Drexel SwingMast Lift Truck SLT22 Operation & Maintenance Manual 1412883 – PDF DOWNLOAD

Drexel SwingMast Lift Truck SLT22 Operation & Maintenance Manual 1412883 - PDF DOWNLOAD

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Drexel SwingMast Lift Truck SLT22 Operation & Maintenance Manual 1412883 - PDF DOWNLOAD

Language : English
Pages : 134
Downloadable : Yes
File Type : PDF

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Drexel SwingMast Lift Truck SLT22 Operation & Maintenance Manual 1412883 - PDF DOWNLOAD

Section 1 DESCRIPTION AND SPECIFICATIONS
11 INTRODUCTION 1-1
12DESCRIPTION 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
Motor Controllers 1-2
Safety Interlocks 1-3
Meters 1-3
14 Hydraulic Subsystem 1-3
141 Steering 1-3
142 Mast Positioning 1-3
1 43 Brake System 1-4
1 44 Pivot and Shift System 1-4
145 Mast 1-4
15 WARNINGS AND CAUTIONS 1-5
151 Warning Plates 1-6
152 Caution Plates 1-6
16 ITEMS FURNISHED 1-6
17 ITEMS REQUIRED 1-6
18 TOOLS AND TEST EQUIPMENT 1-6
19 PREPARATION FOR USE 1-6
110 PREPARATION FOR RESHIPMENT 1-6
111 STORAGE 1-6
Figure 1-1 Rails in "Collapsed" Position 1-4
Figure 1-2 Mast in Free Lift Position 1-5
Figure 1-3 Mast in Extended Position 1-5
Figure 1-4 Quadplex Mast in Collapsed Position 1-5
Table 1-1: Basic Truck Specifications 1-7
Table 1-2: Standard Masts Available for Truck 1-8
Section 2 PREPARATION FOR USE
21 RECEIVING INSPECTION 2-1
22 PREPARATION FOR USE 2-1
23 CHARGING BATTERIES , 2-1
24 PREPARING DRY-CHARGE BATTERIES 2-2
25 OPERATIONAL CHECKS 2-3
26 PROGRAMMING THE DRIVE MOTOR CONTROLLER 2-3
27 PROGRAMMING THE PUMP MOTOR CONTROLLER 2-4
Figure 2-1 Handset for Programming Motor Controllers 2-3
Table 2-1: Specific Gravity Corrections for Electrolyte Temperature 2-2
Table of Contents
Table 2-2: Recommended Function Values for Drive Motor Controller 2-4
Table 2-3: Recommended Function Values for Pump Motor Controller 2-5
Section 3 OPERATION
31 OVERVIEW 3-1
32 SAFETY SUMMARY 3-1
321 Before Operating 3-1
322 Using Dock Boards • 3-1
323 Moving a Load 3-1
33 PRE-OPERATION CHECKLIST 3-2
34 OPERATING CONTROLS 3-2
35 OPERATING LIMITATIONS 3-3
36 ADJUSTING THE SEAT 3-4
37 RUNNING FORWARD AND BACKWARD 3-4
38 MANEUVERING THE MAST 3-5
39 FORK ADJUSTMENT 3-5
310 PICKING UP A LOAD 3-6
311 DEPOSIT! NG A LOAD 3-6
Figure 3-1 Location of Controls and Indicators 3-3
Figure 3-2 Location of Seat Adjustment Controls : 3-4
Figure 3-3 Unlatching the Forks 3-5
Figure 3-4 Latching the Forks 3-6
Figure 3-5 Aligning the Truck to the Rack 3-7
Figure 3-6 Shifting and Pivoting a Load in or Out of the Rack 3-7
Figure 3-7 Inserting a Load Into or Removing a Load from the Rack 3-8
Section 4 PRINCIPLES OF OPERATION
41 GENERAL 4-1
42 HYDRAULIC SYSTEM 4-1
421 Steering System 4-1
422 Mast Systems 4-1
423 Pivot-Tilt System 4-2
424 Lift-Shift System 4-3
43 ELECTRICAL CONTROL SYSTEM 4-3
431 General 4-3
432 Plugging 4-3
433 Accelerator Operation 4-3
434 Power Bypass 4-4
435 Direction Control 4-4
436 Interlocks 4-4
Figure 4-1 Basic Hydraulic Flow, Power Steering 4-1
Figure 4-2 Steering at "Zero" Position (Valve Closed) 4-2
Figure 4-3 Pressure Relief System 4-2
Figure 4-4 "Boost'' Power to Lift-Shift System 4-2
Figure 4-5 Tilt System Anti-Cavitation Circuit 4-2
Figure 4-6 Lift System, Simplified Diagram 4-3
Figure 4-7 Shift System, Simplified Diagram 4-3
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Section 5 PREVENTIVE MAINTENANCE
51 OVERVIEW 5-1
511 Standard Tools Required 5-2
512 Special Tools Required 5-2
513 Safety Equipment Required 5-2
52 DAILY CHECKS AND INSPECTIONS 5-2
521 Check Batteries 5-2
522 Check Power Steering 5-3
523 Check Pump Contactor Delay 5-3
524 Check Return-To-Neutral '' 5-3
525 Daily Lift Chain Inspection 5-3
526 Inspect Tires 5-3
53 WEEKLY CHECKS 5-3
531 Check Hydraulic Oil Level 5-3
532 Check Master Cylinder Fluid Level 5-4
533 Check Pivot Alignment 5-4
534 Check Tilt Alignment 5-4
54 SIX-WEEK CHECKS 5-4
541 Lubricate Truck 5-4
542 Check Lift Operation 5-4
55 TWELVE-WEEK CHECKS 5-4
551 Check Bolts 5-4
552 Change Hydraulic Oil Filter 5-4
56 SEMI-ANNUAL CHECKS 5-6
561 Adjust Lift Chain 5-6
562 Adjust Shift Chain 5-6
563 Inspect Electrical Connections 5-6
564 Fork Inspection 5-6
565 lnspectthe Lift Chain · 5-7
566 Hydraulic Pump Motor Brush Replacement 5-7
567 Power Steering Motor Brush Replacement 5-8
568 Traction Motor Brush Replacement 5-8
57 ANNUAL CHECKS 5-9
571 Change Hydraulic Oil 5-9
572 Change Reservoir Sump Filter 5-9
573 Lubricate Front Wheel Bearings 5-1 O
Figure 5-1 Truck Lubrication Points 5-5
Figure 5-2 Measuring Fork Wear 5-6
Figure 5-3 Measuring Fork Distortion 5-7
Figure 5-4 Maximum Chain Elongation 5-7
Figure 5-5 Brush Rigging 5-8
Table 5-1: Preventive Maintenance Schedule 5-1
Table 5-2: Maximum Y Values, 2,000 lb Trucks 5-6
Table 5-3: Maximum Y Values, 3,000 lb Trucks 5-7
Section 6 TROUBLESHOOTING
61 GENERAL 6-1
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62 PRELIMINARY PROCEDURES 6-1
63 VISIBLE PROBLEMS 6-1
631 Cracks in Forks &-1
632 Leaking Fluid 6-1
633 Fluid Puddled Near Drive Wheel 6-1
634 Fluid Puddled Near Front Wheels 6-1
635 Fluid Puddled Near Mast 6-1
636 Frayed or Broken Wires 6-2
63 7 Lights Inoperative 6-2
638 Loose Electrical Connections 6-2
639 639 Scraped Rails on Mast 6-2
64 64 AUDIBLE PROBLEMS 6-2
641 641 Backup Alarm Inoperative 6-2
642 Noise when truck moves 6-2
643 High RPM in Drive Motor 6-2
644 Horn Inoperative 6-2
645 Main Pump Runs Continuously 6-2
646 Rubbing Noise at Front Wheels 6-2
64 7 Scraping Noise When Mast is Lifted 6-2
65 OPERATIONAL PROBLEMS 6-2
651 Brakes Do Not Stop the Truck 6-2
652 Hydraulic Functions Do Not Shut Off 6-3
653 Mast Does Not Lift 6-3
654 Mast Does Not Pivot 6-3
655 Mast Does Not Shift 6-3
656 Mast Does Not Tilt 6-3
657 Mast Drifts Downward 6-3
658 Mast Lifts Slowly 6-3
659 Parking Brake Does Not Hold the Truck 6-3
651 O Power Steering Motor Does Not Start 6-4
6511 Steering Drifts or is Erratic 6-4
6512 Truck Does Not Move 6-4
6513 Truck Does Not Turn 6-4
6514 Truck Moves Slowly 6-4
6515 Truck Turns Slowly 6-4
Section 7 CORRECTIVE MAINTENANCE
71 GENERAL 7-1
72 ADJUSTMENTS 7-1
721 Brake Adjustment 7-1
722 Brake Pedal Adjustment 7-1
723 Main Pump Relief Valve Adjustment 7-1
724 Parking Brake Adjustment 7-3
725 Stack Valve Switch Adjustment 7-3
726 Steering Pump Relief Valve Adjustment 7-3
727 Brake System Bleeding 7-4
728 Lift Cylinder Bleeding 7-4
729 Brake Shoe Cleaning 7-4
7 21 O Commutator Cleaning 7-4
73 REMOVAL PROCEDURES 7-4
731 Brake Master Cylinder Removal 7-4
732 Drive Unit Removal 7-4
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733 Main Pump and Motor Removal 7-5
734 Mast Removal 7-5
735 Pivot Cylinder Removal 7-6
736 Shift Cylinder Removal 7-6
737 Steering Head Removal 7-6
738 Steering Pump and Motor Removal 7-7
739 Tilt Cylinder Removal 7-7
7 310 Traction Motor Removal 7-7
74 INSTALLATION PROCEDURES 7-8
7 41 Brake Master Cylinder Installation 7-8
742 Drive Unit Installation 7-8
743 Main Pump and Motor Installation 7-8
744 Mast Installation 7-8
745 Pivot Cylinder Installation 7-8
746 Shift Cylinder Installation 7-8
747 Steering Head Installation 7-8
748 Steering Pump and Motor Installation 7-8
749 Tilt Cylinder Installation 7-8
7410 Traction Motor Installation 7-8
75 DISASSEMBLY PROCEDURES 7-8
751 Brake Master Cylinder Disassembly 7-8
752 Drive Unit Servicing 7-8
753 Lift Cylinder Disassembly 7-9
754 Main Pump Disassembly 7-9
7 55 Mast Disassembly , 7-1 O
756 Steering Control Unit 7-10
757 Steering Motor Servicing 7-10
7 58 Tilt Cylinder Disassembly 7-1 O
76ASSEMBLY PROCEDURES 7-10
761 Brake Master Cylinder Assembly 7-10
762 Lift Cylinder Assembly 7-10
763 Main Pump Assembly 7-11
7 64 Mast Assembly 7-11
765 Tilt Cylinder Assembly 7-11
77 REPLACEMENT PROCEDURES 7-11
771 Accelerator Assembly Replacement 7-11
772 Brake Line Replacement 7-11
773 Brake Assembly Replacement 7-11
774 Brake Switch Replacement ~ 7-11
775 Control Fuse Replacement 7-12
776 Bulb Replacement 7-12
777 Centering Spring Replacement (Valve Stack) 7-12
778 Directional Control Switch Replacement 7-12
779 Drive Wheel Replacement 7-13
7710 Emergency Stop Switch Replacement 7-13
7711 Fork Replacement 7-13
7712 Front Wheel Replacement 7-13
7 7 13 Hash Filter Replacement 7-13
7714 Horn Assembly Replacement , : 7-14
7715 Horn Hash Filter Replacement 7-14
7716 Hydraulic Fitting Replacement 7-14
7717 Hydraulic Hose Replacement 7-14
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Table of Contents
7718 Key Switch Replacement 7-15
7719 Power Fuse Replacement 7-15
7720 Relief Valve Replacement 7-15
7721 Rocker Switch Replacement 7-15
7722 Seat Switch Replacement 7-15
7723 Wheel Cylinder Replacement 7-15
7724 Valve Stack Replacement 7-16
Figure 7-1 Brake Pedal Adjustments 7-2
Figure 7-2 Control Valve Connections for Relief Valve Adjustments 7-2
Figure 7-3 Suggested Support Fixture and Cradle 7-5
Figure 7-4 Mast Lifting 7-6
Figure 7-5 Blocking the Mast 7-6
Figure 7-6 Steering Head Hydraulic Lines 7-7
Figure 7-7 Lifting the Drive Motor 7-8
Figure 7-8 Brake Assembly Replacement 7-12
Figure 7-9 Removing the Directional Control Switch 7-13
Section 8 PARTS LIST
81 GENERAL 8-1
82 WELDMENTS 8-1
Section 9 ILLUSTRATED PARTS BREAKDOWN
91 GENERAL 9-1
92 ABBREVIATIONS 9-1
93 PARTS NOT SHOWN 9-2
94 PHANTOM AND REFERENCE PARTS 9-2
SLT22 BASE UNIT, SPECIAL PAYLESS SHOE, PART NO 1412883-A 9-3
DRIVE GROUP, PART NO 1413283-A 9-5
DRIVE ASSEMBLY, PART NO 1400645-E 9-8
DRIVE UNIT, DUAL CHAIN, PART NO 1400695-A: 9-11
DRIVE UNIT, DUAL CHAIN, PART NO 1400695-A (Continued) 9-12
CHAIN ASSY FOR STEER, PART NO 1400109-8 9-14
MOTOR, DRIVE SHUNT, PART NO 1412772 9-15
IDLER ASSY FOR STEER CHAIN, PART NO 1401239-C 9-16
HYDRAULIC GROUP, PORTEC, PART NO 1413285-A 9-17
HYDRAULIC GROUP, PORTEC, PART NO 1413285-A (Continued) 9-18
HYDRAULIC SPOOL VALVE ASSY GE PUMP CONTROLLER, PART NO 1413387-A 9-22
STACK VALVE, PART NO 1400270-A 9-24
HYDRAULIC PUMP/MOTOR ASSEMBLY, PART NO 1413284-A 9-27
PUMP, TANDEM, PART NO 1410451 9-28
MOTOR,PUMP-MODIFIED, PART NO 1413625-A 9-29
MOTOR, PUMP SERIES, PART NO 1412771- 9-30
PUMP & MOTOR ASSEMBLY POWER STEERING ASSEMBLY, PART NO 37506-A 9-31
PUMP, HYDRAULIC, STEER, PART NO 51734-A 9-32
MOTOR, ELECTRIC STEER PUMP, PART NO 51735-8 9-34
HYDRAULIC RESERVOIR ASSY, PART NO 1400258-E 9-36
FILLER CAP ASSY w/ STRAINER,SIDE-MOUNT, PART NO 1400263-A 9-38
OIL FILTER ASSY, PART NO 1400646-E 9-39
HYDRAULIC ASSY, POWER STEER, PART NO 1400649-C 9-40
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MOTOR, HYDRAULIC, S SERIES, PART NO 25950-A 9-41
ASSEMBLY, MANIFOLD, PART NO 1402869-C 9-42
HOSE ASSY,UMBILICAL IMPERIAL HYTRON SB, PART NO 1405392-A 9-44
HOSE KIT, PART NO 1400603-F 9-45
OPERATOR CONSOLE GROUP, PART NO 1413288-A 9-48
CONSOLE PANELASSY, PART NO 1400498-D 9-52
SERVICE BRAKE COMPONENTS, PART NO1400648-M , 9-54
CYLINDER, MASTER 3/4 BORE 1 1/4 STROKE, PART NO 20210-A 9-56
STEERING COMPONENTS, PART NO1400650-H 9-58
STEERING COLUMN, 1 O" w/ 2 WIRE, PART NO 1400968-A 9-60
STEERING CONTROL UNIT 73 CU IN/REV OPEN CTR, PART NO 25975-A 9-62
ELECTRICAL COMPONENTS (CONSOLE GROUP), PART NO 1401464-F 9-64
INSTRUMENT PANELASSY, PART NO 1413287-A 9-66
LEVERASSY, PARTNO10417-B 9-68
SIDE CONSOLE ASSY, PART NO 1400931-F 9-70
JOYSTICK CONTROL PIVOT & SHIFT, PART NO 1406119-A 9-72
JOYSTICK CONTROL LIFT & TILT, PART NO 1406120-A 9-74
COVER PLATE ASSY (STANDARD), PART NO 1401930-C 9-75
CONSOLE COVER ASSY, PART NO 1401860-A 9-76
CATCH & KEEPER ASSY 5# PULL FORCE, PART NO 1401800-A 9-78
FINAL ASSEMBLY GROUP, PART NO 1400639-P 9-80
BATTERY DOOR ASSY, PART NO 1401378-B , 9-82
FLOOR PLATE ASSEMBLY, PART NO 1400660-E , 9-83
LEVEL INDICATOR ASSY, PART NO 1409561-C 9-84
FLUIDS GROUP, PART NO 1400640-D 9-87
REAR COMPARTMENT GROUP, PART NO 1401777-H 9-89
REAR COVERASSY, PART NO 1401755-A 9-90
GAS SPRING ASSY, PART NO 1410120-A 9-91
ELECTRICAL GROUP PORTEC w/TRANSISTOR CONTROLS, PART NO 1413300-B 9-93
ELECTRICAL GROUP PORTEC w/TRANSISTOR CONTROLS, PART NO 1413300-B (Cont) 9-94
CONTROL PANEL MODIF FOR GE SX CONTROL, PART NO 1413417-A 9-96
CONTACTOR PANEL, PART NO 1413294 9-97
ASSEMBLYPANEL PORTEC PATHFINDER, PART NO 1403854-C 9-98
KIT, WIRE GUIDANCE 36 VDC, 625 KHZ - 22/30, PART NO 1402034-D 9-99
PORTEC IDLER ASSY FOR STEER CHAIN, PART NO 1403041-B 9-100
PORTEC GUIDANCE SL T 22/30, PART NO 1403001 9-101
PARKING BRAKE GROUP GE SX TRACTION CONTROL, PART NO 1413377-A 9-104
OVERHEAD GUARD GROUP, PART NO 1400634-D 9-108
SEAT GROUP, PART NO 1400635-K 9-111
SEAT ASSY, GRAMMER WITH ARMS, PART NO 1410161-A 9-112
SEAT, GRAMMER WITH ARMS, PART NO 1402680-A 9-113
SERVICE BREAKDOWN GRAMMER GS12 SEAT, PART NO 1412457-A 9-114
SERVICE PARTS, SEAT, GRAMMER WITH ARMS, PART NO 1410162-A 9-115
SEAT BELT KIT SLT22/30, PART NO 1412363-A 9-116
LOADWHEELGROUPSLT22/30, PARTNO1400636-E 9-118
BRAKE ASSY, 105 X 25 w/RH PARK LEVER, PART NO 51082-01-A 9-120
BRAKE ASSY, 105 X 25 w/LH PARK LEVER, PART NO 51082-02-A 9-122
CUSTOMER ORDER NO 940069 Rev 02 9-125
IDENTIFICATION GROUP, STANDARD, PART NO 1400641-M 9-128
PAINT GROUP ENAMEL YELLOW, PART NO 1401997-A 9-131
TRIPLEX GROUP 95/214/75-31, PART NO 1402465-B 9-133
PIVOT/SHIFT GROUP STD QUAD MAST TO LIMIT REACH*, PART NO 1401784-F 9-135
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SHIFT CYLINDER COMPONENTS, PART NO 1405452-D 9-136
SHIFT CYLINDER ASSY, PART NO 1401785-C 9-138
SHIFT CYLINDER ASSY, PART NO 1401786-F 9-140
TILT CYLINDER COMPONENTS, PART NO 1400604-B 9-142
CYLINDER TILT 300 BORE, PART NO 1400153-A 9-144
PIVOT CYLINDER COMPONENTS, PART NO 1400605-C 9-146
CYLINDER PIVOT, PART NO 1400601-A 9-148
CROSSHEAD AND PIVOT ASSY, PART NO 1400653-H 9-150
MIRROR GROUP OVERHEAD GUARD, PART NO 1410902-A 9-154
SEAT BELTS, PART NO 1402011-A 9-155
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