TECHNICAL MANUAL UNIT, DIRECT SUPPORT AND GENERAL SUPPORT MAINTENANCE INSTRUCTIONS TABLE OF CONTENTS GENERAL INFORMATION PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS) TROUBLESHOOTING (UNIT) TROUBLESHOOTING (DIRECT SUPPORT) TROUBLESHOOTING (GENERAL SUPPORT) TRUCK, FORKLIFT, 4000 LB CAPACITY ROUGH TERRAIN, DED, PNEUMATIC TIRE MODEL MHE-271 (WITH CAB) NSN 3930-01-330-8906 MODEL MHE-270 (WITHOUT CAB) NSN 3930-01-330-8907 APPENDIX B - MAINTENANCE ALLOCATION CHART (MAC) APPENDIX C - EXPENDABLE/ DURABLE SUPPLIES AND MATERIALS APPENDIX E - TOOL IDENTIFICATION LIST DISTRIBUTION STATEMENT A. Approved for public release, distribution is unlimited. HEADQUARTER S DEPARTMENT OF THE ARMY JULY 1994
Unit, Direct Support and General Support Maintenance Manual TM 10-3930-664-24 HEADQUARTERS DEPARTMET OF THE ARMY Washington D.C., 19 July 1994 TRUCK, FORKLIFT, 4000 LB CAPACITY ROUGH TERRAIN, DED, PNEUMATIC TIRE MODEL MHE-271 (3930-01-330--8906) MODEL MHE-270 (3930-01-330-8907) REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS You can help improve this manual. If you find any mistakes, or if you know a way to Improve the procedures, please let us know. Mail your letter or DA Form 2028 (recommended changes to publications and blank forms) directly to: Commander, U.S. Army Tank-Automotive Command, ATNN: AMSTA-MMAA, Warren, MI. 48397-5000 A reply will be sent directly to you. TABLE OF CONTENTS Chapter/Section Title Page CHAPTER 1 INTRODUCTION... 1-1 Section I General Information... 1-1 Section II Equipment Description and Data... 1-6 Section III Principles of Operation... 1-23 Section IV General Maintenance Procedures... 1-31 CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS... 2-1 Section I Repair Parts; Special Tools; Test, Measurement, and... 2-1 Diagnostic Equipment (TMDE); and Support Equipment Section II Service Upon Receipt... 2-2 Section III Unit Preventive Maintenance Checks and Services (PMCS)... 2-3 Section IV Lubrication Instructions... 2-5 Section V Unit Troubleshooting... 2-9 Section VI Engine Component Maintenance... 2-68 Section VII Fuel System Maintenance... 2-92 Section VIII Exhaust System Maintenance... 2-143 Section IX Cooling System Maintenance... 2-145 Section X Electrical System Maintenance... 2-167 Section XI Transmission Maintenance... 2-258 Section XII Propeller and Propeller Shaft Maintenance... 2-273 Section XIII Front Axle Assembly Maintenance... 2-283 Section XIV Rear Axle Assembly Maintenance... 2-287 Section XV Brake Maintenance... 2-291 Section XVI Wheel Maintenance... 2-307 Section XVII Steering Component Maintenance... 2-315 Section XVIII Frame, Towing Attachments, and Drawbar Maintenance... 2-333 Section XIX Body, Cab, Hood, and Hull Maintenance... 2-342 Section XX Body, Chassis, and Hull Accessory Item Maintenance... 2-378 Approved for public release; distribution Is unlimited i
CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS (cont) Section XXI Hydraulic and Fluid Systems Maintenance... 2-392 Section XXII Non-Electrical Gage Maintenance... 2-454 CHAPTER 3 DIRECT SUPPORT MAINTENANCE INSTRUCTIONS... 3-1 Section I Repair Parts; Special Tools: Test, Measurement, and... 3-1 Diagnostic Equipment (TMDE); and Support Equipment Section II Direct Support Troubleshooting... 3-1 Section III Engine Component Maintenance... 3-8 Section IV Fuel System Maintenance... 3-61 Section V Cooling System Maintenance... 3-88 Section VI Electrical System Maintenance... 3-90 Section VII Transmission Maintenance... 3-103 Section VIII Front Axle Maintenance... 3-125 Section IX Rear Axle Maintenance... 3-134 Section X Brake Maintenance... 3-144 Section XI Steering Component Maintenance... 3-146 Section XII Frame, Towing Attachments, and Drawbar Maintenance... 3-162 Section XIII Body, Cab, Hood, and Hull Maintenance... 3-163 Section XIV Body, Chassis, and Hull Accessory Item Maintenance... 3-196 Section XV Hydraulic and Fluid Systems Maintenance... 3-201 CHAPTER 4 GENERAL SUPPORT MAINTENANCE INSTRUCTIONS... 4-1 Section I Repair Parts; Special Tools: Test, Measurement, and... 4-1 Diagnostic Equipment (TMDE); and Support Equipment Section II General Support Troubleshooting... 4-1 Section III Engine Component Maintenance... 4-9 Section IV Transmission Maintenance... 4-38 Section V Front Axle Maintenance... 4-70 Section VI Rear Axle Maintenance... 4-86 Section VII Brake Maintenance... 4-100 Section VIII Frame, Towing Attachments, and Drawbar Maintenance... 4-105 Section IX Hydraulic and Fluid Systems Maintenance... 4-106 APPENDIX A REFERENCES... A-1 APPENDIX B MAINTENANCE ALLOCATION CHART (MAC)... B-1 APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS... C-1 LIST (EDSML) APPENDIX D MANUFACTURED ITEMS LIST... D-1 APPENDIX E TOOL IDENTIFICATION LIST... E-1 ALPHABETICAL INDEX... Index-1 ii
LIST OF ILLUSTRATIONS Figure No. Title Page 1-1 4000 Pound Capacity Rough Terrain Forklift Truck 1-0 Models MHE-270 and MHE-271 1-2 Forklift Assemblies and Major Components 1-7 1-3 Powertrain Assemblies and Major Components 1-8 1-4 Forklift Truck Information and Data Plates 1-9 1-5 Forklift Truck Stencils 1-16 1-6 Fuel System Schematic 1-24 1-7 Engine Fuel System Components 1-24 1-8 Engine Coolant System Components 1-26 1-9 Engine Lubricating System Components 1-27 1-10 Power Component Lubrication 1-28 1-11 Transmission Schematic 1-28 1-12 Brake System Schematic 1-31 2-1 STE/ICE Kit Components 2-13 2-2 Vehicle DCA Connector 2-14 2-3 STE/ICE Test Card 2-17 FO-1 Hydraulic Schematic FP-1 FO-2 Electrical Schematic FP-3 FO-3 Main Wiring Harness FP-5 FO-4 DCA Wiring Harness FP-11 FO-5 Cab Wiring Harness FP-13 LIST OF TABLES Table No. Title Page 1-1 Forklift Exercising During Storage 1-4 1-2 Nomenclature Cross-Reference List 1-5 1-3 Equipment Data 1-18 2-1 Unit Preventive Maintenance Checks and Services 2-6 2-2 Unit Troubleshooting Symptom Index 2-10 2-3 Ohm Reading 2-234 2-4 Voltage Reading 2-236 2-5 Wire Strip Length 2-237 2-6 Main Cable Assembly 2-246 2-7 Dash Cable Assembly 2-247 2-8 Engine Cable Assembly 2-249 2-9 DCA Wiring Harness 2-252 2-10 Cab Wiring Harness 2-255 3-1 Direct Support Troubleshooting Symptom Index 3-2 4-1 General Support Troubleshooting Symptom Index 4-2 iii
Figure 1-1. 4000 Pound Capacity Rough Terrain Forklift Truck, Models MHE-270 and MHE-271 1-0
CHAPTER 1 INTRODUCTION Section I. GENERAL INFORMATION Paragraph Title Page Number Number 1-1 Scope 1-1 1-2 Maintenance Forms and Records 1-1 1-3 Destruction of Army Material to Prevent Enemy Use 1-1 1-4 Preparation for Storage or Shipment 1-2 1-5 Nomenclature Cross-Reference List 1-5 1-6 Reporting Equipment Improvement Recommendations 1-5 1-7 Warranty Information 1-5 1-8 Use of Metric Units 1-5 1-9 Corrosion Prevention and Control 1-5 1-1. SCOPE. a. This manual is combined Unit, Direct Support, and General Support maintenance manual for the 4000 Pound Capacity Rough Terrain Forklift Truck, 4K RTFL, Models MHE-270 and MHE-271, Figure 1-1 (hereafter referred to as forklift). b. Information is provided on principles of operation, service upon receipt, inspection and installation, repair parts and special tools, preventive maintenance checks and services, troubleshooting, Unit, Direct Support and General Support maintenance, and preparation for shipment and storage. c. Appendix A contains a list of reference publications applicable to this manual. 1-2. MAINTENANCE FORMS AND RECORDS. Department of the Army forms and procedures used for equipment maintenance will be those prescribed by DA PAM 738-750, The Army Maintenance Management System (TAMMS). 1-3. DESTRUCTION OF ARMY MATERIAL TO PREVENT ENEMY USE. For destruction of the forklift and related equipment to prevent enemy use, refer to TM 750-244-6, Procedures for the Destruction of Tank-Automotive Equipment to Prevent Enemy Use. 1-1
1-4. PREPARATION FOR STORAGE OR SHIPMENT. a. General. The procedures defined below are necessary to maintain the forklift in storage in such a way as to achieve the maximum Readiness Condition (REDCON). Equipment that is placed in storage should be capable of being readied to perform its mission within a 24-hour period or as otherwise may be prescribed by the approving authority. b. Before the forklift is placed in storage, current maintenance services and equipment serviceability criteria (ESC) evaluations should be completed, shortcomings and deficiencies should be corrected, and all modification work orders (MWO s) should be applied. c. Report equipment in storage in Material Readiness and Unit Readiness reports as prescribed for all reportable equipment. Refer to AR 220-1. d. During the storage period appropriate maintenance records must be kept. Perform inspections, maintenance services, and lubrications in accordance with the Lubrication Order and Preventive Maintenance Checks and Services (PMCS) tables. Ten percent variance is acceptable on the time used to determine maintenance actions required. e. Records and reports to be maintained for equipment in storage are those prescribed by TM 38-750, for equipment in use. f. Storage Site Selection. Select the best available site for storage. Separate stored forklift from equipment in use. Covered storage space is preferred. Open sites should be improved hardstand. Unimproved sites should be firm, well drained, and kept free of excessive vegetation. g. Storage Plan. Store the forklift so as to provide maximum protection from the elements and to provide access for inspection, maintenance, and exercise. Anticipate removal or deployment problems and take suitable precautions. h. Take into account environmental conditions, such as extreme heat or cold; high humidity; blowing sand, dust, or loose debris; soft ground; mud; heavy snows; earthquakes; or combinations thereof and take adequate precautions. i. Maintenance Prior To Storage. (1) Maintenance Services. (a) (b) (c) Prior to storage, perform the next scheduled major preventive maintenance service (monthly, quarterly, or semiannually). Fill fuel tank to maximum allowable level. Ventilate by releasing filler cap. If local fire regulations prohibit storing equipment with fuel in system, completely drain the fuel tank. Remove battery from forklift and store in a cool, well-ventilated area. Recharge and clean before reinstalling. (2) Inspection. Inspect and approve the forklift prior to storage. When applicable, perform an ESC evaluation. Do not place the forklift in storage in RED condition unless RED condition is due only to over age. 1-2
(3) Cleaning. Clean the forklift of dirt, grease, or other contaminants in accordance with paragraph 1-23. TM 10-3930-664-24 (4) Preservation. After cleaning and drying, immediately coat unpainted metal surfaces with an oil or grease, as appropriate. Ensure the following components are properly preserved: (a) (b) (c) (d) (e) (f) (g) (h) Mast assembly Rail assemblies Rotate carriage assembly Sideshift carrier assembly Freelift chain assembly Drive chain assembly Sideshift chain assemblies Cylinder rod ends (5) Weatherproofing. Sunlight, heat, moisture (humidity), and dirt tend to accelerate deterioration. Install all covers authorized for the forklift. Close and secure all openings except those required for ventilation and draining. Seal openings to prevent the entry of rain, snow, or dust. Insert desiccant (item 32, App. C) when complete seal is required. Place forklift at storage site and provide blocking or framing to allow for ventilation and water drainage. NOTE Air recirculation under draped covers reduces deterioration from moisture and heat. CAUTION Place a piece of barrier material (item 31, App. C) between desiccant bags and metal surfaces. Desiccant may leak and deteriorate or corrode adjacent metal. j. Inspection During Storage. Inspection will be visual and consist of a walk-around examination of the entire forklift to observe any deficiencies that may have occurred. Inspect forklifts in open storage weekly and those in covered storage monthly. Immediately after any severe storm or environmental change inspect all equipment. Conduct the following checks during visual inspection: (1) Inspect for leaks: fuel, oil, or hydraulic fluid. Inspect all hoses, tubing, connections, fittings, seals, and gaskets for evidence of leakage. (2) Inspect for low or flat tires. Mark reinflated and repaired tires with a crayon and ensure they are thoroughly checked at next inspection interval. (3) Inspect for corrosion or other deterioration. (4) Inspect for missing or damaged parts. (5) Check for water in compartments. (6) Look for any other recognizable shortcomings or deficiencies. 1-3
k. Repair During Storage. Keep the forklift in an optimum state of readiness. Accomplish required services and repairs as expeditiously as possible. Whenever possible, perform maintenance "on-site". l. Exercising During Storage. Exercise the forklift in accordance with the schedule outlined in Table 1-1. Limit depreservation to removal of materials that will restrict exercising. Perform all Before, During, and After PMCS procedures (Chapter 2). Conduct applicable ESC inspections. m. Immediately take actions to correct shortcomings and deficiencies noted. Record inspection and exercise results on DA Form 2404. Record and report maintenance actions on DA Form 2407. After exercising, restore the preservation to the original condition. n. Replenish fuel and oil used during exercising and note the amount on DA Form 2408-1. o. Removal From Storage. Restore forklift to normal operating condition. Resume the maintenance service schedule in effect at the commencement of storage or service the forklift before the scheduled dates in order to produce a staggered maintenance workload. Table 1-1. Forklift Exercising During Storage INFORMATION TO BE SUPPLIED BY U.S. ARMY TACOM 1-4
1-5. NOMENCLATURE CROSS-REFERENCE LIST. Refer to Table 1-2 for a listing of simplified and common item names used in this manual. Table 1-2. Nomenclature Cross-Reference List Common Name Forklift or 4K RTFL Official Nomenclature Truck, Forklift, 4000 Lb Capacity, Rough Terrain, DED, Pneumatic Tire 1-6. REPORTING EQUIPMENT IMPROVEMENT RECOMMENDATIONS (EIR s). If your forklift needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don t like about your equipment. Put it on an SF 368 (Quality Deficiency Report). Mail it to: Commander, US Army Tank- Automotive Command, Attn: AMSTA-QRT, Warren, MI 48397. We ll send you a reply. 1-7. WARRANTY INFORMATION. Refer to the Warranty Technical Bulletin TB 10-3930-664-14 for information on warranty policies and coverage. 1-8. USE OF METRIC UNITS. The equipment described herein contains metric components and requires metric common and special tools; therefore metric units in addition to English units will be used throughout this publication. 1-9. CORROSION PREVENTION AND CONTROL (CPC). a. Corrosion Prevention and Control (CPC) of Army materiel is a continuing concern. It is important that any corrosion problems with the forklift and its components be reported so that the problem can be corrected and improvements can be made to prevent the problem in future components. b. While corrosion is typically associated with rusting of metals, it can also include deterioration of other materials, such as rubber and plastic. Unusual cracking, softening, swelling, or breaking of these materials may be a corrosion problem. c. If a corrosion problem is identified, it can be reported using Standard Form 368, Product Quality Deficiency Report. Use of key words such as "corrosion", "rust", "deterioration", or "cracking" will ensure that the information is identified as a CPC problem. 1-5