Drexel SwingMast Lift Truck R60SL (CBD) Series Service & Parts Maintenance Manual 1416841 – PDF

Drexel SwingMast Lift Truck R60SL (CBD) Series Service & Parts Maintenance Manual 1416841 – PDF DOWNLOAD

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Drexel SwingMast Lift Truck R60SL (CBD) Series Service & Parts Maintenance Manual 1416841 – PDF DOWNLOAD

Language : English
Pages : 158
Downloadable : Yes
File Type : PDF

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TABLE OF CONTENTS:

Drexel SwingMast Lift Truck R60SL (CBD) Series Service & Parts Maintenance Manual 1416841 – PDF DOWNLOAD

Section 1 Description and Specifications
1 1 Introduction 1-1
1 2 Description 1-1
1 3 Functional Description 1-2
1 3 1 Frame 1-2
1 3 2 Power Plant 1-2
1 3 3 Drive Train 1-2
1 3 4 Electrical System 1-2
1 3:5 Hydraulic Subsystem 1-2
1 3 6 Pivot and Shift System 1-3
1 3 7 Mast 1-3
1 4 Items Furnished 1-4
1 5 Items Required 1-5
1 6 Tools and Test Equipment 1-5
1 7 Preparation for Use 1-5
1 8 Preparation for Re-shipment 1-5
1 9 Storage 1-6
Table 1-1: General Specifications 1-6
Table 1-2: Dimensions of Standard Masts 1-7
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IPB Contents – continued Page
Section 2 Operating your Truck
2 1 Operation
2 1 1 Pre-operation checklist 2-5
2 1 2 Adjusting the driver’s seat 2-5
Figure 2-1: Driver’s seat 2-5
Seat belt 2-7
Figure 2-2: Belt release button 2-7
2 1 3 Tilt steering column 2-7
Figure 2-3: Adjust tilt steering 2-7
2 1 4 Fork adjustment 2-8
Manual fork adjust 2-8
Figure 2-4: Unlocking the forks 2-8
Fork positioner option – automatic 2-9
2 2 driving the truck
2 2 1 Starting diesel engines 2-1 O
Figure 2-5: Glow plugs button 2-1 O
Cold temperature starting 2-11
2 2 2 Practice sessions 2-11
Inching 2-13
2 3 the mast
2 3 1 Practice session 2-13
Figure 2-6: Lift and till function lever icon 2-13
Figure 2-7: Fork level gauge 2-14
Figure 2-8: Pivot and shift function lever icon • , • 2-14
2 4 handling standard loads
2 4 1 To pick up the load • 2-16
Figure 2-9: Aligning the truck to the pallet opening 2-17
Figure 2-1 O: Pivot the forks about 45° 2-17
Figure 2-11: Shifting the forks into the pallet 2-18
Figure 2-12: Pivot the load about 45° 2-19
2 4 2 To deliver a load 2-19
Figure 2-13: Align the load to the rack , 2-20
Figure 2-14: Pivot the load about 45° 2-21
Figure 2-15: Placing the load into the rack 2-21
Figure 2-16: Pivot the forks about 45° 2-22
Figure 2-17: Normal driving position 2-22
2 5 side loading (long loads)
2 5 1 To pick up a “long” load 2-24
Figure 2-18: Aligning the truck to the long load pallet 2-24
Figure 2-19: Shifting the forks into the pallet 2-25
Figure 2-20: Shift and pivot load from the rack 2-26
Figure 2-21: Normal long load driving position 2-26
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IPB Contents – continued Page
2 5 side loading (long loads) – continued
2 5 2 To deliver a “long” load 2-27
Figure 2-22: Aiming the load into the opening 2-27
Figure 2-23: Rotating the long load into the rack 2-28
Figure 2-24: Shifting the load into the opening 2-28
for more experienced driver’s 2-29
Figure 2-25: Backing the load into the slot 2-29
Figure 2-26: Pivoting the load into the opening 2-30
2 5 3 Proximity sensor option 2-30
Figure 2-27: Proximity sensor 2-31
Section 3 Preventive Maintenance
3 1 General 3-1
3 2 Visual Checks – 3-1
Defective Fasteners 3-1
Welding Defects 3-1
Defective Wires or Connectors 3-1
Worn Hydraulic Lines or Loose Fittings 3-2
Rust or Corrosion 3-2
3 3 Lubrication Instructions 3-1
3 4 Procedures 3-2
Check Engine Oil Level 3-2
Adding Engine Oil 3-2
Replacing Engine Oil Filter 3-2
Checking Transmission Fluid Level 3-2
Adding Transmission Fluid 3-3
Replacing Transmission Filter 3-3
Check and Adding Hydraulic Oil 3-3
Replacing Hydraulic Oil Filter 3-3
Check and Adding Drive Axle Oil 3-3
Check Brake Fluid 3-3
Lubricating Pivot Cylinder Clevis 3-4
Lubricating Shift Spherical Bearings and Sheave Block 3-5
Lubricating Side Shift Cam Rollers 3-5
Lubricating Steer Axle Components 3-5
Lubricating Tilt Cylinder Clevis 3-5
Lubricating Side Shift Bearing Housing 3-6
Lubricating Mast Trunnions 3-6
Lubricating Pivot Shaft Bearings 3-7
Check the Parking Brake 3-7
Adjusting the Parking Brake 3-7
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IPB Contents – continued Page
Section 3 Preventive Maintenance – continued
Checking the Air Filter 3-7
Cleaning the Air Filter 3-8
Replacing the Air Filler Element 3-8
Testing Broken Belt Indicator 3-8
Checking Mast Operation 3-8
Table 3-1: Daily Preventive Maintenance Checks 3-9
Table 3-2: Weekly Preventive Maintenance Checks 3-10
Table 3-3: Lubrication Chart 3-11
Section 4 Not Used
Section 5 Maintenance
5-1 Introduction 5-1
5-2 Servicing Precautions 5-1
5-3 General Maintenance 5-2
5 3 1 Replacement of Air Filter , 5-2
5 3 2 Replacement of Engine Oil Filter 5-2
5 3 3 Replacement of Hydraulic Oil Filter • 5-3
5 3 4 Replacement of Transmission Fluid Filter 5-3
5 3 5 Replacement of Alternator Belt 5-3
5 3 6 Replacement of Blower Belt , 5-4
5-4 Overhead Guard Removal 5-4
5-5 Drive Axle Maintenance 5-4
5 5 1 Removal 5-4
5 5 2 Installation 5-5
5 5 3 Removal and Replacement of Disk Brakes 5-5
5 5 4 Disassembly and Assembly of Planetary System 5-5
5 5 5 Adjustment of Bevel Gear Set ; 5-5
5 5 6 Disassembly of Differential 5-5
5 5 7 Assembly of Differential 5-5
5-6 Removal of Engine and Transmission 5-5
5-7 Installation of Engine and Transmission 5-6
5-8 Engine Maintenance 5-6
5-9 Transmission Maintenance 5-6
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IPB · Contents – continued Page
Section 5 Maintenance – continued
5-10 Steer Axle Maintenance 5-6
5 10 1 Removal of Steer Axle 5-6
5 10 2 Installation of Steer Axle 5-7
5 10 3 Disassembly of Wheel Hub 5-7
5 10 4 Reassembly of Wheel Hub 5-7
5 10 5 Disassembly of Steering Knuckle 5-8
5 10 6 Reassembly of Steering Knuckle 5-8
5 10 7 Removal of Steering Cylinder 5-9
5 10 8 Installation of Steering Cylinder 5-9
5-11 Brake System Maintenance 5-9
5 11 1 Bleeding the Brakes 5-9
5 11 2 Adjustment of Brake Linkage 5-10
5 11 3 Adjustment of Service Brake 5-10
5 11 4 Adjustment of Parking Brake 5-1 0
5-12 Battery Maintenance 5-10
5-13 Pivot/Side Shift Maintenance 5-1 0
5 13 1 Removal of Pivot Arm 5-10
5 13 2 Installation of Pivot Arm 5-10
5 13 3 Removal of Pivot Cylinder 5-11
5 13 4 Installation of Pivot Cylinder 5-11
5 13 5 Adjustment of Side Shift Chain 5-11
5 13 6 Removal of Side Shift Cylinder 5-12
5 13 7 Installation of Side Shift Cylinder 5-12
5 13 8 Replacement of Side Shift Bearings 5-12
5-14 Hydraulic Pump Maintenance 5-15
5 14 1 Removal 5-15
5 14 2 Installation 5-15
5-15 Power Steering Unit Maintenance 5-15
5 15 1 Removal 5-15
5 15 2 Installation 5-15
5 15 3 Disassembly and Assembly 5-15
5-16 Mast Maintenance 5-15
5 16 1 Removal 5-15
5 16 2 lnstallation 5-16
5 16 3 Till Cylinder Adjustment 5-16
5 16 4 Adjustment of Carriage Side Rollers 5-16
5 16 5 Adjustment of Rail Guide Rollers 5-16
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□ Table of Contents
IPB Contents – continued Page
Section 5 Maintenance – continued
5-16 Mast Maintenance – continued
5 16 6 Adjustment of Chain 5-16
5 16 7 Disassembly of Rail Guide Rollers 5-16
5 16 8 Disassembly of Primary Cylinder 5-17
5 16 9 Reassembly of Primary Cylinder 5-17
5 16 10 Disassembly of Secondary Cylinder 5-18
5 16 11 Reassembly of Secondary Cylinder 5-18
5 16 12 Bleeding the Mast Cylinder 5-18
Section 6 Troubleshooting
6 1 Introduction 6-1
6 2 Hydraulic System, Pivot and Shift 6-1
Pivot Function Defective 6-1
Shift Function Defective 6-1
Steering Drift 6-1
6 3 Hydraulic System, Pivot and Shift 6-2
Steering Power Loss 6-2
6 4 Hydraulic System, Mast 6-2
Mast Will Not Lift 6-2
Lift Cylinder Does Not Move 6-2
Lifts Load Slowly or Stops 6-2
Lift Cylinder Leak 6-3
Jerky or Spongy Lifting Action 6-3
Sudden Increase in Lift Speed , 6-3
Extended Mast Fails to Lower Completely 6-4
Load DriftsDownward After Control is in Neutral 6-4
Unable to Extend Mast 6-4
Excessive Side Movement 6-4
Carriage Binds in Rails 6-4
Carriage Side Bars Hit or Scrape 6-4
Rails Move Before Carriage 6-4
Carriage Lower Before Rails Retract 6-4
Excessive Spalling on Inner Rail 6-5
Extended Mast Drifts Downward , 6-5
6 5 Hydraulic System, Brake System
Parking Brake Inoperative 6-6
Service Brake Inoperative 6-6
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IPB Contents – continued Page
Section 6 Troubleshooting – continued
6 6 Drive System 6-7
Wheel Studs Shearing Off 6-7
Drive Tries Scuffing 6-7
Broken Axle Shaft 6-7
Load Snapping or Cracking Noises 6-7
Grinding Noises 6-7
Clicking Noises 6-7
Excessive Tire Wear 6-7
Locking Up 6-8
Backlash in Drive Train 6-8
Section 7 Mast IPB
Section 7 “Mast IPB” (illustrated parts breakdown) includes a Mast Assembly and a Mast
Installation manual, each having its own separate “Table of Contents ”
Section 8 Base Unit IPB
Section 8, “Base Unit IPB” (illustrated Parts Breakdown) includes a parts breakdown of the
main body of the SwingMast® Lift Truck This section includes a separate “Table of Contents ”
Section 9 Options IPB
Section 9, “Options IPB” (illustrated parts breakdown) includes a parts breakdown of the most
commonly used option features ordered on Drexel SwingMast Lift Trucks