DREXEL SwingMast Lift Truck SLT30C Operation & Maintenance Manual 1413778 - PDF DOWNLOAD

DREXEL SwingMast Lift Truck SLT30C Operation & Maintenance Manual 1413778 - PDF DOWNLOAD

FILE DETAILS:

DREXEL SwingMast Lift Truck SLT30C Operation & Maintenance Manual 1413778 - PDF DOWNLOAD

Language : English
Pages : 268
Downloadable : Yes
File Type : PDF

TABLE OF CONTENTS:

DREXEL SwingMast Lift Truck SLT30C Operation & Maintenance Manual 1413778 - PDF DOWNLOAD

Section 1 DESCRIPTION AND SPECIFICATIONS
11 INTRODUCTION 1-1
12 DESCRIPTION 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 J -2
SCR Controller 1-2
Solenoid Contactors 1-2
Transit01ized Motor Controller 1-2
Safety Interlocks 1-3
Meters 1-3
14 Hydraulic Subsystem 1-3
141 Steering · , 1-3
1 42 Mast Positioning • 1-3
1 43 Brake System 1-4
144 Pivot and Shift System 1-4
1 45 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
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 SCR CONTROLLER 2-3
27 OPERATION 2-4
28 DESCRIPTION OF FUNCTIONS 2-5
281 Function 1: Display Stored Fault 2-5
282 Function 2: Set Creep Speed 2-5
283 Function 3: Set Controlled Acceleration 2-5
284 Function 4: Set Current Limit 2-5
285 Function 5: Set Plugging Current 2-5
286 Function 6: 1 A Dropout 2-6
287 Function 7: Field Weakening Pickup 2-6
288 Function 8: Field Weakening Dropout 2-6
289 Function 9: Regenerative Braking Current Limit 2-6
2810 Function 1 O: Regenerative Braking Start 2-6
2811 Function 11: Speed Limit 1 2-6
2812 Function 12: Speed Limit 2 2-6
Table of Contents
2813 Function 13: Speed Limit 3 2-6
2814 Function 14: Internal Resistance Compensation 2-6
2815 Function 15: Battery Voltage 2-7
2816 Function 16: Pedal Position Plugging 2-7
2817 Function 17: Card Type Selection 2-7
2818 Function 18: Seat Time Delay 2-8
29 PROGRAMMING THE PUMP SPEED CONTROL 2-8
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 DEPOSITING A LOAD 3-6
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
Section 5 PREVENTIVE MAINTENANCE
51 OVERVIEW 5-1
511 Standard Tools Required 5-2
512 Special Tools Required 5-2
51 3 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
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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 Inspect the 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
57 2 Change Reservoir Sump Filter 5-9
573 Lubricate Front Wheel Bearings 5-1 O
Section 6 TROUBLESHOOTING
61 GENERAL , 6-1
62 PRELIMINARY PROCEDURES 6-1
63 VISIBLE PROBLEMS 6-1
631 Cracks in Forks 6-1
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
637 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
647 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
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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
721 O Commutator Cleaning 7-4
73 REMOVAL PROCEDURES 7-4
7 31 Brake Master Cylinder Removal 7-4
732 Drive Unit Removal 7-4
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
731 O Traction Motor Removal 7-7
74 INSTALLATION PROCEDURES 7-8
741 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
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755 Mast Disassembly 7-10
756 Steering Control Unit 7-10
757 Steering Motor Servicing 7-10
758 Tilt Cylinder Disassembly 7-10
76 ASSEMBLY PROCEDURES 7-10
761 Brake Master Cylinder Assembly 7-10
762 Lift Cylinder Assembly 7-10
763 Main Pump Assembly • 7-11
764 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
7 7 10 Emergency Stop Switch Replacement 7-13
7 7 11 Fork Replacement 7-13
7712 Front Wheel Replacement 7-13
7713 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
7 7 18 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
Section 8 PARTS LIST
81 GENERAL 8-1
82 WELDMENTS 8-1
Section 9 ILLUSTRATED PARTS BREAKDOWN
91 GENERAL 9-1
92 REVISION LEVELS 9-1
93 ABBREVIATIONS 9-1
94 PARTS NOT SHOWN 9-2
95 PHANTOM AND REFERENCE PARTS 9-2
96 TASK GROUPS AND ASSEMBLIES 9-2
DRIVE GROUP DA1 9-3
MOTOR, TRACTION, REAR DRIVE, PART NO1412757-A 9-4
STEER IDLER ASSEMBLY, PART NO1412460-A 9-6
DRIVE WHEEL DA2 9-7
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DRIVE UNIT SU BASS EMBLY DAB 9-8
DRIVE UNIT, DUAL CHAIN, PART NO 1400695-A 9-9
DRIVE UNIT, DUAL CHAIN, PART NO 1400695-A (Continued} 9-10
CHAIN ASSY FOR STEER, PART NO1400109-B 9-12
LOWER DRIVE UNIT DA 11 9-13
STEER IDLER DA9 9-14
CONTROL VALVE HY15 9-15
HYDRAULIC SPOOL VALVE ASSEMBLY, PART NO 1411868-D 9-16
VALVE CONTROL ASSYWITH CAMS SLT-30C, PART NO 1413566-A 9-18
HYDRAULIC PUMP/MOTOR HY16 9-22
HYDRAULIC PUMP/MOTOR ASSEMBLY, PART NO 1411872-B 9-24
MAIN PUMP, PART NO 1400269 9-26
MAIN PUMP MOTOR, PART NO 1400268 9-28
HYDRAULIC TANK HY6 9-31
HYDRAULIC TANK SUBASSY HY44 9-32
POWER STEER HYDRAULIC ASSY HY14 9-35
STEER PUMP/MOTOR SUBASSY HY12 9-37
PUMP & MOTOR ASSEMBLY, STEER, SLT-30C, PART NO 1413444-A 9-38
STEERING PUMP, PART NO 51734 9-39
STEERING PUMP MOTOR, PART NO 51735 9-40
UMBILICAL ASSY HY8 9-42
SIDESHIFT HOSE HY? 9-44
STEER PUMP/MOTOR HY11 9-45
STEER MOTOR SUBASSEMBLY HY21 9-46
MOTOR, HYDRAULIC, S SERIES, PART NO 25950 9-47
UMBILICAL TRAY HY22 9-49
PIVOT & TILT HOSE HY19 9-50
JOYSTICK SUBASSEMBLY HY24 9-52
HOSE HY23 9-53
OPERATOR CONSOLE OH6 9-55
DOLL-UP 103 9-56
INSTRUMENT PANEL ASSEMBLY, PART NO 1413057-C 9-58
LEVER ASS EMBLY, PART NO 10417-B 9-60
SIDE CONSOLE OH? 9-62
KEY SWITCH EL 14 9-64
SIDE CONSOLE SU BASS EMBLY HY20 9-65
CONSOLE COVER SUBASSY OH9 9-66
ACCELERATOR UNIT EL15 9-68
STEERING WHEEL 104 9-70
STACK VALVE COVER 105 9-71
BRAKE WELDMENT ASSEMBLY SB2 9-72
BRAKE PEDAL SB3 9-74
MASTER CYLINDER SB4 9-76
SERVICE BRAKE SB5 9-78
STEER COLUMN HY5 9-80
FLOORPLATE SUBASSEMBLY CO2 9-81
HORN BUTTON OH2 9-82
FLOORPLATE OH3 9-83
BATTERY DOOR OH4 9-85
BATTERY DOOR SUBASSEMBLY OHS 9-86
LEVEL INDICATOR MA2 9-87
FLUIDS FL 1 9-89
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Table of Contents
REAR COMPARTMENT COVERS CO1 9-92
SCR PANEL EL 16 9-96
PANEL, CONTACTOR w/O BOX, PART NO 1405740-A 9-99
PANEL, CONT ACTOR w/O BOX, PART NO 1405740-A (Continued) 9-100
CONTACTOR, 150A, DPDT, 24V, PART NO 1401978-A 9-102
CONTACTOR,300A,SPNO 24V, PART NO 1401979-A 9-104
CONTACTOR, 100A,SPNO 24V, PART NO 1401980-A 9-106
CONTACTOR,SPNO, 300A, 36VDC COIL, PART NO 28889-D 9-107
BATTERY CONNECTOR SUBASSEMBLY EL 17 9-109
WIRE HARNESS EL18 9-110
CABLE EL 19 9-111
PARKING BRAKE PB1 9-114
EQUALIZER PB2 9-116
BRAKE CABLE PB3 9-118
OVERHEAD GUARD OH1 : 9-122
SPINDLE LW3 9-126
LOAD WHEEL LW6 , 9-128
SEATBELTST1 9-129
SEAT ST2 9-130
PIVOT & SHIFT PS10 9-131
CROSSHEAD BEARINGS PS1 , 9-132
PIVOT STOP PAD PS3 9-133
PIVOT ARM PS2 9-134
PIVOT CYLINDER PS4 9-136
CYLINDER PIVOT, PART NO 1400601-A 9-138
SIDE SHIFT CHAINS PSS , 9-140
SHIFT CYLINDER PS6 " 9-142
LOWER BAR SUBASSEMBLY PS? 9-143
LOWER BAR PSS 9-144
SHIFT CYLINDER SUBASSY PS9 9-145
CYLINDER, SHIFT SLT30C, PART N01412889-A 9-146
TILT CYLINDER MA52 9-147
CYLINDER TILT 300 BORE, PART NO1400153-A 9-148
PUMP SPEED CONTROL HY1 9-149
PORTEC-MTG PLATES INSTALL EL22 9-152
PORTEC BOARD INSTALL EL23 9-154
PORTEC GROUND STRAP INST EL24 9-157
PORTEC-STEER IDLER INST EL26 9-158
PORTEC PANEL SUBASSEMBLY EL29 9-160
PORTEC WIRE HARNESS INST EL30 9-162
SWITCH COVER INSTALL EL31 9-164
PORTEC HOSES INSTALL HY45 9-166
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