Drexel SwingMast Lift Truck SL44/3 Technical Manual 1412661 - PDF DOWNLOAD

Drexel SwingMast Lift Truck SL44/3 Technical Manual 1412661 - PDF DOWNLOAD

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Drexel SwingMast Lift Truck SL44/3 Technical Manual 1412661 - PDF DOWNLOAD

Language : English
Pages : 104
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

Drexel SwingMast Lift Truck SL44/3 Technical Manual 1412661 - PDF DOWNLOAD

Section 1 DESCRIPTION AND SPECIFICATIONS
11 INTRODUCTION 1-1
12 DESCRIPTION 1-1
13 FUNCTIONAL DESCRIPTION 1-2
131 Frame 1-2
1 32 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
1 7 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 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
331 O 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
42 ABBREVIATIONS 4-1
43 PARTS NOT SHOWN 4-2
44 PHANTOM AND REFERENCE PARTS 4-2
BASE UNIT SL44/3 3M, PART NO 1412661-A 4-4
SERVICE BRAKE GROUP, PART NO 1412402-A 4-9
SERVICE BRAKE PARTS GROUP, PART NO 15507-E 4-10
CYLINDER, MASTER, 3/4 BORE 1-1/4 STROKE, PART NO 20210-A 4-13
HAND BRAKE ASSY, PART NO 17395 4-14
DRIVE ASSY, SL33HP STD, PART NO 10712-05-K 4-16
AXLE, DRIVE WITH KNOTT BRAKE, PART NO 17133-8 4-19
AXLE, DRIVE WITH KNOTT BRAKE, PART NO 17133-8 (Continued) 4-20
DIFFERENTIAL, NO-SPIN, PART NO 20230-A 4-24
MOTOR, TRACTION, PART NO 51367-B 4-25
BRAKE ASSY MODIFIED 6" DIAMETER, PART NO 30677-B 4-26
FLUIDS & GREASE GROUP, PART NO 30760-01-C 4-27
CONSOLE ASSY, PART NO 1412666-A 4-30
DASH PANEL, WIRE HARNESS & JUMPER ASSY, PART NO 1412560-A 4-32
INSTRUMENT PANELASSYTILT CONSOLE & CURTIS BDI, PART NO1412708-A 4-34
STEERING WHEEL & HORN BUTTON ASSY, PART NO 1410602-A 4-36
ORBITROL SUB-ASSY, PART NO 17430-C 4-37
STEERING CONTROL UNIT, PART NO 25715-B 4-38
COLUMN, STEER w/2 HORN WIRES, PART NO 25040-C 4-40
COVER GP SL-44/3 STD, PART NO1412272-A 4-41
SEAT GROUP SL-33/44 MSG-12, PART NO 1412659-A 4-44
SEAT BELT ASSY MODIFIED, PART NO 17585-B 4-45
SEATBLACKMSG12VINYL, PARTNO1412660-A 4-46
ELECTRICAL GROUP SL-33/44-3 STD, HI-LO, DRIVE IN RACK, PART NO 1412759-A 4-49
ELECTRICAL PANEL MODIFIED FOR CURTIS 933 BDI, PART NO 1412333-A 4-50
FUSE PANEL SUB ASSY, PART NO1412707-A 4-52
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Table of Contents
ELECTRICAL DOOR ASSY 36 voe SL33/44-3, PART NO 15512-10-B 4-55
ELECTRICAL DOOR ASSY 36 voe SL33/44-3, PART NO 15512-10-B Continued) 4-56
SCR TRACTION CONTROL UNIT, PART NO 51170-C 4-60
CONTACTOR, DPDT, 300A, 36VDC COIL, PART NO 28888-D 4-62
CONTACTOR, SPNO, 300A, 36VDC COIL, PART NO 28889-D 4-64
CONNECTOR BATTERY GRAY SB-350 4/0 CABLE 36 VOLT, PART NO 25165-2 4-66
FOOT CONTROLLER ASSY (EV-100), PART NO 17065-C 4-68
SWITCH ASSY, SEAT, PART NO 15659 4-70
HORN ASSY 36V & HASH FILTER, PART NO 15679-A 4-71
STEER PUMP & MOTOR ASSY 36V, w/o THERMOSTAT, PART NO 50661-06-D 4-73
PUMP, POWER STEERING, PART NO 50654-A 4-74
MOTOR, POWER STEERING, 36 V, PART NO 50656-A 4-75
ARTICULATED STEER AXLE ASSY, PART NO 14221-05-F 4-78
CYLINDER ASSY, STEER, PART NO 10834-G 4-81
CYLINDER ASSY, MODIFIED, PART NO 9767-01-B 4-82
CROSSHEAD AND PIVOT ASSY, PART NO 17512-01-E 4-84
COMMON PARTS GROUP, PART NO 1412713-A 4-87
COMMON PARTS GROUP, PART NO 1412713-A (continued) 4-88
COMMON PARTS GROUP, PART NO 1412713-A (continued) 4-89
KNOB, LIFT, PART NO 50382-01 4-91
KNOB, TILT, PART NO 50382-02 4-91
KNOB, PIVOT, PART NO 50382-03 4-91
KNOB, SHIFT, PART NO 50382-04 4-91
DOOR ASSY GROUP w/o STEER PUMP & MOTOR, PART NO 11748-05-A 4-93
CHAIN ANCHOR ASSY, PART NO 17393-B 4-94
INDICATOR, FORK LEVEL, PART NO 36560 , 4-95
CUSTOMER ORDER NO 942915 Rev 03 , 4-97
FINAL ASSY 3M SL44-3 S/N 936919, PART NO 1412558-A , , 4-99
HYDRAULIC ASSY 3M PORTEC AND L-S-P INTERLOCKS, PART NO 1412656-A , 4-102
HYDRAULIC ASSY 3M PORTEC, ETC, PART NO 1412656-A (continued) 4-103
HYDRAULIC ASSY 3M PORTEC, ETC, PART NO 1412656-A (continued) 4-104
CONTROL PANELASSY "E" & "EE" 36 & 48 VOLTS, PART NO 15593-08-A 4-108
CONTROL PANEL ASSY "E" & "EE" 36 & 48 VOLTS, PART NO 15593-08-A, 4-110
VALVEASSY, CONTROL, PART NO11777- , , 4-111
VALVE, CONTROL, MODIFIED, PART NO 50700-A , 4-112
VALVE ASSY, CONTROL, PART NO15592-01-A , , 4-114
VALVE, CONTROL, MODIFIED, PART NO 50701-01-B 4-116
PUMP AND MOTOR ASSEMBLY 36 voe, STD, PART NO 11300-01-A 4-118
MOTOR, PUMP, PART NO 50377-A ,, 4-120
PUMP, HYDRAULIC, PART NO 21150-A , , , , 4-122
RESERVOIRASSY, PART NO10845-02-J , 4-124
VALVE, SOLENOID, SAE 12, 2-WAY NO, 36 voe, PART NO 51310-A, " 4-126
CYLINDER-SHIFT ASSY 11 STROKE, PART NO17394-B,, 4-127
CYLINDER-SHIFT 1107 STROKE, PART NO 51398-01-D , , 4-128
VALVE, SOLENOID, SAE 6, 2-WAY NC,36VDC, PART NO 51199-B 4-129
UMBILICALASSY, PART NO1411667-A 4-130
CYLINDER, PIVOT, PART NO 30071-A , 4-131
CYLINDER, TILT, PART NO 30340-02-B , ,, 4-132
TRIPLEX GROUP 111-251-85, PART NO 1412507-A 4-133
PAINT, ENAMEL YELLOW, PART NO 37260-04-A , , 4-135
LABEL & MARKING GP STD 15020 "DREXEL", PART NO 17559-01-D 4-138
SWITCH GROUP LIFT-SHIFT & PIVOT TRIPLEX MAST, PART NO 1412763-A 4-141
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Table of Contents
LIFT LIMIT SWITCH MODIF ABOVE 192 FH TRIPLEX MAST, PART NO 1412315-A 4-142
SIDESHIFT SWITCH MODIFIED, PART NO 1412762-A 4-144
PIVOT SWITCH INSTALLATION SL33/44, PART NO 1412314-A 4-146
PIN PIVOT & CAM WELDT &ASSY SL33/44 HP, PART NO 1411540-A 4-148
GUIDED STEER INSTALLATION 3M, PART NO1412760-A 4-149
GUIDED STEER INSTALLATION 3M, PART NO1412760-A (Continued) 4-150
REAR SENSOR PLATE FIXED, PART NO 1412761-A 4-154
PATHFINDER GUIDANCE SYS HYDROSTATIC TYPE, PART NO 12849-A 4-156
DRIVER, LINE, 625 KHZ, PART NO 52539-A 4-160
SERVO DRIVER/HEATSINK, PART NO 1412770-A 4-162
POSITION POTENTIOMENTER BODY, PART NO 22554-A 4-164
SERVO, HYDRAULIC STEERING ASSY 36 VOLT, PART NO 22539-A 4-166
SOLENOID VALVE, PART NO 50508-A 4-167
CONTROL BOX ASSY, PART NO 22555-A 4-169
CONTROL RELAY ASSY, PART NO 28447-A 4-170
WIRE HARNESS ASSY, PART NO1413786-A 4-172
DRIVE TIRE GROUP POLY 18 X 10 X 1213, PART NO 1412260-A 4-173
LIGHTS MOUNTED FRONT BOTH SIDES OVERHEAD GUARD, PART NO 1412941-A 4-176
HEADLIGHT 36 VOLTS w/o GUARD MODEL 6700 SERIES, PART NO 1412924-A 4-178
STROBE LIGHT AMBER MOUNT REAR OF OHG, PART NO 1412945-B 4-180
STROBE LIGHT, AMBER, PART NO 2771995-A 4-182
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
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Table of Contents
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
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 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 CONTACTORS 5-42
5135 DOUBLE POLE CONTACTORS 5-43
5136 ACCELERATOR MODULE 5-43
5137 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
62WELDMENTS 6-1
Section 7 TROUBLESHOOTING
71 ELECTRICAL SYSTEM 7-1
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Table of Contents
711 Traction Fuse 1FU Open 7-1
712 Pump Fuse 2FU Open 7-2
713 Control Fuses 3FU, 4FU or 5FU Open 7-3
7 14 Loss of Drive Power 7-4
7 15 Loss of Drive Speed 7-6
72 HYDRAULIC SYSTEM 7-7
721 Pump Does Not Operate 7-7
722 Pump Runs Continuously 7-9
7 23 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
7 26 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
731 Loss of Power Steering 7-14
732 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
76 SCR CONTROL CIRCUIT 7-17
761 Theory of Operation 7-17
762 Oscillator 7-18
7 63 Current Limit 7-18
764 Plugging 7-18
765 Ramp Start 7-19
766 Full Power Transition 7-19
767 1A Control 7-19
768 Static Return to OFF 7-19
769 Coil Driver Modules 7-19
7 61 O 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

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