US Army 6000 lb Variable Reach Rough Terrain Forklift Repair Parts Manual TM 10-3930-660-24P

U.S. Army Repair Parts and Special Tools List

TM 10-3930-660-24P – Published as of 24 November 1992 (March 1993 Edition)

This is the complete U.S. Army repair parts and special tools list for the 6,000 lb Variable Reach Rough Terrain Forklift, published under manual number TM 10-3930-660-24P and current as of 24 November 1992 (March 1993 edition). The 663-page RPSTL covers NSN 3930-01-158-0849 and gives unit, direct support and general support maintenance personnel a full illustrated parts breakdown for every functional group on the truck — engine, transmission, axles, brakes, steering, cab, hydraulics, boom and attachment hardware.

If you maintain, rebuild or restore one of these Army forklifts, the TM 10-3930-660-24P Repair Parts Manual is the fastest way to put the correct part number, NSN, CAGE code and quantity in your hands. Every entry is tied to a numbered exploded-view illustration, so there is no guessing which bolt, bearing, seal, hose or gasket belongs in which assembly.

File Details

• Manual type: Repair Parts and Special Tools List (RPSTL)
• Document number: TM 10-3930-660-24P
• Equipment: Truck, Forklift; 6,000 lb Variable Reach, Rough Terrain
• NSN: 3930-01-158-0849
• Language: English
• Page count: 663 pages
• File format: PDF
• Current as of: 24 NOV 92
• Edition: March 1993
• Supersedes: TM 10-3930-660-24P dated 14 Oct 89
• Distribution: Approved for public release; distribution is unlimited

Groups and Assemblies Covered

The Repair Parts Manual is organised into the same functional groups the Army uses for the truck, so parts are easy to find whether you are chasing a single o-ring or a complete assembly:

IMAGES PREVIEW

• Group 01 — Engine Assembly: engine assembly, mounting and lifting brackets, cylinder block, service short block, cylinder head, crankshaft/bearings/vibration damper, flywheel and flywheel housing, flywheel coupling and housing cover, piston/rings/connecting rod, front housing and cover, camshaft and valve tappet, rocker arm assembly, push rod cover, rocker arm covers, tachometer drive and accessory cover, oil pan and oil level gauge, engine oil pump, oil sampling valve, oil cooler and filter, oil filler tube, exhaust manifold and intake manifold cover
• Group 03 — Fuel System: fuel injector, fuel injection pump and coupling, fuel injection pump assembly, fuel transfer pump, air cleaner assembly, turbocharger and piping, turbocharger assembly, fuel/hydraulic tank assembly, fuel lines and fittings, water separator, engine STE/ICE assembly, fuel filter assemblies, engine starting aid, accelerator pedal and cable
• Group 04 — Exhaust System
• Group 05 — Cooling System: radiator and overflow, radiator shroud mounting bracket, thermostat and radiator hoses, water inlet connection, engine water pump, fan and fan guard, engine fan drive and spacer, drive belt and belt tensioner
• Group 06 — Electrical: alternator and mounting, starter relay and wiring, starting motor, cab instrument panel and cover plates, circuit breakers, engine/heater switches, blackout light switch, water temperature and oil pressure switches, boom electric controller joystick, boom electric box, fork auto leveler switch, front and rear light assemblies, adjustable work light, water temp/oil pressure senders, transmission temperature switch and sender, fuel level sender, back-up alarm and switch, horn, batteries and cables, battery box, cab wiring harness, main wiring harness, STE/ICE harness, electric joystick harness, slave receptacle
• Group 07 — Transmission: transmission shifter and cables, transmission disconnect foot control, torque converter assembly, transmission and mounting, main case and covers, output yoke, output shaft, front housing, front cover group and assembly, input shaft, first/second/third stage clutch packs, control valve, transmission oil pump, pump drive adapters, hydraulic gear pump drive, transmission oil filter, oil sampling valve
• Group 09 — Propeller Shafts: front differential, rear differential and transmission shafts
• Group 10 — Front Axle: axle assembly, housing assembly, differential assembly, planetary wheel end
• Group 11 — Rear Axle: axle assembly, housing assembly, differential assembly, planetary wheel end
• Group 12 — Brakes: parking brake assembly, parking brake lever and cable, disc brake caliper assembly, hydraulic brake control valve, hydraulic brake accumulator, brake lines and axle breather hoses (front and rear), hydraulic brake foot control
• Group 13 — Wheels and Tires: wheel assembly, tire
• Group 14 — Steering: steering wheel assembly, steering column and control valve, steering knuckle/tie rod/universal joint/spindle, emergency steering pump and motor, hydraulic steering lines and fittings (front and rear), steering cylinders, steering select valve
• Group 15 — Frame: frame assembly and pivot pins, counterweight assembly, pintle hook
• Group 18 — Cab and Body: miscellaneous frame covers, cab assembly, cab mounting hardware, cab door assembly, interior cover plates and floor mat, cab skylight guard, cab sound suppression panels, cab windows and skylight, cab door window, fender assemblies, cab floor plate, seat assembly
• Group 22 — Accessory Items: front wiper assembly, rear wiper assembly, wiper/washer assembly, mirror assembly, defroster fans, heater assembly, heater control cable, heater hoses/lines/fittings, data plates, decals and stencils
• Group 24 — Hydraulic and Fluid Systems: hydraulic tandem gear pump, piston pump, main control valve assembly, 5060B and 4545B relief valve assemblies, MLRS attachment control valve, priority valve, frame tilt/brake relief valve, hydraulic control joystick and frame tilt control valve, frame tilt valve, shuttle valve, frame tilt cylinder mounting and assembly, carriage tilt cylinder, MLRS attachment and carriage, boom assembly, and the full set of hydraulic line assemblies (transmission oil filter, transmission oil cooler, transmission disconnect, hydraulic oil reservoir, main control valve, dual gear pump, piston pump, oil filter, brake valve accumulator, priority valve, relief valve, frame tilt valve, steering valve, steering select valve, emergency steering pump and shuttle valve, tow line, boom extend cylinder, boom lines, attachment control valve, fork tilt cylinders, fork sideshift cylinders), boom extend cylinder, boom hoist cylinder, fork sideshift cylinder, MLRS attachment cylinder
• Group 31 — Basic Issue Items: emergency boom lift/retract kit, MLRS hook attachment, stabilizer hooks L.H. and R.H.
• Group 47 — Gages: air cleaner restriction indicator, hydraulic oil level sight gauge
• Section III — Special Tools List: transmission kit, wrench kit
• Section IV — Cross-Reference Index: National Stock Number index, part number index, figure and item number index

Taken together, these groups give you a complete picture of the machine — from the block, head and rotating assembly on one end, through the fuel, cooling and electrical systems, to the Funk powershift transmission, both axles, the hydraulic system that drives the frame tilt, boom and forks, and every bracket, cover and cab panel in between.

How the TM 10-3930-660-24P Repair Parts Manual Is Organised

The RPSTL is built the way an Army mechanic actually works. Section II lists the authorised spare and repair parts in ascending alphanumeric sequence, grouped by functional group. Each line item carries the item number, SMR code, CAGE code, part number, description and quantity per figure. The SMR (Source, Maintenance and Recoverability) code tells you how the item is supplied, what maintenance level is authorised to install or repair it, and what to do with it when it becomes unserviceable. Items that only exist as part of a kit are called out as part of that kit, and bulk materials such as hose, wire and moulding are listed with the length or size you need to cut.

Section III covers the special tools and support equipment the manual authorises, including the transmission clutch-alignment and bearing-driver kit and the spanner wrench set, with basis-of-issue information for each item.

Section IV is the fastest way to reverse-search the manual. If you already know the NSN, you look it up in the National Stock Number index and jump straight to the figure and item number. If you only know the part number, you look it up in the part number index. If you know the figure and item number from a friend or from the old paper copy, the figure/item index gives you the NSN, CAGE and part number back in one line.

What This 6000 lb Variable Reach Forklift Parts Manual Lets You Do

• Identify any part on the truck by NSN, part number or CAGE code, with a matching illustration to confirm it is the right one before you order.
• Work through an engine, transmission, axle or brake rebuild with the correct fasteners, seals, bearings, shims and gasket kits called out for each stage of disassembly.
• Rebuild hydraulic cylinders, control valves, relief valves and pumps with the correct packing, seal and shim part numbers instead of generic kits that may not seal properly.
• Trace hydraulic, fuel and air lines from the pump or tank to the cylinder or component, using the line-assembly breakdowns for the boom, frame tilt, steering, brakes and attachment circuits.
• Match kit part numbers to the individual pieces inside them, so you know exactly what you get when you order the kit and what still has to be ordered separately.
• Locate and replace cab, body, fender, window and sound-suppression hardware by part number for trucks that have gone through years of service.
• Look up the special tools called out for the transmission work before starting a job, so you have them on the bench when you need them.

Why a Proper Parts Manual Matters on This Machine

The 6,000 lb Variable Reach Rough Terrain Forklift shares its Cummins 6BT5.9 engine, Funk powershift transmission, Clark-style axles and open-centre hydraulics with a small family of related military trucks, but every part is not interchangeable across them. A part number that looks right in a photo can turn out to be the wrong shim thickness, the wrong seal material, the wrong thread pitch or the wrong hose length for the boom circuit. TM 10-3930-660-24P takes the guesswork out of that. When you quote an NSN from this manual, the Army supply system returns exactly the item the truck was built around.

The manual also gives you the correct source and recoverability codes. Some items are field-replaceable, some must go back to a higher maintenance level, and some are non-repairable — this is the document that tells you which is which, so you do not waste time trying to rebuild something the Army treats as throwaway, and you do not try to repair a component that should be condemned for safety reasons.

For anyone restoring or returning one of these trucks to service, the illustrated breakdowns are also the best available reference for the correct assembly order. Every figure shows the parts in position with an item number you can cross-reference back to the list, which is far more reliable than working from memory, photographs or another manual for a similar machine.

Instant PDF Delivery

The complete US Army 6000 lb Variable Reach Rough Terrain Forklift Repair Parts Manual TM 10-3930-660-24P is delivered as a PDF download the moment payment clears — no shipping, no waiting, no physical book to keep track of in the workshop. The file opens on any laptop, tablet or phone, and the pages can be printed for the ones you need at the bench, so you can keep the sensitive pages clean and take only the figures you are using out to the machine. Whether you are running a motor pool, rebuilding a single truck in a private shop or maintaining a fleet of these forklifts, this manual is the reference that lets you do the job with the right parts, the first time.