DREXEL SL66, SL77 & SL88 SERIES SERVICE & PARTS MAINTENANCE MANUAL 1421635 – PDF DOWNLOAD
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Language : English
Pages : 428
Downloadable : Yes
Pages : 428
Downloadable : Yes
File Type : PDF
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TABLE OF CONTENTS:
DREXEL SL66, SL77 & SL88 SERIES SERVICE & PARTS MAINTENANCE MANUAL 1421635 – PDF DOWNLOAD
8.1 Site Supervision
8.2 Operator Seat Belt
8.2 Operator Seat Belt
Figure 1: Belt Release Button
Seat Safety Switches and Battery Latch
Parking Brake
Parking Brake
8.3 Tipping Hazards
Longitudinal tipping can occur when:
Lateral tipping can occur when:
Longitudinal tipping can occur when:
Lateral tipping can occur when:
8.4 Traveling and Load Handling
8.5 Load Handling
Front Load Traveling
Side Load Traveling – Long Loads
8.5 Load Handling
Front Load Traveling
Side Load Traveling – Long Loads
8.6 Speed
8.7 Visibility
8.8 Battery Care
Battery Compartment Interlock Options
8.7 Visibility
8.8 Battery Care
Battery Compartment Interlock Options
Figure 2: Optional Battery Retainer Safety Gate & Interlocks
8.9 Service Repair
8.10 Safety Labels
8.11 Available Options
Fork Positioner, Non-Side Shifting
8.10 Safety Labels
8.11 Available Options
Fork Positioner, Non-Side Shifting
Figure 3: Fork Check Points
Fire Extinguisher
In Case of a Fire
Overload Sensing Option
Lift Limit Interlock Option
In Case of a Fire
Overload Sensing Option
Lift Limit Interlock Option
Figure 4: Lift Limit Interlock
Truck Overview
1.1 Introduction
1.1.1 Description
1.1.2 Functional Description
Frame
Propellant
Drive Train
Electrical System
Safety Interlock
Battery
SCR Controller
Solenoid Contactors
Safety Interlocks
Meters
Hydraulic Sub-System
Pivot and Shift System
Mast
1.1 Introduction
1.1.1 Description
1.1.2 Functional Description
Frame
Propellant
Drive Train
Electrical System
Safety Interlock
Battery
SCR Controller
Solenoid Contactors
Safety Interlocks
Meters
Hydraulic Sub-System
Pivot and Shift System
Mast
Figure 1-1: Mast in Collapsed Position
Figure 1-2: Mast in Free Lift
Figure 1-3: Mast in Extended Position
Figure 1-4: Quadplex Mast in Collapsed Position
Figure 1-2: Mast in Free Lift
Figure 1-3: Mast in Extended Position
Figure 1-4: Quadplex Mast in Collapsed Position
1.2 Operating Controls
Figure 1-5: Driver’s Controls
Figure 1-5: Driver’s Controls
1.3 Truck Specifications
SL66 Series Reach Lift Trucks
SL77 Series Reach Lift Trucks
SL88 Series Reach Lift Trucks
SL66 Series Reach Lift Trucks
SL77 Series Reach Lift Trucks
SL88 Series Reach Lift Trucks
1.4 Models
1.4.1 EE Series (Electrical Enclosure)
1.4.2 Hi-Low Series (Optional)
1.4.1 EE Series (Electrical Enclosure)
1.4.2 Hi-Low Series (Optional)
General
Figure 1-8: Thermal Switches
Figure 1-7: Air Filter
Figure 1-8: Heat Exchanger
Figure 1-9: Closed-Loop Mode
Figure 1-10: Open-Loop Mode
Figure 1-11: Console Intake
Figure 1-12: Electrical Compartment Vent
Figure 1-8: Thermal Switches
Figure 1-7: Air Filter
Figure 1-8: Heat Exchanger
Figure 1-9: Closed-Loop Mode
Figure 1-10: Open-Loop Mode
Figure 1-11: Console Intake
Figure 1-12: Electrical Compartment Vent
1.5 Options
1.5.1 Auto-Guidance System
Figure 1-13: Automatic Guidance System Overview
1.5.2 Fire Extinguisher
1.5.3 Fork Positioner
Figure 1-14: Fork Positioner Overview/Setting
1.5.4 Lift Limit Interlock Option
Figure 1-15: Lift Limit Interlock
1.5.5 Lights and Alarms
Figure 1-16: Lights and Alarm
1.5.6 Overload Sensing Option
1.5.7 Proximity Sensor Option
Figure 1-17: Proximity Sensor
1.5.8 Rear View Mirror
1.5.9 Turn and Hazard Signals
Figure 1-18: Turn/Hazard Module
1.5.1 Auto-Guidance System
Figure 1-13: Automatic Guidance System Overview
1.5.2 Fire Extinguisher
1.5.3 Fork Positioner
Figure 1-14: Fork Positioner Overview/Setting
1.5.4 Lift Limit Interlock Option
Figure 1-15: Lift Limit Interlock
1.5.5 Lights and Alarms
Figure 1-16: Lights and Alarm
1.5.6 Overload Sensing Option
1.5.7 Proximity Sensor Option
Figure 1-17: Proximity Sensor
1.5.8 Rear View Mirror
1.5.9 Turn and Hazard Signals
Figure 1-18: Turn/Hazard Module
Receiving and Inspection
2.1 Receiving Your Truck
2.1.1 Items Furnished with Your Truck
2.1.2 Items Required
2.1.3 Tools and Test Equipment
2.2 To Prepare the Truck
2.2.1 Charging a Wet Battery
Using the Hydrometer
2.1 Receiving Your Truck
2.1.1 Items Furnished with Your Truck
2.1.2 Items Required
2.1.3 Tools and Test Equipment
2.2 To Prepare the Truck
2.2.1 Charging a Wet Battery
Using the Hydrometer
Figure 2-1: Battery Charge State Using a Hydrometer
Table 2-1: Specific Gravity Corrections for Electrolyte Temperature
Table 2-1: Specific Gravity Corrections for Electrolyte Temperature
2.2.2 Charging a Dry Battery
2.3 Inspection Checklist
2.3.1 Visual Checks
2.3.2 Routine Checks
2.3 Inspection Checklist
2.3.1 Visual Checks
2.3.2 Routine Checks
Figure 2-2: Battery Retainer Safety Gate and Bar (Optional)
Figure 2-3: Seat Battery Retainer Latch
Figure 2-4: Lift Limit Interlock Option
Figure 2-3: Seat Battery Retainer Latch
Figure 2-4: Lift Limit Interlock Option
2.4 Replacing the Battery
2.4.1 To Replace a Battery
2.4.1 To Replace a Battery
Figure 2-5: Removing the Battery
Figure 2-6: Checking Steer Axle and Articulating Blocks
Figure 2-6: Checking Steer Axle and Articulating Blocks
2.5 Storage, Towing, or Shipping
2.5.1 Truck Storage
2.5.2 Battery Storage
2.5.3 Towing the Truck (Optional)
2.5.1 Truck Storage
2.5.2 Battery Storage
2.5.3 Towing the Truck (Optional)
Figure 2-7: Optional Tie-Down/Lift Post Used for Towing
2.5.4 To Ship the Truck
2.5.4 To Ship the Truck
Basic Operation
3.1 To Begin Operating
3.1.1 Pre-Operation Checklist
3.1.2 Adjusting the Driver’s Seat
3.1 To Begin Operating
3.1.1 Pre-Operation Checklist
3.1.2 Adjusting the Driver’s Seat
Figure 3-1: Sample: Driver’s Seat Controls
Figure 3-2: Weight Adjustment (Optional)
Figure 3-2: Weight Adjustment (Optional)
Seat Belt
Figure 3-3: Driver’s Seat Belt
Figure 3-3: Driver’s Seat Belt
3.1.3 Tilt Steering Panel (Optional)
Figure 3-4: Tilt Steering Adjust (Optional)
Figure 3-4: Tilt Steering Adjust (Optional)
3.1.4 Fork Adjustment
Manual Fork Adjust
Manual Fork Adjust
Figure 3-5: Unlocking the Forks
Fork Positioner Option – Automatic
Fork Positioner Option – Automatic
3.2 Driving the Truck
3.2.1 Practice Session
3.2.1 Practice Session
3.3 The Mast
3.3.1 Practice Session
3.3.1 Practice Session
Figure 3-6: Lift Lever Icon
Figure 3-7: Tilt Lever Icon
Figure 3-8: Fork Level Gauge
Figure 3-9: Pivot Lever Icon
Figure 3-10: Shift Lever Icon
Figure 3-7: Tilt Lever Icon
Figure 3-8: Fork Level Gauge
Figure 3-9: Pivot Lever Icon
Figure 3-10: Shift Lever Icon
3.4 Handling Normal Loads
3.4.1 To Pick Up the Load
3.4.1 To Pick Up the Load
Figure 3-11: Sample – Aligning the Truck to the Pallet Opening
Figure 3-12: Sample – Pivoting the Forks 45°
Figure 3-13: Sample – Shifting the Forks into the Pallet
Figure 3-14: Tilting the Load
Figure 3-15: Sample – Pivoting the Load 45°
Figure 3-12: Sample – Pivoting the Forks 45°
Figure 3-13: Sample – Shifting the Forks into the Pallet
Figure 3-14: Tilting the Load
Figure 3-15: Sample – Pivoting the Load 45°
3.4 Handling Normal Loads – Continued
3.4.2 To Deliver a Load
3.4.2 To Deliver a Load
Figure 3-16: Tilting the Load
Figure 3-17: Sample – Aligning the Load to the Rack
Figure 3-18: Sample – Pivoting the Load 45°
Figure 3-19: Sample – Placing the Load into the Rack
Figure 3-20: Leveling the Load
Figure 3-21: Sample – Normal Driving Position
Figure 3-17: Sample – Aligning the Load to the Rack
Figure 3-18: Sample – Pivoting the Load 45°
Figure 3-19: Sample – Placing the Load into the Rack
Figure 3-20: Leveling the Load
Figure 3-21: Sample – Normal Driving Position
3.5 Side Loading (Long Loads)
3.5.1 To Pick Up a Long Load
3.5.1 To Pick Up a Long Load
Figure 3-22: Sample – Aligning the Truck to the Long Load Pallet
Figure 3-23: Sample – Shifting the Forks into the Pallet
Figure 3-24: Sample – Removing the Load
Figure 3-25: Sample – Traveling with a Long Load
Figure 3-23: Sample – Shifting the Forks into the Pallet
Figure 3-24: Sample – Removing the Load
Figure 3-25: Sample – Traveling with a Long Load
3.5.2 To Deliver a Long Load
Figure 3-26: Sample – Aligning the Load to the Rack
Figure 3-27: Sample – Rotating the Long Load into the Rack
Figure 3-28: Sample – Shifting the Load into the Rack
Figure 3-27: Sample – Rotating the Long Load into the Rack
Figure 3-28: Sample – Shifting the Load into the Rack
For More Experienced Drivers…
Figure 3-29: Sample – Backing the Load into the Slot
Figure 3-30: Pivoting the Load into the Slot
Figure 3-30: Pivoting the Load into the Slot
Available Options
3.6 Auto-Guidance Option
3.6.1 Approaching the Aisle
3.7 Fire Extinguisher Option
3.6 Auto-Guidance Option
3.6.1 Approaching the Aisle
3.7 Fire Extinguisher Option
Preventive maintenance
4 1 tables
4 1 1 Preventive maintenance schedule 4-9
Table 1: Preventive maintenance schedule 4-9
4 1 2 Recommended lubricants 4-12
Table 2: Recommended lubricants 4-12
4 1 3 Torque values, English 4-13
Table 3: English torque specifications 4-13
4 1 4 Torque values, Metric 4-14
Table 4: Metric torque specifications 4-14
4 2 overview
4 2 1 Tools or equipment required 4-16
Special tools required 4-17
Safety equipment required 4-17
4 3 daily inspection
4 3 1 Check batteries 4-17
To check the battery: 4-18
Figure 4-1: Battery charge state using a hydrometer 4-18
4 3 2 Check power steering 4-19
Figure 4-2: Check power steering 4-19
4 3 3 Check control lever reaction 4-20
Figure 4-3: Control levers Uoystick) 4-20
4 3 4 Check the return-to-neutral 4-20
4 3 5 Check primary lift chain 4-21
Figure 4-4: Fork heel to floor adjust 4-21
4 3 6 Inspect tires 4-22
Figure 4-5: Tire tread inspection 4-22
Chunking (chipping) or embedded objects 4-23
Undercutting and uneven wear 4-23
Flat-spotting 4-24
To expand tire life 4-24
4 3 7 Check driver’s seat micro switch 4-25
Figure 4-6: Driver’s seat limit switch 4-25
“SL66/77/889 Series Service, Preventive maintenance, pin: 1421635 Mb, 07/03 4-3
D Preventive maintenance
Contents – continued Page
4 4 weekly inspection
4 4 1 Check hydraulic oil level 4-26
Figure 4-7: Reservoir oil fill/dipstick cap 4-26
4 4 2 Check master cylinder fluid level 4-27
Figure 4-8: Master cylinder location 4-27
4 4 3 Check brake shoes 4-28
4 4 4 Checking/adding drive axle fluid 4-28
Figure 4-9: Checking drive axle fluid 4-28
4 5 every six weeks
4 5 1 Check pivot and shift settings 4-29
Normal (front) carry position setting 4-30
Figure 4-10: Sample: Normal carry position 4-30
Figure 4-11: Front carry adjustment 4-30
Pivot cylinder clevis adjust 4-31
Figure 4-12: Pivot cylinder clevis adjust 4-31
90° pivot and reach setting 4-32
Figure 4-13: 90° pivot setting 4-32
Figure 4-14: Sample: 90° pivot adjustment 4-33
Figure 4-15: Checking reach 4-33
Pivot arm deflection 4-33
Figure 4-16: Pivot arm stop pad 4-34
Tilt cylinder racking and degree setting 4-34
Figure 4-17: Tilt degree adjust 4-36
Figure 4-18: Tilt cylinder pinch bolt 4-36
4 5 2 Check parking brake 4-38
Adjusting the Parking Brake 4-38
4 5 3 Lubricating the truck 4-38
Figure 4-19: Grease-gun and brush icons • 4-39
Pivot cylinder clevis 4-39
Figure 4-20: Pivot cylinder clevis lubrication 4-40
Pivot arm shaft bearings 4-40
Figure 4-21: Pivot arm shaft bearing lubrication 4-40
Tilt cylinder clevises 4-41
Figure 4-22: Tilt cylinder clevis lubrication 4-41
Mast trunnion bearings 4-41
Figure 4-23: Mast trunnion bearings 4-42
Steer axle 4-42
Figure 4-24: Lubricating steer axle 4-43
4-4 “SL66/88n Serles Service, Preventive maintenance, pfn: 1421635 -a, 07/02
Contents – continued
4 5 every six weeks – continued
4 5 3 Lubricating the truck – continued
Preventive maintenance D
Page
Side shift bearing pads 4-44
Figure 4-25: Side Shift bearing pad lubrication 4-45
Forks – manual 4-45
Figure 4-26: Forks – manual 4-46
4 5 4 Replace motor brushes 4-46
Drive motor 4-46
Figure 4-27: Removing brushes 4-47
Pump motor brushes 4-48
Figure 4-28: Remove brush cover 4-48
Figure 4-29: Brush holder clips 4-49
Figure 4-30: EE Model access door 4-49
Figure 4-31: Checking commutator 4-50
Steering pump motor brushes 4-51
Figure 4-32: Exposing the brushes 4-51
Figure 4-33: Removing the brushes 4-52
4 5 5 Check lift operation 4-53 –
Figure 4-34: Channel roller contact 4-53
Figure 4-35: Channel galling 4-53
4 6 three month inspection
4 6 1 Check nuts, bolts and screws 4-54
4 6 2 Change hydraulic oil filter 4-55
Figure 4-36: Changing oil filter 4-55
4 7 semi-annual
4 7 1 Inspecting lift chains 4-56
Figure 4-37: Maximum chain stretch 4-56
4 7 2 Chain and roller adjustment, triplex mast 4-57
Primary lift chain 4-58
Figure 4-38: Primary lift chain and anchor 4-58
Secondary lift chain 4-59
Figure 4-39: Secondary chain, roller and anchor adjustment 4-59
Rail channel roller inspection 4-60
Figure 4-40: Roller clearance 4-61
~SL66!77/88″ Serles Service, Preventive maintenance, p/n: 1421635-b, 07/03 4-5
□ Preventive maintenance
Contents – continued Page
4 7 semi-annual – continued
4 7 2 Chain and roller adjustment, triplex mast- continued
Carriage channel roller inspection 4-61
Figure 4-41: Center and bottom rollers 4-62
Figure 4-42: Top roller 4-63
Shift chains 4-63
Figure 4-43: Shift chain adjustment 4-64
Figure 4-44: 1/8” (3 175 mm) deflection 4-64
4 7 3 Inspect electrical connections 4-65
4 7 4 Fork inspection 4-65
Figure 4-45: Measuring fork thickness 4-65
Figure 4-46: Measuring fork distortion 4-66
Table 5: Maximum “Y” values 4-66
4 8 annual inspection
4 8 1 Lubricate steer wheel bearings 4-67
Figure 4-47: Sample: Outer steer wheel bearing 4-67
Figure 4-48: Inner steer wheel bearing 4-67
4 8 2 Change hydraulic oil 4-68
Figure 4-49: Hydraulic oil drain 4-69
4 9 SCR controller
4 9 1 General practice 4-70
4 10 options
4 10 1 Air filter, Hi-low 4-71
Figure 4-50: Air filter location 4-71
Figure 4-51: Removing air filter 4-71
4 10 2 Console I accelerator switch 4-72
4 10 3 Vent doors 4-72
Figure 4-52: Vent door 4-72
4 10 4 Lubrication, Fork positioner, non-side shifting 4-72
Figure 4-53: Fork positioner, non-side shifting 4-72
4 10 5 Cooling fans, enclosure – optional 4-73
Figure 4-54: Cooling fans 4-74
4-6 “SL66/88” Serles Service, Preventive maintenance, p/n: 1421635 ~a, 07/02
Preventive maintenance D
Contents – continued Page
4 10 options – continued
4 10 6 Lift limit interlock option 4-74
Figure 4-55: Lift limit interlock 4-7 4
4 10 7 Overload sensing interlock option 4-75
4 10 8 Inspecting lift chains, quad mast 4-75
Figure 4-56: Maximum chain stretch 4-76
Chain and roller adjustment, quad mast 4-77
Primary lift chain 4-78
Figure 4-57: Primary lift chain and anchor 4-78
Secondary lift chain 4-78
Figure 4-58: Secondary chain and roller adjustment 4-78
Figure 4-59: Secondary chain adjustment anchor 4-79
Rail channel roller inspection 4-79
Figure 4-60: Roller clearance 4-80
Carriage thrust rollers, quad mast only 4-81
Figure 4-61: Thrust roller eccentric cam adjust 4-82
Troubleshooting
5 1 electrical system
5 1 1 Traction fuse 1 FU open 5-9
Figure 5-1: Electrical panel/ Power fuses 5-9
Reduced IA SCR Timing/ Frequent Rapid Starts 5-9
Skidding or Pushing of Loads 5-10
FW Field weakening/ Bad contactor tips 5-10
Service Brake, Seat Brake (Parking Brake) 5-10
5 1 2 Hydraulic fuse/ traction fuse (2FU/1 FU) 5-10
Loose power fuse block connections 5-10
Overheated electrical compartment 5-11
Improper pump pressure (2,000 psi) 5-11
Figure 5-2: Relief valve 5-11
Figure 5-3: Valve cartridge 5-12
Excessive hydraulic pressure 5-12
Repeated opening of power fuses 5-13
5 1 3 Control fuses 3FU, 4FU or 5FU open 5-13
Figure 5-4: Control fuse location – inside electrical compartment door 5-13
Shorted Contactor Coils 5-14
Shorted Solenoid Valve Coils 5-14
Figure 5-5: Solenoid valve location – underside of hydraulic door 5-14
Shorted hash filters 5-15
Loose control wiring 5-15
Figure 5-6: T3 connector location 5-15
5 1 4 Loss of drive power 5-16
Open control fuse 3FU 5-16
Open power fuse 1 FU 5-16
Figure 5-7: power fuse location 5-16
Battery power cable connections 5-17
Control circuit connections 5-17
Figure 5-8: Dash and accelerator harness connectors 5-18
Inoperative F and R contactors 5-18
Contactor coil driver modules 5-19
Return-to-Neutral 5-19
Logic card terminal pin connections 5-19
Inoperative directional switch 5-20
“SL66/77/88” Serles Service, nTroubleshoollng,• pin: 1411635 -b, 07/03 5-3
□ Troubleshooting
Contents – continued Page
5 1 electrical system – continued
5 1 5 Loss of drive speed 5-20
Misadjusted accelerator switch 5-20
Inoperative accelerator switch 5-21
Misadjusted accelerator potentiometer 5-21
Figure 5-9: Testing accelerator module 5-21
SCR or logic card failure 5-22
Contactor problems 5-22
SCR terminal 5-22
Figure 5-10: Thermal protector 5-23
Damaged Accelerator – mechanical 5-23
Service Brakes Drag 5-23
Discharged battery , 5-24
Traction motor problems 5-24
5 2 hydraulic system
5 2 1 Pump does not operate 5-25
Figure 5-11: Attach switch and resistor ; 5-27
5 2 2 Pump runs continuously 5-27
Time delay module testing 5-28
Shorted coil driver module 5-29
Electrical switches stick • 5-29
Hydraulic valve switch adjustment 5-30
Figure 5-12: LIFT, PIVOT, SHIFT and TILT microswitch location 5-30
Welded pump contactor tips 5-30
5 2 3 Pivot function inoperative 5-31
5 2 4 Shift function inoperative 5-32
5 2 5 Loss of hydraulic lift 5-32
Figure 5-13: Lift hydraulic pressure setting 5-33
Table 5-1: Normal lift pressures 5-34
Figure 5-14: Pivot, Shift & Tilt hydraulic pressure 5-34
Table 5-2: Function pressures at 00 lbs (00 kg ) load 5-35
Table 5-3: Function pressures at 4,000 lbs (1,814 4 kg ) load 5-35
Table 5-4: Function pressures at 6,000 lbs (2,721 5 kg ) load 5-35
5 2 6 Loss of lift speed 5-36
5 2 7 Drift of raised load 5-37
5 2 8 Loss of mast tilt 5-37
5-4 “SL66ITT/88” Serles Service, “Troubleshootlng,• p/n: 1411635-b, 07/03
Troubleshooting □
Contents – continued Page
5 3 power steering system
5 3 1 Loss of power steering 5-38
5 3 2 Slow steering response 5-40
Figure 5-15: Power steering pump pressure line 5-40
5 3 3 Drift of steering 5-42
5 4 brake system
5 4 1 No service brake, 2 or optional 4 Wheel 5-42
5 4 2 No seat brake 5-43
5 4 3 Hydraulic parking brake 5-44
5 5 no-spin differential
Table 5-5: NoSpin differential troubleshooting 5-44
Hub stud shearing 5-44
Drive tire scuffing 5-44
Broken shafts and/or undue stress 5-44
Vehicle pulls to one side 5-45
No differential action or differentiation 5-46
Binding during turns 5-46
Drive axle tire wear during sharp turns 5-46
Loud snap or cracking noises 5-47
Excessive tire wear 5-48
Grinding Noises 5-48
Continuous indexing or clicking sound – 5-48
Sudden lock-up during straight forward driving 5-48
Excessive backlash in drive train 5-49
Engine lug or surge during turns 5-49
Excessive backlash in drive train – continued 5-50
Engine lug or surge during turns – continued 5-50
5 6 pump
Table 5-6: Troubleshooting pump 5-50
No hydraulic pressure 5-50
Insufficient pressure build-up 5-51
Pump making noise 5-51
“SL66/77/88″ Serles Service, •Troubleshootlngt pin: 1411635 -b, 07/03 5-5
D Troubleshooting
Contents – continued Page
5 7 SCR control circuit
Figure 5-16: EV-1 SCR controller 5-52
5 7 1 EV-1 SCR controller diagnostics 5-53
EV-1 Card terminal functions 5-54
Table 5-7: EV-1 card terminal functions 5-54
Reduced or NO motor torque 5-56
Table 5-8: Reduced or NO motor torque 5-56
No control voltage from positive to negative 5-56
Control volts present from positive to negative with proper polarity 5-56
NO power and NO SCR hum with accelerator in SCR range 5-57
Little or no power Normal SCR hum , 5-57
Little or no power Abnormal SCR hum 5-57
Little power No SCR hum 5-57
One contactor closes with normal operation –
opposite contactor does not close 5-57
PMT trips after operating in 1A 5-58
Table 5-9: Failures causing FULL motor torque 5-58
Full SCR speed immediately with audible hum NO PMT trip 5-58
Contactors close once or twice and then remain open PMT trips 5-58
Stall currents – 5-58
Table 5-10: Misoperation of other features 5-59
1A or FW contactors close with key switch 5-59
For R closes without returning direction switch to OFF 5-59
PMT does not open For R contactor , 5-59
1A will not close at run (percent pickup) , 5-59
1A will not close at SCR stall (time pickup) 5-60
1 A will not open until start switch is opened 5-60
FW contactor will not close after 1A pickup , 5-60
FW contactor will not drop out with increasing load 5-60
Stiff plug – Severe reversal 5-60
Very soft reversal 5-60
Blown power fuse – Very hot power cables 5-61
Hour meter feeder faults: 5-61
5 8 temperature control
5 8 1 System will not heat, close-loop 5-61
Figure 5-17: Air intake vent 5-62
Figure 5-18: Solenoid Electrics 5-63
5 8 2 System will not cool, open-loop 5-63
Introduction
6 1 introduction
6 1 1 Tools needed 6-9
6 2 before you begin
6 2 1 Lifting the truck 6-10
Figure 6-1: Jack and support the truck 6-11
6 2 2 Hydraulic fittings and hoses 6-11
Figure 6-2: Removing hoses I fittings 6-12
6 2 3 Cleaning and inspection 6-13
Repair and/or Replace
6 3 Drive unit
6 3 1 Repair 6-15
Removing the drive axle 6-15
Figure 6-3: Removing the dress cover 6-16
Figure 6-4: Release and disconnect the parking brake 6-16
Figure 6-5: Disconnect traction electrical cables 6-17
Figure 6-6: Brake line 6-17
Figure 6-7: Drive-to-chassis mounting bolts 6-18
Figure 6-8: Trunnion bolts 6-18
Figure 6-9: Torque mounting bolts 6-19
Removing the wheel 6-19
Figure 6-10: Removing the wheel 6-20
Figure 6-11: Planetary pinion, retainer and spacers 6-20
Figure 6-12: Planetary pinion gears/ Axle shaft 6-21
Figure 6-13: Ring gear and gasket 6-21
Figure 6-14: Thrust washer/ Wheel bearing locknut 6-22
Figure 6-15: Wheel bearing adjust nut/ Planetary spider gear 6-22
•sL66ll7/88” Serles Service, Corrective maintenance, p/n: 1421635 -b, 07/03 6-3
□ Corrective maintenance
Contents – continued Page
6 3 Drive unit – continued
6 3 1 Repair – continued
Inspection 6-23
Figure 6-16: Pinion and ring gear inspection 6-23
Figure 6-17: Planetary gear bore and shaft 6-24
Figure 6-18: Inspect bearing rollers 6-24
Re-assembly hints 6-25
Figure 6-19: Outer wheel bearing installation 6-25
6 3 2 Brakes 6-26
Figure 6-20: Sample: Self-adjusting brake assembly 6-26
Figure 6-21: Replacing brakes 6-28
6 3 3 Wheel cylinder 6-29
Figure 6-22: Wheel cylinder 6-29
6 3 4 Bleeding brakes 6-30
Figure 6-23: Bleeding brakes 6-31
Motor support assembly 6-32
Figure 6-24: Differential assembly 6-33
Figure 6-25: Seat parking brake 6-33
Differential 6-34
Figure 6-26: Differential assembly 6-35
Figure 6-27: Differential I Axle housing tube 6-35
Figure 6-28: Removing differential and shims 6-36
Bevel and pinion gears 6-36
Differential bearings 6-37
Gear backlash 6-38
Tooth contact check • 6-38
Re-assembly hints 6-40
6 4 no-spin unit
Figure 6-29: No-spin differential overview ; 6-41
Figure 6-30: No-spin differential assembly 6-41
Inspection 6-42
Re-assembly hints 6-43
Figure 6-31: No-spin re-assembly 6-43
Figure 6-32: Ring gear – case half 6-43
6-4 “SL66/88” Serles Service, Preventive maintenance, pin: 1421635 -a, 07/02
Corrective maintenance D
Contents – continued Page
6 5 traction motor
6 5 1 Cleaning 6-45
6 5 2 Bearings 6-46
6 5 3 Insulation 6-46
6 6 steer axle
6 6 1 Removing the wheels 6-4 7
Figure 6-33: Wheel cap 6-47
Figure 6-34: Bearing lock washer/ nut 6-48
Figure 6-35: Removing the wheel and grease seal 6-48
Installing the wheels 6-49
Figure 6-36: Installing the wheels 6-49
6 6 2 Steer axle service 6-50
Figure 6-37: Steer cylinder lines 6-51
Figure 6-38: Tie rod, spindle & bell crank 6-51
Figure 6-39: Grease caps 6-51
Figure 6-40: Removing steer cylinder (3 illustrations) 6-52
Figure 6-41: Kingpin lock bolts I Thrust bearings, 3 illustrations 6-53
Assembly 6-53
Figure 6-42: Inserting new bearings 6-54
Figure 6-43: Installing kingpins 6-54
Wheel alignment 6-54
Figure 6-44: Tie rod I spindle alignment, left wheel-to-right wheel 6-55
Installation 6-55
6 7 service brakes
6 7 1 Pedal travel adjust 6-56
Figure 6-45: Brake pedal adjust 6-56
Figure 6-46: Master cylinder adjust 6-57
6 7 2 Master cylinder 6-57
Figure 6-47: Removing the master cylinder 6-58
Figure 6-48: Master cylinder breakdown 6-58
Bench bleed the master cylinder 6-60
Figure 6-49: Sample: Support and bench bleed the cylinder 6-61
6 7 3 Backing plate assemblies 6-61
Figure 6-50: Wheel cylinder breakdown 6-63
Figure 6-51: Piston cylinder diameter 6-63
“SL66/77/88” Serles Service, Corrective maintenance, pin: 1421635-b, 07/03 6-5
D Corrective maintenance
Contents – continued Page
6 7 service brakes – continued
6 7 4 Parking/seat brake 6-64
Figure 6-52: Seat brake assembly 6-64
6 8 removing forks
Figure 6-53: Changing forks 6-65
6 9 pivot and sideshift
6 9 1 Tile cylinders 6-66
6 9 2 Crosshead 6-67
Figure 6-54: Hydraulic hoses and electrical connections 6-67
6 9 3 Pivot arm 6-68
Figure 6-55: Secure crosshead / dust covers 6-69
Figure 6-56: Locknut and washer 6-69
Re·-assem bly hints 6-70
6 9 4 Pivot cylinder 6-71
6 9 5 Sideshift assembly 6-71
Sideshift bearing shoe adjust 6-71
Figure 6-57: Sideshift bearing shoe 6-72
Telescoping Slide 6-72
Sideshift chain • 6-73
Figure 6-58: Sideshift chain tension block 6-73
6 10 pump motor
Figure 6-59: Exposing motor connections 6-75
Figure 6-60: Pump/ motor – viewed from underneath truck 6-76
Servicing the motor (hints) • 6-76
Cleaning • • 6-77
Bearings 6-77
Insulation 6-78
6 10 1 Hydraulic pump 6-78
Figure 6-61: Pump/ motor coupling 6-79
Servicing the pump 6-79
Inspection 6-80
Re-assembly hints 6-80
Figure 6-62: Double vs single lip seal 6-81
Figure 6-63: Right vs left hand rotation 6-82
6-6 “SL66/88” Serles Service, Preventive maintenance, p/n: 1421635 -a, 07/02
Corrective maintenance □
Contents – continued Page
6 11 hydraulic control valves
Pivot, shift and tilt 6-82
Figure 6-64: Pivot, shift and tilt valve assembly 6-83
Inspection 6-84
Re-assembly hints 6-85
6 11 1 Lift control valve 6-85
Inspection 6-86
Figure 6-65: Lift Valve Spool Assembly 6-86
Re-assembly hints 6-87
6 12 power steer pump
6 12 1 Removing the pump 6-88
Figure 6-66: Power steering motor/pump location 6-88
Figure 6-67: Electrical connections 6-89
6 12 2 To service the pump 6-89
6 12 3 Orbitrol unit 6-89
Figure 6-68: Sample: Orbitrol assembly 6-90
Figure 6-69: Orbitrol hydraulic lines 6-90
6 12 4 To service the orbitrol 6-90
6 13 electrical system
6 13 1 Compartment door 6-91
Figure 6-70: Electrical panel main and pin connections 6-91
Figure 6-71: Quick disconnect and door clevis pin 6-92
6 13 2 Contactors and coils 6-92
6 13 3 Accelerator module 6-93
Figure 6-72: Driver’s cap floor panel – accelerator access 6-93
Figure 6-73: Accelerator module location 6-93
Potentiometer 6-94
Figure 6-7 4: Potentiometer 6-94
Replacement and adjustment 6-95
Figure 6-75: Replacing switch 6-95
6 14 dash panel
Figure 6-76: Dash panel removal 6-96
Figure 6-77: Panel electrical connectors 6-96
“SL66/77/88” Serles Service, Corrective maintenance, p/n: 1421635-b, 07/03 6-7
□ Corrective maintenance
Contents – continued Page
6 15 pivot & shift
Figure 6-78: Pivot/ shift hydraulic and electrical relationship 6-97
6 15 1 Circuit functions 6-98
Figure 6-79: Shift interlock switch 6-98
Figure 6-80: Extended shift stroke option 6-99
6 15 2 Operation check 6-99
Shift interlock switch 6-99
Figure 6-81: Check shift interlock switch 6-100
Pivot interlock switch 6-101
Figure 6-82: Check pivot interlock switch 6-101
4 1 tables
4 1 1 Preventive maintenance schedule 4-9
Table 1: Preventive maintenance schedule 4-9
4 1 2 Recommended lubricants 4-12
Table 2: Recommended lubricants 4-12
4 1 3 Torque values, English 4-13
Table 3: English torque specifications 4-13
4 1 4 Torque values, Metric 4-14
Table 4: Metric torque specifications 4-14
4 2 overview
4 2 1 Tools or equipment required 4-16
Special tools required 4-17
Safety equipment required 4-17
4 3 daily inspection
4 3 1 Check batteries 4-17
To check the battery: 4-18
Figure 4-1: Battery charge state using a hydrometer 4-18
4 3 2 Check power steering 4-19
Figure 4-2: Check power steering 4-19
4 3 3 Check control lever reaction 4-20
Figure 4-3: Control levers Uoystick) 4-20
4 3 4 Check the return-to-neutral 4-20
4 3 5 Check primary lift chain 4-21
Figure 4-4: Fork heel to floor adjust 4-21
4 3 6 Inspect tires 4-22
Figure 4-5: Tire tread inspection 4-22
Chunking (chipping) or embedded objects 4-23
Undercutting and uneven wear 4-23
Flat-spotting 4-24
To expand tire life 4-24
4 3 7 Check driver’s seat micro switch 4-25
Figure 4-6: Driver’s seat limit switch 4-25
“SL66/77/889 Series Service, Preventive maintenance, pin: 1421635 Mb, 07/03 4-3
D Preventive maintenance
Contents – continued Page
4 4 weekly inspection
4 4 1 Check hydraulic oil level 4-26
Figure 4-7: Reservoir oil fill/dipstick cap 4-26
4 4 2 Check master cylinder fluid level 4-27
Figure 4-8: Master cylinder location 4-27
4 4 3 Check brake shoes 4-28
4 4 4 Checking/adding drive axle fluid 4-28
Figure 4-9: Checking drive axle fluid 4-28
4 5 every six weeks
4 5 1 Check pivot and shift settings 4-29
Normal (front) carry position setting 4-30
Figure 4-10: Sample: Normal carry position 4-30
Figure 4-11: Front carry adjustment 4-30
Pivot cylinder clevis adjust 4-31
Figure 4-12: Pivot cylinder clevis adjust 4-31
90° pivot and reach setting 4-32
Figure 4-13: 90° pivot setting 4-32
Figure 4-14: Sample: 90° pivot adjustment 4-33
Figure 4-15: Checking reach 4-33
Pivot arm deflection 4-33
Figure 4-16: Pivot arm stop pad 4-34
Tilt cylinder racking and degree setting 4-34
Figure 4-17: Tilt degree adjust 4-36
Figure 4-18: Tilt cylinder pinch bolt 4-36
4 5 2 Check parking brake 4-38
Adjusting the Parking Brake 4-38
4 5 3 Lubricating the truck 4-38
Figure 4-19: Grease-gun and brush icons • 4-39
Pivot cylinder clevis 4-39
Figure 4-20: Pivot cylinder clevis lubrication 4-40
Pivot arm shaft bearings 4-40
Figure 4-21: Pivot arm shaft bearing lubrication 4-40
Tilt cylinder clevises 4-41
Figure 4-22: Tilt cylinder clevis lubrication 4-41
Mast trunnion bearings 4-41
Figure 4-23: Mast trunnion bearings 4-42
Steer axle 4-42
Figure 4-24: Lubricating steer axle 4-43
4-4 “SL66/88n Serles Service, Preventive maintenance, pfn: 1421635 -a, 07/02
Contents – continued
4 5 every six weeks – continued
4 5 3 Lubricating the truck – continued
Preventive maintenance D
Page
Side shift bearing pads 4-44
Figure 4-25: Side Shift bearing pad lubrication 4-45
Forks – manual 4-45
Figure 4-26: Forks – manual 4-46
4 5 4 Replace motor brushes 4-46
Drive motor 4-46
Figure 4-27: Removing brushes 4-47
Pump motor brushes 4-48
Figure 4-28: Remove brush cover 4-48
Figure 4-29: Brush holder clips 4-49
Figure 4-30: EE Model access door 4-49
Figure 4-31: Checking commutator 4-50
Steering pump motor brushes 4-51
Figure 4-32: Exposing the brushes 4-51
Figure 4-33: Removing the brushes 4-52
4 5 5 Check lift operation 4-53 –
Figure 4-34: Channel roller contact 4-53
Figure 4-35: Channel galling 4-53
4 6 three month inspection
4 6 1 Check nuts, bolts and screws 4-54
4 6 2 Change hydraulic oil filter 4-55
Figure 4-36: Changing oil filter 4-55
4 7 semi-annual
4 7 1 Inspecting lift chains 4-56
Figure 4-37: Maximum chain stretch 4-56
4 7 2 Chain and roller adjustment, triplex mast 4-57
Primary lift chain 4-58
Figure 4-38: Primary lift chain and anchor 4-58
Secondary lift chain 4-59
Figure 4-39: Secondary chain, roller and anchor adjustment 4-59
Rail channel roller inspection 4-60
Figure 4-40: Roller clearance 4-61
~SL66!77/88″ Serles Service, Preventive maintenance, p/n: 1421635-b, 07/03 4-5
□ Preventive maintenance
Contents – continued Page
4 7 semi-annual – continued
4 7 2 Chain and roller adjustment, triplex mast- continued
Carriage channel roller inspection 4-61
Figure 4-41: Center and bottom rollers 4-62
Figure 4-42: Top roller 4-63
Shift chains 4-63
Figure 4-43: Shift chain adjustment 4-64
Figure 4-44: 1/8” (3 175 mm) deflection 4-64
4 7 3 Inspect electrical connections 4-65
4 7 4 Fork inspection 4-65
Figure 4-45: Measuring fork thickness 4-65
Figure 4-46: Measuring fork distortion 4-66
Table 5: Maximum “Y” values 4-66
4 8 annual inspection
4 8 1 Lubricate steer wheel bearings 4-67
Figure 4-47: Sample: Outer steer wheel bearing 4-67
Figure 4-48: Inner steer wheel bearing 4-67
4 8 2 Change hydraulic oil 4-68
Figure 4-49: Hydraulic oil drain 4-69
4 9 SCR controller
4 9 1 General practice 4-70
4 10 options
4 10 1 Air filter, Hi-low 4-71
Figure 4-50: Air filter location 4-71
Figure 4-51: Removing air filter 4-71
4 10 2 Console I accelerator switch 4-72
4 10 3 Vent doors 4-72
Figure 4-52: Vent door 4-72
4 10 4 Lubrication, Fork positioner, non-side shifting 4-72
Figure 4-53: Fork positioner, non-side shifting 4-72
4 10 5 Cooling fans, enclosure – optional 4-73
Figure 4-54: Cooling fans 4-74
4-6 “SL66/88” Serles Service, Preventive maintenance, p/n: 1421635 ~a, 07/02
Preventive maintenance D
Contents – continued Page
4 10 options – continued
4 10 6 Lift limit interlock option 4-74
Figure 4-55: Lift limit interlock 4-7 4
4 10 7 Overload sensing interlock option 4-75
4 10 8 Inspecting lift chains, quad mast 4-75
Figure 4-56: Maximum chain stretch 4-76
Chain and roller adjustment, quad mast 4-77
Primary lift chain 4-78
Figure 4-57: Primary lift chain and anchor 4-78
Secondary lift chain 4-78
Figure 4-58: Secondary chain and roller adjustment 4-78
Figure 4-59: Secondary chain adjustment anchor 4-79
Rail channel roller inspection 4-79
Figure 4-60: Roller clearance 4-80
Carriage thrust rollers, quad mast only 4-81
Figure 4-61: Thrust roller eccentric cam adjust 4-82
Troubleshooting
5 1 electrical system
5 1 1 Traction fuse 1 FU open 5-9
Figure 5-1: Electrical panel/ Power fuses 5-9
Reduced IA SCR Timing/ Frequent Rapid Starts 5-9
Skidding or Pushing of Loads 5-10
FW Field weakening/ Bad contactor tips 5-10
Service Brake, Seat Brake (Parking Brake) 5-10
5 1 2 Hydraulic fuse/ traction fuse (2FU/1 FU) 5-10
Loose power fuse block connections 5-10
Overheated electrical compartment 5-11
Improper pump pressure (2,000 psi) 5-11
Figure 5-2: Relief valve 5-11
Figure 5-3: Valve cartridge 5-12
Excessive hydraulic pressure 5-12
Repeated opening of power fuses 5-13
5 1 3 Control fuses 3FU, 4FU or 5FU open 5-13
Figure 5-4: Control fuse location – inside electrical compartment door 5-13
Shorted Contactor Coils 5-14
Shorted Solenoid Valve Coils 5-14
Figure 5-5: Solenoid valve location – underside of hydraulic door 5-14
Shorted hash filters 5-15
Loose control wiring 5-15
Figure 5-6: T3 connector location 5-15
5 1 4 Loss of drive power 5-16
Open control fuse 3FU 5-16
Open power fuse 1 FU 5-16
Figure 5-7: power fuse location 5-16
Battery power cable connections 5-17
Control circuit connections 5-17
Figure 5-8: Dash and accelerator harness connectors 5-18
Inoperative F and R contactors 5-18
Contactor coil driver modules 5-19
Return-to-Neutral 5-19
Logic card terminal pin connections 5-19
Inoperative directional switch 5-20
“SL66/77/88” Serles Service, nTroubleshoollng,• pin: 1411635 -b, 07/03 5-3
□ Troubleshooting
Contents – continued Page
5 1 electrical system – continued
5 1 5 Loss of drive speed 5-20
Misadjusted accelerator switch 5-20
Inoperative accelerator switch 5-21
Misadjusted accelerator potentiometer 5-21
Figure 5-9: Testing accelerator module 5-21
SCR or logic card failure 5-22
Contactor problems 5-22
SCR terminal 5-22
Figure 5-10: Thermal protector 5-23
Damaged Accelerator – mechanical 5-23
Service Brakes Drag 5-23
Discharged battery , 5-24
Traction motor problems 5-24
5 2 hydraulic system
5 2 1 Pump does not operate 5-25
Figure 5-11: Attach switch and resistor ; 5-27
5 2 2 Pump runs continuously 5-27
Time delay module testing 5-28
Shorted coil driver module 5-29
Electrical switches stick • 5-29
Hydraulic valve switch adjustment 5-30
Figure 5-12: LIFT, PIVOT, SHIFT and TILT microswitch location 5-30
Welded pump contactor tips 5-30
5 2 3 Pivot function inoperative 5-31
5 2 4 Shift function inoperative 5-32
5 2 5 Loss of hydraulic lift 5-32
Figure 5-13: Lift hydraulic pressure setting 5-33
Table 5-1: Normal lift pressures 5-34
Figure 5-14: Pivot, Shift & Tilt hydraulic pressure 5-34
Table 5-2: Function pressures at 00 lbs (00 kg ) load 5-35
Table 5-3: Function pressures at 4,000 lbs (1,814 4 kg ) load 5-35
Table 5-4: Function pressures at 6,000 lbs (2,721 5 kg ) load 5-35
5 2 6 Loss of lift speed 5-36
5 2 7 Drift of raised load 5-37
5 2 8 Loss of mast tilt 5-37
5-4 “SL66ITT/88” Serles Service, “Troubleshootlng,• p/n: 1411635-b, 07/03
Troubleshooting □
Contents – continued Page
5 3 power steering system
5 3 1 Loss of power steering 5-38
5 3 2 Slow steering response 5-40
Figure 5-15: Power steering pump pressure line 5-40
5 3 3 Drift of steering 5-42
5 4 brake system
5 4 1 No service brake, 2 or optional 4 Wheel 5-42
5 4 2 No seat brake 5-43
5 4 3 Hydraulic parking brake 5-44
5 5 no-spin differential
Table 5-5: NoSpin differential troubleshooting 5-44
Hub stud shearing 5-44
Drive tire scuffing 5-44
Broken shafts and/or undue stress 5-44
Vehicle pulls to one side 5-45
No differential action or differentiation 5-46
Binding during turns 5-46
Drive axle tire wear during sharp turns 5-46
Loud snap or cracking noises 5-47
Excessive tire wear 5-48
Grinding Noises 5-48
Continuous indexing or clicking sound – 5-48
Sudden lock-up during straight forward driving 5-48
Excessive backlash in drive train 5-49
Engine lug or surge during turns 5-49
Excessive backlash in drive train – continued 5-50
Engine lug or surge during turns – continued 5-50
5 6 pump
Table 5-6: Troubleshooting pump 5-50
No hydraulic pressure 5-50
Insufficient pressure build-up 5-51
Pump making noise 5-51
“SL66/77/88″ Serles Service, •Troubleshootlngt pin: 1411635 -b, 07/03 5-5
D Troubleshooting
Contents – continued Page
5 7 SCR control circuit
Figure 5-16: EV-1 SCR controller 5-52
5 7 1 EV-1 SCR controller diagnostics 5-53
EV-1 Card terminal functions 5-54
Table 5-7: EV-1 card terminal functions 5-54
Reduced or NO motor torque 5-56
Table 5-8: Reduced or NO motor torque 5-56
No control voltage from positive to negative 5-56
Control volts present from positive to negative with proper polarity 5-56
NO power and NO SCR hum with accelerator in SCR range 5-57
Little or no power Normal SCR hum , 5-57
Little or no power Abnormal SCR hum 5-57
Little power No SCR hum 5-57
One contactor closes with normal operation –
opposite contactor does not close 5-57
PMT trips after operating in 1A 5-58
Table 5-9: Failures causing FULL motor torque 5-58
Full SCR speed immediately with audible hum NO PMT trip 5-58
Contactors close once or twice and then remain open PMT trips 5-58
Stall currents – 5-58
Table 5-10: Misoperation of other features 5-59
1A or FW contactors close with key switch 5-59
For R closes without returning direction switch to OFF 5-59
PMT does not open For R contactor , 5-59
1A will not close at run (percent pickup) , 5-59
1A will not close at SCR stall (time pickup) 5-60
1 A will not open until start switch is opened 5-60
FW contactor will not close after 1A pickup , 5-60
FW contactor will not drop out with increasing load 5-60
Stiff plug – Severe reversal 5-60
Very soft reversal 5-60
Blown power fuse – Very hot power cables 5-61
Hour meter feeder faults: 5-61
5 8 temperature control
5 8 1 System will not heat, close-loop 5-61
Figure 5-17: Air intake vent 5-62
Figure 5-18: Solenoid Electrics 5-63
5 8 2 System will not cool, open-loop 5-63
Introduction
6 1 introduction
6 1 1 Tools needed 6-9
6 2 before you begin
6 2 1 Lifting the truck 6-10
Figure 6-1: Jack and support the truck 6-11
6 2 2 Hydraulic fittings and hoses 6-11
Figure 6-2: Removing hoses I fittings 6-12
6 2 3 Cleaning and inspection 6-13
Repair and/or Replace
6 3 Drive unit
6 3 1 Repair 6-15
Removing the drive axle 6-15
Figure 6-3: Removing the dress cover 6-16
Figure 6-4: Release and disconnect the parking brake 6-16
Figure 6-5: Disconnect traction electrical cables 6-17
Figure 6-6: Brake line 6-17
Figure 6-7: Drive-to-chassis mounting bolts 6-18
Figure 6-8: Trunnion bolts 6-18
Figure 6-9: Torque mounting bolts 6-19
Removing the wheel 6-19
Figure 6-10: Removing the wheel 6-20
Figure 6-11: Planetary pinion, retainer and spacers 6-20
Figure 6-12: Planetary pinion gears/ Axle shaft 6-21
Figure 6-13: Ring gear and gasket 6-21
Figure 6-14: Thrust washer/ Wheel bearing locknut 6-22
Figure 6-15: Wheel bearing adjust nut/ Planetary spider gear 6-22
•sL66ll7/88” Serles Service, Corrective maintenance, p/n: 1421635 -b, 07/03 6-3
□ Corrective maintenance
Contents – continued Page
6 3 Drive unit – continued
6 3 1 Repair – continued
Inspection 6-23
Figure 6-16: Pinion and ring gear inspection 6-23
Figure 6-17: Planetary gear bore and shaft 6-24
Figure 6-18: Inspect bearing rollers 6-24
Re-assembly hints 6-25
Figure 6-19: Outer wheel bearing installation 6-25
6 3 2 Brakes 6-26
Figure 6-20: Sample: Self-adjusting brake assembly 6-26
Figure 6-21: Replacing brakes 6-28
6 3 3 Wheel cylinder 6-29
Figure 6-22: Wheel cylinder 6-29
6 3 4 Bleeding brakes 6-30
Figure 6-23: Bleeding brakes 6-31
Motor support assembly 6-32
Figure 6-24: Differential assembly 6-33
Figure 6-25: Seat parking brake 6-33
Differential 6-34
Figure 6-26: Differential assembly 6-35
Figure 6-27: Differential I Axle housing tube 6-35
Figure 6-28: Removing differential and shims 6-36
Bevel and pinion gears 6-36
Differential bearings 6-37
Gear backlash 6-38
Tooth contact check • 6-38
Re-assembly hints 6-40
6 4 no-spin unit
Figure 6-29: No-spin differential overview ; 6-41
Figure 6-30: No-spin differential assembly 6-41
Inspection 6-42
Re-assembly hints 6-43
Figure 6-31: No-spin re-assembly 6-43
Figure 6-32: Ring gear – case half 6-43
6-4 “SL66/88” Serles Service, Preventive maintenance, pin: 1421635 -a, 07/02
Corrective maintenance D
Contents – continued Page
6 5 traction motor
6 5 1 Cleaning 6-45
6 5 2 Bearings 6-46
6 5 3 Insulation 6-46
6 6 steer axle
6 6 1 Removing the wheels 6-4 7
Figure 6-33: Wheel cap 6-47
Figure 6-34: Bearing lock washer/ nut 6-48
Figure 6-35: Removing the wheel and grease seal 6-48
Installing the wheels 6-49
Figure 6-36: Installing the wheels 6-49
6 6 2 Steer axle service 6-50
Figure 6-37: Steer cylinder lines 6-51
Figure 6-38: Tie rod, spindle & bell crank 6-51
Figure 6-39: Grease caps 6-51
Figure 6-40: Removing steer cylinder (3 illustrations) 6-52
Figure 6-41: Kingpin lock bolts I Thrust bearings, 3 illustrations 6-53
Assembly 6-53
Figure 6-42: Inserting new bearings 6-54
Figure 6-43: Installing kingpins 6-54
Wheel alignment 6-54
Figure 6-44: Tie rod I spindle alignment, left wheel-to-right wheel 6-55
Installation 6-55
6 7 service brakes
6 7 1 Pedal travel adjust 6-56
Figure 6-45: Brake pedal adjust 6-56
Figure 6-46: Master cylinder adjust 6-57
6 7 2 Master cylinder 6-57
Figure 6-47: Removing the master cylinder 6-58
Figure 6-48: Master cylinder breakdown 6-58
Bench bleed the master cylinder 6-60
Figure 6-49: Sample: Support and bench bleed the cylinder 6-61
6 7 3 Backing plate assemblies 6-61
Figure 6-50: Wheel cylinder breakdown 6-63
Figure 6-51: Piston cylinder diameter 6-63
“SL66/77/88” Serles Service, Corrective maintenance, pin: 1421635-b, 07/03 6-5
D Corrective maintenance
Contents – continued Page
6 7 service brakes – continued
6 7 4 Parking/seat brake 6-64
Figure 6-52: Seat brake assembly 6-64
6 8 removing forks
Figure 6-53: Changing forks 6-65
6 9 pivot and sideshift
6 9 1 Tile cylinders 6-66
6 9 2 Crosshead 6-67
Figure 6-54: Hydraulic hoses and electrical connections 6-67
6 9 3 Pivot arm 6-68
Figure 6-55: Secure crosshead / dust covers 6-69
Figure 6-56: Locknut and washer 6-69
Re·-assem bly hints 6-70
6 9 4 Pivot cylinder 6-71
6 9 5 Sideshift assembly 6-71
Sideshift bearing shoe adjust 6-71
Figure 6-57: Sideshift bearing shoe 6-72
Telescoping Slide 6-72
Sideshift chain • 6-73
Figure 6-58: Sideshift chain tension block 6-73
6 10 pump motor
Figure 6-59: Exposing motor connections 6-75
Figure 6-60: Pump/ motor – viewed from underneath truck 6-76
Servicing the motor (hints) • 6-76
Cleaning • • 6-77
Bearings 6-77
Insulation 6-78
6 10 1 Hydraulic pump 6-78
Figure 6-61: Pump/ motor coupling 6-79
Servicing the pump 6-79
Inspection 6-80
Re-assembly hints 6-80
Figure 6-62: Double vs single lip seal 6-81
Figure 6-63: Right vs left hand rotation 6-82
6-6 “SL66/88” Serles Service, Preventive maintenance, p/n: 1421635 -a, 07/02
Corrective maintenance □
Contents – continued Page
6 11 hydraulic control valves
Pivot, shift and tilt 6-82
Figure 6-64: Pivot, shift and tilt valve assembly 6-83
Inspection 6-84
Re-assembly hints 6-85
6 11 1 Lift control valve 6-85
Inspection 6-86
Figure 6-65: Lift Valve Spool Assembly 6-86
Re-assembly hints 6-87
6 12 power steer pump
6 12 1 Removing the pump 6-88
Figure 6-66: Power steering motor/pump location 6-88
Figure 6-67: Electrical connections 6-89
6 12 2 To service the pump 6-89
6 12 3 Orbitrol unit 6-89
Figure 6-68: Sample: Orbitrol assembly 6-90
Figure 6-69: Orbitrol hydraulic lines 6-90
6 12 4 To service the orbitrol 6-90
6 13 electrical system
6 13 1 Compartment door 6-91
Figure 6-70: Electrical panel main and pin connections 6-91
Figure 6-71: Quick disconnect and door clevis pin 6-92
6 13 2 Contactors and coils 6-92
6 13 3 Accelerator module 6-93
Figure 6-72: Driver’s cap floor panel – accelerator access 6-93
Figure 6-73: Accelerator module location 6-93
Potentiometer 6-94
Figure 6-7 4: Potentiometer 6-94
Replacement and adjustment 6-95
Figure 6-75: Replacing switch 6-95
6 14 dash panel
Figure 6-76: Dash panel removal 6-96
Figure 6-77: Panel electrical connectors 6-96
“SL66/77/88” Serles Service, Corrective maintenance, p/n: 1421635-b, 07/03 6-7
□ Corrective maintenance
Contents – continued Page
6 15 pivot & shift
Figure 6-78: Pivot/ shift hydraulic and electrical relationship 6-97
6 15 1 Circuit functions 6-98
Figure 6-79: Shift interlock switch 6-98
Figure 6-80: Extended shift stroke option 6-99
6 15 2 Operation check 6-99
Shift interlock switch 6-99
Figure 6-81: Check shift interlock switch 6-100
Pivot interlock switch 6-101
Figure 6-82: Check pivot interlock switch 6-101
S.S 05/24
