Drexel R60SL CBD Series Base IPB SwingMast Lift Truck Parts Manual – PDF

Drexel R60SL CBD Series Base IPB SwingMast Lift Truck Parts Manual 1409265 – PDF DOWNLOAD

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Drexel R60SL CBD Series Base IPB SwingMast Lift Truck Parts Manual 1409265 – PDF DOWNLOAD

Language : English
Pages : 554
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Drexel R60SL CBD Series Base IPB SwingMast Lift Truck Parts Manual 1409265 – PDF DOWNLOAD

General 8-1
Abbreviations 8-1
Phantoms / Reference Parts 8-1
Task Groups/Assemblies 8-1
Drive Axle Installation, DA326-A 8-4
Figure 8-1: Drive Axle Installation, DA326-A 8-5
U-joint Installation, DA322 1-A 8-8
Figure 8-2: U-joint Installation, DA322 1-A 8-9
Drive Axle, Modified, DA322-A 8-12
Figure 8-3: Drive Axle, Modified, DA322-A 8-13
Disk Brake Service, p/n: 1415954-A 8-14
Figure 8-4: Disk Brake Service, p/n: 1415954-A 8-15
Differential Breakdown, p/n: 1410322-A 8-16
Differential Breakdown, p/n: 1410322-A (continued) 8-17
Figure 8-5: Differential Breakdown, p/n: 1410322-A 8-19
Axle Breakdown, p/n: 1415946-A 8-20
Axle Breakdown, p/n: 1415946-A (Continued) 8-21
Figure 8-6: Axle Breakdown, p/n: 1415946-A 8-23
Housing and Covers, Service, p/n: 1415933-A 8-24
Figure 8-7: Housing and Covers, Service, p/n: 1415933-A 8-25
Park Brake Installation, DA326 1-A 8-28
Figure 8-8: Park Brake Installation, DA326 1-A 8-29
Master Cylinder Tube Installation, DA469-A 8-32
Figure 8-9: Master Cylinder Tube Installation, DA469-A 8-33
D A Brake Tube Installation, DA324-A 8-36
Figure 8-10: D A Brake Tube Installation, DA324-A 8-37
Park Brake Cable Connection, DA481-A 8-40
Figure 8-11: Park Brake Cable Connection, DA481-A 8-41
Brake Pedal Sub-Assembly, OH467-C 8-44
Figure 8-12: Brake Pedal Sub-Assembly, OH467-C 8-45
Brake Linkage Installation, OH396-B 8-48
Figure 8-13: Brake Linkage Installation, OH396-B 8-49
Master Cylinder, Brake, p/n: 1407337-A 8-50
Figure 8-14: Master Cylinder, Brake, p/n: 1407337-A 8-50
Lower Cam Sub-Assembly, OH466-C 8-51
Figure 8-15: Lower Cam Sub-Assembly, OH466-C 8-51
Brake Line Installation, OH405-B 8-54
Figure 8-16: Brake Line Installation, OH405-B 8-55
Park Brake Installation, OH391-B 8-58
Figure 8-17: Park Brake Installation, OH391-B 8-59
Park Brake Switch Assembly, OH465-B 8-62
Figure 8-18: Park Brake Switch Assembly, OH465-B 8-63
Steer Axle Installation, SA478-A 8-66
Figure 8·19: Steer Axle Installation, SA478-A 8-67
Steer Axle Assembly, p/n: 1407432-D 8-68
Figure 8-20: Steer Axle Assembly, p/n: 1407432-D (sheet 1 of 2) 8-69
Figure 8-21: Steer Axle Assembly, p/n: 1407432-D (sheet 2 of 2) 8-71
Steering Cylinder, p/n: 2805184-A 8-72
Figure 8-22: Steering Cylinder, p/n: 2805184-A 8-73
Axle Oscillation Pad Installation, SA457-A 8-75
Figure 8-23: Axle Oscillation Pad Installation, SA457-A 8-75
Rear Tires and Nuts, SA361-A 8-77
Figure 8-24: Rear Tires and Nuts, SA361-A 8-77
Steering Tire and Wheel Assembly, p/n: 1400854-B 8-78
Figure 8-25: Steering Tire and Wheel Assembly, p/n: 1400854-B 8-78
Front Tires and Nuts, DA362-A 8-80
Figure 8-26: Front Tires and Nuts, DA362-A 8-81
Drive Wheel Assembly, Inner, p/n: 1400451-A 8-82
Figure 8-27: Drive Wheel Assembly, Inner, p/n: 1400451-A 8-82
Drive Wheel Assembly, Outer, p/n: 1400177-B 8-83
Figure 8-28: Drive Wheel Assembly, Outer, p/n: 1400177-B 8-83
Drive Tire Nut Re-torque, IA 192-E 8-86
Figure 8-29: Drive tire Nut Re-torque, IA 192-E 8-87
Accelerator Pedal Assembly, OH476-C 8-89
Figure 8-30: Accelerator Pedal Assembly, OH476-C 8-89
Accelerator Cable Installation, OH404 1-A 8-92
Figure 8-31: Accelerator Cable Installation, OH404 1-A 8-93
Silicone Insulation Pins, OH392 1-A 8-95
Figure 8-32: Silicone Insulation Pins, OH392 1-A 8-95
Engine and Transmission Installation, ET 415-A 8-98
Figure 8-33: Engine and Transmission Installation, ET415-A 8-99
Engine and Transmission Installation, ET341 4-A 8-102
Figure 8-34: Engine & Transmission Installation, ET341 4-A 8-103
Engine Front Cover Bolts, ET345 5-A 8-105
Figure 8-35: Engine Front Cover Bolts, ET345 5-A 8-105
Engine and Transmission Assembly, ET441-A 8-108
Figure 8-36: Engine and Transmission Assembly, ET 441-A 8-109
Engine Mount Installation, ET315-A 8-112
Figure 8-37: Engine Mount Installation, ET315-A 8-113
Engine Mount Sub-Assembly, ET314 1-A 8-116
Figure 8-38: Engine Mount Sub-Assembly, ET314 1-A 8-117
Engine and Transmission Mounting, ET356 1-A 8-120
Figure 8-39: Engine and Transmission Mounting, ET356 1-A 8-121
Torque Converter Installation, ET346-A 8-124
Figure 8-40: Torque Converter Installation, ET346-A 8-125
Transmission Installation, ET 449-A 8-128
Figure 8-41: Transmission Installation, ET449-A 8-129
Hydraulic Pump Sub-Assembly, ET440-A 8-132
Figure 8-42: Hydraulic Pump Sub-Assembly, ET440-A 8-133
Tandem Gear Pump Service, p/n: 1409398-A 8-135
Figure 8-43: Tandem Gear Pump Service, p/n: 1409398-A 8-135
Transmission Remote Filter, ET345 3-A 8-138
Figure 8-44: Transmission Remote Filter, ET345 3-A 8-139
Inch Bracket Installation, ET352-A 8-142
Figure 8-45: Inch Bracket Installation, ET352-A 8-143
Transmission Drain Port Line, ET 450-A 8-146
Figure 8-46: Transmission Drain Port Line, ET450-A 8-147
Fuel Lines Installation, ET345 1-A 8-150
Figure 8-47: Fuel Lines Installation, ET345 1-A 8-151
Transmission Cooler Lines, ET495-A 8-154
Figure 8-48: Transmission Cooler Lines, ET495-A 8-155
Transmission Filter Lines Installation, ET474-A 8-158
Figure 8-49: Transmission Filter Lines Installation, ET474-A 8-159
Dipstick Installation, ET353-A 8-162
Figure 8-50: Dipstick Installation, ET353-A 8-163
Air Filter Installation, Al340 1-A 8-166
Figure 8-51: Air Filter Installation, Al340 1-A 8-167
Air Guide Installation, CO458-A 8-170
Figure 8-52: Air Guide Installation, CO458-A 8-171
Blower Adapter Ring Installation, ET341 2-A 8-17 4
Figure 8-53: Blower Adapter Ring Installation, ET341 2-A 8-175
Blower Duct Assembly, p/n: 1407857-B 8-176
Figure 8-54: Blower Duct Assembly, p/n: 1407857-B 8-177
Heater Lever Stop Bracket, ET351 3-A 8-180
Figure 8-55: Heater Lever Stop Bracket, ET351 3-A 8-181
Tachometer Drive Installation, ET345 7-A 8-184
Figure 8-56: Tachometer Drive Installation, ET345 7-A 8-185
Alternator Installation, ET443-A 8-188
Figure 8-57: Alternator Installation, ET443-A 8-189
Alternator Service, p/n: 1402695-B 8-190
Figure 8-58: Alternator, Service, p/n: 1402695-B 8-191
Shut-Down Solenoid, ET444-A 8-193
Figure 8-59: Shut-Down Solenoid, ET444-A 8-193
Engine Filter Lines Installation, ET345 4-A 8-196
Figure 8-60: Engine Filter Lines Installation, ET345 4-A 8-197
Throttle Linkage Installation, ET351-A 8-200
Figure 8-61: Throttle Linkage Installation, ET351-A 8-201
Lever Sub-Assembly, ET494-A 8-203
Figure 8-62: Lever Sub-Assembly, ET494-A 8-203
Fuel Drain Line Installation, ET438-A 8-206
Figure 8-63: Fuel Drain Line Installation, ET 438-A 8-207
Engine Sump Drain, ET445 6-A 8-210
Figure 8-64: Engine Sump Drain, ET445 6-A 8-211
Muffler Installation, EX411-A 8-214
Figure 8-65: Muffler Installation, EX411-A 8-215
Muffler Assembly, p/n: 1408279-B 8-216
Figure 8-66: Muffler Assembly, p/n: 1408279 – 8 8-217
Filter Tray Installation, FT305-A 8-220
Figure 8-67: Filter Tray Installation, FT305-A 8-221
Filter Tray Sub-Assembly, FT376-A 8-224
Figure 8-68: Filter Tray Sub-Assembly, FT376-A 8-225
Engine Oil Filter Sub-Assembly, FT387-A 8-228
Figure 8-69: Engine Oil Filter Sub-Assembly, FT387-A 8-229
Transmission Filter Sub-Assembly, FT388-A 8-232
Figure 8-70: Transmission Filter Sub-Assembly, FT388-A 8-233
Fuel Filter Sub-Assembly, FT319-A 8-235
Figure 8-71: Fuel Filter Sub-Assembly, FT319-A 8-235
Fuel and Water Separator Assembly, FT320-A 8-238
Figure 8-72: Fuel and Water Separation Assembly, FT320-A 8-239
Fuel Water Separator Breakdown, p/n: 1408265-A 8-240
Figure 8-73: Fuel Water Separator Breakdown, p/n: 1408265-A 8-241
Dash Panel Installation, OH380 1-A 8-244
Figure 8-74: Dash Panel Installation, OH380 1-A 8-245
Instrument Panel Assembly, p/n: 1411574-B 8-246
Instrument Panel Assembly, p/n: 1411574-B (Continued) 8-247
Figure 8-75: Instrument Panel Assembly, p/n: 1411574-B 8-249
Console Sub-Assembly, OH389-C 8-252
Figure 8-76: Console Sub-Assembly, OH389-C 8-253
Steering Column Installation, OH422-D 8-256
Figure 8-77: Steer Column Installation, OH422-D 8-257
Steering Column Sub-Assembly, OH399-A 8-260
Figure 8-78: Steering Column Sub-Assembly, OH399-A 8-261
Wire, Wheel Installation, OH384-D 8-264
Figure 8-79: Wire, Wheel Installation, OH384-D 8-265
Orbitrol Installation, OH403-B 8-268
Figure 8-80: Orbitrol Installation, OH403-B 8-269
Orbitrol Sub-Assembly, OH365-B 8-272
Figure 8-81: Orbitrol Sub-Assembly, OH365-B 8-273
Steering Control Unit, p/n: 1404339-B 8-274
Figure 8-82: Steering Control Unit, p/n: 1404339-B 8-275
Steering Lines Frame Installation, HY338-C 8-278
Figure 8-83: Steering Lines Frame Installation, HY338-C 8-279
Steering Lines Installation, Rear, HY339-B 8-282
Figure 8-84: Steering Lines Installation, Rear, HY339-B 8-283
Horn Installation, EL373 1-A 8-286
Figure 8-85: Horn Installation, EL373 1-A 8-287
Joystick Installation, OH402-B 8-289
Figure 8-86: Joystick Installation, OH402-B 8-289
Joystick Assembly, OH378-B 8-292
Figure 8-87: Joystick Assembly, OH378-B 8-293
Joystick Cable to Valve, OH381-D 8-296
Figure 8-88: Joystick Cable to Valve, OH381-D 8-297
Seat Installation, OH397-F 8-300
Figure 8-89: Seat Installation, OH397-F 8-301
Fuse Panel Door Installation, OH395 1-B 8-304
Figure 8-90: Fuse Panel Door Installation, OH395 1-B 8-305
Fuse Panel Door Assembly, p/n: 1410127-A 8-306
Figure 8-91: Fuse Panel Door Assembly, p/n: 1410127-A 8-307
Wire Harness Installation, Right, EL430 1-A 8-310
Figure 8-92: Wire Harness Installation, Right, EL430 1-A 8-311
Wire Harness Routing, Front, EL373-A 8-314
Figure 8-93: Wire Harness Routing, Front, EL373-A 8-315
Wire Harness, Left, EL451 1-A 8-318
Figure 8-94: Wire Harness, Left, EL451 1-A 8-319
Ground, OHG Installation, EL431 3-A 8-322
Figure 8-95: Ground, OHG Installation, EL431 3-A 8-323
Fluids and Lubricants, FL331-A 8-326
Figure 8-96: Fluids and Lubricants, FL331-A 8-327
Fuel Tank Installation, FG308-A 8-330
Figure 8-97: Fuel Tank Installation, FG308-A 8-331
Hydraulic Tank Installation, HY309-D 8-334
Figure 8-98: Hydraulic Tank Installation, HY309-D 8-335
Hydraulic Tank Assembly, p/n: 1414745-A 8-336
Figure 8-99: Hydraulic Tank Assembly, p/n: 1414745-A 8-337
Drain Lines Installation, HY318-B 8-340
Figure 8-100: Drain Lines Installation, HY318-B 8-341
Drain Plate Sub-Assembly, HY317-B 8-343
Figure 8-101: Drain Plate Sub-Assembly, HY317-B 8-343
Standard Hydraulics, HY67-A 8-346
Figure 8-102: Standard Hydraulics, HY67-A 8-347
Valve to Manifold Hose Installation, HY303-D 8-350
Figure 8-103: Valve to Manifold Hose Installation, HY303-D 8-351
Stack Valve, Low Hose Installation, HY304-C 8-354
Figure 8-104: Stack Valve, Low Hose Installation, HY304-C 8-355
Filter Assembly, 10 Micron, p/n: 1408618-A 8-357
Figure 8-105: Filter Assembly, 10 Micron, p/n: 1408618-A 8-357
Stack Valve Installation, HY416-B 8-360
Figure 8-106: Stack Valve Installation, HY 416-B 8-361
Control Valve Assembly, p/n: 1410228-A 8-362
Figure 8-107: Control Valve Assembly, p/n: 1410228-A 8-363
Valve Spool, 4 Function, p/n: 1408724-A 8-364
Valve Spool, 4 Function, p/n: 1408724-A (Continued) 8-365
Figure 8-108: Valve Spool, 4 Function, p/n: 1408724-A 8-367
Hydraulic Hose Installation, HY325-A 8-370
Figure 8-109: Hydraulic Hose Installation, HY325-A 8-371
Hydraulic Hose Routing, HY310-A 8-374
Figure 8-11 0: Hydraulic Hose Routing, HY310-A 8-375
Umbilical Manifold Installation, HY368 2-C 8-378
Figure 8-111: Umbilical Manifold Installation, HY368 2 C 8-379
Umbilical Assembly, p/n: 1409002-B 8-380
Figure 8-112: Umbilical Assembly, p/n: 1409002-B 8-381
Pivot and Shift Installation, PS437-A 8-384
Figure 8-113: Pivot and Shift Installation, PS437-A 8-385
Pivot Manifold Installation, PS471-A 8-388
Figure 8-114: Pivot Manifold Installation, PS471-A 8-389
Pivot Cylinder Installation, PS426-A 8-392
Figure 8-115: Pivot Cylinder Installation, PS426-A 8-393
Pivot Cylinder Breakdown, p/n: 1407231-A 8-394
Figure 8-116: Pivot Cylinder Breakdown, p/n: 1407231-A 8-395
Pivot and Shift Hose Installation, PS436-A 8-398
Figure 8-117: Pivot and Shift Hose Installation, PS436-A 8-399
Pivot, Shift and Tilt Lines, PS442-A 8-402
Figure 8-118: Pivot, Shift and Tilt Lines, PS442-A 8-403
Tilt Cylinder Line Installation, PS473-A 8-406
Figure 8-119: Tilt Cylinder Line Installation, PS473-A 8-407
Pivot Seal Installation, PS419-A 8-41 O
Figure 8-120: Pivot Seal Installation, PS419-A 8-411
Mast Lines Installation, Lower, PS447-A 8-414
Figure 8-121: Mast Lines Installation, Lower, PS447-A 8-415
Roller Bearing Cup Installation, PS417 1-A 8-417
Figure 8-122: Roller Bearing Cup Installation, PS417 1-A 8-417
Radial Bushing Installation, PS417-A 8-420
Figure 8-123: Radial Bushing Installation, PS417-A 8-421
Pivot Bearing Installation, PS419 1-A 8-424
Figure 8-124: Pivot Bearing Installation, PS419 1-A 8-425
Fixed Side Shift Chain Installation, PS425-A 8-428
Figure 8-125: Fixed Side Shift Chain Installation, PS425-A 8-429
Yoke and Chain Sheave Sub-Assembly, PS428-A 8-432
Figure 8-126: Yoke and Chain Sheave Sub-Assembly, PS428-A 8-433
Side Shift Cylinder Installation, PS423-A 8-436
Figure 8-127: Side Shift Cylinder Installation, PS423-A 8-437
Shift Cylinder Breakdown, p/n: 1400006-B 8-438
Figure 8-128: Shift Cylinder Breakdown, p/n: 1400006-B 8-439
Side Shift Bearing Installation, PS432-A 8-442
Figure 8-129: Side Shift Bearing Installation, PS432-A 8-443
Crosshead Pivot Arm Installation, PS429-A 8-446
Figure 8-130: Crosshead Pivot Arm Installation, PS429-A 8-447
Bearing Assembly, PS421-A 8-450
Figure 8-131: Bearing Assembly, PS421-A 8-451
Side Shift Roller Bearing Installation, PS432 1-A 8-454
Figure 8-132: Side Shift Roller Bearing Installation, PS432 1-A 8-455
Stop Block Installation, PS434-A 8-458
Figure 8-133: Stop Block Installation, PS434-A 8-459
Overhead Guard Installation, OH377 2-A 8-461
Figure 8-134: Overhead Guard Installation OH377 2-A 8-461
Overhead Guard Installation, OH468-B 8-464
Figure 8-135: Overhead Guard Installation, OH468-B 8-465
Overhead Guard Sub-Assembly, OH487-B 8-468
Figure 8-136: Overhead Guard Sub-Assembly, OH487-B 8-469
Overhead Guard Foam Installation, OH488-A 8-472
Figure 8-137: Overhead Guard Foam Installation, OH488-A 8-473
Floor Plate Installation, OH490-A 8-476
Figure 8-138: Floor Plate Installation, OH490-A 8-477
Access Door Installation, OH491-A 8-480
Figure 8-139: Access Door Installation, OH491-A 8-481
Fuel Sender Cover, OH489 1-A 8-484
Figure 8-140: Fuel Sender Cover, OH489 1-A 8-485
Battery Tray Installation, EL477-A 8-488
Figure 8-141: Battery Tray Installation, EL477-A 8-489
Battery Cables Installation, EL307 1-A 8-492
Figure 8-142: Battery Cables Installation, EL307 1-A 8-493
Rear View Mirror Installation, OH512-A 8-496
Figure 8-143: Rear View Mirror Installation, OH512-A 8-497
Brake and Tail Light Installation, OH379-C 8-500
Figure 8-144: Brake and Tail Light Installation, OH379-C 8-501
Lamp, Single Bulb, p/n: 28789-A 8-502
Figure 8-145: Lamp, Single Bulb, p/n: 28789-A 8-502
Lower Counterweight Installation, CT311-A 8-504
Figure 8-146: Lower Counterweight Installation, CT311-A 8-505
Side Counterweight Installation, CT335-A 8-508
Figure 8-147: Side Counterweight Installation, CT335-A 8-509
Rear Counterweight Installation, CT359 1-A 8-512
Figure 8-148: Rear Counterweight Installation, CT359 1-A 8-513
Rear Counterweight Sub-Assembly, CT337 1-A 8-516
Figure 8-149: Rear Counterweight Sub-Assembly, CT337 1-A 8-517
Standard Cover Installation, CO360 9-A 8-519
Figure 8-150: Standard Cover Installation, CO360 9-A 8-519
Rear Covers Installation, CO560-A , 8-522
Figure 8-151: Rear Covers Installation, CO560-A 8-523
Side Cover and Hood Installation, CO363-A 8-526
Figure 8-152: Side Cover and Hood Installation, CO363-A 8-527
Identification – Decals, ID982-A 8-530
Identification – Decals, ID982-A (Continued) 8-531
Figure 8-153: Identification – Decals, ID982-A (sheet 1 of 2) 8-532
Figure 8-154: Decals, ID982-A (sheet 2 of 2) 8-533
Standard “Yellow” Paint, PA1401-A 8-535
Mast Adjustment, IA480-A 8-537
Figure 8-155: Mast Adjustment, IA480-A 8-537
Front End Adjustment, IA 179-D 8-539
Figure 9-156: Front End Adjustment, IA 179-D (sheet 1 of 2) 8-540
Figure 9-157: Front End Adjustment, IA 179-D (sheet 2 of 2) 8-541
Load Backrest Inspection, IA 193-B 8-543
Figure 8-158: Load Backrest Inspection, IA 193-B 8-543