Drexel SL44/4 SwingMast Lift Truck Service & Parts Manual 17543-04 - PDF DOWNLOAD

Drexel SL44/4 SwingMast Lift Truck Service & Parts Manual 17543-04 - PDF DOWNLOAD

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Drexel SL44/4 SwingMast Lift Truck Service & Parts Manual 17543-04 - PDF DOWNLOAD

Language : English
Pages : 280
Downloadable : Yes
File Type : PDF

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Drexel SL44/4 SwingMast Lift Truck Service & Parts Manual 17543-04 - PDF DOWNLOAD

Section 1 DESCRIPTION AND SPECIFICATIONS
11 INTRODUCTION 1-1
12 DESCRIPTION 1-1
1 3 FUNCTIONAL DESCRIPTION 1-2
1 3 1 Frame 1-2
132 Powerplant 1-2
133 Drive Train 1-2
1 34 Electrical System 1-2
Battery : , 1-2
SCR Controller • 1-2
Solenoid Contactors · 1-2
Safety Interlocks • 1-2
Meters 1-3
1 35 Hydraulic Subsystem 1-3
1 36 Pivot and Shift System 1-3
137 Mast 1-3
14 WARNINGS AND CAUTIONS 1-5
1 4 1 Warning Plates 1-5
1 42 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
1 9 PREPARATION FOR RESHIPMENT 1-5
1 1 0 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 OPERATING PRECAUTIONS 2-2
24 TIPPING HAZARDS 2-3
25 SERVICING PRECAUTIONS 2-4
26 STARTING AND DRIVING THE TRUCK 2-5
27 OPERATING THE HYDRAULIC FUNCTIONS 2-6
28 DEPOSITING A LOAD 2-6
29 RETRIEVING A LOAD 2-7
210 LONG LOAD HANDLING 2-8
2101 DEPOSITING A LONG LOAD 2-8
2102 RETRIEVING A LONG LOAD 2-9
211 OPERATOR'S SEAT ADJUSTMENT 2-9
212 FORK ADJUSTMENT 2-9
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
Table of Contents
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
Section 4 ILLUSTRATED PARTS BREAKDOWN
41 GENERAL 4-1
42 REVISION LEVELS 4-1
43 ABBREVIATIONS 4-1
44 PARTS NOT SHOWN 4-2
45 PHANTOM AND REFERENCE PARTS 4-2
FINAL ASSY FOR SL44/4 ESS, PART NO 17543-04-D ; 4-3
TOP PARTS GROUP FOR STD 15020, PART NO 17544-01-R 4-4
TOP PARTS GROUP FOR STD 15020, PART NO 17544-01-R (Continued) 4-5
TOP PARTS GROUP FOR STD 15020, PART NO 17544-01-R (Continued) 4-6
OPERATOR CONSOLE PARTS GROUP w/o EMER SWITCH, PART NO 17372-01-E 4-12
COVER PANEL ASSY, PART NO 17371-01 · 4-14
ORBITROL SUB-ASSY, PART NO 17430-C 4-1 5
STEERING CONTROL UNIT, PART NO 25715-B 4-16
COLUMN, STEER w/2 HORN WIRES, PART NO 25040-C 4-18
STEERING WHEEL & HORN BUTTON ASSY, PART NO 1410602-A 4-19
DASH PANEL & WIRE HARNESS ASSEMBLY w/JUMPER CIRCUIT, PART NO 17563-A 4-20
PANEL, INSTRUMENT, ASSY, PART NO 17369-F 4-22
LEVER ASSY, PART NO 10417-B 4-24
KNOB, LIF1, PART NO 50382-01 4-26
TAIL LAMP, INSTALLATION, PART NO 10902-A 4-28
LIGHT, STOP AND TAIL,36V, PART NO 25055-B 4-30
SWITCH ASSY, SEAT, PART NO 15659 4-31
HAND BRAKE ASSY, PART NO 17395 4-32
HORN ASSY 36V & HASH FILTER, PART NO 15679-A 4-33
DOOR ASSY GROUP w/o STEER PUMP & MOTOR, PART NO 11748-05-A 4-34
CHAIN ANCHOR ASSY, PART NO 17393-B 4-35
INDICATOR, FORK LEVEL, PART NO 36560 4-36
Table of Contents
CROSSHEAD AND PIVOT ASSY, PART NO 17512-01-E 4-38
DRIVE ASSY FOR SL44/4 ESS, PART NO 10712-10-H 4-40
AXLE, DRIVE WITH KNOTT BRAKE, PART NO 17133-S 4-43
AXLE, DRIVE WITH KNOTT BRAKE, PART NO 17133-S (Continue(:!) 4-44
DIFFERENTIAL, NO-SPIN, PART NO 20230-A 4-48
MOTOR, TRACTION, PART NO 51367-8 4-49
BRAKE ASSY MODIFIED 6" DIAMETER, PART NO 30677-8 4-50
ARTICULATED STEER AXLE ASSY SL44/3, PART NO 14221-06-F 4-52
CYLINDER ASSY, STEER, PART NO 10834-G ·'" 4-55
CYLINDER ASSY, MODIFIED, PART NO 9767-01-8 4-56
HYDRAULIC ASSY, 36 voe SL44/4 ESS "E", PART NO 17527-11-D 4-57
HYDRAULIC ASSY, 36 voe SL44/4 ESS "E", PART NO 17527-11-D (Continued) 4-58
RESERVOIR ASSY, PART NO 10845-02-J 4-62
CONTROL PANEL ASSY, PART NO 15593-01-B 4-64
VALVE ASSY, CONTROL, PART NO 11777- 4-67
VALVE, CONTROL, MODIFIED, PART NO 50700-A 4-68
VALVE ASSY, CONTROL, PART NO 15592-01-A 4-70
VALVE, CONTROL, MODIFIED, PART NO 50701-01-B • 4-72
PUMP AND MOTOR ASSEMBLY SL44/4 ESS "E", PART NO 14051-01-A 4-74
MOTOR, PUMP, PART NO 21000 • 4-76
PUMP, HYDRAULIC, PART NO 21150-A 4-78
CYLINDER, TILT, PART NO 30340-02-B 4-80
CYLINDER, PIVOT, PART NO 30071-A 4-81
VALVE, SOLENOID, SAE 6, 2-WAY NC,36VDC, PART NO 51199-8 4-82
CYLINDER-SHIFT ASSY 11 STROKE, PART NO 17394-8 4-83
UMBILICAL ASSY, PART NO 17392-C 4-84
VALVE ASSY, SOLENOID, LIFT LIMIT, PART NO 17574-A 4-86
VALVE, SOLENOID, SAE 12, 2-WAY NO, 36 voe, PART NO 51310-A 4-87
STEER PUMP & MOTOR ASSY 36V, w/o THERMOSTAT, PART NO 50661-06-D 4-88
PUMP, POWER STEERING, PART NO 50654-A : 4-89
MOTOR, POWER STEERING, 36 V, PART NO 50656-A • 4-90
ELECTRICAL GROUP, 36 VDC SL44/4 ESS "E", PART NO 17535-13-A 4-92
ELECTRICAL PANEL ASSY, PART NO 15640-01-M 4-96
PANEL ASSY, FUSE MTG, PART NO 17370-01-E 4-98
CONNECTOR BATTERY GREY SB-350 3/0 CABLE 36 VOLT, PART NO 25165-5-A 4-99
SPOTLIGHT, w/GUARD 36 VDC, PART NO 25054-8 4-100
ELECTRICAL DOOR ASSY 36 VDC SL44/4 "E", PART NO 15512-08-D 4-101
ELECTRICAL DOOR ASSY 36 VDC SL44/4 "E", PART NO 15512-08-D (Continued) 4-102
SCR TRACTION CONTROL UNIT, PART NO 51170-C 4-104
CONTACTOR, DPDT, 300A, 36VDC COIL, PART NO 28888-D 4-106
CONTACTOR, SPNO, 300A, 36VDC COIL, PART NO 28889-D 4-108
EMERGENCY SWITCH KIT OPTIONAL, PART NO 17429 4-110
FOOT CONTROLLER ASSY (EV-100), PART NO 17065-C 4-112
SERVICE BRAKE PARTS GROUP, PART NO 15507-E 4-114
CYLINDER, MASTER 3/4 BORE 1 1/4 STROKE, PART NO 20210-A 4·117
FLUIDS & GREASE GROUP, PART NO 30760-01-C 4-118
LABEL & MARKING GROUP STD "DREXEL", PART NO 17559-01-C 4-120
Section 5 MAINTENANCE
5-1 GENERAL 5-1
5-2 SERVICING PRECAUTIONS 5-1
5-3 DRIVE ASSEMBLY 5-2
iii
Table of Contents
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 5-1 5
534 FINAL ASSEMBLY OF DRIVE AXLE · 5-15
5-4 STEER AXLE 5-1 6
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 ASSEMBLY 5-30
583 PIVOT ARM RACKING ADJUSTMENT • 5-31
5-9 HYDRAULIC PUMP AND MOTOR 5-31
591 REMOVAL 5-31
59,2 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
511 1 HYDRAULIC OIL RESERVOIR SUCTION FILTER REMOVAL 5-35
5112 HYDRAULIC RETURN LINE FILTER REMOVAL AND 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
5134 SINGLE POLE CONT ACTORS 5-42
5135 DOUBLE POLE CONT ACTORS 5-43
5136 ACCELERATOR MODULE 5-43
5137 DASH PANEL MODULE 5-44
5-14 MAST ASSEMBLY • 5-45
5 141 REMOVAL FROM TRUCK , 5-45
5142 MAST RACKING ADJUSTMENT 5-46
5143 MAST ADJUSTMENT 5-46
5144 MAST DISASSEMBLY 5-47
5-1 5 PRIMARY CYLINDER 5-4 7
5151 DISASSEMBLY 5-47
5152 REASSEMBLY 5-48
5-16 SECONDARY CYLINDER 5-48
5 1 61 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
7 1 ELECTRICAL SYSTEM 7-1
711 Traction Fuse 1 FU Open 7-1
71 2 Pump Fuse 2FU Open 7-2
713 Control Fuses 3FU, 4FU or 5FU Open 7-3
7 1 4 Loss of Drive Power 7-4
7 1 5 Loss of Drive Speed 7-6
72 HYDRAULIC SYSTEM 7-7
7 2 1 Pump Does Not Operate 7-7
722 Pump Runs Continuously 7-9
723 Pivot Function Defective 7-11
724 Shift Function Defective 7-11
725 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
728 Loss of Mast Tilt 7-14
73 POWER STEERING SYSTEM 7-14
7 31 Loss of Power Steering 7-14
7 32 Slow Steering Response 7-15
733 Drift of Steering 7-16
74 BRAKE SYSTEM 7-16
741 No Service Brake 7-16
742 No Seat Brake 7-17
743 No Parking Brake 7-17
75 NO-SPIN DIFFERENTIAL 7-17
7 6 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
766 Full Power Transition 7-19
767 1 A Control 7-19
768 Static Return to OFF 7-19
769 Coil Driver Modules 7-19
7610 Thermal Protector (TP) 7-19
7611 1A 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