Landoll Drexel SLT30 AC User manual

F-459-R1
LANDOLL CORPORATION
1900 North Street
Marysville, Kansas 66508
[phone]
800-428-5655 ~ WWW.LANDOLL.COM
Model SLT30/35 AC
Maintenance Manual
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F-459-0910 i
1 Intro, Safety, Inspection and Dash Operations
Introduction ..............................................................1-1
Operating Instructions ......................................................1-1
Service Training ..........................................................1-1
Tools Needed ............................................................1-1
Replacement Parts ........................................................1-1
General Maintenance Instructions ................................................1-2
For your Safety ................................................................1-3
Battery Safety Rules: ...........................................................1-3
Battery Care and Charging ......................................................1-4
Battery Removal and Installation .................................................1-4
Hydraulic System ..............................................................1-4
Towing the Truck ..............................................................1-5
General Safety Tips: .......................................................1-5
Towing Vehicle Requirements ................................................1-5
Towing a Truck in the Reverse Direction .......................................1-5
Lifting and Blocking the Truck ...................................................1-5
Cleaning the truck .............................................................1-6
Maintenance Introduction .......................................................1-6
Inspection Sheets .............................................................1-6
Operator’s Daily Checklist ......................................................1-7
Lubrication Specifications .....................................................1-12
Torque Specifications .........................................................1-12
Fluid Capacities ..............................................................1-12
2 Tires, Brakes and Drivetrain
Floor Plate ....................................................................2-1
Floor Plate Removal and Assembly ...........................................2-1
Tire Inspection ................................................................2-1
Visual Inspection ..........................................................2-2
Replacing the Drive Tire ........................................................2-3
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ii F-459-0910
Load Wheel Bearing Maintenance ................................................2-3
Replacing the Load Tires ........................................................2-4
Brake System .................................................................2-4
Brake System Service ..........................................................2-5
Check Service Drum Brakes .................................................2-5
Brake Adjustment .........................................................2-5
Repairing Brake Wheel Cylinders .............................................2-7
Hydraulic Brake Drums .........................................................2-8
Measure Brake Drum Diameter ...............................................2-8
Replacing Brake Drum Assemblies ............................................2-8
Parking Brake Assembly ........................................................2-8
Checking the Parking Brake .................................................2-8
Park Brake Installation and Mounting ..........................................2-9
Park Brake Maintenance ....................................................2-9
Brake Pedal Assembly .........................................................2-10
Brake Pedal .............................................................2-10
Service Brake Linkage .....................................................2-10
Replacing the linear pot ....................................................2-10
Master Cylinder ...............................................................2-10
Replacing Master Cylinder ..................................................2-10
Bench Bleed the Master Cylinder ............................................2-11
Check Master Cylinder Fluid Level ...........................................2-11
Bleeding Brakes ..........................................................2-12
Service Brake Pedal Assembly ..............................................2-13
Traction Motor and Gear Box ...................................................2-13
Removing the Drive Wheel .................................................2-13
Checking Drive Wheel Gearbox .............................................2-13
Servicing the Drive Train Assembly ...........................................2-13
Gearbox Replacement .........................................................2-14
Traction Drive Motor Service ....................................................2-15
Accelerator Pedal .............................................................2-15
Adjusting Accelerator Pedal .................................................2-15
3 Hydraulic Oil, Motors, Pumps and Cylinders
Hydraulic Components .........................................................3-1
Hydraulic System Maintenance ...................................................3-1
Checking Hydraulic Oil Level .................................................3-1
Changing Hydraulic Oil .....................................................3-2
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F-459-0910 i
Change the Hydraulic Oil Filter ...................................................3-2
Checking and Adjusting Hydraulic Pressure .......................................3-3
Hydraulic Pump Service ........................................................3-4
Replacing the Hydraulic Pump and Motor .......................................3-4
Hydraulic Control Valve Assembly ................................................3-4
General .................................................................3-4
Mast Service Precautions .......................................................3-5
Disconnecting the Tilt Cylinder ..................................................3-5
Mast Removal Precautions ......................................................3-5
Hydraulic Fittings and Hoses ....................................................3-6
Check Hydraulic Functions ..................................................3-6
Steering Motor ................................................................3-6
Steer Motor (with gearbox attached) Replacement ................................3-6
4 Electrical System
Steering Column/Dash Assembly .................................................4-1
Removing the Display Panel .................................................4-1
Key Switch ...............................................................4-1
Steering Wheel Removal ....................................................4-2
Steering Column (Console) Removal ..........................................4-2
Steering Torque Feedback Device ............................................4-3
Batteries - Care and Replacement ................................................4-3
Battery Safety .................................................................4-3
Checking Batteries ........................................................4-3
Battery Care .............................................................4-4
Charging the Battery .......................................................4-4
Battery Removal ..........................................................4-5
Battery Installation .........................................................4-5
Electrical Controls and Levers ...................................................4-5
Joystick .................................................................4-5
Check the Return-to-Neutral .................................................4-5
Replacing a Complete Control Panel ..........................................4-5
Horn Service .............................................................4-6
Seat Switch Assembly ......................................................4-6
Truck Lighting ............................................................4-7
Headlights ...............................................................4-7
Brake and Tail Lights .......................................................4-7
Back Up Alarms ...........................................................4-7
Overhead Guard, Lighting and Alarms .........................................4-7
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ii F-459-0910
Side Shift Circuit Maintenance ...................................................4-7
Check Side Shift Circuit Performance ..........................................4-8
Fuses ........................................................................4-8
ESD Strap ...............................................................4-8
5 Drexel SLT30/35 AC Calibration Programming
Dashboard Truck Calibration ....................................................5-1
Clock Set ................................................................5-8
Throttle and Brake Calibration ................................................5-8
Wire Guidance Calibration ...................................................5-9
6 Truck Lubrication and Chain Maintenance
Lubricating the Truck ...........................................................6-2
Main Rotation Bearings .....................................................6-2
Fork Positioner Lubrication, Non-Side Shifting (Option) ............................6-4
Chain Lubrication ..............................................................6-5
Chain Adjustment .........................................................6-5
Measuring Chain Stretch ....................................................6-5
Check Primary Lift Chain ....................................................6-5
Check Lift Operation .......................................................6-5
Checking and Adjusting Degree of Tilt .........................................6-6
Removing the Tilt Cylinders .....................................................6-7
Removing the Mast From Truck ..................................................6-7
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F-459-R1 1-1
Chapter 1
Intro, Safety, Inspection and Dash Operations
Introduction
This manual is intended for the service technician who is
seeking information on product maintenance and service
replacement parts. It contains troubleshooting tips and
information on repair which will help the technician solve
problems that may occur.
Operating Instructions
This manual does not contain operating instructions.
Operating instructions are sent with each truck. If the
operators manual is missing on your SLT30/35 AC truck,
call Landoll Corporation to order a replacement.
ServiceTraining
ServiceTraining is available for the forklift technician from
Landoll Corporation. This includes operation, repair,
maintenance, hydraulic system, electrical system and
wire guidance. Contact your regional Landoll service
representative for more information.
Tools Needed
The tools needed will be the same tools that are often
found in well-equipped service centers, in both SAE and
metric sizes. For example, an assortment of open-end
and box-end wrenches, sockets, as well as Allen and
adjustable wrenches, assorted screwdrivers and
non-marring mallets should be available.
Replacement Parts
When ordering parts that will be used for the repair and
maintenance of your Landoll SLT30/35 AC truck, the
model and serial number of the truck being repaired will
be required. This information is located on the serial
number and capacity plate located on the right operators
console. See Figure 1-1.
Figure 1-1: Serial Number and Capacity Plate
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1-2 F-459-R1
INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
Below are the Notice, Caution, Warning and Danger
safety notices and their descriptions that will be used in
this book.
NOTICE
CAUTION
WARNING
DANGER
General Maintenance Instructions
CAUTION
IMPORTANT
Maintenance and inspection shall be performed in
conformance with the following practices:
1. A scheduled planned maintenance, lubrication and
inspection system should be followed. A daily check
before each shift is an OSHA requirement.
2. Only qualified and authorized personnel shall be
permitted to inspect, maintain and service the truck.
3. Before leaving the truck:
• Stop the truck.
• Completely lower the mast.
• Place directional controls in neutral.
• Turn off the power and disconnect the battery.
• Block the wheels, especially if the truck is on an
incline.
4. Before working on the truck:
• Perform a Lock Out/Tag Out operation on the truck.
• Raise drive wheel free of floor or disconnect the
power sources.
• Use chocks or other positive positioning devices.
• Block load engaging means, inner masts or chassis
before working under them.
• Operation to check performance of truck or
attachments shall be conducted in an safe clearance
area.
5. Before starting to operate the truck:
• Be in an operating position.
• Apply brake.
• Place directional control in neutral.
• Check functions of lift systems, directional control,
speed control, steering, warning devices, brakes and
any attachments if any are used.
6. To avoid fire hazards have fire protection equipment
present. Do not use an open flame to check fluid
levels or for leakage of electrolyte and fluids or oil. Do
not use open pans of fuel or flammable cleaning
fluids to clean parts.
7. Keep shop well ventilated, clean and dry.
8. Brakes, steering mechanisms, control mechanisms,
lift overload devices, guards and safety devices shall
be inspected regularly and maintained in safe
operating condition.
9. Capacity, operation and maintenance instruction
plates or decals shall be maintained in legible
condition.
10. All parts of lift mechanisms shall be inspected to
maintain them in safe operating condition.
Special notices that include helpful maintenance
hints. Read and thoroughly understand.
Proceed with caution. Failure to heed may cause
injury to person or damage product.
Proceed with caution. Failure to heed warning will
cause injury to person or damage product.
Proceed with caution. Failure to heed warning will
cause injury to person or damage product.
Steel toe shoes and eye protection are required
when maintaining or repairing a lift truck. Ear
protection may also be required if the repair
facilities are excessively noisy, per OSHA
standards. Keep feet, hands and all other body
parts away from all mast areas and pinch points.
Powered industrial trucks may become
hazardous if scheduled maintenance is
neglected. Therefore, adequate maintenance
facilities, trained personnel and procedures
should be provided.
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INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
1-3
11. All hydraulic systems shall be regularly inspected
and maintained in conformance with good practice.
Cylinders, valves and other similar parts shall be
checked to assure that“drift” has not developed to an
the extent that it would create a hazard.
12. Batteries, motors, controllers, limit switches,
protective devices, electrical conductors and
connections shall be maintained in conformance with
good practice. Special attention shall be paid to the
condition of electrical insulation.
13. Trucks shall be kept in a clean condition to minimize
fire hazards and facilitate detection of loose or
defective parts.
14. Modifications and additions which affect capacity and
safe truck operation shall not be performed by the
customer or user without manufacturers prior written
approval. Capacity, operation and maintenance
plates or decals shall be changed accordingly.
15. Care must be taken to assure that all replacement
parts are interchangeable with the original and are of
equal quality to what was originally installed on the
truck at the factory.
16. Be sure that any optional equipment added to the
truck is positioned so that it does not block the vision
of the operator or interfere with safe and efficient
operation of the truck.
For your Safety
NOTICE
When doing maintenance or repair on the SLT30/35 AC
truck, unless the truck must be on for testing, remove the
key from the key switch. In addition, because it’s possible
to have a duplicate key, remove the main power fuse and
install a commercially available Lock Out/Tag Out device
on the battery connectors. Also, install a lockout warning
reminder on the steering wheel warning that the truck is
not available for use.
Battery Safety Rules:
CAUTION
Lock Out/Tag Out
In the interest of operator safety and operator
compliance with OSHA regulations, guidelines
have been developed to perform service and
maintenance on the truck.
Before performing service and maintenance on
the truck, review the following sections in this
manual for addition procedures to be followed.
• Wear protective clothing, rubber apron, boots
gloves and full-face shield when performing
any maintenance on batteries.
• DO NOT allow electrolyte to come in contact
with eyes, skin, clothing or floor. If electrolyte
contacts eyes, flush immediately with clean
water. OBTAIN MEDICAL ATTENTION
IMMEDIATELY! Should electrolyte be spilled
on skin, rinse promptly with clean water and
soap. A baking soda solution (one pound to
one gallon of water) will neutralize acid
spilled on clothing, floor or other surfaces.
Apply solution until bubbling stops and rinse
with clean water.
• Keep battery vent plugs firmly in place at all
times, except when adding water or taking
hydrometer readings.
• DO NOT bring any type of flame or spark near
the battery.
• DO NOT place any electrically conductive tool
on the battery that could cause a spark. Gas
formed while the battery is charging is highly
explosive.This gas remains in the cells long
after charging is complete.
• Keep the battery clean. Foreign matter in the
electrolyte will result in poor battery
performance.
• Follow the battery manufacturer’s
instructions concerning maintenance and
repair.
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1-4 F-459-R1
INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
Battery Care and Charging
CAUTION
Battery Removal and Installation
CAUTION
CAUTION
Good Battery Care Recommendations:
• Add approved water only - never add acid.
• Keep electrolyte levels proper.
• Keep Battery top clean and dry.
• Keep flame and metal away from battery top.
• Keep vent caps tightened.
• Cool before charging/operating battery above 115ºF.
• Use only approved correct voltage/current charger.
• Keep battery cover open while charging.
• If in doubt, call your local Landoll service technician.
Hydraulic System
WARNING
IMPORTANT
When maintenance is to be performed on the
hydraulic system, make sure the system hydraulic
pressure is relieved by:
• Moving the truck to a level area.
• Have no load on the forks.
• Completely lower the mast, or if the mast is the
object of repair, have blocks under the mast.
• Only qualified and experienced personnel
should perform maintenance and repair on
batteries.
• Make certain the charger being used matches
the voltage and amperage of the truck battery.
This voltage is listed on the truck serial plate.
See Figure 1-1.
• Before connecting or disconnecting batteries
to the charger, make sure the charger is OFF.
Attempts made to do this while the charger is
ON could result in serious injury to the
operator and damage could occur to the
charger, with sparks or electrical spikes.
• Keep sparks or open flame away from the
battery or the charging area.
BATTERY FUMES ARE EXPLOSIVE!
• NEVER smoke or have an open flame near the
battery. Gas formed during charging is
explosive and can cause injury. Consult the
charger manufacturer’s manual covering your
charger for operation and maintenance.
• The battery must meet size, weight and
voltage requirements of the truck.
Battery Removal:When removing the battery
move the truck to an area intended for battery
care, on a level floor.
• Turn the key switch to the OFF position and
remove the key.
• Disconnect battery and lock out the truck as
described in the Lock Out/Tag Out section
described on page 1-3.
• Never remove the battery partially from the
truck without a roller stand in place.
• Lower load completely. If battery is removed
with load raised, use hoist attached to mast
to protect against tip over.
• DO NOT allow any metallic object to come in
contact with the top of the battery.This may
cause a short circuit when removing or
transporting the battery. Use an insulator
(such as plywood) to cover the top of the
battery during removal.
Battery Installation:
• When installing the battery move truck to an
area intended for battery care.
• The load forks must be all the way down to
the floor.
• Turn key or toggle switch to OFF position and
put the key in a secure place.
• High pressure fluids are dangerous and can
puncture the skin and cause severe injury!
• Relieve all pressure from the hydraulic
system before attempting to work on it.
• Make sure all hydraulic lines are tight before
starting the system. Any fluid injected into
the skin under high pressure should be
considered a medical emergency despite a
normal appearance of the skin. Medical
attention should be given immediately.
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INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
1-5
Towing theTruck
General SafetyTips:
WARNING
Towing Vehicle Requirements
• The towing vehicle must have a pull and braking
capacity greater than 8000 lbs.
• Brakes on a towed truck will operate, but could
operate differently versus an operational truck.
• Maximum towing speed should not exceed 2mph.
• Always tow the truck in the reverse direction.
• Towed vehicle’s forks should be empty and no
higher than 12 in. off the ground.
• Be careful. With the emergency brake released,
vehicle will roll and steering will be difficult.
Towing aTruck in the Reverse
Direction
1. Key must be in the OFF position.
2. When attaching the towing vehicle to lift truck to be
towed, 2 towing chain slots have been provided on
the rear bottom side of the counter weight. See
Figure 1-2. Firmly attach tow device to these slots.
3. Keep towing speed below 2 mph. Remember that the
person on the towed lift has to turn his head to
observe operations.
Figure 1-2: Forklift Tow Slots
4. To easily disarm the braking system for towing, open
the rear compartment on the forklift and disconnect
the jumper connector and re-connect the connection
to the “Tow Plug”. See Figure 1-3.
Figure 1-3Tow Plug Connection
Lifting and Blocking theTruck
Figure 1-4: Truck Blocking
• Have the service brake applied when hooking
up the tow chain.
• Release the emergency brake only when
ready to tow the truck and the operator is on
the truck being towed.
• Tow the truck at a speed of 2 mph or less.
• DO NOT make sharp turns when towing the
truck.The towed truck will be difficult to
steer. USE EXTREME CAUTION and keep the
towed vehicle at a slow, manageable speed.
• Forks must be empty and preferably not more
than 12” off the floor.
• With the emergency brake disabled, the truck
can roll easily - USE EXTREME CARE!
Forklift Tow Points
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1-6 F-459-R1
INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
• Move truck to a level area designated for repair.
• Keep forks empty and low to the ground.
• Turn the key off and remove it from the console.
• Unhook the battery.
• Attach Lock Out/Tag Out device to the truck.
• Use a jack or hoist with a 8000 lb. minimum lift.
• Set the lift on designated hardwood blocks. See
Figure above for block(s) placement. Four blocks
are required on all four corners of the truck to
provide a safe, stable repair position.
• Keep the height of the lifted truck to a minimum.
Cleaning the truck
Landoll Corporation recommends that their fork trucks
NOT be cleaned with a power washer. Electrical boards,
circuitry and wiring can be damaged by high pressure
water and soap. Moisture and soap left on components
can rust, corrode or leave a residue that can damage
everything that it comes in contact with. The preferred
method of removing dust is compressed air. For localized
cleaning, use a non-flammable solvent parts washer and
compressed air after the part or area is cleaned.
Maintenance Introduction
Preventative maintenance is an important part of all
industrial equipment.
A well planned preventative maintenance program is
essential to keeping the working environment safe for the
operator and the longevity of the affected equipment.
Regular and planned maintenance is the responsibility of
both the daily operator and the forklift technician.
Inspection Sheets
The following pages are OSHA (Occupational Safety and
Health Administration) required check sheets.These
sheets should be copied and the copies used for
maintenance checks on your SLT30/35 AC lift. The
pre-shift inspection on your SLT30/35 AC lift is an OSHA
requirement. It is the operator’s duty to inspect the lift
before each shift and report all problems to the person in
charge of forklift maintenance. Have a qualified mechanic
correct all noted problems.
Daily pre-shift inspection is an OSHA requirement.
These inspections must be documented.
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INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
1-7
Operator’s Daily Checklist
Date: Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Hydraulic Oil
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1-8 F-459-R1
INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
These checks must be done after 50-100 hours of use. The
To be performed after 250 hrs of truck operation in
addition to the required pre-shift daily inspection.
Date: Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Hydraulic Oil
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INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
1-9
Technicians 250 Hour Checklist Action Needed Status Landoll / Drexel
Lift
SAFETY & OPERATIONAL CHECKS
Have a qualified technician correct all
problems.
Description OK -Yes, No Comments
Mast, Carriage or Attachment Clean, inspect for wear and lube.
Lift Chains Clean and lubricate
Front Carry Position Setting Distance between truck and sides
of mast must be even
90° Pivot and Reach Setting Forks must have 3” reach and
mast must have 90° pivot
Pivot Arm Deflection Check pivot arm’s deflection
when pivoting to travel position
Tilt Cylinder Racking & Degree Adjust Check mast for racking when
tilting. Check fwd/rwd tilt angles
Attachment Control Operational
Accelerator Functioning smoothly
Controls (turn power on) investigate unusual noises
Joystick Check all functions
Dash Display Check BDI, hourmeter
Parking Brake Check for function
Service Brake Check for leaks, shoe wear
Hydraulic Fluid Level Check and fill
Exterior of HydraulicTank &Tank Breather Clean
Lift and Power Steering Pumps Clean dust from motors
Battery Box and Connector Neutralize and clean
Battery Thoroughly clean
Check electrolyte level
Check structure and electrical
conditions
Traction Motor Clean dust from compartment
Seat Belt, Buckle, and Retractor Functioning smoothly
Tires/Wheels Remove debris, torque lug nuts
Wheel Bearings Clean and fill with grease
Leaks Gearbox, brake components,
hydraulic oil, battery
Hydraulic Hoses and Connections Check for wear
Switches (Interlock, Direction, Parking/Seat,
Key) Check for proper operation
Wire Harness Check for abrasions
Pivot/Shift Assembly Service bearing pads, grease
zerks, lubricate shift chain
OHG Mounting Bolts Check and Retorque
Steering Gear Inspect and Lube
Electrical Power Connections Inspect & Retorque
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1-10 F-459-R1
INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
To be performed each 500 hrs of truck operation in
addition to the required pre-shift daily inspection
Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil
Technicians 500 Hour Inspection Action Needed Status Landoll / Drexel
Lift
SAFETY & OPERATIONAL CHECKS
Have a qualified technician correct all
problems.
Description OK -Yes, No MaintenanceNote
if Applicable
Forks,Top Clip Retaining Pin Function & condition
Load Rollers No greater than 1/16” movement
Steering Operation Functions smoothly
Brake Fluid Check Level
Hydraulic Oil Filter Change element
Battery Check B+ and B to frame current
must be less than 1.0 milliamp
Battery Rollers Clean, repack, check for wear
Contactor Points & Microcswitches Check operation
Controllers Clean surfaces
Operational Compartment Capacity Plate Make sure it is attached & that
info matches model, serial
number & attachments
All Fasteners Retorque
Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil
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INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
1-11
To be performed each 1000 hrs of truck operation in
addition to the required pre-shift daily inspection.
To be performed each 2000 hrs of truck operation in
addition to the required pre-shift daily inspection.
Technicians 1000 Hour
Inspection Action Needed Status Landoll /Drexel Lift
SAFETY & OPERATIONAL CHECKS
Have a qualified technician correct all
problems.
Description OK (X) MaintenanceNote
if Applicable
Motors Clean cooling holes of debris
Primary Lift Chain Check
Secondary Lift Chain Check
Rear Channel Roller Inspection Check
Carriage Channel Roller Inspection Check
Inspect Side Shift Chains Check
Date Inspector: Truck No. Model No. Location Serial No. Shift Hr. Meter Battery Fluid Hydraulic Oil
Technicians 2000 Hour Checklist Action Needed Status Landoll /Drexel
IC
SAFETY & OPERATIONAL CHECKS
Have a qualified technician correct all
problems.
Description OK (X) MaintenanceNote
if Applicable
Hydraulic Oil Change
Hydraulic Reservoir Suction Screen Clean with solvent
Gear Box Drain, flush & refill
Date Inspector: Truck No. Model No. Location Serial No. Shift Hr. Meter Battery Fluid Hydraulic Oil
Technicians 4500 Hour Checklist Action Needed Status Landoll /Drexel
IC
SAFETY & OPERATIONAL CHECKS
Have a qualified technician correct all
problems.
Description OK (X) MaintenanceNote
if Applicable
Hydraulic Oil Change
Date Inspector: Truck No. Model No. Location Serial No. Shift Hr. Meter Battery Fluid Hydraulic Oil
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1-12 F-459-R1
INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
Lubrication Specifications
Torque Specifications
Fluid Capacities
Name Lubrication Notes
Mast Chain/Shift Chain SAE 40W. oil or Bowman Heavy Load Red Grease Clean and re-oil
Mast Rail Chassis Lube or Kendall Sr-12X Lube inner side of upright rail
Rotation Bearings Texaco Ref. C&C #880 Use standard lubrication gun
Steering Knob Light weight oil Lightly oil
Reservoir Cap SAE 30W oil Clean in solvent and re-oil
Hydraulic Reservoir Conoco Power flow HE (ISO Grade 46) Filtered to
ISO 4406 cleanliness code 15/13/11 or equivalent
Grade oil filtered to 15/13/11.
Drain, flush, and refill
Gear Case 8SW/40 gearlube Drain, flush, and refill
Master Cylinder Heavy duty brake fluid DOT 3 Check level. Add if necessary
Steering Gears Exposed Gear Lube, Mobil 375 NC,C&C#880 Aerosol Spray/Brush
application
Cylilnder Cleavis Texaco Ref.C&C#880 Use standard lubrication gun
Shift Chain Rollers Texaco Ref.C&C#880 Brush or spray on lubricant
Splines of the Drive Motor and Gearbox Kluberplex BEM 34-132 Apply to splines
Carriage Slide Pads Gredag 741 or AeroShell 33MS Brush on slide pads
*Failure to refill with oil that meets ISO 4406 cleanliness code 15/31/11 may void the warranty. Typical“NEW” oil DOES NOT
meet this specification. Contact Landoll Corporation or your lubricant supplier for recommendation.
Component Torque
Drive Wheel 125 ft. lbs. (305 Nm.)
Fluid draining and filling plug 16 ft. lbs. (22 Nm.)
Hydraulic braking unit 37 ft. lbs. (50 Nm.)
Electrical Connection M6 35 in. lbs. (4 Nm.)
Electrical Connection M8 85 in. lbs. (10 Nm.)
Electrical Connection M10 170 in. lbs. (19 Nm.)
Drive Plate 150 ft. lbs.
Drive Motor Mount 60 ft. lbs.
Mast and Side Shift Mechanism
Chain guard capscrews 48-52 ft. lbs. (65-71 Nm.)
Main lift cyl. plunger retainer 95-125 ft. lbs. (129-169 Nm.)
Free lift cyl. plunger retainer 275-300 ft. lbs. (373-407 Nm.)
Carriage roller capscrews 70-80 ft. lbs. (95-108 Nm.)
Chain and hose sheave screws 26-30 ft. lb. (35-41 Nm.)
Lift chain adjusting nuts 50-70 ft. lbs. (68-90 Nm.)
Backrest screws 145 ft. lbs. (197 Nm.)
Side shift mounting hooks 115-125 ft. lbs. (156-170 Nm.)
Overhead Guard Bolts 170 Ft-lbs (230 Nm.)
Item Capacity - Quarts (Liters)
Hydraulic Tank 11.6 gallons (44 liters)
Brake Fluid 0.21 quarts (0.20 liters)
Gear Box 1.85 gallons (7 liters)
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INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
1-13
GeneralTorque Specifications (rev. 4/97)
TORQUE SPECIFIED IN FOOT POUNDS
Hydraulic FittingTorque Specifications
This chart provides tightening torques for general purpose applications when special torques are not specified on process or
drawing. Assembly torques apply to plated nuts and capscrews assembled without supplemental lubrication (as received condition).
They do not apply if special graphite moly-disulfide or other extreme pressure lubricants are used. When fasteners are dry (solvent
cleaned) add 33% to as received condition torque. Bolt head identification marks indicate grade and may vary from manufacturer to
manufacturer. Thick nuts must be used on grade 8 capscrews. Use value in [ ] if using prevailing torque nuts.
UNC
SIZE SAE Grade 2 SAE Grade 5 SAE Grade 8 UNF SIZE SAE Grade 2 SAE Grade 5 SAE Grade 8
1/4-20 4 [5] 6 [7] 9 [11] 1/4-28 5 [6] 7 [9] 10 [12]
5/16-18 8 [10] 13 [13] 18 [22] 5/16-24 9 [11] 14 [17] 20 [25]
3/8-16 15 [19] 23 [29] 35 [42] 3/8-24 17 [21] 25 [31] 35 [44]
7/16-14 24 [30] 35 [43] 55 [62] 7/16-20 27 [34] 40 [50] 60 [75]
1/2-13 35 [43] 55 [62] 80 [100] 1/2-20 40 [50] 65 [81] 90 [112]
9/16-12 55 [62] 80 [100] 110 [137] 9/16-18 60 [75] 90 [112] 130 [162]
5/8-11 75 [94] 110 [137] 170 [212] 5/8-18 85 [106] 130 [162] 180 [225]
3/4/10 130 [162] 200 [250] 280 [350] 3/4-16 150 [188] 220 [275] 320 [400]
7/8-9 125 [156] 320 [400] 460 [575] 7/8-14 140 [175] 360 [450] 500 [625]
1-8 190 [237] 408 [506] 680 [850] 1-14 210 [263] 540 [675] 760 [950]
1-1/8-7 270 [337] 600 [750] 960 [1200] 1-1/8-12 300 [375] 660 [825] 1080 [1350]
1-1/4-7 380 [475] 840 [1050 1426 [1782] 1-1/4-12 420 [525] 920 [1150] 1500 [1875]
1-3/8-6 490 [612] 1010 [1375] 1780 [2225] 1-3/8-12 560 [700] 1260[1575] 2010 [2512]
1-1/2-6 650 [812] 1460 [1825] 2360 [2950] 1-1/2-12 730 [912] 1640[2050] 2660 [3325]
METRIC:
Coarse thread metric class 10.9 fasteners and class 10.0 nuts and through hardened flat washers, phosphate coated, Rockwell “C”
38-45. Use value in [ ] if using prevailing torque nuts.
Nominal
thread
diameter
(mm)
Newton
Meters
(Standard
Torque)
Foot
Pounds
(Standard
Torque)
Nominal
Thread
Diameter
(mm)
Newton
Meters
(Standard
Torque)
Foot
Pounds
(Standard
Torque
6 10 [14] 7 [10] 20 385 [450] 290 [335]
7 16 [22] 12 [16] 24 670 [775] 500 [625]
8 23 [32] 17 [24] 27 980 [1105] 730 [825]
10 46 [60] 34 [47] 30 1330 [1470] 990 [1090]
12 80 [125] 60 [75] 33 1790 [1950] 1340 [1450]
14 125 [155] 90 [115] 36 2325 [2515] 1730 [1870]
16 200 [240] 150 [180] 39 3010 [3210] 2240 [2380]
18 275 [330] 205 [245]
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1-14 F-459-R1
INTRO, SAFETY, INSPECTION AND DASH OPERATIONS
TORQUE SPECIFIED IN FOOT POUNDS
PARKER® BRAND FITTINGS
AEROQUIP® BRAND FITTINGS
GATES® BRAND FITTINGS
37 degree JIC, ORS, &ORB (REV. 10/97)
This chart provides tightening torques for general purpose applications when special torques are not specified on process or drawing.
Assembly torques apply to plated nuts and capscrews assembled without supplemental lubrication (as received condition). They do
not apply if special graphite moly-disulfide or other extreme pressure lubricants are used. When fasteners are dry (solvent cleaned)
add 33% to as received condition torque. Bolt head identification marks indicate grade and may vary from manufacturer to
manufacturer. Thick nuts must be used on grade 8 capscrews. Use value in [ ] if using prevailing torque nuts.
Dash Size 37 Deg. JIC O-ring (ORS) O-ring boss
-4 11-13 15-17 13-15
-5 14-16 --------------- 21-23
-6 20-22 34-36 25-29
-8 43-47 58-62 40-44
-10 55-65 100-110 58-62
-12 80-90 134-146 75-85
-16 115-125 202-218 109-121
-20 160-180 248-272 213-237
-24 185-215 303-327 238-262
-32 250-290 -------------- 310-340
Dash Size 37 Deg. JIC O-ring (ORS) O-ring boss
-4 11-12 10-12 14-16
-5 15-16 --------------- 16-20
-6 18-20 18-20 24-26
-8 38-42 32-35 50-60
-10 57-62 46-50 75-80
-12 79-87 65-70 125-135
-14 -------------- -------------- 160-180
-16 108-113 92-100 200-220
-20 127-133 125-140 210-280
-24 158-167 150-165 270-360
Dash Size 37 Deg. JIC O-ring (ORS) O-ring boss
-4 10-11 10-12 14-16
-5 13-15 --------------- ---------------
-6 17-19 18-20 24-26
-8 34-38 32-40 37-44
-10 50-56 46-56 50-60
-12 70-78 65-80 75-83
-14 -------------- 65-80 --------------
-16 94-104 92-105 111-125
-20 124-138 125-140 133-152
-24 156-173 150-180 156-184
-32 219-243 -------------- --------------
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