Drexel SL44/4 Swingmast Lift Truck Parts Manual 942396 - PDF DOWNLOAD

Drexel SL44/4 Swingmast Lift Truck Parts Manual 942396 - PDF DOWNLOAD

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Drexel SL44/4 Swingmast Lift Truck Parts Manual 942396 - PDF DOWNLOAD

Language : English
Pages : 112
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Drexel SL44/4 Swingmast Lift Truck Parts Manual 942396 - PDF DOWNLOAD

Section 1 DESCRIPTION AND SPECIFICATIONS
11 INTRODUCTION 1-1
12 DESCRIPTION 1-1
13 FUNCTIONAL DESCRIPTION 1-2
131 Frame 1-2
132 Powerplant 1-2
133 Drive Train 1-2
134 Electrical System 1-2
Battery 1-2
SCR Controller 1-2
Solenoid Contactors 1-2
Safety Interlocks 1-2
Meters 1-3
135 Hydraulic Subsystem 1-3
136 Pivot and Shift System : 1-3
137 Mast 1-3
14 WARNINGS AND CAUTIONS 1-5
141 Warning Plates 1-5
142 Caution Plates 1-5
15 ITEMS FURNISHED 1-5
16 ITEMS REQUIRED 1-5
17 TOOLS AND TEST EQUIPMENT 1-5
18 PREPARATION FOR USE 1-5
19 PREPARATION FOR RESHIPMENT , 1-5
110 STORAGE 1-6
Table 1-1: General Specifications 1-6
Table 1-2: Dimensions of Standard Masts 1,7
Section 2 OPERATION
21 INTRODUCTION 2-1
22 OPERATING CONTROLS 2-1
23 STARTING AND DRIVING THE TRUCK 2-2
24 OPERATING THE HYDRAULIC FUNCTIONS 2-3
25 OPERATING THE AUTOMATIC GUIDANCE SYSTEM (OPTIONAL) 2-4
26 NARROW-AISLE LOAD HANDLING 2-4
261 Depositing a Load 2-5
262 Retrieving a Load 2-5
27 LONG LOAD HANDLING 2-6
271 Depositing a Long Load 2-6
272 Retrieving a Long Load 2-7
28 OPERATOR'S SEAT ADJUSTMENT 2-7
29 SEAT BELT ADJUSTMENT 2-7
210 FORK ADJUSTMENT 2-8
211 SAFETY PRECAUTIONS 2-8
212 TIPPING HAZARDS 2-9
213 SERVICING PRECAUTIONS 2-10
214 WARNING DECALS 2-11
"Pinch-Point" Warning 2-11
"Fork-Hazard" Warning 2-11
"Tipping" Warning 2-11
Battery Connector Warning 2-11
Table of Contents
Battery Hazard Warning 2-12
Block-Up Warning 2-12
Use Handbrake Warning 2-12
Battery Replacement Warning 2-13
Tire Replacement Warning 2-13
Don't Paint Notice 2-13
General Warnings 2-13
Capacity Plate 2-13
Figure 2-1 Location of Controls and Indicators 2-2
Figure 2-2 Lift Control Symbol 2-3
Figure 2-3 Tilt Control Symbol 2-3
Figure 2-4 Pivot Control Symbol 2-3
Figure 2-5 Shift Control Symbol 2-4
Figure 2-6 Aligning Truck with Rack Opening 2-5
Figure 2-7 Pivoting the Load into Load Position 2-5
Figure 2-8 Load Shifted Right into Rack 2-5
Figure 2-9 Positioning Truck at Slot 2-6
Figure 2-10 Rotating the Load Into the Slot (Forward) 2-6
Figure 2-11 Pnshing the Load into the Slot 2-6
Figure 2-12 Backing the Truck into the Slot 2-7
Figure 2-13 Rotating the Load into the Slot (Rearward) 2-7
Figure 2-14 Operator's Seat Adjnstments 2-7
Figure 2-15 Fork Latch in Release Position 2-8
Figure 2-16 Fork Latch in Lock Position 2-8
Figure 2-17 Pinch Point Warning, P/N 1408792 (small) or 1408793 (large) 2-11
Figure 2-18 Fork Hazard, PIN 1408791 2-12
Figure 2-18 Tipping Warning, PIN 1409832 2-12
Figure 2-19 Battery Connector, P/N 50367-Y 2-12
Figure 2-20 Battery Hazard, PIN 50366-Y 2-12
Figure 2-21 Block-Up Warning, PIN 50690 2-12
Figure 2-22 Use Handbrake Warning, P/N 30300 2-13
Figure 2-23 Battery Replacement, PIN 51023-R 2-13
Figure 2-24 Tire Replacement, PIN 37433 2-13
Figure 2-25 Don't Paint Notice, PIN 50368-Y 2-13
Figure 2-26 General Warnings, PIN 50365-Y 2-14
Figure 2-27 Capacity Plate (Unique to Truck No PIN) 2-15
Section 3 PREVENTIVE MAINTENANCE
31 GENERAL 3-1
32 VISUAL CHECKS 3-1
321 Defective Fasteners 3-1
322 Welding Defects 3-1
323 Defective Wires or Connectors 3-1
324 Worn Hydraulic Lines or Loose Fittings 3-2
325 Rust or Corrosion 3-2
33 LUBRICATION INSTRUCTIONS 3-2
331 General Procedures 3-2
332 Checking Brake Fluid Level 3-2
333 Checking Hydraulic Oil Level 3-2
334 Replacing Hydraulic Fluid Filter 3-2
335 Checking and Adding Drive Axle Oil 3-3
336 Lubricating Pivot Cylinder Clevises 3-3
337 Lubricating Tilt Cylinder Clevises 3-3
338 Lubricating Steer Axle Components 3-4
339 Lubricating the Mast Trunnions 3-4
3310 Lubricating the Pivot Shaft Bearings 3-4
34 Checks and Adjustments 3-5
341 Testing the Parking Brake 3-5
342 Adjusting the Parking Brake 3-5
343 Checking Mast Operation 3-5
Table 3-1: Daily Preventive Maintenance Checks 3-6
Table 3-2: Weekly Preventive Maintenance Checks 3-6
Table 3-3: Lubrication Chart 3-6
Section 4 ILLUSTRATED PARTS BREAKDOWN
41 GENERAL 4-1
42ABBREVIATIONS 4-1
43 PARTS NOT SHOWN 4-2
44 PHANTOM AND REFERENCE PARTS 4-2
BASE UNIT SL44/4, 48 voe, PART NO 1413338-A 4-3
SERVICE BRAKE GROUP, PART NO 1412402-A 4-5
SERVICE BRAKE PARTS GROUP, PART NO 15507-E 4-6
CYLINDER, MASTER, 3/4 BORE 1-1/4 STROKE, PART NO 20210-A 4-9
HAND BRAKEASSY, PARTNO17395 , 4-10
DRIVEASSY, SL33HP STD, PART NO 10712-05-K , 4-12
AXLE, DRIVE WITH KNOTT BRAKE, PART NO 17133-8 4-15
AXLE, DRIVE WITH KNOTT BRAKE, PART NO 17133-S (Continued) 4-16
DIFFERENTIAL, NO-SPIN, PART NO 20230-A 4-20
MOTOR, TRACTION, PART NO 51367-8 4-21
BRAKE ASSY MODIFIED 6" DIAMETER, PART NO 30677-8 4-22
FLUIDS & GREASE GROUP, PART NO 30760-01-C 4-23
COVER GROUP SL-44/4 STD, PART NO 1412273-A 4-25
SEAT GROUP, PART NO 1412286-A 4-27
SEAT BELT ASSY MODIFIED, PART NO 17585-8 4-28
ELECTRICAL GP SL44/4 STD 48 VOL TS, PART NO 1413361-C 4-29
ELECTRICAL PANEL ASSY 48 VOL TS, PART NO 1413362-A 4-30
FUSE PANEL SUB ASSY 48 VOL TS SL33/44, PART NO 1413364-A 4-32
ELECTRICAL DOOR ASSY 48 VOLTS, PART NO 15512-12-C 4-35
ELECTRICAL DOOR ASSY 48 VOL TS , PART NO 15512-12-C (Continued) 4-36
SCR TRACTION CONTROL UNIT, PART NO 51170-C 4-40
CONTACTOR,300A,DPDT, 48V, PART NO 28888-50-8 4-42
CONTACTOR,300A, SPNO, 48V, PART NO 28889-50-8 4-44
BATTERY CONNECTOR SBE320 BLUE FOR 3/0 WIRE 48 VOLT, PART NO 1413425 4-46
CAPACITORASSY, PART NO 15547-A 4-47
FOOT CONTROLLER ASSY (EV-100), PART NO 17065-D 4-48
SWITCH ASSY, SEAT, PART NO 15659- 4-50
HORN ASS'Y 48V DC 48VOLT, PART NO 10200-01-A 4-51
INSTALLATION TAIL LAMP 48, PART NO 10902-01- 4-52
LIGHT,STOP & TAIL,48 V, PART NO 25055-2-A 4-54
STEER PUMP & MOTOR ASSY 48V, w/O THERMOSTAT, PART NO 50661-04-C 4-55
PUMP, POWER STEERING, PART NO 50654-A 4-56
MOTOR, POWER STEER DC 48 VOLT, PART NO 50656-02-A 4-57
ARTICULATED STEER AXLE ASSY, PART NO 14221-05-F 4-60
CYLINDER ASSY, STEER, PART NO 10834-G 4-63
CYLINDER ASSY, MODIFIED, PART NO 9767-01-B 4-64
CROSSHEAD AND PIVOT ASSY, PART NO 17512-01-E 4-66
COMMON PARTS GROUP SL33/44, PART NO 1412401-C 4-70
COMMON PARTS GROUP SL33/44, PART NO 1412401-C (Continued) 4-71
COMMON PARTS GROUP SL33/44, PART NO 1412401-C (Continued) 4-72
KNOB, LIFT, PART NO 50382-01 4-78
DOOR ASSY GROUP w/o STEER PUMP & MOTOR, PART NO 11748-05-A 4-80
CHAIN ANCHOR ASSY, PART NO 17393-B 4-81
INDICATOR, FORK LEVEL, PART NO 36560 4-82
BATTERY RETAINER & SPACER PLTINSTALL GP SL443-44, PART NO 1413324-A 4-83
CUSTOMER ORDER NO 942396 REV 00 4-85
DRIVE TIRE GP NON MARKING 18 X 10 X 1213, PART NO 1412261-A 4-87
OPERATOR CONSOLEASSY & COVER HYO CONTROLS STD, PART N01412398-A 4-89
OPERATOR CONSOLEASSY STD SL-33/44, PART NO17372-12-A 4-90
COVER PANEL ASSEMBLY, PART NO 17371-01 4-92
DASH PANEL, WIRE HARNESS ASSY & JUMPER SL33/44HP, PART NO 1411615-A 4-93
PANEL ASSY, INSTRUMENT, PART NO 17369-G 4-94
LEVERASSY, PARTNO10417-B 4-96
ORBITROL SUB-ASSY, PART NO 17430-C 4-97
STEERING CONTROL UNIT, PART NO 25715-B 4-98
COLUMN, STEER w/2 HORN WIRES, PART NO 25040-C 4-100
STEERING WHEEL & HORN BUTTON ASSY, PART NO 1410602-A 4-101
HYDRAULIC ASSY 48Vw/O LIFT- SHIFT & PIVOT, PART NO 1413365-C 4-103
HYDRAULIC ASSY 48Vw/O LIFT- SHIFT & PIVOT, PART NO 1413365-C (Continued) 4-104
CONTROL PANEL ASSY "E" & "EE" 36 & 48 VOL TS, PART NO 15593-08-A 4-108
VALVEASSY, CONTROL, PART NO11777 4-111
VALVE, CONTROL, MODIFIED, PART NO 50700-B 4-112
VALVEASSY, CONTROL, PARTNO15592-01-A 4-115
VALVE, CONTROL, MODIFIED, PART NO 50701-01-A 4-116
PUMP AND MOTOR ASSEMBLY SL44/4 ESS "E", PART NO 14051-01-A 4-118
MOTOR, PUMP, PART NO 21000-A 4,120
PUMP, DOUBLE VANE, 13GPM/5GPM OUTLET 1 OPP INPUT, PART NO 21150-A 4-122
HOSE KIT, PART NO 1413454-A 4-124
HOSE KIT, PART NO1413455-B 4-125
RESERVOIR ASSY, PART NO 10845-02-J 4-126
FILTER ASSY, HYDRAULIC, PART NO17397-B 4-128
CYLINDER-SHIFT ASSY 11 STROKE, PART NO 17394-01-B 4-129
CYLINDER-SHIFT 1107 STROKE, PART NO 51398-01-D 4-130
UMBILICALASSY, PART NO 1411667-A 4-131
CYLINDER, PIVOT, PART NO 30071-A 4-132
CYLINDER, TILT, PART NO 30340-02-B 4-133
QUAD GP 855-240-63 1400 SERIES, PART NO 1412516-A 4-135
INTER GP QUAD MAST 48V w/LIFT-SHIFT & PIVOT, PART NO 1413371-A 4-137
PARTS GROUP HYO 48 VOLTS w/LIFT-SHIFT & PIVOT, PART NO 1413373-B 4-138
SWITCH GROUP, LIFT, SHIFT & PIVOT QUAD MAST, PART NO 1412481-A 4-140
LIFT LIMIT SWITCH MODIF ABOVE 192 FH QUAD MAST, PART NO 1412404-B 4-142
SIDESHIFT SWITCH MODIF 16 SHIFT, PART NO 17365-01-B 4-144
PIVOT SWITCH INSTALLATION SL33/44, PART NO 1412314-B 4-146
PAINT, ENAMEL YELLOW, PART NO 37260-04-A 4-149
DECALS & MARKINGS, PLATES 15019 DUTCH, PART NO 15647-07-C 4-152
Table of Contents
Section 5 MAINTENANCE
5-1 GENERAL 5-1
5-2 SERVICING PRECAUTIONS 5-1
5-3 DRIVE ASSEMBLY 5-2
531 REMOVAL 5-2
532 INSTALLATION 5-3
533 DISASSEMBLY 5-4
SATISFACTORY TOOTH CONTACT 5-14
HIGH TOOTH CONTACT 5-14
LOW TOOTH CONTACT 5-15
534 FINAL ASSEMBLY OF DRIVE AXLE 5-15
5-4 STEER AXLE 5-16
541 REMOVAL 5-16
542 INSTALLATION 5-17
543 DISASSEMBLY 5-17
544 REASSEMBLY 5-21
5-5 SERVICE BRAKE 5-21
551 MASTER BRAKE CYLINDER LINKAGE ADJUSTMENT 5-21
552 BRAKE SHOE INSPECTION 5-21
553 BLEEDING THE BRAKES 5-21
554 STEER AXLE BRAKE REMOVAL 5-22
5-6 PARKING BRAKE ADJUSTMENT 5-23
561 HAND BRAKE 5-23
562 SEAT BRAKE 5-23
5-7 BATTERY MAINTENANCE 5-23
571 REMOVAL OF BATTERY FROM VEHICLE 5-25
572 CHECKING STATE-OF-CHARGE 5-26
573 WATERING 5-26
574 CHARGING 5-27
575 CLEANING 5-27
576 RECORDS 5-28
5-8 PIVOT ASSEMBLY 5-28
581 REMOVAL OF PIVOT/SIDESHIFT ASSEMBLY FROM TRUCK 5-28
582 PIVOT SHAFT ASS EMBLY : 5-30
583 PIVOT ARM RACKING ADJUSTMENT 5-31
5-9 HYDRAULIC PUMP AND MOTOR 5-31
591 REMOVAL 5-31
592 INSTALLATION 5-32
5-10 POWER STEERING PUMP AND MOTOR 5-34
5101 REMOVAL OF PUMP MOTOR 5-34
5102 REMOVAL OF THE PUMP 5-35
5-11 HYDRAULIC SYSTEM 5-35
5111 HYDRAULIC OIL RESERVOIR SUCTION FILTER REMOVAL 5-35
5112 HYDRAULIC RETURN LINE FILTER REMOVALAND INSTALLATION 5-38
5-12 PIVOT/SHIFT INTERLOCKS 5-38
5121 OPERATIONAL DESCRIPTION 5-38
5122 DETAILED FUNCTION OF CIRCUIT COMPONENTS 5-39
5123 PIVOT/SHIFT INTERLOCK SWITCH ADJUSTMENTS 5-40
5-13 ELECTRICAL SYSTEM 5-41
5131 REMOVAL OF SCR CONTROL UNIT 5-41
5132 REPLACING THE SCR CONTROL MODULE 5-42
5133 SCR CONTROL ADJUSTMENTS 5-42
Table of Contents
5134 SINGLE POLE CONTACTORS 5-42
5135 DOUBLE POLE CONTACTORS 5-43
5136ACCELERATOR MODULE 5-43
513 7 DASH PANEL MODULE 5-44
5-14 MAST ASSEMBLY 5-45
5141 REMOVAL FROM TRUCK 5-45
5142 MAST RACKING ADJUSTMENT 5-46
5143 MAST ADJUSTMENT 5-46
5144 MAST DISASSEMBLY 5-47
5-15 PRIMARY CYLINDER 5-47
5151 DISASSEMBLY 5-47
5152 REASSEMBLY 5-48
5-16 SECONDARY CYLINDER 5-48
5161 DISASSEMBLY 5-48
5162 REASSEMBLY 5-49
5163 BLEEDING THE CYLINDER 5-49
5-17 ORBITROL UNIT 5-50
5171 REMOVAL 5-50
5172 INSTALLATION 5-50
5173 DISASSEMBLY AND REASSEMBLY 5-50
Table 5-1: Standard Torque Values for "English" Fasteners 5-51
Table 5-2: Standard Torque Values for Metric Fastener 5-52
Section 6 PARTS LIST
61 GENERAL 6-1
62 WELDMENTS 6-1
Section 7 TROUBLESHOOTING
71 ELECTRICAL SYSTEM 7-1
71 1 Traction Fuse 1 FU Open 7-1
7 12 Pump Fuse 2FU Open 7-2
713 Control Fuses 3FU, 4FU or 5FU Open 7-3
7 14 Loss of Drive Power 7-4
715 Loss of Drive Speed 7-6
72 HYDRAULIC SYSTEM 7-7
721 Pump Does Not Operate 7-7
722 Pump Runs Continuously 7-9
723 Pivot Function Defective 7-11
7 24 Shift Function Defective 7-11
7 25 Loss of Hydraulic Lift 7-11
Table 7-1: Normal Hoist Pressures 7-12
Table 7-2: No-Load Function Pressures 7-13
Table 7-3: Function Pressures @2500 lb Load 7-13
726 Loss of Lift Speed 7-13
727 Drift of Raised Load 7-14
7 28 Loss of Mast Tilt 7-14
73 POWER STEERING SYSTEM 7-14
731 Loss of Power Steering 7-14
732 Slow Steering Response 7-15
733 Drift of Steering 7-16
74 BRAKE SYSTEM 7-16
Table of Contents
741 No Service Brake 7-16
742 No Seat Brake 7-17
743 No Parking Brake 7-17
75 NO-SPIN DIFFERENTIAL 7-17
76 SCR CONTROL CIRCUIT 7-17
761 Theory of Operation 7-17
762 Oscillator · 7-18
763 Current Limit 7-18
764 Plugging 7-18
765 Ramp Start 7-19
7 66 Full Power Transition 7-19
767 1A Control 7-19
768 Static Return to OFF 7-19
7 69 Coil Driver Modules 7 -19
7 61 O Thermal Protector (TP) 7-19
7 611 1 A Thermal Hold-Off 7-19
7612 Must Pulse to Time 7-19
7613 Trouble-Shooting Instructions 7-19
Table 7-4: Control Card Component Checks 7-21
Table 7-5: Troubleshooting Pump 7-24
Table 7-6: Troubleshooting NoSPIN Differential 7-26

S.S 05/24