-2 I-1 through 1-61 3. File this change sheet in front of the publication for reference purposes. Approved for public release; distribution is unlimited. 1

TM 10-3930-622-24P By Order of the Secretary of the Army: GORDON R. SULLIVAN General, United States Army Chief of Staff Official: MILTON H. HAMILTON Administrative Assistant to the Secretary of the Army Distribution: To be distributed in accordance with DA Form 12-25-E (Block 5770) requirements for TM10-3930-622-24P. 2

TM 10-3930-622-24P TECHNICAL MANUAL HEADQUARTERS DEPARTMENT OF THE ARMY Washington D.C., 26 August 1992 *TM 10-3930-622-24P UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS TRUCK, FORKLIFT. GASOLINE ENGINE, PNEUMATIC TIRES, 6000 LB CAPACITY, 173 IN. LIFT BAKER MODEL FJF-O80 (NSN 3930-00-235-4674) ARMY MODEL MHE210 Current u of 21 February 1992 REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help Improve this manual. If you find any mistakes or If you know of a way to Improve the procedures, please let us know. Mail your letter, DA Form 2028 (Recommended Changes to Publications and Blank Forms), or DA Form 2028-2, located in the back of this manual, direct to: Commander, U.S. Army Tank-Automotive Command, ATTN: AMSTA-MB, Warren, MI 48397-5000. A reply will be furnished to you. Approved for public release; distribution Is unlimited. TABLE OF CONTENTS Page SECTION I. SECTION II. GROUP 01 INTRODUCTION REPAIR PARTS UST Illus Fig 1 1-1 ENGINE 0100 0101 0102 0103 0104 - ENGINE ASSEMBLY . ENGINE MOUNTS . CRANKCASE. BLOCK. CYLINDER HEAD . CYLINDER BLOCK AND CRANKCASE . CYLINDER HEAD . CRANKSHAFT . CRANKSHAFT AND BEARING . FLYWHEEL ASSEMBLY . FLYWHEEL AND FLYWHEEL HOUSING . PISTONS AND CONNECTING RODS. PISTONS, PISTON RINGS, AND CONNECTING RODS. 1-1 1-1 2-1 2-1 3-1 4-1 4-1 5-1 5-1 6-1 6-1 *This manual supersedes TM 10-3930-622-20P, dated 10 March 1971 and TM 10-3930422-35P, dated 10 March 1971, and all changes 1 2 3 4 5 6

TM 10-3930-622-24P TABLE OF CONTENTS (Con’t) Page 0105 0106 - 0108 0125 GROUP 02 0302 0304 0306 0308 0312 - 16 14 FLUID COUPULING, TORQUE CONVERTER. FLUID TORQUE CONVERTER CLUTCH. CARBURETOR, FUEL INJECTOR . CARBURETOR. FUEL PUMPS . FUEL PUMP . AIR CLEANER . AIRCLEANER . TANKS, ULINES, FITTINGS, HEADERS. FUEL TANK AND LINES . ENGINE SPEED GOVERNOR AND CONTROLS. ENGINE SPEED CONTROL GOVERNOR. ACCELERATOR, THROTTLE, OR CHOKE CONTROLS. ACCELERATOR PEDAL AND LINKAGE, AND CHOKE CONTROL. 17-1 17-1 18-1 18-1 19-1 19-1 20-1 20-1 21-1 21-1 22-1 22-1 22 23-1 23-1 23 17 18 19 20 21 MUFFLER AND PIPES . EXHAUST SYSTEM. COOLING SYSTEM 0501 0503 0504 0505 - GROUP 06 16-1 16-1 9 10 11 12 13 EXHAUST SYSTEM 0401 - GROUP 05 15 7 8 FUEL SYSTEM 0301 - GROUP 04 7-1 7-1 8-1 9-1 9-1 10-1 11-1 12-1 13-1 14-1 14-1 15-1 15-1 CLUTCH 0203 - GROUP 03 VALVES, CAMSHAFTS, AND TIMING SYSTEM. TIMING GEAR FRONT COVER . VALVES, CAMSHAFT, AND TIMING GEAR . ENGINE LUBRICATION SYSTEM. LUBRICATING OIL LEVEL INDICATOR AND FILLER TUBE . LUBRICATING OIL PUMP. POSITIVE CRANKCASE VENTILATION VALVE AND TUBING . LUBRICATION OIL FILTER. OIL PAN AND OIL PUMP SCREEN . MANIFOLDS . EXHAUST AND INTAKE MANIFOLDS. ACCESSORY DRIVE ASSEMBLY . HYDRAULIC PUMP DRIVE . Illus Fig RADIATOR, EVAPORATIVE COOLER, OR HEAT EXCHANGER. RADIATOR . WATER MANIFOLD, HEADERS, THERMOSTATS, AND HOUSING . GASKET . COOLANT THERMOSTAT AND HOUSING. WATER PUMP. COOLANT PUMP . FAN ASSEMBLY. COOLANT FAN. 24-1 24-1 25-1 25-1 26-1 26-1 27-1 27-1 24 25 26 27 ELECTRICAL SYSTEM 0601 - GENERATOR, ALTERNATOR . ENGINE GENERATOR. ii 28-1 28-1 28

TM 10-3930-622-24P TABLE OF CONTENTS (Con’t) Page 0603 0605 0607 0609 0610 0612 0613 GROUP 07 0701 0703 0705 0721 - 1002 - 31 32 33 34 35 TRANSMISSION ASSEMBLY. TRANSMISSION. TRANSMISSION SHAFTS. TRANSMISSION SHAFTS AND GEARS. TRANSMISSION CLUTCH AND CLUTCH CONTROLS. TRANSMISSION DIRECTION CONTROL DRIVE CLUTCH. TRANSMISSION SHIFTING COMPONENTS. TRANSMISSION DIRECTION CONTROL AND INCHING VALVE. TRANSMISSION SHIFT CONTROL AND INCHING VALVE. COOLERS, PUMPS, MOTORS . TRANSMISSION OIL PUMP. TRANSMISSION AND CLUTCH OIL COOLER LINE . 36-1 36-1 37-1 37-1 38-1 38-1 39-1 39-1 40-1 41-1 41-1 42-1 36 37 38 39 40 41 42 PROPELLER SHAFTS . PROPELLER SHAFT COUPLER PARTS. 43-1 43-1 43 FRONT AXLE ASSEMBLY . FRONT AXLE ASSEMBLY . FRONT DRIVE AXLE. DIFFERENTIAL . FRONT DRIVE AXLE DIFFERENTIAL . 44-1 44-1 45-1 46-1 46-1 44 45 46 REAR AXLE 1100 1104 - GROUP 12 30 FRONT AXLE 1000 - GROUP 11 29 PROPELLER, PROPELLER SHAFTS, UNIVERSAL JOINTS, COUPLER, AND CLAMP ASSEMBLY 0900 - GROUP 10 29-1 29-1 30-1 30-1 31-1 31-1 32-1 32-1 33-1 33-1 34-1 34-1 35-1 35-1 TRANSMISSION 0700 - GROUP 09 STARTING MOTOR. STARTER MOTOR . IGNITION COMPONENTS. IGNITION DISTRIBUTOR AND SPARK PLUGS . INSTRUMENT OR ENGINE CONTROL PANEL. INSTRUMENT CLUSTER AND CONTROL SWITCH. LIGHTS . FLOODLIGHT AND COMBINATION STOPLIGHT-TAILLIGHT. SENDING UNITS AND WARNING SWITCHES . INSTRUMENT SENDING UNITS. BATTERIES, STORAGE. BATTERY. HULL OR CHASSIS WIRING HARNESS . TRUCK CHASSIS WIRING HARNESS AND CLAMPS . Illus Fig REAR AXLE ASSEMBLY. REAR AXLE ASSEMBLY. STEERING, SIDESHIFT, AND WHEEL LEANING MECHANISM . REAR AXLE STEERING MECHANISM. 47-1 47-1 48-1 48-1 48 49-1 49-1 49 47 BRAKES 1201 - HANDBRAKES . HAND PARKING BRAKE. iii

TM 10-3930-622-24P TABLE OF CONTENTS (Con’t) Page 1202 1204 - GROUP 13 1313 - 1407 1411 1412 - 1806 - 53-1 53-1 54-1 55-1 55-1 53 54 55 MECHANICAL STEERING GEAR ASSEMBLY. STEERING ASSEMBLY. POWER STEERING GEAR ASSEMBLY. STEERING GEAR ASSEMBLY . HOSES, LINES, FITTINGS. POWER ASSIST STEERING BOOSTER HYDRAULIC LINES . HYDRAULIC OR AIR CYLINDERS. POWER STEERING BOOSTER CYLINDER. 56-1 56-1 57-1 57-1 58-1 58-1 59-1 59-1 56 57 58 59 COUNTERWEIGHTS . LIFT TRUCK COUNTERWEIGHT . 60-1 60-1 60 BODY, CAB, HOOD, AND HULL ASSEMBLIES. ENGINE COMPARTMENT COVERS AND FLOOR PLATE . UPHOLSTERY, SEATS, AND CARPETS. OPERATOR’S SEAT. 61-1 61-1 62-1 62-1 61 62 BUMPERS, GUARDS, AND MARINE FENDERS 2101 - GROUP 24 WHEEL ASSEMBLY . REAR AXLE, SINGLE WHEEL . FRONT AXLE, DUAL WHEEL . TIRES, TUBES, TIRE CHAINS. TIRE AND TUBE. BODY, CAB, HOOD, AND HULL 1801 - GROUP 21 51 52 FRAME, TOWING ATTACHMENTS, DRAWBARS, AND ARTICULATION SYSTEMS 1502 - GROUP 18 50 STEERING 1401 - GROUP 15 50-1 50-1 51-1 51-1 52-1 WHEELS AND TRACKS 1311 - GROUP 14 SERVICE BRAKES. FRONT AXLE HYDRAULIC BRAKE. HYDRAUUC BRAKE SYSTEM. HYDRAUUC BRAKE SYSTEM. MASTER CYLINDER . Illus Fig BUMPERS, BRACKETS, GUARDS, AND PROTECTIVE DEVICES. OPERATOR’S OVERHEAD SAFETY GUARD. 63-1 63-1 63 HYDRAULIC AND FLUID SYSTEMS 2401 2402 - 2404 2405 - PUMP AND MOTOR. HYDRAULIC PUMP . MANIFOLD AND/OR CONTROL VALVES . HYDRAULIC LIFT AND TILT CONTROL VALVE . HYDRAULIC LIFT AND POWER STEERING SUPPLY FLOW DMDER VALVE HYDRAULIC CONTROL VALVE AND CONTROL LEVER. TILT CYLINDERS AND TILT CRANK. MAST TILT CYLINDER. MAST COLUMN. HYDRAULIC LIFT CYLINDER AND MAST. HYDRAULIC LIFT CYLINDER. iv 64-1 64-1 65-1 65-1 66-1 67-1 68-1 68-1 69-1 69-1 70-1 64 65 66 67 68 69 70

TM 10-3930-622-24P TABLE OF CONTENTS (Con’t) 2408 - GROUP 94 71-1 71-1 72-1 71 72 REPAIR KITS. REPAIR KITS. KIT-1 KIT-1 KIT BULK-1 BULK-1 BULK GENERAL USE STANDARDIZED PARTS 9501 - SECTION III. SECTION IV. llus Fig REPAIR KITS 9401 - GROUP 95 STRAINERS, FILTERS, UNES, AND FITTINGS, ETC . HYDRAUUC SYSTEM AND LINES . HYDRAUUC FLUID FILTER . Page BULK MATERIEL. BULK MATERIEL. SPECIAL TOOLS (NOT APPUCABLE) CROSS-REFERENCE INDEXES NATIONAL STOCK NUMBER INDEX. PART NUMBER INDEX . FIGURE AND ITEM NUMBER INDEX . v/(vi Blank) I-1 I-10 I-36

TM 10-3930-622-24P UNIT, DIRECT SUPPORT, AND GENERAL SUPPORT MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS SECTION I. INTRODUCTION figure and item number Index lists figure and Item numbers in alphanumeric sequence and crossreferences NSN, CAGE, and part numbers. 1. Scope. This RPSTL lists and authorizes spares and repair parts; special tools; special test, measurement, and diagnostic equipment (TMDE); and other special support equipment required for performance of Unit, Direct Support, and General Support Maintenance of the Forklift Truck. It authorizes the requisitioning, issue, and disposition of spares, repair parts and special tools as indicated by the source, maintenance and recoverability (SMR) codes. 3. Explanation of Columns (Sections II and IIl). a. ITEM NO. (Column (1)). Indicates the number used to identify items called out In the Illustration. The Source, b. SMR CODE (Column (2)). Maintenance, and Recoverability (SMR) code is a 5position code containing supply/requisitioning information, maintenance category authorization criteria, and disposition instructions, as shown in the following breakout: 2. General. In addition to Section I. Introduction, this Repair Parts and Special Tools List is divided into the following sections: a. Section II. Repair Parts List. A list of spares and repair parts authorized by this RPSTL for use In the performance of maintenance. The list also Includes parts which must be removed for replacement of the authorized parts. Parts lists are composed of functional groups in ascending alphanumeric sequence, with the parts in each group listed in ascending figure and Item number sequence. Bulk materials are listed in item name sequence. Repair kits are listed separately In their own functional group within Section II. Repair parts for reparable special tools are also listed in the section. Items listed are shown on the associated illustration(s)/figure(s). b. Section III. Special Tools List. A list of special tools, special TMDE, and other special support equipment authorized by this RPSTL (as Indicated by Basis of Issue (BOI) information in DESCRIPTION AND USABLE ON CODE column) for the performance of maintenance. c. Section IV Cross-reference Indexes. A list, in National Item Identification Number (NIIN) sequence, of all National stock numbered items appearing in the listing, followed by a list in alphanumeric sequence of all part numbers appearing in the listings. National stock numbers and part numbers are cross-referenced to each illustration/figure and item number appearance. The *Complete Repair: Maintenance capacity, capability, and authority to perform all corrective maintenance tasks of the ’Repair" function in a use/user environment in order to restore serviceability to a failed item. (1) Source Code. The source code tells you how to get an Item needed for maintenance, repair, or overhaul of an end item/equipment. Explanations of source codes follows: 1

TM 10-3930-622-24P Code Application/Explanation PA PB PC** PD PE Stocked items; use the applicable NSN to request/requisition Items with the se source codes. They are authorized to the category Indicated by the code entered In the 3d position of the SMR code. PF PG ** Items coded PC are subject to deterioration. drawing, number given. XC- Installation diagram, instruction sheet, field service drawing, that is identified by the manufacturer’s part number. XDItem is not stocked. Order an "XD"-coded item through normal supply channels using the CAGE and part number given, If no NSN Is available. NOTE: Cannibalization authorized, may be used the above source codes, or those aircraft support AR 700-42. Items with these codes are not to be KD requested/requisitioned individually. They KF are part of a kit which Is authorized to the maintenance category Indicated In the 3d KB position of the SMR code. The complete kit must be requisitioned and applied. MO-(Made at UMI Items with these codes are not to AVUM Level) be requested/requisitioned MF-(Made at DSI Individually. They must be made AVUM Level) from bulk material which Is MH-(Made at GS Identified by the part number In the DESCRIPTION AND USABLE ON CODE (UOC) column and ML-(Made at Spelisted In the Bulk Material group cialized Repair of the repair parts list In this Activity (SRA)) RPSTL. If the Item Is authorized MD-(Made at to you by the 3d position code of Depot) the SMR code, but the source code indicates it Is made at a higher level, order the Item from the higher level of maintenance. Items with these codes are not to be requested/requisitioned AO-(Assembled by Individually. The parts that make UMI AVUM up the assembled Item must be Level) requisitioned or fabricated and AF-(Assembled by assembled at the level of maintenance indicted by the DS/AVIM Level) source code. If the 3d position GS Category code of the SMR code authorizes you to replace the item, but the source code AL-(Assembled by indicates the item is assembled SRA) at a higher level, order the item AD-(Assembled by from the higher level of Depot) maintenance. XA - Do not requisition an "XA"-coded Item. Order Its next higher assembly. (Also refer to the NOTE following.) XB - if an "XB" Item is not available from salvage, order It using the CAGE and part or controlled exchange, when as a source of supply for Items with except for those source coded "XA" items restricted by requirements of (2) Maintenance Code. Maintenance codes tell you the level(s) of maintenance authorized to USE and REPAIR support items. The maintenance codes are entered in the third and fourth positions of the SMR code as follows: (a) The maintenance code entered In the third position tells you the lowest maintenance level authorized to remove, replace, and use an Item. The maintenance code entered in the third position will indicate authorization to one of the following levels of maintenance. Code Application/Explanation C- Crew or operator maintenance done within unit maintenance or aviation unit maintenance. OUnit maintenance or aviation unit category can remove, replace, and use the item. FDirect support or aviation intermediate level can remove, replace, and use the Item. HGeneral support level can remove, replace, and use the item. LSpecialized repair activity can remove, replace, and use the Item. DDepot level can remove, replace, and use the Item. (b) The maintenance code entered in the fourth position tells whether or not the item Is to be re-paired and identifies the lowest maintenance level with the capability to do complete repair (i.e., perform all authorized repair functions). (NOTE: Some limited repair may be done on the item at a lower level of mainten-ance, If authorized by the Maintenance Allocation Chart (MAC) and SMR codes.) This position will contain one of the following maintenance codes: Code Application/Explanation OUnit maintenance or aviation unit is the lowest level that can do complete repair of the Item. FDirect support or aviation intermediate is the lowest level than can do complete repair of the item. 2

TM 10-3930-622-24P H- d. PART NUMBER (Column (4)). Indicates the primary number used by the manufacturer (individual, company, firm, corporation, or Government activity), which controls the design and characteristics of the item by means of its engineering drawings, specifications standards, and Inspection requirements to identity an item or range of items. General support Is the lowest level that can do complete repair of the Item. LSpecialized repair activity is the lowest level that can do complete repair of the item. DDepot is the lowest level that can do complete repair of the Item. ZNonreparable. No repair Is authorized. BNo repair Is authorized. (No parts or special tools are authorized for the maintenance of a ’B"-coded item.) However, the item may be reconditioned by adjusting, lubricating, etc., at the user level. (3) Recoverability Code. Recoverability codes are assigned to Items to Indicate the disposition action on unserviceable items. The recoverability code Is entered in the fifth position of the SMR code as follows: Code Z- O- F- HD- LA- NOTE: When you use an NSN to requisition an Item, the item you receive may have a different part number from the part ordered. e. DESCRIPTION AND USABLE ON CODE (UOC) This column Includes the following (Column (5)). information: (1) The Federal item name and, when required, a minimum description to identify the item. (2) Physical security classification. Not Applicable (3) Items that are included in kits and sets are listed below the name of the kit or set on Figure KIT. (4) Spare/repair parts that make up an assembled item are listed immediately following the assembled item line entry. (5) Part numbers for bulk materials are referenced in this column In the line item entry for the item to be manufactured/fabricated. (6) When the item is not used with all serial numbers of the same model, the effective serial numbers are shown on the last line(s) of the description (before UOC). Not Applicable. (7) The usable on code, when applicable (see paragraph 5, Special Information). (8) In the Special Tools List section, the basis of issue (BOI) appears as the last line(s) in the entry for each special tool, special TMDE, and other special support equipment. When density of equipment supported exceeds density spread Indicated in the basis of issue, the total authorization is Increased proportionately. (9) The statement "END OF FIGURE" appears Just below the last item description in Column 5 for a given figure in both Section II and Section III. f. QTY (Column (6)). The QTY (quantity per figure column) indicates the quantity of the item used in the breakout shown on the illustration/figure, which is prepared for a functional group, sub-functional group, or an assembly. A "V" appearing in this column in lieu of a quantity indicates that the quantity is variable and the quantity may vary from application to application. Application/Explanation Nonreparable item. When unserviceable, condemn and dispose of the item at the level of maintenance shown In the 3d position of the SMR code. Reparable item. When uneconomically reparable, condemn and dispose of the item at unit maintenance or aviation unit level. Reparable item. When uneconomically reparable, condemn and dispose of the item at the direct support or aviation intermediate level. Reparable item. When uneconomically reparable, condemn and dispose of the item at the general support level. Reparable item. When beyond lower level repair capability, return to depot. Condemnation and disposal of item not authorized below depot level. Reparable item. Condemnation and disposal of item not authorized below specialized repair activity (SRA). Item requires special handling or condem nation procedures because of specific reasons (e.g., precious metal content, high dollar value, critical material, or hazardous material). Refer to appropriate manuals/directives for specific instructions. c. CAGEC (Column (3)). The Commercial and Government Entity (CAGE) Code (C) is a 5-digit alphanumeric code which is used to identify the manufacturer, distributor, or Government agency, etc., that supplies the Item. 4. Explanation of Columns (Section IV). a. NATIONAL STOCK NUMBER (NSN) INDEX. (1) STOCK NUMBER column. This column lists the NSN by National item Identification Number (NIIN) 3

TM 10-3930-622-24P (3) STOCK NUMBER column. This column lists the NSN for the Item. (4) CAGEC column. The Commercial and Government Entity (CAGE) Cod

MAINTENANCE REPAIR PARTS AND SPECIAL TOOLS LISTS TRUCK, FORKLIFT: GASOLINE ENGINE, PNEUMATIC TIRES, 6000 LB CAPACITY, 173 IN. LIFT BAKER MODEL FJF-060 (NSN 3930-00-235-4674) . *This manual supersedes TM 10-3930-622-20P, dated 10 March 1971 and TM 10-3930422-35P, dated 10 March 1971, and all changes.

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