Drexel SL60 & SL80 SepEx SWINGMAST Maintenance Manual – PDF

Drexel SL60 & SL80 SepEx SWINGMAST Maintenance Manual_F-511-0411 – PDF DOWNLOAD

FILE DETAILS:

Drexel SL60 & SL80 SepEx SWINGMAST Maintenance Manual_F-511-0411 – PDF DOWNLOAD

Language : English
Pages : 262
Downloadable : Yes
File Type : PDF

IMAGES PREVIEW OF THE MANUAL:

TABLE OF CONTENTS:

Drexel SL60 & SL80 SepEx SWINGMAST Maintenance Manual_F-511-0411 – PDF DOWNLOAD

Using This Manual 1-1
Maintenance 2-1
Overview 2-2
Tools or Equipment Required 2-3
Special Tools Required 2-3
Safety Equipment Required 2-3
Inspection and Maintenance Program 2-4
Inspection Program 2-4
Maintenance Program 2-5
Inspection and Maintenance Responsibilities 2-5
Operator’s Daily Checklist 2-5
Shift Inspection 2-6
Hourly Inspection 2-6
Installation Inspection 2-6
Routine Maintenance Schedule for SL Series Forklifts 2-7
Inspection and Maintenance Practices 2-7
Inspection and Maintenance Practices for SL Series Forklift Operations 2-8
Inspection and Maintenance Practices for Authorized Facilities ONLY 2-9
Preparing for Inspection or Maintenance 2-9
Performance Testing 2-10
Completing Performance Testing 2-11
Fork Inspection 2-12
Measuring Fork Thickness and Distortion 2-13
Mast Maintenance 2-15
Inspection Check List 2-16
Load Roller Maintenance 2-16
Chain Maintenance 2-17
Chain Inspection 2-17
Chain Lubrication 2-17
Chain Adjustment 2-18
Measuring Chain Stretch 2-18
Check Lift Operation 2-19
Check Primary Lift Chain 2-20
Checking and Adjusting Degree of Tilt 2-21
Side Shift Circuit Maintenance 2-23
ii F-511-0411
Checking for Leaks 2-23
Identification Plate and Safety Warnings 2-24
Lubricating the Truck 2-24
Tilt Cylinder Clevis 2-26
Main Rotation Bearings/Gears 2-27
Bearing Pad Lubrication 2-28
Fork Positioner Lubrication, Non-Side Shifting (Option) 2-30
Inspect Tires 2-31
Chunking (Chipping) or Embedded Objects 2-32
Undercutting and Uneven Wear 2-32
Flat-Spotting 2-33
To Extend Tire Life 2-33
Drive Wheel Lug Nuts 2-34
Check Planetary Gear Box 2-34
Replacing Motor Brushes 2-37
Exposing the Motors 2-37
Traction Drive Motor Brushes 2-38
Lift Pump and Power Steering Motor Brushes 2-40
Check Service Disc Brakes 2-41
To Check the Brakes 2-42
Power Steering System Maintenance 2-43
Check Power Steering 2-44
Filling and Air Bleeding the Power Steering System 2-45
Lubricate Steer Wheel Knob 2-45
Check Hydraulic Functions 2-46
Check the Return-To-Neutral 2-47
Check Driver’s Seat Switch 2-48
Floor Plate Removal 2-49
Check Master Cylinder Fluid Level 2-50
Hydraulic System Maintenance 2-51
Check Hydraulic Oil Level 2-52
Change Hydraulic Oil Filter 2-54
Change Hydraulic Oil 2-55
Battery Care and Maintenance 2-56
Electrical Static Discharge 2-57
Check Batteries 2-58
To Check the Battery 2-59
Battery Charging 2-60
Lubricate the Steering Knuckles 2-61
Lubricate the Bearings, Race and Inner Seal 2-62
Check Nuts, Bolts and Screws 2-64
Inspect Electrical Connections 2-65
Curtis Controller 2-65
General Practice 2-67
F-511-0411 iii
Troubleshooting 3-1
Preliminary Procedures 3-1
Hydraulic Problems 3-3
Brake Problems 3-14
Electrical Problems 3-16
Audible Problems 3-17
Visible Problems 3-20
Corrective Maintenance 4-1
Introduction 4-1
Tools Needed 4-2
Before You Begin 4-2
Lifting the Truck 4-3
Cleaning and Inspection 4-4
Mast Service 4-4
Forks 4-4
Removing the Forks 4-4
Repairing the Forks 4-5
Load Testing Forks 4-5
Removing the Tilt Cylinders 4-5
Mast 4-6
Removing the Mast From the Truck 4-6
Pressure Compensating Flow Control Valve 4-7
Removing the Pivot Cylinder 4-7
Pivot Arm Removal 4-7
Pivot Inspection 4-10
Pivot Arm Reassembly 4-10
Pivot Joint Reassembly 4-10
Crosshead 4-11
Removal 4-11
Inspection 4-11
Side Shift Bearing Shoe Adjustment 4-12
Removing Bearing Pads 4-12
Pivot Interlock Switch 4-14
Shift Interlock Switch 4-14
Sideshift Chain Assembly 4-16
Adjustment 4-16
Removal and Installation 4-17
Traction Drive Motor and Gearbox 4-18
Replacing the Gear Box 4-19
Replacing the Traction Drive Motor 4-20
Brake System 4-21
Brake Caliper Assembly 4-23
Changing Brake Pads 4-24
Replacing the Brake Caliper Assembly 4-27
iv F-511-0411
Repairing Brake Caliper Pistons 4-28
Disc Brake Rotors 4-30
Measuring Thickness 4-30
Check Lateral Runout (Warping) 4-30
Replacing Brake Rotor Assembly 4-31
Parking Brake Assembly 4-32
Parking Brake Lever 4-32
Checking Parking Brake Adjustment 4-33
Replacing Parking Brake Lever Assembly 4-34
Parking Brake Switch 4-35
Checking Parking Brake Switch 4-35
Replacing Parking Brake Switch 4-36
Replacing the Parking Brake Cable 4-37
Parking Brake Caliper Assembly 4-38
Adjusting Parking Brake Caliper 4-38
Changing Parking Brake Pads or Replacing Parking Brake Caliper 4-39
Brake Pedal Assembly 4-40
Disc Brakes 4-40
Brake Pedal 4-40
Service Brake Linkage 4-41
Brake Light/Accelerator Switch 4-43
Brake Light/Accelerator Switch Adjustment 4-43
Brake Light/Accelerator Switch Replacement 4-44
Master Cylinder 4-45
Replacing Master Cylinder 4-45
Bench Bleed the Master Cylinder 4-47
Bleeding Brakes 4-47
Service Brake Pedal Assembly 4-50
Replacing Any Other Hydraulic Brake Component 4-50
Accelerator Pedal Assembly 4-51
Floor Plate Removal 4-51
Adjusting Accelerator Pedal 4-52
Replacing Linear Accelerator Module 4-53
Hydraulic Components 4-54
Servicing Lift/Steer Motor and Pump 4-54
Replacing Lift Motor Only 4-55
Replacing Pump (Without Removing Motor) 4-55
Replacing Pump (Motor Removed) 4-55
Steer Motor and Pump 4-56
Checking Steering Pump Pressure 4-57
Hydraulic Return Filter 4-58
Change Hydraulic Oil Filter 4-58
Hydraulic Control Valve Assembly 4-59
Hydraulic Control Valve and Switches Removal 4-60
Spool Section Rebuild 4-62
F-511-0411 v
Hydraulic Lift Pot 4-62
To Replace 4-62
Steering Axle Assembly 4-65
Removing Rear Axle 4-65
Disassembling and Inspecting Rear Axle Mounting Blocks 4-66
Checking Steer Wheels 4-66
Disassembling and Inspecting Wheel Bearings 4-68
Assembling Wheel Bearings 4-69
Disassembling and Inspecting Steering Knuckles 4-71
Assembling the Steering Knuckle 4-71
Hydraulic Fittings and Hoses 4-72
Electrical System 4-74
Steering Column/Dash Assembly 4-74
Remove Right Side Cover 4-75
Display 4-76
Brush Wear Indicator (BWI) LED’s 4-77
Key Switch 4-77
Option Rocker (On/Off) Switches 4-78
Steering Wheel 4-79
Steering Column 4-80
Steering Orbital Control Unit 4-80
Direction Control Lever 4-83
Replacing Direction Control Lever 4-83
Model 1311 Handset 4-84
Description 4-84
Directions for Use 4-84
Calibration of Steering and Throttle Pot 4-85
Recording Throttle and Steer Pot Values 4-85
Programming Throttle and Steer Pot Parameters 4-85
Setting the Lift Pot 4-86
Replacement 4-87
Replacing Complete Control Panel 4-87
Horn 4-87
Removing the Horn 4-87
Replacing Any Other Single Controller Component 4-88
Replacing Hydraulic Tank 4-88
Seat Assembly 4-88
Seat Switch 4-91
Replacing the Switch and Cable 4-91
Overhead Guard, Lighting and Alarms 4-92
Lights 4-93
Back Up Alarms 4-95
Electrical Control System 4-96
Curtis SE Electrical Control Panel 4-96
System Overview 4-97
vi F-511-0411
Troubleshooting Tools 4-97
Using Curtis 1314 Software 4-98
Calibration 4-101
Controllers 4-104
840 Display 4-111
1244 Traction Controller 4-116
1254 Hydraulic Pump Controller 4-131