SL120 Series

SwingMast® Lift Truck

Maintenance Manual

LANDOLL CORPORATION
1900 North Street
Marysville, Kansas 66508
(785) 562-5381
800-428-5655 ~ WWW.LANDOLL.COM
F-602-R1
 Table of Contents

1 Introduction, Safety, and Specifications

Before You Begin (Please Read) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
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
Lock Out/Tag Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Prior to Tilt Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6
Mast Service Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Fluid Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Cleaning the truck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10

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2 Preventative Maintenance Inspections
Inspection Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Inspection Sheets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Preventative Maintenance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Tools or Equipment Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Preparing for Inspection or Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Performance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Static Straps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Power Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
Slide Assembly and Upper Channel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Safety Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Inspect Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Flat-spotting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
To Extend Tire Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
50 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Pivot Arm Racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Mast Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Mast Racking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Mast Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Mast Chain Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
250 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Grease Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
General Mast Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Mast Chain Wear Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Mast Rollers/Sheaves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Mast Uprights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
500 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Return Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Changing Hydraulic Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Suction Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Drive Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Major Bolt Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
1000 Hour Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Controller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

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3 Troubleshooting and Corrective Maintenance
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Traction Fuse Opening (1 FU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Hydraulic Fuse Opening (2 FU) and Traction Fuse (1 FU) Opening . . . . . . . . . . . . . . . . . . . 3-1
Pump Motor Power Fuse Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Loss of Drive Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Lift Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Motor Does Not Operate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Pressure Loss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Insufficient Pressure Build-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Relief Valve Set Too Low . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Pump Making Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Pivot Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Shift Function Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Inoperative Pivot and Shift Control Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Hydraulic Leak in the Cover End Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Loss of Hydraulic Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Damaged Pump Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Loss of Hydraulic Lift and Loss of Lift Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Proper Hoist Cylinder Sequencing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Overload of Hydraulic Hoist Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Loss of Mast Tilt or Loss of Lift Speed/Drift of Raised Load . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Damaged or Worn Cylinder Seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Loss of Power Steering - Motor Inoperative . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Loose or Open Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
No Voltage at Power Steering Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Slow Steering Response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Drift of Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Loss of Service Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Drive Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Loss Of Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Incorrect Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Loss Of Brake Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Soft Brake Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Ineffective Safety Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Brake/Wheel Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Oil Coming Out of the Breather . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Noise Under Power Greater Than During Coast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Noise During Coast Greater Than Under Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Noise During Turn (without NoSpin) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Noise (“stick-slip”) When Shifting from Forward to Reverse . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Noise (“tick-tick-tick”) When Traveling Forward or Reverse at Low Creep Speeds. . . . . . . 3-12
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13

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 Mast and Front Load Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Pivot/Sideshift Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Tilt Cylinder Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-13
Crosshead Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Pivot Arm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Sideshift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15
Load Roller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Mast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16
Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Brake Linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-17
Master Cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18
Brake Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Bleeding the Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Drive Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Removal of Drive Disc Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Hydraulic Pump Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22
Hydraulic Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-23
Lift Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-24
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Traction Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-25
Steer Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-27
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Line and Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Forward and Reverse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-29
Dash Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-30
Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-32
Steering and Pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Pedal Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Power Steering pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-35
Steer Orbital . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37
Accelerator Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Potentiometer (Pot) Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Switch Replacement and Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Safety Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Seat Switch Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43
Pivot/Shift Interlock System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44
Function of Circuit Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44

5 Supplier Provided Documentation

Lift Technologies Mast Service Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
1200 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Table of Contents - page 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

iv
 Chapter 1

Introduction, Safety, and Specifications

Before You Begin (Please Read) maintenance, hydraulic system and electrical system.
Contact Landoll Corporation at www.Landoll.com for
more information.
Introduction
This manual is intended for the service technician who is Tools Needed
seeking information on product maintenance and service
replacement parts. It contains troubleshooting tips and The tools needed will be the same tools that are often
information on repair which will help the technician solve found in well-equipped service centers, in both SAE and
problems that may occur. metric sizes. For example, an assortment of open-end
and box-end wrenches, sockets, as well as Allen and
adjustable wrenches, assorted screwdrivers and
Operating Instructions non-marring mallets should be available.
This manual does not contain operating instructions.
Operating instructions are sent with each truck. If the Replacement Parts
Operators Manual is missing on your SL120 truck, call
When ordering parts that will be used for the repair and
Landoll Corporation to order a replacement (Part Number
maintenance of your Drexel SL120 truck, the model and
F-397).
serial number of the truck being repaired will be required.
This information is located on the serial number and
Service Training capacity plate located on the right operators console.
Service Training is available for the forklift technician from See Figure 1-1 Only Landoll parts are to be used for any
Landoll Corporation. This includes operation, repair, repairs.
C

B
LBS. MAXIMUM

INCHES SHIFT
UL TYPE:

MANUFACTURED UNDER ONE OR MORE OF THE FOLLOWING PATENTS

MEXICO 156,505
REQUIREMENTS OF ANSI B56.1 1983 SAFETY STANDARD
THIS TRUCK MEETS ALL THE APPLICABLE MANDATORY
AH @ 6 HR

A
DATE:
LBS.

U.S. 3,382,994 3,532,238 3,637,100 4,087,776 4,364,444

MATERIAL:

FOR POWERED INDUSTRIAL TRUCKS

MARYSVILLE KS 66508

LOAD FORK LOAD

DIM. A DIM. B DIM. C
LANDOLL CORP.

CTR.
LBS. MINIMUM

INTERLOCK TYPE:

MAST VERTICAL OR TILTED REARWARD

INCHES REACH
SERIAL NO.

CAPACITY RATINGS FOR EVENLY

DISTRIBUTED LOADS WITH
TRUCK WEIGHT WITHOUT BATTERY:

HT.

CANADIAN 873,719 1,167,820

CARRIAGE TYPE: I.T.A. CLASS

CTR.
VOLTS,

GUIDED RATING ONLY

ATTACHMENT:
SERIAL NO.:
DEG.

LBS.
CAP.
MAX
BATTERY WEIGHT:

CONFIGURATION:

LOAD TIRE SIZE:

P/N: 1403978 REV-E

FORKS:
BACK TILT :
MODEL NO.
BATTERY:

Figure 1-1: Serial and Capacity Plate

1-1
INTRODUCTION, SAFETY, AND SPECIFICATIONS
Below are the Notice, Caution, Warning and Danger
safety notices and their descriptions that will be used in
this book.
NOTICE
Special notices that include helpful maintenance
hints. Read and thoroughly understand.
! CAUTION
Proceed with caution. Failure to heed may cause
injury to person or damage product.
! WARNING
Proceed with caution. Failure to heed warning will
cause injury to person or damage product.
! DANGER
Proceed with caution. Failure to heed warning will
cause injury to person or damage product.
General Maintenance Instructions
! CAUTION
• 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.
• Power industrial trucks may become
hazardous if scheduled maintenance is
neglected. Therefore adequate maintenance
facilities, as well as trained personnel and
procedures, should be provided.
IMPORTANT
Maintenance and inspection shall be performed in
conformance with the following practices:
1. A scheduled preventative 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.
1-2
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 wheels free of the floor or disconnect the
power source.
• 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, in the seat with seatbelt
fastened.
• 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 when checking for leakage of electrolyte and
fluids or oil.
7. Do not use open pans of fuel or flammable cleaning
fluids to clean parts.
8. Keep shop well ventilated, clean and dry.
9. Brakes, steering mechanisms, control mechanisms,
lift overload devices, guards and safety devices shall
be inspected regularly and maintained in safe
operating condition.
10. Capacity, operation and maintenance instruction
plates or decals shall be maintained in legible
condition.
11. All parts of lift mechanisms shall be inspected to
maintain them in safe operating condition.
12. 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
the extent that it would create a hazard.
13. 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.
F-602-R1 Edition
 INTRODUCTION, SAFETY, AND SPECIFICATIONS
14. Trucks shall be kept in a clean condition to minimize
fire hazards and facilitate detection of loose or
defective parts.
15. 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 not be changed accordingly.
16. Care must be taken to assure that all replacement
parts are interchangeable with the original parts and
are of equal quality of parts that were originally
installed on the truck at the factory. Landoll
Replacement Parts Manual is part number F-394.
17. 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
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 additional procedures to be followed.
IMPORTANT
Anytime you are doing maintenance or repair on the
Landoll Drexel SL120 truck, unless it must be on for
investigative testing, remove the key from the Keyswitch
console. Disconnect the battery cable connector and
install a commercially available Lock Out/Tag Out device
at the battery connectors. 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
• 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.
1-3
INTRODUCTION, SAFETY, AND SPECIFICATIONS
Battery Care and Charging
! CAUTION
• 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 and Installation
! CAUTION
Battery Removal:
• When removing the battery move the truck to
an area intended for battery care, on a level
floor.
• Turn the Keyswitch 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.
1-4
! CAUTION
Battery Installation:
• When installing the battery move the truck to
an area intended for battery care.
• The load forks must be all the way down to
the floor.
• Turn Keyswitch to OFF position and put the
key in a secure place.
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
• 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. Leaks in the hydraulic
system can pierce the skin and cause severe
injury. 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 administered immediately.
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.
• Relieve all system pressure by moving the
hydraulic levers to both extents several times.
F-602-R1 Edition
 INTRODUCTION, SAFETY, AND SPECIFICATIONS

Towing the Truck

General Safety Tips:

! WARNING
• Have the service brake applied when hooking
up the tow chain.
• 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! Figure 1-2: Tow Pin
• Failure to reset park brakes will result in an
unsafe condition.

Towing Vehicle Requirements

• The towing vehicle must have a pull and braking
capacity greater than 27000 lbs (12,383 kg).
• Brakes and steering 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. Vehicle will roll and steering will be
difficult.

Towing a Truck in the Reverse

Direction
1. Key must be in the OFF position.
2. When attaching the towing vehicle to lift truck to be
towed, a tiedown has been provided on the lower
rear sides of the frame. See Figure 1-2 Firmly attach
tow device to these tiedowns.
3. Keep towing speed below 2 mph. Remember that the
person on the towed lift has to turn his head to
observe operations.

1-5
INTRODUCTION, SAFETY, AND SPECIFICATIONS

Figure 1-3: Truck Blocking

Lifting and Blocking the Truck Prior to Tilt Cylinder Repair

• Move truck to a level area designated for repair.
• Keep forks empty and low to the ground. ! WARNING
• Turn the Keyswitch off and remove it from the console. Do not place feet or hands in any area through
• Disconnect the battery cables. the mast or in truck pinch points. Servicing the
• Attach Lock Out/Tag Out device to the truck. tilt cylinders requires the use of an overhead
hoist, hoist slings and wheel blocks. The
• Use a jack or hoist with a 30,000 lb. minimum lift.
overhead hoist and slings must have a rating of
• Set the lift on designated hardwood blocks. See 30,000 lb. or greater. Do not work under or around
Figure 1-3 above for block(s) placement. Four blocks a truck that is not properly secured.
are required on all four corners of the truck to provide
a safe, stable repair position.
• Truck repair must be in a level, designated area.
• Keep the height of the lifted truck to a minimum.
• Lower the mast completely to the floor.
• Turn the truck off and observe Lockout/Tagout
procedures.
• Chock wheels so that the truck cannot move.
• Attach a sling and hoist to all the top cross braces so
the mast sections cannot move.

1-6 F-602-R1 Edition

 INTRODUCTION, SAFETY, AND SPECIFICATIONS

Mast Service Precautions 9. Support the mast using the sling and an overhead
hoist.

!
10. Chain the individual sections of mast together at the
WARNING upper cross braces. Chain the lower mast carriage to
• When servicing the mast or sections of the the lower section of the mast, keeping the sections
mast, hardwood blocks (4”X4”, 100 X 100mm from moving when the mast is laid down on the floor.
minimum) should be used to keep individual 11. Remove all pins holding the tilt cylinder to the mast.
sections of the mast from falling. In addition
to the hardwood blocks, chains should be IMPORTANT
used to hold the mast sections from moving, The mast is EXTREMELY heavy. Extra care should be
in both the vertical and horizontal directions. taken to minimize possible injury. Make sure the
• Mast work to be done in a flat, designated hoist is rated for the weight of the mast. Make sure
area. the blocks you will lay the mast on can hold the
• NEVER walk under or stand upon forks. weight. Also, be SURE that no one and nothing is in
the path of the mast.
• Remove forks before starting mast repairs.
• NEVER reach through the upright open areas
of the mast.
• NEVER maintain or repair the mast without
supports or while anyone is near the truck.
(ASME B56.1-2000)
• Raise mast and position blocks under the
second stage mast.
• Using an appropriate set of C-clamps, secure
wooden blocks to mast channel.
• Lower mast until it sits firmly on wooden
blocks.
• For mast inspection, use only an approved
safety platform or step ladder.
• NEVER repair chains, they are to be replaced.
• NEVER replace chain sets with only one
chain. All chains are to be replaced in pairs.

Before Servicing Mast

For mast information, refer to Chapter 4, “Supplier
Provided Documentation.”
1. Move the truck to a level, designated area.
2. Turn the key off and remove it from the ignition
switch.
3. Remove the forks.
4. Move all levers back and forth several times to relieve
internal hydraulic pressure.
5. Pivot the mast to the right.
6. Slowly and carefully remove the lift, tilt, pivot and
sideshift hoses. Use a container to catch oil and an
oil absorbent product to absorb any spills.
7. Remove the four hex head cap screw and hardware
that hold the mast stub shafts to the pivot arm.
8. Disconnect all wiring (if used) between the mast and
the truck body.

1-7
INTRODUCTION, SAFETY, AND SPECIFICATIONS

Lubrication Specifications
Name Lubrication Notes
Drive Axle Texaco, THD 1893, Ford 193 Clean and re-oil
Hydraulic System SAE 10W API SF/CD MIL-L-2105C or Equivalent Drain, flush and refill
Brake System DOT 5 Silicone Brake Fluid Fill
Steer Wheel Bearings Alvania Grease No. 2 Clean and re-grease
Side Shift Chain/Slide Assembly Molybdenum EP Chassis Grease Clean and re-grease
Pivot Shaft Bearings Lithium EP No. 2 Clean and re-grease
Grease Fittings Molybdenum EP Chassis Grease Clean and re-grease
Mast Rails Molybdenum EP Chassis Grease Clean and re-grease
Mast Chains 03032 CRC MIL-C-16173D Store & Lube Spray Clean and spray
General Lubrication SAE 10 Lubricating Oil Clean and re-oil

Torque Specifications
Component
Load Wheels
Fluid draining and filling plug
Drive motor with vehicle frame
Steering Control Unit
Plug and o-ring assy #8 SAE fitting
Steer control unit assy bolt (M8 X1.0)
Mounting bolts
Mast and Side Shift Mechanism
Chain guard capscrews
Main lift cyl. plunger retainer
Free lift cyl. plunger retainer
Chain and hose sheave screws
Lift chain adjusting nuts
Backrest screws
Side shift mounting hooks
Overhead Guard Bolts
Torque
530 ft. lbs. (720 Nm.)
16 ft. lbs. (22 Nm.)
130 ft. lbs. (176 Nm.)
44-48 ft. lbs. (60-65 Nm.)
18-23 ft. lbs. (24-31 Nm.)
23-25 ft. lbs. (31-34 Nm.)
48-52 ft. lbs. (65-71 Nm.)
95-125 ft. lbs. (129-169 Nm.)
275-300 ft. lbs. (373-407 Nm.)
26-30 ft. lb. (35-41 Nm.)
50-70 ft. lb. (77-95 Nm.)
145 ft. lbs. (197 Nm.)
115-125 ft. lbs. (156-169 Nm.)
170 ft. lbs. (230 Nm.)

Fluid Capacities
Item Capacity - Quarts (Liters)
Hydraulic Tank 18 gallons (68 liters)
Brake Fluid 0.21 pints (0.20 liters)
Gear Box 16 oz. (0.47 liters)

1-8 F-602-R1 Edition

 INTRODUCTION, SAFETY, AND SPECIFICATIONS

General Torque Specifications (rev. 4/97)

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

TORQUE SPECIFIED IN FOOT POUNDS

UNC SAE SAE SAE UNF SAE SAE SAE

SIZE Grade 2 Grade 5 Grade 8 SIZE Grade 2 Grade 5 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 Newton Foot Nominal Newton Foot

thread Meters Pounds Thread Meters Pounds
diameter (Standard (Standard Diameter (Standard (Standard
(mm) Torque) Torque) (mm) Torque) 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]

1-9
INTRODUCTION, SAFETY, AND SPECIFICATIONS

Hydraulic Fitting Torque Specifications

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

TORQUE SPECIFIED IN FOOT POUNDS GATES® BRAND FITTINGS

PARKER® BRAND FITTINGS Dash 37 Deg. O-ring O-ring
Size JIC (ORS) boss
Dash 37 Deg. O-ring O-ring -4 10-11 10-12 14-16
Size JIC (ORS) boss -5 13-15 --------------- ---------------
-4 11-13 15-17 13-15 -6 17-19 18-20 24-26
-5 14-16 --------------- 21-23 -8 34-38 32-40 37-44
-6 20-22 34-36 25-29 -10 50-56 46-56 50-60
-8 43-47 58-62 40-44 -12 70-78 65-80 75-83
-10 55-65 100-110 58-62 -14 -------------- 65-80 --------------
-12 80-90 134-146 75-85 -16 94-104 92-105 111-125
-16 115-125 202-218 109-121 -20 124-138 125-140 133-152
-20 160-180 248-272 213-237 -24 156-173 150-180 156-184
-24 185-215 303-327 238-262 -32 219-243 -------------- --------------
-32 250-290 -------------- 310-340

AEROQUIP® BRAND FITTINGS

Dash 37 Deg. O-ring O-ring

Size JIC (ORS) 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

Cleaning the truck

Landoll Corporation recommends that Landoll forklifts
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.

1-10 F-602-R1 Edition

 INTRODUCTION, SAFETY, AND SPECIFICATIONS

SPECIFICATIONS
MODEL SL120
SWINGMAST® LIFT TRUCK
ELECTRIC MULTI-PURPOSE
12,000 LB (5,443KG) CAPACITY
The Landoll SwingMast® Electric Forklift, with
a 90° pivoting and shifting mast maximizes
cube utilization while providing front loader
versatility. The SwingMast® also can handle,
store and transport long loads as a side loader
for long load handling applications.

STANDARD FEATURES
t
Four Wheel Configuration - Front Wheel Drive -
Rear Wheel Steering
t
High Visibility Mast, 3 Stage
t
90° Pivoting and Shifting Mast
t
72 Volt Electrical System
t
Safety Driver's Seat Switch, Cuts Power
t
Seatbelt (Retractable)
t
4-wheel Hydraulic Brakes
t
Hand Actuated Parking Brake
t
GE "SCR" Controls
t
Battery Discharge Indicator with Lift Interrupt
t
Type "E" Construction
t
Hydrostatic Power Steering
t
Battery Compartment Covers
t
Automatic Return-to-Neutral
OPTIONAL FEATURES t
SB6320G1 Gray Battery Connector
t
Strobe Warning Light
t
Locking Differential
t
Flashing Backup Light in Amber, Red, Yellow and Blue
t
Key Switch
t
Headlights, Mast or Overhead Guard Mounted
t
Overhead Guard
t
Backup Alarm
t
Load Backrest
t
Fire Extinguisher
t
Polyurethane Drive Tires (2)
t
Type "EE" Construction
t
Polyurethane Steer Tires (2)
t
Battery Compartment Rollers
t
Horizontal Fork Indicator
t
Long Load Handling Package
t
Tail/Stop Light
t
Meets ANSI B56.1

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#EVWCNFKOGPUKQPUCPFRGTHQTOCPEGFCVCIKXGPJGTGKPOC[XGT[FWGVQOCPWHCEVWTKPIVQNGTCPEGU
+HCP[URGEKſECVKQPUKUETKVKECNVQ[QWTCRRNKECVKQPRNGCUGEQPVCEV[QWT.CPFQNN&TGZGN&GCNGT

LANDOLL CORPORATION
MATERIAL HANDLING PRODUCT DIVISION
WWW.LANDOLL.COM/MHP

Figure 1-4: SL120 Specs (1 of 2)

1-11
INTRODUCTION, SAFETY, AND SPECIFICATIONS

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Model SL120
Capacity 24' LC Ibs/kg 12,000 / 5,443
Power Source Battery, electric
Weight With Battery Ibs/kg 27,300 / 12,383
Travel Speed Loaded mph/kph 5 / 8.05
Unloaded mph/kph 6 / 9.65
Lift Speed Loaded (5,500 lbs/2,495 kg) fpm/mm 30 / 9
Unloaded fpm/mm 40 / 12
Lower Speed Loaded fpm/mm 80 / 24
Unloaded fpm/mm 35 / 11
Mast Tilt Forward/Backward deg. 3/6
Lost Load Center E With Triple Mast in/mm 32 / 800
Wheel Base F in/mm 58 / 1,470
Rear Overhang G With Triple Mast in/mm 29 / 740
Overall Length H in/mm 119 / 3,020
Under Clearance I In/mm 5 / 130
Clearance Under Guard J in/mm 39 / 990
Overhead Guard Height K in/mm 91 / 2,310
Overall Width L in/mm 65 / 1,640
Fork Width O/O M in/mm 54 / 1,370
Mast Shift N in/mm 44* / 1,120*
Side Reach O in/mm 4 / 100
Grade Clearance P deg 21°
Under Clearance Q deg 11°
Overhead Guard Width R in/mm 23 / 580
Load Backrest Height S 42 / 1,070 Notes:
Turning Radius T 108 / 2,740 *Shift with mast in 'front' position equals 22" (56cm).

Battery Compartment Height U 30 / 760

Deck Height V 49 / 1,250
Fork Size (Standard) in 2.5x7x42
ITA CLASS II cm 6x18x107
Gradeability Loaded % 10
Wheel sizes Front (2 each) in/cm 22x14x16 / 56x36x41
Rear (2 each) in/cm 16.2x8x11.2 / 41x20x29
Minimum battery weight 2 Required Ibs/kg 2,140 / 971
Voltage 72

RECOMMENDED BATTERY
MAST DIMENSIONS
Battery Designation
SL120 MAST OPTIONS
Battery Type: Flooded or Sealed - 2 Required
Max. Fork Height (A) Collapsed Hieght (B) Free Lift Height* (C) Max Overall Height (D)
Volts: 36V
IN CM IN CM IN CM IN CM
Amp. Hours: 765
135 345 82 208 42 108 177 450 Nominal Size: 44.56"x19.44"x22.63" (113x49x58cm) Each
153 389 88 224 48 122 195 495 Dealer will select battery size based on the application
168 427 94 239 54 137 210 533 Usage hours will vary with load weight, number of lift cycles, lift
178 452 98 249 58 147 220 559 height, attachment use and travel distance
193 490 104 264 64 163 235 597 Battery compartment inside dimensions - 45"x39-3/4"x22-3/4"
(114x101x58cm)
207 526 110 279 70 179 249 633
Battery model 18 - 85 - 19, (two required) with SB 6320G1
233 592 120 305 80 203 275 699
 
 !#$&&
243 617 124 315 84 213 285 724 weight 2,140 lbs. (971 kg) minimum, 2,440 lbs. (1,107kg)
ABOVE DIMENSIONS ARE BASED ON A 16" (41cm) MAST UNDERCLEARANCE maximum) Each

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MATERIAL HANDLING
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INDUSTRY
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02/10

Figure 1-5: SL120 Specs (2 of 2)

1-12 F-602-R1 Edition

 Chapter 2

Preventative Maintenance Inspections

Inspection Introduction IMPORTANT

Preventative maintenance & inspections are an essential Recommended service inspections are based on
part of all industrial equipment. A well planned inspection normal operating conditions. If the truck is subjected
program is essential to operator safety and truck to severe or above normal operating conditions,
longevity. extreme temperatures, excessive dust or wet
environments, or if the truck is around corrosive
The inspection program designed by Landoll Corporation materials, service must be performed at shorter
periodically checks the integrity of Drexel forklift systems intervals.
such as:
• Checking performance of operator functions - lift, tilt,
side shift, pivot, attachment and traction systems.
• Checking for leaks.
• Checking fluid levels.
• Making sure components are securely attached.
• Checking the tires.

Regular and preventative maintenance is the

responsibility of both the daily operator and the forklift
technician.
To make sure these and other systems are checked
periodically, Landoll Corporation has developed a system
of checklists. A blank copy of each checklist can be found
on pages 2-2 through 2-7.
These checklists include:
• Operator’s Daily Checklist
• 1st 50 Hour Inspection Checklist
• 250 Hour Inspection Checklist Inspection Sheets
• 500 Hour Inspection Checklist
The following pages are OSHA (Occupational Safety and
• 1000 Hour Inspection Checklist
Health Administration) required check sheets. These
• 2000 Hour Inspection Checklist sheets should be copied and the copies used for
Except for the Operator’s Daily Checklist, these maintenance checks on your SL120 lift. It is the
inspections are to be performed by a service tech and operator’s duty to inspect the lift before each shift and
maintenance facility that is approved by Landoll report all problems to the person in charge of forklift
Corporation. These inspection sheets should be copied, maintenance. Have a qualified mechanic correct all noted
completed and maintained by the forklift technicians. The problems.
Operator’s Daily Checklist may be performed by either
the operator or service personnel.

2-1
PREVENTATIVE MAINTENANCE INSPECTIONS

Daily pre-shift inspection is an OSHA requirement. These inspections must be documented.

Operator's Daily Checklist Status Comments

Check Condition
Tires
Torque Lugnuts (225 ft-lbs/305 Nm)
ESD Straps Check Condition
Battery Check Water, Electrolyte and Charge

Seat Switch Check Operation

Check Adjustment
Battery Restraint System
Check Rollout Switch Operation
Parking Brake Check Operation
Check Operation
Service Brakes
Check Fluid Level
Lift Chains Check Condition
Forks Check Condition
Load Back Rest Torque Fasteners
Hydraulic Oil Check Fluid Level
Hydraulic Cylinders Check for Leaks
Slide Bearing Pads Check for Lubrication
Hydraulic Hoses/Fittings Check for Wear and Leaks
Check Accelerator Operation
Check Lift/Lower Control Operation
Check Tilt Control Operation
Controls Check Side-shift Control Operation
Check Directional Switch Operation
Check Return-to-Neutral Operation
Check Horn Operation
Pivot/Shift Interlocks Check Operation
Lights and Alarm Check Operation
Steering Check Operation
Check BDI Operation
Dash Display
Check Hourmeter Operation
Check Overhead Guard for Cracks
Major Structural Points
Check Frame for Cracks
Safety Labels Replace as Necessary
Info Matches Model, Serial No., and
Capacity Plate
Atachments

Date: Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Hydraulic Oil

2-2 F-602-R1 Edition

 PREVENTATIVE MAINTENANCE INSPECTIONS

These checks must be done after 50 hours of use.

1st 50 Hour Inspection Checklist Status Comments
Inspect
Mast Chains
Lubricate
Pivot Arm Racking Check for Proper Pivot Operation

Mast Racking Check for Proper Lift Operation

Drive Wheels Retorque lug nuts

Check Adjustment
Battery Restraints
Check Rollout Switch Operation

Date: Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Hydraulic Oil

2-3
PREVENTATIVE MAINTENANCE INSPECTIONS

To be performed after 250 hrs of truck operation in addition to the required pre-shift daily inspection.
Technicians 250 Hour Checklist Action Needed Status Drexel Lift
SAFETY & OPERATIONAL CHECKS Description OK - Yes/No Comments
Have a qualified technician correct all
problems.
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
Tilt Cylinder Degree Adjust Check fwd/rwd tilt angles
Attachment Control Operational
Direction/Speed Control Functioning smoothly
Controls (turn power on) Investigate unusual noises
Dash Display Check BDI, hourmeter
Parking Brake Check for function, pad wear
Service Brake Check for leaks, shoe wear
Hydraulic Fluid Level Check and fill
Exterior of Hydraulic Tank & Tank Breather Clean
Hydraulic Pump Clean dust from motors
Battery Box and Connector Neutralize and clean
Thoroughly clean
Battery Check electrolyte level
Check structure and electrical
conditions
Traction Motor Clean dust
Tires/Wheels Remove debris, torque lug nuts (530
ft.lb./ 718 Nm)
Wheel Bearings Clean and fill with grease
Leaks Gearbox, brake components,
hydraulic oil, battery
Hydraulic Hoses and Connections Check for wear
Switches (Direction, Operator’s Presence Check
Sensor, Key and Battery Restraint)
Wire Connections Check
Lubricate Service bearing pads, grease zerks

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr Meter Battery Fluid Hydraulic Oil

2-4 F-602-R1 Edition

 PREVENTATIVE MAINTENANCE INSPECTIONS

To be performed each 500 hrs of truck operation in addition to the required pre-shift daily inspection
Technicians 500 Hour Inspection Action Needed Status Drexel Lift
SAFETY & OPERATIONAL CHECKS Description OK - Yes/No Maintenance Note
Have a qualified technician correct all if Applicable
problems.
Forks, Top Clip Retaining Pin Function & condition
Steering Operation Functions smoothly
Brake Fluid Check Level
Hydraulic Return Filter Replace element
Grease Fittings Fill with grease
Load Rollers Check for galling and proper
sequencing
Mast Rails Grease
Battery Check case to frame resistance
between truck body and
negative/positive terminal
Battery Sliders Clean, check for wear
Contactor Points & Microcswitches Check operation
Retorque fasteners
Steer Axle Components Check bearings
Check for excessive play
Drive Axle Oil Check
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

2-5
PREVENTATIVE MAINTENANCE INSPECTIONS

To be performed each 1000 hrs of truck operation in addition to the required pre-shift daily inspection.
Technicians 1000 Hour Inspection Action Needed Status Drexel Lift
SAFETY & OPERATIONAL CHECKS Description OK (X) Maintenance Note
Have a qualified technician correct all if Applicable
problems.
Motors Clean cooling holes of debris
Motor Brushes Check condition
Motor/Electrical Connections Check that connections are tight
Electric Controller Clean and reapply heatsink grease.
Pump/Drive Motor Couplings Inspect
Primary Lift Chain Inspect
Secondary Lift Chain Inspect
Inspect Side Shift Chains Inspect
Drive Axle Oil Change

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr. Meter Battery Fluid Hydraulic Oil

2-6 F-602-R1 Edition

 PREVENTATIVE MAINTENANCE INSPECTIONS

To be performed each 2000 hrs of truck operation in addition to the required pre-shift daily inspection.
Technicians 2000 Hour Checklist Action Needed Status Drexel IC
SAFETY & OPERATIONAL CHECKS Description OK (X) Maintenance Note if
Have a qualified technician correct all Applicable
problems.
Hydraulic Oil Change
Hydraulic Reservoir Suction Screen Clean with solvent

Date Inspector: Truck No. Model No. Location Serial No. Shift Hr. Meter Battery Fluid Hydraulic Oil

2-7
PREVENTATIVE MAINTENANCE INSPECTIONS
Preventative Maintenance
Requirements
This section describes the preventative maintenance
requirements, adjustments and lubrication necessary to
keep your Drexel SL120 forklift truck models operating
safely and efficiently. Planned maintenance procedures
are designed to extend the service life of the truck and
prevent service repairs. This section must be thoroughly
understood before you inspect or perform maintenance
on the forklift.
Safety precautions and inspection schedules are
provided in the beginning of this chapter (also found in
the Operator’s Manual provided with the truck). A 1st 50
Hour Inspection Checklist, a 250 Hour Inspection
Checklist, a 500 Hour Inspection Checklist, a 1000 Hour
Inspection Checklist and a 2000 Hour Inspection
Checklist are provided.
Recommended lubricants and torque values are found in
Chapter 1, page 1-8.
Tools or Equipment Required
In addition to a good portable light source and various
tightening tools, as explained on page 1-1, the following
tools and equipment may be required:
• Hydraulic jack, appropriate for the weight being
raised.
• Safety stands, appropriate for the weight being
supported.
• Overhead crane, appropriate for the weight being
lifted and/or supported.
• Grease gun.
• Torque wrench - capable of measuring at least 550 ft.
lbs. (745 Nm).
• Drain pan, capable of holding at least 6 gallons (22.7
liters) of hydraulic fluid.
Special Tools Required
The following special tools may be required:
• Angle wrenches
IMPORTANT
Read and comply with all applicable SAFETY
precautions when servicing this truck. See the Safety
Chapter 1 at the beginning of this manual.
2-8
NOTE
Common sense and standard precautions apply when
servicing machinery and must always be observed:
• Before using any solvent or cleaning solution, be
sure that it will not damage the part you are cleaning.
For example, gasoline should never be used to clean
parts. Gasoline is highly flammable and may damage
some types of rubber and plastic. Hydraulic brake
fluid (standard, not silicone type) is often used to
clean rubber parts. It also removes paint quickly, so
care should be exercised when it is used.
• Tag all parts for identification and location before
removal and mark all mating parts for accurate
reassembly.
• Protect finished surfaces from damage caused by
dropped wrenches, spilled solvent, etc.
• Use a penetrating oil to loosen difficult screws, nuts
or bolts. A hand-held impact driver is a handy tool
when removing tight fasteners.
• Certain bolts, screws, or nuts are secured with a
non-permanent thread-locking compound at the
factory, (i.e. Loctite Primer and Blue sealant #243 or
equivalent Landoll p/n:115627). When these parts
are replaced, a non-permanent thread-locking
compound must be reapplied.
• No parts, except those press-fit assembled, require
unusual force to disassemble. If you encounter
trouble, determine the reason for the difficulty, before
proceeding.
• Cover all openings caused by removing parts or
sub-assemblies with clean rags to keep objects from
falling in where additional damage could result.
• When assembling two parts, start all of the fasteners
first, then tighten them evenly and in a staggered
manner. Be sure both mating surfaces are aligned,
not tilted
• or off-center.
• Observe standard torque ratings for the size and type
of fastener as listed starting on page 1-8.
• Be sure to use the proper nuts, bolts and other
fasteners as rated; SAE Grade 5, SAE Grade 8, ISO
Prop Class 8.8, etc.
• All fasteners must be replaced with the identical type.
• It is recommended to use only Landoll authorized
replacement parts.
F-602-R1 Edition
 PREVENTATIVE MAINTENANCE INSPECTIONS

Performance Testing
! DANGER
Failure to follow these guidelines can cause seri- NOTE
ous injury or death: Make sure all accessories are off before continuing.
• Never perform any maintenance or service Make sure you are in the operating position:
procedures unless specifically indicated in
this manual or requested by your supervisor. 1. Make sure you are in the driver’s seat with seatbelt
All other service and maintenance on your fastened.
SL120 forklift must be provided by a facility 2. Turn the Keyswitch to ON.
authorized by Landoll Corporation to perform 3. Press the accelerator.
these services. 4. Check functions described in the Operator’s Daily
• Wipe up any spills immediately to prevent Checklist or other Checklists starting on page 2-2.
slipping, fire, explosion, or contact with haz-
ardous materials. IMPORTANT
• Failure to use lifting equipment of adequate Before you leave the truck make sure that:
capacity to lift and move your SL120 forklift
• The parked truck will not cause an obstruction or
can cause lifting equipment failure.
safety hazard and is clear of fire exits/equipment.
• Removing the counterweights or uprights will
• The truck is not left unattended on an incline.
change the center of gravity of the truck and
can cause the truck to tip. The battery is con- • If the truck is inoperative and you must leave it
sidered part of the truck’s counterweight. parked on an incline, securely block the wheels
and remove the key.
To help avoid fire hazards:
• Have fire extinguishing equipment present in
the work area. Daily Inspection
• Do not allow sparks or open flames while
checking fluid level, leaking oil, or electrolyte. NOTE
• Do not use fuel or flammable cleaning fluids Daily inspection is an OSHA requirement. Report any
to clean parts. defect immediately to your supervisor.
The daily inspection includes:
Preparing for Inspection or • Visual inspection of the entire truck for any defect.
Maintenance • Visual check for any hydraulic fluid leaks.
• Check that all controls and gauges work properly.
Before inspecting or maintaining the truck you must
completely understand the general maintenance A complete Daily Checklist is included on page 2-2 of this
instructions and cautions described on page 1-2: maintenance manual as well as in the Drexel SL120
Operator's Manual F-397.
• Inspect the truck in an area that has sufficient
clearance to check all operator functions. Some specific guidelines follow in the next several pages
to aid in the daily inspection of your forklift.
• Lower forks to the ground and tilt mast forward.
• If you will not be operating the truck to check operator
functions, block the wheels with chocks and/or other
positive truck-positioning devices.
• If you will be operating the truck to perform operator
functions, raise the drive wheels so they clear the
floor.
• Block the mast to prevent it from engaging.
• If you need to hoist the truck make sure the hoisting
equipment has adequate size and capacity to move
the equipment.
• Never remove counterweights or uprights. This will
change the center of gravity and can cause an
unstable condition.

2-9
PREVENTATIVE MAINTENANCE INSPECTIONS
Static Straps
The ESD Strap is installed just behind the front axle. This
strap will drain all static electricity build up that may occur
on the LSC AC forklift. ESD Straps should be in fair
condition, bolted securely to the body and touching the
ground. See Figure 2-1.
Figure 2-1: ESD Strap
Power Steering System
1. Sit on the operator’s seat and turn the Keyswitch ON.
The power steer pump motor should start at once. If
not, refer to the Troubleshooting section.
2. With the steer pump motor running, turn the steering
wheel in one direction and then the other. Check that
the wheels move correctly and that movement of the
steering wheel is easy. If a defect is noted, refer to
the troubleshooting section.
3. Turn the steering wheel in a clockwise direction until
the steer axle wheels are turned completely to the
right. Next, turn the steering wheel in a
counterclockwise direction, counting the number of
revolutions of the hand steering wheel, until the steer
axle wheels are turned completely to the right.
NOTES
There should be 8 revolutions of the steering wheel. If the
count is more than 1/2 revolution off, refer to the
Troubleshooting section.
4. Repeat step 3 for the clockwise direction.
2-10
5. The steering pump and motor assembly is mounted
in front of the hydraulic reservoir beneath the right
side cover. The assembly is mounted on four
vibration isolation mounts. Visual inspection when
starting the pump motor indicates a counter
clockwise rotational jarring motion (viewed from the
pump end), which will dampen out to a smooth
running condition. If this result is not obtained, refer
to the Troubleshooting section.
Batteries
Proper care of the batteries is extremely important to
obtain the expected performance and service life from
the unit. Perform the following operations daily:
1. Check state-of-charge.
2. Check electrolyte level.
3. Charge the batteries.
These procedures are outlined in the maintenance
section of this manual, starting with “Checking Battery
State-of-Charge” on page 3-31.
! DANGER
• The truck battery contains concentrated sulfuric
acid which can cause severe chemical burns.
• When the battery is charging it releases hydrogen,
a highly explosive gas.
• Shorting the battery terminals together releases
enormous amounts of energy, causing sparks and
flames which can ignite the hydrogen gases or it
can heat nearby components to dangerous
temperatures.
• The battery is very heavy and if restraints are not
replaced after maintenance, the battery could slide
out of the truck causing electrical shorts and/or
spilling acid.
IMPORTANT
The battery is part of the counterweight system for
the forklift. Removal of the battery greatly effects the
center of gravity.
Checking Hydraulic Oil Level
Check the hydraulic oil level every day.
Before checking the hydraulic oil, ensure that:
1. The forks are fully lowered and the mast is tilted
back.
2. The mast is shifted fully to the right.
3. The mast is in the front-loading position (forks
straight ahead).
F-602-R1 Edition
 PREVENTATIVE MAINTENANCE INSPECTIONS
After the previous 3 steps are performed, continue with
the following:
1. Remove the oil dip stick and check the level.
Figure 2-2: Hydraulic Reservoir
Grease
Figure 2-3: Slide and Upper Channel Grease
2. If necessary, top off the level with the recommended
hydraulic fluid. See the Recommended Lubricants
Chart on 1-8. If repeated additions are required over
a short period of time, check the system and
determine the reason for fluid loss.
3. If the hydraulic fluid is dirty, check the truck’s
maintenance log for the last fluid or filter change.
Slide Assembly and Upper Channel
Proper lubrication of the slide assembly, upper channel
and its bearing pads is important for proper operation of
the side-shift function and to prevent corrosion damage
to the bearing pads and sliding surfaces. See Figure 2-3.
Refer to the Recommended Lubricants chart on 1-8 in
this section of the manual for the correct grease for your
truck. Liberally apply grease to all sides of the
telescoping slide and to the upper guide channel. Also, fill
lubricating grooves in the bearing pads.See Figure 2-3.
Grease
2-11
PREVENTATIVE MAINTENANCE INSPECTIONS

Safety Brake Adjustment 8. Excessive wear may be an operator problem. Too

With the Keyswitch set to ON, drive forward slowly and
then steadily apply the brake pedal. The truck should
stop smoothly without noticeable vibration. Any problems
with the brake system must be repaired immediately. Do
not use the truck until problems are resolved.
much throttle when starting a sharp turn causes the
inside tire to spin quicker, producing abnormal wear.
More careful driving habits can add additional miles
to tire life.

Inspect Tires

! WARNING
• The truck is equipped with tires of a size and
hardness that provide the necessary traction
and still maintain a proper shape to minimize
tipping.
• To maintain stability and maximum reliability,
you must always replace tires with the type
originally supplied, consult your Landoll
dealer for ordering information.
• It is also recommended to replace worn tires
in pairs. Treaded drive tires must be replaced Figure 2-4: Tire Damage Types
when the tread depth is less than 0.0625”
(1.6mm) at the shallowest point. Chunking (Chipping) or Embedded Objects
• Check all wheel lug nuts after 2 to 5 hours of Chunking, or chipping is caused by repeatedly running
operation: when new lift trucks begin over objects on a littered floor which can chip away or
operation and on all lift trucks when the drive produce deep cuts to the rubber surface of the tire.
wheels have been removed and installed. Embedded objects, such as glass, metal chips, or nails
Tighten the nuts in a cross pattern to the
left in a tire, and truck overloading cause the same effect.
correct torque value shown on page 1-8.
When the nuts stay tight for eight hours, the Sharp, rapid turns at quick speeds, jack-rabbit starts and
interval for checking the torque can be stops and other such bad driving habits can cause the
extended to 300 hours. same kind of damage. See Figure 2-4.
1. Remove any embedded foreign material from the tire
as soon as it is noticed. Also remove torn pieces of
1. Inspect the tires for chunking (or chipping),
tread.
embedded foreign material (wire, rocks, glass, metal,
etc.), cuts, gouges, undercutting or uneven wear. 2. To avoid overloading, always center the payload on
the truck to equalize the load on all tires. Do not
2. Remove any object that will cause damage.
dangle the load on the ends of the forks. Also avoid
3. Check for loose or missing hardware. fast cornering, which can cause an overload affect.
4. Remove any wire strapping or other material that is 3. If the tires are chunked bad enough to produce a
wrapped around the axle. bouncy ride, replace them.
5. Make sure drive wheel nuts are tight. Tighten the
wheel nuts in a cross pattern to a correct torque Undercutting and Uneven Wear
value of 530 ft.-lbs (720 Nm).
Undercutting is caused by continuous overloads, rapid,
6. Squeaking or friction noises coming from the tires sharp turns, operating on slopes, a faulty steer axle,
during operation may be caused by separation of the
transporting loads with a high center of gravity, or
tire layers. Separation is sometimes visible as a crack
transporting off-center loads.
around the sidewall of the tire.
Uneven tire wear is usually the result of mechanical
7. If one tire is found to be overworn, both tires must be
replaced as a pair. defects misaligned wheels (misaligned steer axle) or a
faulty drive axle.
Undercutting causes the rubber to bulge out over the
edge of the steel band, cutting the rubber just above the

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 PREVENTATIVE MAINTENANCE INSPECTIONS
base band. Check that the tires remain centered on the
wheels to prevent splitting of the base band and tread
separation. Correct such defects as soon as possible.
Flat-spotting
Flat-spotting occurs when:
• The truck has been sitting idle for some time after
heavy use and is usually caused by overheated tires.
• The truck has standing loads (loads left on the forks
overnight).
• Locking the brakes while traveling in either direction
on grades (slopes), with or without a load, causing
excessive skidding. Polyurethane tires are extremely
susceptible to this type of abuse.
1. Avoid excessive heat. Where possible, avoid contact
with hot metal or operation for long periods in hot
oven rooms. Excessive heating will break-down the
tire structure. Shields, which prevent heat from
striking tires directly, will often prolong life.
2. Avoid standing loads. Solid tires will flat-spot when
loads are left standing on the truck overnight. In
extreme cases, a flat spot develops and the tire
bounces with every revolution.
3. If the tires are flat-spotted bad enough to produce a
bouncy ride, replace them.
4. Do not indulge in stunt driving or horseplay
particularly on grades (slopes).
To Extend Tire Life
A few simple measures can help increase tire life and
reduce maintenance (downtime) and cost of operation:
1. Inspect tires regularly and remove embedded objects
immediately.
2. Check that the tires remain centered on the wheels.
3. Lubricate the truck according to the schedules
provided on page 2-2 through page 2-7, however,
avoid over lubricating.
4. Keep runways clean and maintain floors in good
repair, free from breaks, ruts, cracks and debris.
5. Avoid excessive heat, overloading and standing
loads.
6. Regularly check axle alignment and steering.
7. Avoid sharp turns and quick starts and stops.
8. Avoid oil, grease, gasoline and acid. Wipe these
compounds off as soon as possible.
9. Do not allow hydraulic oil to drip onto the tires.
50 Hour Inspection
Pivot Arm Racking
Examine the following pivot arm racking functions:
1. With the Keyswitch turned to ON, pivot the mast
counterclockwise to the front loading position.
2. Ensure the pivot arm meets the crosshead stop when
the pivot cylinder bottoms.
3. If an upward motion of the pivot arm occurs when
bottoming, this indicates racking. Adjust the pivot
cylinder rod.
4. If clearance exists between the rear face of the pivot
arm and the crosshead stop, adjust the pivot cylinder
rod. Refer to “Pivot Cylinder Removal and
Installation” on page 3-15 for procedures.
Mast Operation
Follow these rules when operating the mast:
• Do not overload the mast.
• Raise and lower; stop and start, heavy or bulky loads
slowly.
• Tilt mast slowly and carefully.
• Do not carry passengers on the mast or forks.
• Do not use mast or forks as battering rams.
• Center load a closely to the mast centerline as
possible.
• Place the load as close to carriage face bars as
possible.
• Transport loads with forks as close to the ground as
possible.
• Do not jerk mast with tilt cylinders.
• Whenever possible, raise and lower with mast
straight, vertically or back tilted.
• Do not apply heavy torsional loads or side loads to
mast. The mast is designed to handle downward
loads applied at or near the centerline of the
carriage.
• Lift and lower loads with the mast tilted rearward.
• Rest forks on the ground when not in use or
unattended
• Keep all parts of your body out of the working zone of
the mast. Do not stand under the mast load. Do not
allow other personnel under the mast load.
• Inspect the mast and lift hose daily.
• Do not climb on the mast.
2-13
PREVENTATIVE MAINTENANCE INSPECTIONS

Mast Racking
Perform the following general mast inspections:
1. With the Keyswitch turned to ON, tilt the unloaded
mast rearward. The mast should stop when the tilt
cylinders bottom with no evidence of mast twist
(racking).
2. If twisting occurs, adjust the tilt cylinder rods. Refer to
“Mast Racking Adjustment” on page 3-16.

Mast Lubrication
Roller bearings are sealed and do not require periodic
lubrication. However, periodic checks on roller bearing
condition is recommended.
Under normal operating conditions, mast chains and
uprights need lubrication as follows:
1. Every 50 hrs./weekly: Oil chains.
2. Every 1000hrs.: Remove the chains and clean by
brushing with kerosene or another safe solvent.
Inspect the chain’s condition; then soak the chains in
oil before installation.
NOTE
The recommended intervals for lubrication are based
upon normal operating conditions. If the truck is operated
in dusty or wet environments, or subjected to severe use,
lubricate more often.
Mast Chain Adjustment
Perform the following for mast chain adjustment:
1. Turn Keyswitch to the OFF position and remove key.
2. Disconnect the batteries. Exercise appropriate
Lockout/Tagout procedures.
3. Clean and lubricate chains before adjustment. Dirty
chains become tighter because of dirt between the
pins and rollers.
4. With the mast fully collapsed, ensure chain tension is
the same for all of the mast.
5. Make any necessary adjustments with the chain
adjusters. See Figure 2-5.
Figure 2-5: Mast Chain Adjustment
6. To remove sufficient slack, adjust chains. However,
ensure chains are not taunt or under tension. It is
important that tension be the same for each set of
chains.
250 Hour Inspection
Grease Fittings
Location of the grease fittings is illustrated in Figure 2-3
on page 2-11. Proper lubrication, on schedule, is an
important safety consideration and extends the service
life of the truck and its component parts. The steer axle
assembly, hydraulic cylinders and the mast assembly
(including the pivot shaft), are all equipped with grease
fittings.
NOTE
Some joints have grease fittings at both top and bottom.
Electrical Connections
Examine the following electrical system conditions:
1. Turn Keyswitch to the OFF position and remove key.
2. Disconnect the batteries and exercise appropriate
Lockout/Tagout procedures.
3. Check if fuses are open due to loose electrical
connections in the power and control circuits.
4. Check operating pressures and current draws
against standard values in the tables in the
Troubleshooting Section of this manual.
5. Check all electrical mechanical connections for
tightness. Direct special attention to the power fuse’s
(1FU and 2FU) mounting block fuse connections.
See Figure 3-1 on page 3-2.

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 PREVENTATIVE MAINTENANCE INSPECTIONS
General Mast Inspection
Perform the following general mast inspections:
1. Check the hoist cylinder for proper sequencing.
2. Check if the unloaded mast elevates to full lift (relief
valve should open). If mast will not go to full lift, check
the hydraulic fluid level in the reservoir and add fluid
if required.
3. With load on forks in front carry position, elevate to
approximately 5 feet (1.524 meters). Lower fast to
within 6 inches (152.4 mm) of floor and stop abruptly.
The mast should stop with a solid effect. if bouncy,
bleed the hydraulic cylinder.
4. Check the carriage rollers and elevating channel
rollers for proper contact with mating surface.
5. Look for signs of galling where the rollers contact the
rail. See Figure 2-6 on page 2-15
Figure 2-6: Channel Galling
6. Galling is indicated by track marks in the rails that are
1/4” to 1/2” (6.35 mm to 12.7 mm) wide running up
the rail. Normal track marks are no more than 1/4”
(6.35 mm) wide.
7. If galling is detected, adjust the rollers for the proper
clearance over the full length of the mast rails.
8. Check for proper lift chain adjustments.
9. Check for chain contact with retaining lip on sheaves.
Mast Chain Wear Inspection
! WARNING
Chain condition is critical to safe operation.
Inspect chains carefully and often. Always
replace paired chains in sets if one or both
chains are worn.
Perform the following when inspecting chains:
1. Replace chains when the measured length of a given
section is 3% greater than the nominal length.
2. Measure chain stretch by:
a. Measure the actual length of a chain section with
a nominal length of 12 inches. For a chain with a
pitch of 3/4 inches, counting off 16 pins gives you
the 12 inch nominal section. For a chain with a
one 1 inch pitch, 12 pins equals 12 inches.
b. The replacement limit for a 12 inch minimal
length of chain is 12 x 3% or 0.036 inches
(approximately 5/16 inch) over the nominal
length. See Figure 2-7.
c. When making the above measurement, apply a
small amount of tension on the chain(s) by
raising the carriage or mast, without a load on
the forks.
Figure 2-7: Chain Stretch
3. Check the chains for rust or corrosion. Proper
lubrication reduces rust and corrosion.
4. Check for cracked side plates. On paired chains,
cracked side plates on either one requires
replacement of both chains.
5. Check for free movement of all links. Dirt and rust
causes the chain to bind or kink. Penetrating oil frees
the chain bind or kink. Replace chains where
binding/kinking is caused by bent pins or plates.
6. Check for protruding or turned pins and replace the
chain(s).
7. Check chains for side wear. If present, check
alignment of sheaves and anchors. Correct the
alignment. Replace the chains if side wear is severe.
2-15
PREVENTATIVE MAINTENANCE INSPECTIONS
IMPORTANT
Lift chains must be replaced as a set, regardless of
presence of wear on only a single chain.
Mast Rollers/Sheaves
Perform the following for mast rollers/sheaves:
1. Mast rollers and sheaves have sealed bearings
which do not require periodic lubrication.
2. Replace rollers and sheaves that have visible wear,
flat spots or cracks.
3. Spin the rollers and sheaves to check bearing
condition. Replace rollers and sheaves if they bind or
are rough or noisy when they turn.
4. Check for damaged stub shafts of cracked stub shaft
bases.
5. Ensure carriage outside thrust rollers are tight.
Check outside carriage thrust rollers often and
tighten when necessary.
Mast Uprights
Perform the following for mast uprights:
1. Wipe off the old dirt from the uprights rolling surfaces
to check condition. Check for excessive wear,
grooves or scoring. Lack of proper lubrication or
damaged rollers causes excessive wear.
2. Some flaking of material from the carriage rolling
surface of the inner rail after a few hundred hours of
operation is normal. Remove the flaked material with
a wire brush. Keep the rail clean as outlined above.
Flaking should diminish with further operation.
500 Hour Inspection
Hydraulic Fluid
Proper Maintenance of the hydraulic system is critical to
proper operation of the truck’s hydraulic functions and to
the service life of the seals and cylinders. The system is
equipped with 2 filters. The first filter is a metal screen
suction filter located inside and at the bottom of the
hydraulic reservoir. The second filter is a cartridge return
line filter at the top of the reservoir, which is reached by
lifting the right side cover. See Figure 2-8.
2-16
Figure 2-8: Hydraulic Filter
A filter screen is fitted in the reservoir’s filler hole. The
reservoir holds 16 gallons. Another 3 gallons remain in
the hydraulic system at any given time.
Return Line Filter
The return line filter is a replaceable cartridge filter similar
to that used on automobiles. The return line filter is the
most frequent maintenance item in the system and needs
changing according to the recommended maintenance
schedule.
1. The return line filter needs replacement every 500
hours of operation or more often if severe operating
conditions occur.
2. Lift the right side cover to gain access to the return
line filter cartridge.
3. Ensure the Keyswitch is turned to OFF and the forks
are on the floor.
4. Disconnect the battery and exercise Lockout/Tagout
procedures.
5. Use a filter wrench or strap wrench to unscrew the
filter element.
6. Wipe off the filter gasket mating surface with a clean
rag. Use a light coating of the hydraulic fluid to lube
the new filter’s gasket.
7. Spin the new filter on until the gasket contacts the
mating surface, then use the wrench to turn it an
additional 7/8 to 1 turn.
8. Operate the truck’s hydraulics for a few moments and
check for leaks.
Changing Hydraulic Fluid
Perform the following steps when changing the hydraulic
fluid:
F-602-R1 Edition
 PREVENTATIVE MAINTENANCE INSPECTIONS
1. The hydraulic fluid should be changed every 2000
hours or 52 weeks under normal operating conditions
- more often if severe operating conditions occur.
2. Change the fluid when the equipment is at operating
temperature.
3. Place a container of at least 20 gallon capacity
beneath the drain plug on the right side of the truck.
Refer to See Figure 2-9.
Figure 2-9: Drain Plug
4. Ensure the Keyswitch is turned to OFF; the battery is
disconnected; you’ve accomplished the
Lockout/Tagout; the mast shifted to the right; and the
forks in the front loading position on the floor.
5. Remove the drain plug to drain the fluid. Look at the
old fluid for future reference. If the fluid is dirty,
consider more frequent fluid or filter changes.
6. Fit the drain plug. Use a non-permanent
thread-locking or non-hardening sealant compound
on the drain plug.
7. Remove the suction filter from the bottom of the
reservoir. Refer to “Suction Filter” below.
8. Remove the filter hole screen and clean it in a safe
solvent. Replace the screen if it is clogged or
punctured.
9. After replacing the filler hole screen, add the
recommended fluid for your truck to the reservoir
(See “Lubrication Specifications” on page 1-8). The
proper level is approximately 2 inches below the lip of
the filler cap hole.
10. Operate all hydraulic functions on the truck for
several minutes; return the mast to the right side,
front loading position, forks on the floor. Check fluid
level. Add extra fluid if necessary.
Suction Filter
Perform the following steps when changing the suction
filter:
1. Complete steps 3 through 6 of “Changing Hydraulic
Fluid” above.
2. The metal screen suction filter is located at the
bottom of the reservoir. Remove the suction filter
screen and clean when changing the fluid.
3. After the reservoir has cooled sufficiently, remove the
access plate where the filler cap is mounted. Reach
into the reservoir and unscrew the suction filter
(normal right-hand thread). See Figure 2-10.
Figure 2-10: Suction Filter
4. Clean the suction filter with a safe solvent. Check for
foreign matter. Use a stiff non-metal brush to remove
stubborn particles from the screen.
5. If the screen is clogged with non-removable particles,
punctured or crushed, replace the suction filter.
6. Dry the filter with compressed air and install in
reverse order.
Drive Axle Oil
1. Check the differential oil levels on a monthly basis.
2. Change the differential and planetary reduction oil as
shown in Figure 2-11
3. Under normal use, grease the axle monthly; under
heavy duty use, grease weekly.
2-17
PREVENTATIVE MAINTENANCE INSPECTIONS

Oil

Oil

Figure 2-11: Drive Axle Oil Change

Steer Axle Major Bolt Connections

Examine the following steer axle functions: Check and periodically tighten all major mechanical
1. Check the steer axle trunnion mounting bolts; torque connections. Under severe operating conditions, perform
to 210-250 ft. lbs. (285-340 Nm). this operation more frequently.
2. Check the wheel bearing nuts. With the wheel off the The major bolt connections consist of, but are not limited
floor, tighten the wheel nut to 50 ft. lbs. (68 Nm). to:
Back it off 1/4 turn to no less than 20 ft. lbs. (27 Nm). a. Drive axle trunnions
Check for rotation of the wheel. b. Drive assembly support
3. Check the cotter pins on the spindle tie rod end c. Drive wheel nuts
trunnions; replace if required.
d. Steer axle trunnions
4. Check the steer cylinder for leaks around the hose
e. Steer wheel nuts
connection and the rod gland. Repair if required.
f. Mast trunnions
5. Raise the rear end of the truck, support it with safety
stands, and check for wheel bearing play indicating g. Hydraulic valve control levers
loose or damaged bearings. Adjust the bearings as h. Service brake master cylinder
outlined in step 2 above. Rotate the wheel and check i. Hydraulic pump/motor mounts
for bearing noise or roughness indicating damaged
j. Steer pump/motor mounts
bearings. Replace if necessary. Refer to “Steer Axle
Bearing Inspection” on page 3-29 for procedures. k. Cylinder pin locking bolts
6. Check the steer cylinder ends for excessive play.
7. Check the tie rod bearing ends for excessive play.

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 PREVENTATIVE MAINTENANCE INSPECTIONS

1000 Hour Inspection

Controller Maintenance
The controller has some thermal losses. The
semi-conductor junctions have finite temperature limits
and, if exceeded, may be damaged. Normal maintenance
should guard against any action which exposes the
components to excessive heat. For example, steam
cleaning and restricting air flow reduce the heat
dissipation ability of the controller.
Perform the following for controller maintenance:
1. Inform Landoll Corporation of any controls used in
ambients of 100°F (40°C) or over.
2. In dusty areas, use low-pressure air to blow off the
control. In oily or greasy areas, use a mild solution of
detergent, Denatured alcohol or Freon TF degreaser
to wash off the control; then dry with blown, low
pressure air.
3. The use of heat-transfer grease (Wakefield
Engineering Type 120 or equivalent) is
recommended when reinstalling the control panel.
4. Keep terminal boards and other exposed control
parts free of dirt and paint. Dirt or paint changes the
effective resistance between points.
5. Do not hipot (or megger) the control. The control
becomes damaged if the terminals of each
semi-conductor are not connected.
6. Use a lead-acid battery with the voltage and ampere
hour rating specified for the vehicle. Follow normal
battery maintenance procedures, re-charging before
80 percent discharged and with periodic equalizing
charges.

2-19
PREVENTATIVE MAINTENANCE INSPECTIONS

Table provided for your general use with this manual.

NOTES:

2-20 F-602-R1 Edition

 Chapter 3

Troubleshooting and Corrective Maintenance

Troubleshooting 3. Visually examine terminals on the electric door

assembly, traction motor and pump motor. Tighten if
The following sections will explain troubleshooting required. Check battery cables and examine all bus
procedures for the various area of the forklift. Be sure to bar connections at the power contactors on the
read “Before You Begin (Please Read)” on electric door module assembly.
page 1-1before performing any service on the Drexel 4. An overheated electrical compartment causes power
SL120 forklift. fuses 1 FU and 2 FU to open. Prolonged use of the
vehicles in speed control range causes overheating.
Electrical System 5. Setting the hydraulic system relief valves for a
pressure tighter than 2500 psi causes the pump
motor power fuse to open. A higher relief pressure
Traction Fuse Opening (1 FU) setting occurs only if the valve is disassembled for
The following problems may cause the traction fuse to service and washers were left out at reassembly.
open (1FU). The fuse is located on the electrical
compartment door. See Figure 3-1.
1. Reduced 1A timing coupled with frequent rapid starts
causes high power demands exceeding the capacity
of the traction fuse (1 FU). The time-delay pick-up of
1A is provided by a circuit on the hydraulics card
(EV100). The feature picks up the 1A circuit after a
time delay which allows the truck to reach 80% of the
top speed in it’s range. The time delay adjusts by a
1A trimpot on the hydraulics card. Normal 1A pick-up
acceleration is 1/2 to 3/4 seconds.
2. Skidding or pushing loads causes high traction motor
power demands and opens fuse 1 FU. Opening of
the 1 FU fuse protects the power cables, batteries,
contactors and traction motor. See Figure 3-1.

Hydraulic Fuse Opening (2 FU) and

Traction Fuse (1 FU) Opening
1. Loose power fuse block connections cause a high
resistance, which creates overheating of (1 FU)
traction fuse, (2 FU) hydraulic fuse, battery power
cables, and burning of the fuse block studs and
hardware. See Figure 3-1. Unplug battery connector.
Tighten all associated hardware.
2. Loose or improperly crimped cable ends causes high
resistance, excessive power requirements and
overheated cables and terminals.

3-1
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

6.

Figure 3-1: Control Panel Fuses

Pump Motor Power Fuse Valve

Removal
Perform the following to remove the pump motor power
fuse valve:
1. Remove the pump inlet hose from the inlet elbow.
2. Loosen the elbow and rotate it away from the o-ring
plug directly beneath it.
3. Remove the relief valve o-ring. To retract the
cartridge from the valve body, use a magnet.
4. Examine the ground lands of the valve for nicks,
scratches or debris.
5. Clean as required.
6. You must also disassemble this valve. Use vice grips
to firmly hold the valve body between ground lands.
Use a box-wrench to remove the hex end from the
body.
7. Spread out the individual parts and examine for
metal chips or contamination.
8. Clean parts and reassemble in the order shown in
Figure 3-2.
! CAUTION
Do not omit any washers as removal of each one
greatly effects the relief pressure settings. Insert
the assembled cartridge into the valve bore,
round end first, and the hexagon end toward the
outside and visible. The retainer spring fits over
the hex. Installing the o-ring completes the
assembly.
Figure 3-2: Valve Assembly
9. Extending the mast to the full height stop position
and holding the control in this position frequently or
for extended periods of time causes hydraulic
pressure to climb to the relief valve level of 2250 psi.
This may also occur with other hydraulic functions,
i.e., tilt, pivot and shift.

3-2 F-602-R1 Edition

 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

10. A problem in the pump or traction motor causes

repeated opening of the power fuses. The problems
include:
a. Open armature - evidenced by burning of
commutator bars 180° apart. This is usually from
a high resistance point. Open armature occurs
on new motors after 100 to 200 hours of service.
b. Excessive wear on one brush - indicates the
opposite brush is the problem and is not
conducting its share of current. Also indicates
internal shorts.
c. Shorted field coil - evidenced by excessive brush
wear (dusting), high rotational speed and
commutator arcing, all due to a loss of
magnetism in one field pole, thus higher current
draw.
d. High bar-damaged brushes or purple, burnt
commutator bars 90° apart - this is due to stalling
the pump motor. To restore the vehicle to normal Cam Location

operation, remove and repair or replace the

pump motor.

Loss of Drive Speed Figure 3-3: Accelerator Cam Location

If loss of drive speed occurs, perform the following:
1. Remove the traction motor circuit fuse. Sitting in the
operator's seat, turn the Keyswitch to the ON
position.
2. Place the directional control switch to the forward
position and slowly begin depressing the accelerator
pedal. Within the first 5° to 11° of travel, listen for the
forward contactor kicking in. The 1A contactor kicks
in during the last 5° of pedal travel.
If one or both of the above events fails, remove the
accelerator assembly module from the vehicle. Refer to
“Accelerator Module” on page 3-43 for specific removal
instructions.
Inoperative Accelerator Switch
An inoperative accelerator switch causes loss of drive
power and speed. To correct, open the accelerator box lid
and check the accelerator cam location (See Figure 3-3).
Adjust the cam and start switch so that actuation takes
place within the first 2° of accelerator switch lever
movement. If initial actuation still does not occur, check
the switch for continuity and replace as required. Also,
check if the accelerator switch adjustments are the
correct potentiometer setting.
Traction Motor
Check the following to ensure the traction motor is not
defective:
1. Open armatures - evidence of open armatures is
known by the burning of commutator bars 180° apart.
This is usually from a high resistance joint. Open
armatures usually occur around 100 to 200 hours of
motor service. Open armature testing requires a
hi-pot check to determine if insulation resistance of
the armature assembly meets a minimum value.
2. Excessive wear of one brush - excessive wear of one
brush indicates the opposite brush is the problem
and is not conducting its share of current. Another
indication is internal shorts. Testing for excessive
wear of one brush requires a no-load speed test.
Excessive armature speed or current draw indicates
shorts or air gap problems. With drive wheels off the
floor and running in 1A, set draw between 70 and 85
amps and traction motor RPM between 200 and
2500.
NOTE
The above data applies only to a motor operating in the
full field condition.

3-3
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
3. Shorted Field Coil - evidence of a short is shown by
excessive brush wear (dusting), high rotational speed
and commutator arcing. The reason is a loss of
magnetism in one field pole, resulting in higher
current draw. Testing for a shorted field coil is done
with a load placed on the traction motor. Use a
dynamometer to determine current draw and RPM
from a given torque setting and a set voltage. Only
one point is checked in both directions of rotation.
4. High Bar - high bar is evidenced by damaged
brushed or purple, burnt commutator bars, 90° apart.
This is due to hard plugging or stalling the drive
motor and occurs when the motor is in service.
Testing for high bar is done by visual inspection and
instructing operators on avoidance of plugging or
stalling the drive motor.
5. Noise in the Control Mode - an unusual noise when
the controller pulses the motor current is caused by
shorted field coils or loose rocking field pole pieces.
The “wow,” “whumping,” or “wurble” noise, as
variously described, indicates a field coil is shorting
out under the influence of an alternating current.
Testing for noise in the control mode is done by
listening while driving in the speed control range. The
“wow,” “whumping,” or “wurble” noise at certain
speeds indicates that field coil shorting is starting.
NOTE
Removal and repair or replacement of the drive motor is
recommended to restore the vehicle to normal operation.
Control Card Malfunction
A control card malfunction causes no power and no hum
while the contactor closed and the accelerator is in the
range. If no other cause is found, replace the control
card. Refer to “EVT-1000 Panel Replacement” on
page 3-32 for removal and installation procedures.
Load (Pounds) Hydraulic Pressure (PSI)
0 Primary 550/Secondary 600
11,000 Primary 1725/Secondary 1900
Table 3-1: Mast
3-4
Hour Meter Inoperative
An inoperative hour meter is caused by a malfunction in
the hour meter or a wiring problem. Check for battery
voltage at the number 11 side of the hour meter. If
voltage is not present, repair the wiring. If voltage is
present, replace the hour meter.
Hydraulic System
Lift Circuit
NOTE
When troubleshooting hydraulic system problems, check
and record the hydraulic pressures first.
To determine lift circuit relief pressure and hoist cylinder
operating pressure, connect a 3000 psi hydraulic gauge
with a flexible hose ending in a 1/8 NPTF male to the lift
valve pressure inlet elbow.
Raise the hoist assembly until the sections fully extend
and cylinder travel stops. Continue to pull back on the lift
control handle. Relief pressure on the gauge should read
2250 psi, plus or minus 50 psi.
Control Circuit
To determine the vehicle hydraulic control circuit
operating pressures, connect a 3000 psi hydraulic gauge
with a flexible hose to the lift valve inlet.
Table 3-1 lists normal hydraulic pressures for typical
loads on the hoist assembly and is used for reference
when analyzing system performance. Lift capacity must
not exceed the load weights and centers shown on the
vehicle rating plate. Fully open the control valve. Perform
each function, tilt, pivot and shift, without rated loads.
Table 3-2 provides normal hydraulic pressures for typical
loads on the hoist assembly and operation of the three
functions.
Battery Current (AMP)
Primary 120/Secondary 126
Primary 255/Secondary 270
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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Function Load (Pounds) Hydraulic Pressure (PSI) Battery Current (AMP)

Tilt Back 0 1,350 180
Tilt Forward 0 2,200 239
Pivot Out 0 200-300 35-40
Pivot In 0 300-400 40-45
Shift Left 0 850-950 145-150
Shift Right 0 1,000-1,100 148-158
Tilt Back 11,000 2,100 223
Tilt Forward 11,000 1,700 182
Pivot Out 11,000 300-400 40-45
Pivot In 11,000 350-450 40-45
Shift Left 11,000 1,500 200
Shift Right 11,000 1,650 216
Table 3-2: Hydraulic Pressures

Perform the following if low pressures occur:

1. Tighten all hydraulic connections. A loose connection
in a pressure line permits oil leakage. If the oil level
becomes so low it uncovers the inlet pipe opening in
the reservoir, extensive damage to the pump results.
In suction lines, loose connections permit air to draw
into the systems and causes pump cavitation
resulting in noisy, erratic operation with final results of
pump destruction.
2. Clean oil is the best insurance for long service life.
Check the reservoir periodically for dirt or other
contaminants. If the oil becomes contaminated,
thoroughly drain the system and clean the reservoir
before adding new oil.
3. Check the filter elements and replace periodically. A
clogged filter element results in a higher pressure
drop. Ordinarily trapped particles are forced through Figure 3-4: Controller Fuse Block
the filter, causing the bypass to open, resulting in
partial or complete loss of filtration. Motor Does Not Operate
4. A pump running excessively hot or noisy is a If the motor does not operate, check to see if the pump
potential failure. If the pump becomes noisy and runs control fuse (6 FU) is open. Examine the ribbon for signs
hot, shut down the truck and determine the cause of of over-current damage. Shorts in associated
improper operation. components or wiring can cause excessive fuse opening.
If the pump contactor is inoperative, causing loss of
power to the pump motor, check the following:
1. With the battery disconnected, push the contactor
armature and contacts inward to check for restriction
of free movement.
2. Check for loose power or control wiring at the
contactor tips and coil.
3. Check for an open coil with a voltmeter placed across
the two coil terminals.

3-5
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Faulty Seat Switch

A faulty seat switch prevents operation of the pump motor
electrical control circuits. Figure 3-5.
Perform the following:
1. Disconnect the battery and turn the Keyswitch to
OFF and raise the operator's seat exposing the
switch- plunger and sealing boot.
2. Manually depress and release the switch plunger. An
audible click indicates normal mechanical operation.
If the click is not heard for one or both functions, a
damaged switch is indicated.
Also, with the battery disconnected, locate on the control
panel the two terminals referenced in Figure 3-6. Attach
an ohmmeter between the two terminals. With the seat
switch released, you should read infinate ohms. With the
seat switch depressed, the meter should read very low
ohms. If there is no change in the ohmmeter when the
seat plunger is depressed, replace the seat switch.

Figure 3-6: Seat Switch Terminals

Hydraulic Control Valve Electrical Switches

The hydraulic control valve electrical switches stick in the
closed position if out of adjustment, causing the pump
motor to run continuously. If this occurs, perform the
following:
1. Remove the cover from the front of the lift control
valve assembly and from the front of the tilt, pivot and
shift control valve assemblies. The lift switch is
Figure 3-5: Seat Switch positioned by a plate attached to the battery
compartment front wall. Examine for tightness and
switch actuator contact with lift control handle.
2. The stack switch assembly (tilt, pivot and shift) is
mounted on a cam bar support structure attached to
the base of the hydraulic control valve. Examine for
tightness and switch actuator contact with the cam
bar. Examine the plastic cams attached to the bottom
of each valve spool for tightness and full insertion
into the spool. Move each handle to observe cam,
cam bar and switch action.

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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Hydraulic Valve Switch Adjustment
If hydraulic valve switch adjustment is necessary,
disconnect the battery and loosen the two #10 pan head
screws holding the switch in place. Adjust the switch by
moving it slightly forward or backward. Tighten the
screws and check adjustment. The switch will actuate
when you move the control handles approximately 1/2” to
3/4”. Readjust as necessary.
Place all handles in the normal, neutral position. Try each
handle, determining if handle base rotates freely and
each valve spool does not stick in the housing. Lubricate
the handle base and support the shaft if required.
Welded Pump Contactor Tips
A welded pump contactor tip causes a continuously
running pump motor. The pump contactor is located on
the electric door assembly. To check for welded contactor
tips, disconnect the battery and open the electrical door.
Examine the pump contactor tips. Welded contactor tips
are rigidly joined and no air gap is visible between the
upper and lower contactor tips. Replace the contactor
tips if it is necessary to pry them apart.
Pressure Loss
The pump rotating in the wrong direction causes loss of
pressure. Change the drive direction immediately to
prevent seizure. Correct the pump cartridge ring position
for each direction of rotation.
Coupling or Shaft Sheared/Disengaged
The coupling or shaft sheared or disengaged causes a
loss of pressure. Disassemble the pump and check the
shaft and cartridge for damage. Replace parts as
needed.
Restricted Oil Intake Pipe in Reservoir
If the oil intake pipe in the reservoir is restricted, causing
low oil pressure, check all strainers and filter for dirt and
sludge. Clean or replace as necessary.
Hydraulic Viscosity Too Heavy
If the hydraulic viscosity is too heavy, it will not pick up the
prime. Completely drain the system. Add new filtered oil
of the proper viscosity.
Intake Air Leaks
Air leaks at the intake cause a loss of pressure. Check
the inlet connections for air leakage. Tighten any loose
connections. Ensure the oil in the reservoir is above the
intake pipe opening. Check if the minimum drive speed is
too slow to prime the pump.
Stuck Relief Valve
A stuck relief valve causes low to no pressure.
Disassemble the pump and wash the valve in clean
solvent. Return the valve to its bore and check for any
stickiness. Polish any gritty feeling on the valve periphery
with a crocus cloth. Do not remove excess material;
round-off the edges of the lands or attempt to polish the
bore. Wash all parts and reassemble the pump.
Vane(s) Stuck in the Rotor Slot(s)
Vane(s) stuck in the rotor slot(s) cause a loss of pressure.
Disassemble the pump. Check for dirt or metal chips.
Clean the parts thoroughly and replace any damaged
pieces. If necessary, flush the system and refill it with
clean oil.
Insufficient Pressure Build-Up
Relief Valve Set Too Low
The relief valve set too low causes a loss of pressure
build-up. Use a pressure gauge to correctly adjust the
relief valve.
Internal Pump Parts Worn
Worn internal pump parts cause leakage of pump
delivery. Replace the pump cartridge.
Pump Making Noise
Pump Intake Partially Blocked
The pump intake partially blocked causes strained pump
operation. Service the intake strainers. Check the fluid
condition and, if necessary, drain and flush the system.
Refill with clean oil.
Air Leaks at the Intake or Shaft Seal
Air leaks at the intake or shaft seal cause the pump to
make noise. Also, oil in the reservoir is foamy. Replace
the hydraulic pump or replace shaft seals.
Coupling Misalignment
Coupling misalignment causes noisy pump operation.
Check for damaged shaft seal bearings or other parts.
Replace any damaged parts. Realign the coupled shafts.
Pivot Function Inoperative
If the pivot function is inoperative, inspect the pivot
cylinder hydraulic hose and fitting connections, rod seals,
and the piston seals for leaks or excessive wear. Replace
as required. Refer to the Landoll Drexel SL120 Parts
Manual, F-394 for cylinder parts list and location.
3-7
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Bent Pivot Cylinder Rod
To find a bent pivot cylinder rod, examine the cylinder and
piston rod for alignment, surface finish smoothness and
straightness. Replace as required. Use new seals when
replacing piston rod.
Worn or Misaligned Pivot Cylinder Cushion
Valve or Rings
Worn or misaligned pivot cylinder cushion valves or rings
cause slow movement of the piston and a sudden burst
of speed ending with a slamming of the piston. This
indicates a defective cushion valve or piston rings.
Inspect the cushion valve ports in the piston by removing
the o-ring hydraulic fittings (one end at a time) and
pushing the piston toward the open port until a complete
stroke is obtained. Rotate the piston rod until the cushion
valve port is visible. Examine for restrictions or dirt and
clean with a fine wire. Repeat the procedure above for
the other cylinder port. If erratic operation is still
apparent, remove the cylinder from the truck and
disassemble. Inspect the piston rings for cracks or
misalignment. Replace as required, using a ring
compressor.
Crossed Hoses
To find crossed hoses between pivot and tilt, observe the
general operation of all hydraulic functions. For example,
crossed hydraulic hoses indicate tilt movement in the
operation of the pivot control lever. See “Reversed
Hydraulic Lines” on page 3-9.
Shift Function Inoperative
Worn Shift Cylinder Seals
To find worn shift cylinder seals, inspect the shift cylinder
hydraulic hose and fitting connections, rod seals, and the
piston seals for leaks or uneven wear. Replace any worn
or damaged pads.
Bent Shift Cylinder Rod
To find a bent shift cylinder rod, examine the cylinder and
piston rod for alignment, surface finish smoothness, and
straightness. Replace as required. If replacement of the
piston rod is necessary, use only new seals when
reassembling the shift cylinder.
Shift Cylinder Spacers Blocking Hydraulic
Port
If the shift cylinder spacers block the hydraulic port,
remove and disassemble the shift cylinder. Check the
cylinder spacer for damage or misalignment. The piston
end port needs clear passage through the spacer for oil
flow.
3-8
Contamination of the Control Valve
Hydraulic Pressure Relief Cartridge
Contamination of the control valve hydraulic pressure
relief cartridge prevents full hydraulic pressure to the
pivot, shift or tilt cylinder. see “Control Circuit” on
page 3-4 for cartridge troubleshooting.
Leaky Hydraulic Solenoid Interlock Valves
To find leaky hydraulic solenoid interlock valves, review
the truck features given in the Landoll Drexel SL120
Operator’s Manual, F-397, for correct pivot and shift
interlock system operation. Inspect solenoid valves for
visual external leaks and damage. Examine the electrical
actuation of the solenoids to determine proper
functioning and electrical power delivery of the solenoid
coils. If the solenoids work but the valve is faulty,
disassemble and replace the valve coil plunger and
internal seals.
Inoperative Pivot and Shift Control
Switch
To check for an inoperative pivot and shift control switch,
turn the Keyswitch OFF; slowly operate the hydraulic
control handles individually, listening for switch actuating
and looking for cam and switch misalignment or damage.
Refer to the adjustment procedure given above and
replace or adjust as required.
Hydraulic Leak in the Cover End
Section
A hydraulic leak in the cover end section of the pump
causes a loss of shift function. See Table 3-2 on page 3-5
for pivot and shift function pressure indications. If
pressure is not building, check the pump for
cross-threaded fittings, damaged seals, cracks in the
pump housing or over-torquing of the end cover bolts.
Loss of Hydraulic Lift
Discharged Battery, Hydraulic System
A discharged battery causes the lift lock-out to energize.
It also causes failure of the pump motor to turn on and
operate the hydraulic lift. Then, the lift lock-out relay
interrupts power to the pump contactor. Other hydraulic
functions remain operational without interruptions and
interlock, preventing their use from over-riding the locked
lift function.
To resume normal operation, charge the battery or
remove it and replace with a fully charged battery.
Normal lift function resumes with a battery charged to
over 80% of rated capacity.
F-602-R1 Edition
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Inoperative Lift Valve Switch or Switch
Mis-adjustment
An inoperative lift valve switch or switch mis-adjustment
restricts the controller from turning on the motor. Adjust
or replace the switch as needed.
Low Reservoir Oil Level
Low reservoir oil level causes the lift system hydraulic
pump to cavitate and restricts full lift of the mast. Lower
the hoist cylinder and close the tilt, pivot and shift
cylinders. Check the hydraulic oil level. Add to full mark if
required, and check the hydraulic systems for possible
leakage.
Damaged Pump Coupling
A damaged pump coupling or sheared key causes a loss
of hydraulic lift. Replace the coupling or key as needed.
Loss of Hydraulic Lift and Loss
of Lift Speed
Mechanical Damage of Mast Assembly
Mechanical damage of the mast assembly causes
reduced tilt speed. Upright and carriage rollers
sometimes dig into the upright channel and I-beam
sections. A clean, raw, metal track where the roller
contacts the surface of the section is evidence of this
condition. Lubricate and adjust roller clearance as shown
in “Mast Racking Adjustment” beginning on page 3-16.
Proper Hoist Cylinder Sequencing
Proper hoist cylinder sequencing is mandatory to
maintain full operating lift speeds to full lift heights.
Overload of Hydraulic Hoist
Assembly
Overload of the hydraulic hoist assembly in the front
loading operation causes the hoist system relief valve to
dump system oil back to the reservoir and creates an
overload of hydraulic fuse 2 FU (see Figure 3-1 on
page 3-2). Avoid loads in excess of the load weights and
load centers displayed on the vehicle rating plate.
Excessive or non-centered loads create an unsafe
vehicle stability condition.
Leaking or Damaged Lift Control Valve
A leaking or damaged lift control valve causes drift of the
raised load. Perform the following:
1. If oil bypasses between the spool and body, the valve
is not repairable. Remove the valve and replace.
2. If the spool is not centering properly, the spring is
broken. Remove the spring and replace.
Loss of Mast Tilt or Loss of Lift
Speed/Drift of Raised Load
Worn or Damaged Dual Hydraulic Pump
Sections
Worn or damaged dual hydraulic pump sections cause
loss of lift or tilt functions. Impairment of the tilt, pivot and
shift functions occurs with damage to the end section
rotor, ring or vanes. Also, impairment of the lift function
occurs with damage to the shaft end section rotor, ring or
vanes. When operating the pump, listen for any unusual
noise.
Determine the lift circuit system pressure. Compare to
the figures shown in Table 3-1 on page 3-4. Determine
the control circuit pressure and compare to the figures in
Table 3-2 on page 3-5.
Damaged or Worn Cylinder Seals
Damaged or worn cylinder seals cause internal leakage
and may impair the speed or static holding ability of the
cylinder. Check for cylinder drift as follows:
1. The lift assembly is incapable of holding the rated
load at a maximum no less than 2 minutes with no
more than 1-3/4 inch vertical drift, and no more than
1° of rotational drift from the vertical.
2. If drift exceeds the above specifications, replace the
cylinder seals. Replace the hoist cylinder seals by
contacting your mast’s vendor.
Reversed Hydraulic Lines
Hydraulic lines reversed to one cylinder cause loss of
mast tilt. Refer to the Hydraulic Assembly in the Parts
manual, F-394, to identify and correct reversed hoses.
Always tag all hydraulic lines prior to removal from
cylinder.
Loss of Power Steering - Motor
Inoperative
Control Circuit Fuse Open
If the control circuit fuse is open (4 FU), replace the fuse.
The control circuit fuse (4 FU) is located on the controller
panel. An open fuse prevents the line contactor from
closing, thus activating the steering motor. See
Figure 3-4 on page 3-5
3-9
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Steer Pump Motor Power Fuse Open
If the power steering fuse (3 FU) is open, replace the
fuse. The power steering fuse is located on the electrical
compartment door, between the 1A and line contactors. If
the fuse continues to open, check for circuit shorts or
excessive current draw from the steering motor. See
Figure 3-1 on page 3-2
Loose or Open Control Circuit Connections
Loose or open control circuit connections cause loss of
control current to steering contactor solenoid. This
contactor controls the current to the steering pump motor.
Location of the control connectors for the power steering
motor is on the electrical compartment door.
Clean or tighten any corroded or loose connections.
Replace any open wires.
Loose or Open Power Cable
Connections
Loose or open power cable connections is caused by
loose hardware at the power steering pump motor. Check
the pump motor cables for continuity and loose or
corroded terminal connection hardware.
Clean and tighten connections or replace the cable as
needed.
No Voltage at Power Steering Pump
Motor
If there is no voltage at the power steering pump motor,
check the power cables from the motor to the contactor
conductor bar on the electrical compartment door.
Clean and tighten the connections or replace cables as
needed.
Contactor Tips and Conductor Bars
Corroded/Eroded
For corroded/eroded contactor tips and conductor bars,
replace the tips and bars as needed.
Contactor Not Closing
If the contactor is not closing, disconnect the battery and
check for free movement of the contactor. Replace
binding or seized contactor or assemblies.
Slow Steering Response
Slow steering is caused by the following conditions:
1. Damaged Steer Cylinder seals or drift of steering. To
correct, remove the steer cylinder from the steer axle.
Replace all seals.
3-10
2. Mis-adjustment of the pressure relief valve due to a
reduction in system pressure. Foreign material
causes sticking or improper seating of the relief
valve. Remove the valve to inspect and clean it. The
relief valve is built into the steering pump housing.
The adjustment shaft, locking nut and protective cap
are located externally on the side of the housing.
NOTE
Determine the power steering system hydraulic pressure
before making any adjustments to the pressure relief
valve or replacing the pump or orbiter units. Attach a
3000 psi pressure gauge to the pump pressure line.
When the system is idling, hydraulic pressure is
approximately 50-100 psi. Pressure when the steering
wheel is rotated to allow the steer axle to achieve the
maximum turning angle is 750-900 psi. If not, adjust as
necessary.
Worn or Damaged Hydraulic Pump
Loss of power steering, slow steering response or failure
to achieve the correct pressure relief setting indicates
that the hydraulic pump is worn or damaged. Wear to the
gears or housing allows a reduction output pressure.
Remove the pump unit from the motor. Examine the
pump motor. Examine the coupling, pump input shaft and
motor armature end for damage. Rotate the pump shaft
to check for smooth rotation.
Failure of the Steer Axle King Pin & Spindle
Thrust Bearings
Failure of the steer axle king pin & spindle thrust bearings
requires higher steer cylinder operating pressures which
slows down cylinder response and requires increased
manual effort at the hand steer wheel. Check and replace
bearings as needed.
Also, a bent steer cylinder rod causes higher pressure
requirements and increased steering effort. Replace the
steer cylinder rod.
Drift of Steering
A failed or weak orbitol centering spring allows the
orbitrol valve to return to its neutral position and causes
the steer system to drift.
Remove the orbitrol unit from the truck as shown in
“Orbital Unit Removal and Installation” on page 3-37 and
replace the valve spool centering spring.
Worn Steer Axle Components
Worn steer axle components cause drift in the straight
line tracking ability of the power steering system.
F-602-R1 Edition
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Raise the rear of the truck so the steer tires clear the
floor. Grab either tire and move right, then left. Free play
at the outer edge of the tire exceeding 0.030" contributes
to drift and or chatter problems. Examine the spherical
bearing joints at the spindle arms, bell crank and steer
cylinder for excessive axial and vertical free play. Replace
as required.
Steer Axle Alignment Off-Center
An off-center steer axle alignment causes a drift or pull to
the misaligned wheel(s). Set the toe to 0° or straight
ahead. Refer to “Steer Axle Wheel Alignment” on
page 3-29 for procedures.
Loss of Service Brakes
Spongy Brake Pedal Operation
Air in lines or wheel cylinders causes a loss of braking
action indicated by spongy brake pedal operation.
Examine the brake lines and wheel cylinders for leaks;
repair if necessary.
Low Fluid in Master Cylinder
Low fluid in the master cylinder causes a loss of service
braking. Remove the filler cap from the master cylinder,
located under the left-hand floor plate. If the fluid level is
not even with the bottom of the filler cap threads, add
fluid. Examine the brake system for leaks and assure a
full fluid level.
Master Cylinder Seals Leaking
Leaking master cylinder seals cause a loss of service
braking. Remove the master cylinder filler cap and slowly
actuate the brake pedal. A pulse of fluid is evident in the
cylinder reservoir; if not, replace the piston assembly and
the internal seals. Then, bleed the brakes.
Wheel Cylinder Seals Leaking
Leaking wheel cylinder seals cause a loss of service
braking. If the drive assembly is fluid-saturated, remove
the brake drum and inspect the wheel cylinder for leaks
or damage. Refer to “Drive Brakes” on page 3-20 for the
drum and brake shoe removal procedure.
Repair or replace the wheel cylinders and bleed the
brake system. Refer to “Bleeding the Brakes” on
page 3-20 for bleeding procedures.
Brake Line Leaking
A leaking brake line causes a loss of braking action.
Inspect the brake lines for cracks, cross-threaded fittings
or damage. Repair as necessary. Bleed the hydraulic
brake system.
Brake Shoe Adjustment
Brake shoe mis-adjustment causes a loss of braking
ability. Adjust or replace the brake linings. Excess
dragging or brake pedal travel indicates an adjustment or
replacement of brake shoes is required. Refer to
“Removal of Drive Disc Brakes” on page 3-20 for service
brake adjustment or replacement.
Axle Seal Leaking
A leaking axle seal causes a loss of braking action at the
wheel involved. Replace the axle seal(s) and
fluid-saturated linings.
Drive Axle
Loss Of Brakes
If brakes are incorrectly adjusted or brake discs are worn
out, inspect disc thickness. Disc minimum thickness is
S=4, 5 mm. Replace discs if thickness does not meet
S=4, 5 mm.
Incorrect Brake Fluid
If incorrect brake fluid is used, replace all the seals and
brake hoses in the axle that made contact with the
incorrect fluid. If incorrect fluid leaked into the axle oil,
replace the seals and o-rings.
Loss Of Brake Fluid
Inspect for and repair any leaks in the outside circuit or
the master cylinder. If the leak is to the outside, replace
the o-rings between the center and intermediate
sections. If the leak is to the inside, replace the o-rings
between the center and intermediate sections and the
brake piston o-rings.
Soft Brake Pedal
Air in the brake fluid causes a soft brake pedal. Bleed the
brakes as described on “Bleeding the Brakes” on
page 3-20.
Ineffective Safety Brake
One or both overrides engaged causes an ineffective
safety brake. Check the override bolts and adjust if
needed.
Brake/Wheel Overheating
Oil contained at the wrong level causes overheating.
Drain, flush and refill oil to the proper level.
3-11
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Too small of a brake gap causes overheating. Readjust
the brakes as described in “Brake Adjustment” on
page 3-19.
If the parking brake drags, overheating occurs. Unlock
the brake and adjust the correct gap.
No free-play at the master cylinder causes overheating.
Readjust the brake pedal as described in “Removal of
Drive Disc Brakes” on page 3-20.
A restriction in the return line of the brake servo system
causes overheating. Inspect for and replace the
damaged return line. Inspect for and remove any filter,
tee in the line or any other source of back pressure from
the return line.
Incorrect oil in the drive axle causes overheating. Drain,
flush and refill to the proper level with Shell Donax TD,
Texaco TDH 1893, or equivalent Super Tractor oil.
Oil Coming Out of the Breather
A hydraulic leak in the brake system causes oil to come
out of the breather. Replace all the seals and brake
hoses in the axle. If fluid leaked into the axle oil, replace
the seals and o-rings.
Noise (“stick-slip”) When Shifting
from Forward to Reverse
A loose wheel causes a “stick-slip” noise when shifting
from forward to reverse.
Inspect for wheel and wheel stud damage. Replace if
needed and re-torque the nuts.
Spider pins loose in the carrier causes a “stick-slip” noise
when shifting from forward to reverse. Inspect for damage
through the rear axle cover.
Damaged or missing spider and/or side gear washers
causes a “stick-slip” noise when shifting from forward to
reverse. Replace as needed.
Noise (“tick-tick-tick”) When Traveling
Forward or Reverse at Low Creep
Speeds.
Inspect for loose wheel nuts and torque to specification.
See “Torque Specifications” on page 1-8.

Noise Under Power Greater Than

During Coast
Low oil level causes noise under power greater than
during coast. To correct, refill oil to the proper level.
Incorrect oil also causes noise under power greater than
during coast. To correct, drain, flush and refill to the
proper level with Shell Donax TD, Texaco TDH 1893, or
equivalent Super Tractor oil.
A worn ring and pinion can cause noise. Inspect for
damage through the rear axle cover.
Additionally, worn planetary gears or bearings causes
noise under power greater than during coast.
Replace gears or bearings as needed.

Noise During Coast Greater Than

Under Power
A loose pinion nut causes noise during coast greater than
under power. Inspect the ring, pinion and pinion bearings.
If undamaged, re-tighten the nut.
One damaged pinion bearing causes noise during coast
greater than under power.
Inspect for damage through the rear axle cover.

Noise During Turn (without NoSpin)

Worn spider and/or side gears causes noise during a turn
(without NoSpin). Replace as needed.

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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Corrective Maintenance
This section is divided by features. For each feature,
major adjustment and/or settings, mechanical repairs
and electrical control system repairs are addressed.
Specific features are listed in the Table of Contents, at
the front of this book, along with page reference
information.
As a Safety Reminder - Duplicate Safety Information
and Precautions from Chapter 1 are shown here.
IMPORTANT
• It is important to always locate the section which
pertains to your needs, then read the entire
procedure before attempting to adjust, repair
and/or replace parts.
• It is recommended to always use genuine Landoll
replacement parts to maintain the overall high
quality performance and guarantee maximum
truck stability and to minimize downtime.
When it becomes necessary to do an electrical or
mechanical service repair or maintenance procedure, it is
important to have the proper tools required, in both
English and Metric sizes, and to review/practice the
following safety suggestions.
! WARNING
• You could be injured and the truck could be
damaged if you try to do service work without
qualified experience.
• If you use the wrong grade replacement parts,
in time, they can break or loosen and serious
injury could occur.
• It is recommended to use Landoll
replacement parts before you attempt any
truck maintenance.
• Be sure to use the proper nuts, bolts and other
fasteners. Many are specifically rated; i.e. SAE
Grade 5, SAE Grade 8, ISO Prop Class 8.8, etc., and
must be replaced with the identical type.
• Whenever possible, return the truck to a service area
having sufficient lighting, work space and an
assortment of tools needed to complete the repair.
• Set the Keyswitch to OFF and remove the key.
• Set the direction control lever to NEUTRAL and set
the parking brake.
! CAUTION
To be certain the truck will not move, place
wedges (or blocks of wood) at the front and back
of the tires. If you are servicing the brakes or
tires, place the block at the front and rear of the
tire farthest away from the one being serviced,
that is, the tire on the opposite side of the truck
and at the opposite end.
• Starting on page 1-1 refer to general maintenance,
safety and battery safety instructions.
Disconnect the battery. Never place a tool or any metal
object on top of the battery where it could possibly touch
battery terminals causing a short or serious electrical
shock.
Mast and Front Load Assembly
Pivot/Sideshift Assembly
Perform the following when removing/installing the tilt
cylinders:
1. Remove the mast as outlined in “Mast Removal” on
page 3-17.
2. Disconnect the four hydraulic lines at the tilt cylinders
and tag each line as it is disconnected.
NOTES
Use caution when installing and removing hydraulic
hoses. Hoses bent too sharply will kink. If kinks occur, do
not re-use hoses.
3. Remove the outside cotter pin from each tilt cylinder
clevis pin. With a suitable punch, knock the clevis pin
out. Remove the tilt cylinders from the pivot arm. Tag
each cylinder “right” and “left.”
4. Remove and tag the two sets of hydraulic lines inside
the pivot arm.
5. Installation is the reversal of removal. Lubricate the
clevis and clevis pins. Inspect all connections for leakage
and correct as necessary.
Tilt Cylinder Inspection
Clean and inspect all parts. Lay each part out in order as
it is removed to ease reassembly. If reference material is
necessary, refer to your SL120 Parts Manual, F-394.
3-13
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Crosshead Removal and Installation
Remove the crosshead and pivot arm assemblies from
the truck as a unit. Before beginning these procedures,
remove the mast and tilt cylinders, then perform the
following:
1. Pivot the mast out 90°. Shift the crosshead to the
extreme left. Disconnect both of the battery
connectors.
2. Tag and disconnect the electrical wiring and tie it out
of the way. Tag and disconnect the hydraulic lines at
both ends. Cap all lines to prevent fluid loss.
3. Remove the 4 chain anchor bolts. Remove the chain
connecting pin located under the chain anchors.
4. Remove the chain anchors.
5. Push the pivot arm to the closed position. Clamp it
firmly in place. Place a strap in the middle of the pivot
arm.
6. With an overhead hoist, lift the assembly slightly,
taking the weight off the crosshead assembly. Slide
the entire crosshead off to either side of the truck.
7. Installation is the reverse of removal. Lubricate all
moving parts, pads and bearing shoes.
8. Ensure all dirt and foreign matter is removed from the
telescoping slide, pads and shoes before installing
the crosshead.
9. Install hoses carefully. Do not over-tighten fittings
when installing hoses.
10. Before installing the crosshead, tie the chain on top
of the telescoping slide. This holds the chain in
position for installation of chain blocks.
Pivot Arm
Pivot Arm Disassembly
Perform the following when disassembling the pivot arm:
NOTE
“Top” and “bottom” in the following procedures refers to
the pivot arm assembly as it is installed on the truck.
1. After removing the crosshead from the truck, clamp
the entire assembly firmly on a workbench with a
sling and an overhead hoist attached.
2. Remove the capscrews from the top and bottom dust
covers. Remove the covers and gaskets.
3. Straighten the locking tabs on the top and bottom
lockwashers.
4. Remove the first locknut on top of the pivot shaft. Pull
off the lockwasher; then remove the second locknut.
5. Remove the bottom locknut and lockwasher.
6. With an overhead hoist, take the weight off the pivot
shaft. Carefully move both roller bearing cups.
3-14
7. Thread one locknut onto the top of the pivot shaft
until flush with the end of the shaft. With a soft-faced
mallet, rap sharply to drive the shaft out of the
crosshead. Remove the pivot arm with the hoist and
set it aside.
8. Remove the top and bottom spacer rings from the
crosshead.
9. Inspect the bearing shoes and pads located at the
bottom of the crosshead. Correct any unusual
conditions before re-installing the crosshead. Treat
the bolts and screws retaining the shoes and pads
with a permanent stud-locking compound.
10. Examine all parts of the pivot arm and crosshead
assemblies for excessive wear and chipping. Correct
as necessary. Clean all parts thoroughly. Do not use
gasoline as a solvent.
Pivot Arm Installation
Perform the following when installing the pivot arm:
1. Place the roller bearing cup over the bore in the
crosshead and use a soft-bar or soft faced hammer
to tap it firmly into place. Seat the cup squarely
against its retaining shoulder.
2. Place the top and bottom spacers into position.
3. Using an overhead hoist, lift the pivot arm into
position. Align the bores for the pivot shaft.
4. Lightly coat the pivot shaft with machine oil. Insert
the shaft into the bores from the bottom of the
crosshead. Ensure the shaft passes through the
bottom spacer. If necessary, rap the shaft into place
with a soft-faced hammer.
5. Pack the roller bearing cups with grease. Position
them over the ends of the shaft and carefully seat
them in the cups.
6. Thread the first top locknut onto the shaft.
7. Place a lockwasher over the bottom of the pivot shaft.
Thread the bottom locknut on the shaft until a 1/2”
clearance exists between the locknut and the bottom
bearing cone.
8. Place a spanner wrench in the holes provided in the
bottom of the pivot shaft. While holding the wrench to
prevent the shaft from turning, torque the top locknut
to 260 ft. lbs. Place a lockwasher over the first top
locknut. Thread the second top locknut snugly
against the first, and torque it to 20 ft. lbs.
9. Snug up the bottom locknut. Torque to 540 ft. lbs.
10. Half fill the dust caps with grease. Install the cups,
gaskets and cap screws. Apply a non-permanent
thread locking compound to the cap screw threads.
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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Pivot Cylinder Removal and Installation
Perform the following when removing/installing the pivot
cylinder:
1. Disconnect and tag the two hydraulic lines at the
pivot cylinder.
2. Remove the 2 bolts securing the pivot interlock
switch. Tie the switch out of the way.
3. Remove the clevis pins from the pivot cylinder and
remove the cylinder.
4. Clean and inspect all parts.
5. Installation is the reverse of removal. Lubricate both
clevises.
Sideshift
Sideshift Assembly
When performing maintenance on the sideshift assembly,
clean and thoroughly lubricate all parts when installing.
Failure to clean and lubricate parts results in excessive
and rapid wear.
Sideshift Bearing Shoe Adjustment
Check the clearance between the bearing shoe and
telescoping slide every three months or whenever
excessive yawing is noticed in the crosshead during
shifting. At the same time, perform a visual inspection of
the sideshift assembly for loose bolts or other unusual
conditions and correct immediately. Also, adhere to the
following procedures:
1. Using a feeler gauge, measure the clearance
between the bearing shoe and the telescoping slide.
If clearance exceeds 0.025”, adjust the slide. See
Figure 3-7.
Figure 3-7: Clearance Between Bearing Shoe and
Telescoping Slide
2. Break the bearing shoe retaining bolts 1/4 turn on the
side needing adjustment. Loosen the holding bolts 1
to 1-1/2 turns.
3. Adjust the shoe clearance by turning the adjusting
screws in for more clearance; out for less.
4. Tighten the holding and retaining bolts and re-check
the clearance. Repeat the procedure until you obtain
a clearance of 0.025”
Telescoping Slide Removal and Installation
Remove the telescoping slide from the truck without
removing the crosshead assembly. If the crosshead is
removed, refer to step 7 in the following procedures:
1. Pivot the mast assembly to the fully open position.
2. Shift to the full right position.
3. Disconnect the chain as described below. Pull the
chain out until it hangs free on both sides of the truck.
4. With a sling, attach an overhead hoist to the top of
the mast.
5. Shift the sideshift assembly to the extreme left.
6. Lift slightly on the sling to remove friction between
the slide and related assemblies.
7. Undo the rod and clevis pin from the shift cylinder.
8. Using a sling and overhead hoist, pull the telescoping
slide from the truck.
9. When installing, coat all slide surfaces with grease.
10. Position the slide at the left side of the truck.
Sideshift Chain Assembly Removal and
Installation
Perform the following when removing/installing the
sideshift and chain assembly:
1. Remove the 4 bolts holding the chain tension
retainers in place. Figure 3-8 on page 3-16.
2. While holding the adjusting screw, preventing it from
turning, loosen the adjusting nut until 1 inch of lateral
play exists in the chain.
3-15
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Sideshift Chain Assembly Adjustment

Check the sideshift chain periodically for proper
adjustment. Ensure the chain is completely free of lateral
play, and perform the following:
1. Pivot the mast fully open. Shift as far as possible to
the left.
2. Place a wrench on the flattened end of the chain
adjusting screw, preventing it from turning. Tighten
the adjusting nut against the chain tension block until
all play in the chain is removed. Repeat this
procedure alternately for both blocks in order to
maintain even tension on both ends of the chain.
3. Shift the crosshead as far as possible to the right.
Re-check the adjustment and re-adjust if necessary.

Load Roller Maintenance

Figure 3-8: Chain Tensioner Retainer Bolts Check for proper load roller shimming:
3. Raise the chain tension block and drive out the chain 1. The maximum side-to-side clearance, between load
pins on the bottom of the chain tension blocks. rollers, and the outer, or inner intermediate upright
assemblies, is 1/16 in. (1.5 mm).
4. Pull the chain out both sides of the crosshead until
the ends hang free. 2. To check the clearance, insert a pry bar between the
upright and roller, and measure the clearance at the
5. Remove the crosshead and telescoping slide
“XXX”. See Figure 3-9.
assembly.
3. If additional shims are required, refer to the
6. Remove the stationary way by removing the bolts
appropriate manufacturer’s mast service manual.
securing it to the frame. Use a sling to lift the
stationary way from the truck.
7. Turn the stationary way on its slide. Remove the
flex-nut securing the chain block mounting bolt. Treat
this bolt with non-permanent thread-locking
compound.
8. Use a punch to drive the mounting bolt free of the
stationary way and chain block. Do not damage
threads on the bolt.
9. Drive out the pins securing the chain lengths to the
chain block.
10. Installation is the reverse of the removal procedure.

Figure 3-9: Load Roller Maintenance, Top View

Mast
Mast Racking Adjustment
Perform the following when adjusting the mast rack:
1. The tilt cylinders adjust to prevent mast racking
caused by uneven tilt cylinder strokes.
2. With the mast forks empty, loosen the clevis locking
screws on the tilt cylinders with an allen wrench.

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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
3. Adjust the tilt cylinder rod strokes with a 1-1/8”
open-end wrench on the flats provided on the rods
until the cylinder strokes, extending and retracting,
equalize. Turn the rods clockwise to shorten and
counterclockwise to lengthen. The mast should
operate without racking or twisting. Maintain the
standard 3° forward/4° rearward tilt angles. See
Figure 3-10
4. Re-tighten the clevis lock screws.
Figure 3-10: Rearward Tilt Adjustment
Figure 3-11: Mast Lift Hose Disconnection
Mast Removal
Perform the following when removing the mast:
1. Position the truck in an open area beneath an
overhead crane with a capacity of at least 2 tons
(4000 lbs.) (1814 kg.)
2. With the key switch off, operate all hydraulic control
lever to release any residual pressure in the system.
3. Remove the forks and ensure the carriage is lowered
as far as possible.
4. Disconnect the mast lift hose, plugging the end to
prevent fluid loss and tie it back. Refer to Figure n-n.
5. Attach a sling through the mast and lift it just enough
to assume the weight of the mast.
6. Remove the tilt cylinder clevis and bolts and drive out
the clevis pins.
7. Remove the 2 trunnion bolts on each side and take
off the trunnion caps.
Mast Installation
Installation is the reverse of removal, with the following
exceptions:
1. Lubricate the trunnion bearings and torque the
trunnion bolts.
2. Secure the hydraulic connections.
Brake System Service
Brake Linings
Perform the following when replacing brake linings:
1. Replace brake linings as a set when thickness
measures less than 1/16” at the thinnest point. See
Figure 3-12.
2. Check the linings for scoring, glazing, or an
oil-soaked condition. Also, check the brake drum for
damage.
Figure 3-12: Brake Lining Thickness
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TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
3. Rough up glazed brakes with sand paper. If linings
appear oil-soaked or scored by entrapped foreign
matter, replace as needed.
4. Check the condition of the return spring. A faulty
spring or frozen wheel cylinder piston causes brake
drag.
5. Adjust the brakes to fit new linings.
NOTE
Overhaul wheel cylinders when fitting new linings.
Master Cylinder
Master Cylinder Removal
Perform the following when removing the master cylinder:
1. Remove the floor plate above the master cylinder.
2. Disconnect the two brake lines located on the side of
the master cylinder. Plug the outlets to avoid fluid
spillage, or allow the reservoir to drain into a suitable
container. Pumping the brake pedal speeds draining.
3. Loosen and remove the 2 master cylinder retaining
bolts located at the front of the master cylinder.
4. Remove the master cylinder from the brake pedal
linkage and remove the master cylinder from the
vehicle.
Master Cylinder Disassembly
Perform the following when disassembling the master
cylinder:
1. Remove the reservoir cover and discard the old
brake fluid. Remove the rubber boot.
2. Remove the snap ring and push rod washer. Hold the
piston assembly down when removing the snap ring.
The spring pressure forces the components outward.
3. Remove the piston assemblies.
Master Cylinder Inspection
Perform the following when inspecting the master
cylinder:
1. Clean all rubber parts in clean brake fluid. Clean all
metal parts in denatured alcohol.
2. Clean out the master cylinder reservoir, removing all
traces of dirt or moisture.
3. Check for clear fluid passages in the master cylinder.
If necessary, blow passages clear with compressed
air.
4. Inspect the cylinder bore. The bore should appear
smooth and featureless--free of rust, pitting or signs
of wear. Remove minor pressure marks or
discolorations with a crocus cloth. Do not use sand
paper or an emery cloth.
3-18
NOTE
Even minor bore damage can cause the unit to leak.
Replace or hone the master cylinder if the bore damage
exists.
5. Check the condition of the piston assembly. The
edges of the piston should appear smooth and
featureless.
NOTE
After the unit is disassembled, replace rubber parts
regardless of their condition.
6. If the spring contains lost tension, replace as
necessary.
7. Minor damage to the master cylinder is remedied
with a hone. Clean the master cylinder thoroughly as
outlined above.
8. Coat the bore with clean brake fluid.
9. Secure in a bench vise.
10. Remove material from the cylinder bore in single
passes, checking bore condition after each pass.
Remove only enough material to remove
imperfections.
11. Wash the master cylinder in hot soapy water and dry
it thoroughly. Check for burns around the fluid
passage hole.
12. Coat all inner surfaces with clean brake fluid
immediately.
Master Cylinder Assembly
Perform the following when assembling the master
cylinder:
1. Install the secondary and primary piston assemblies
into the body casting.
2. Install the push rod washer and snap ring.
3. Re-install the rubber boot.
Master Cylinder Installation
Perform the following when installing the master cylinder:
1. Installation is the reverse of the removal procedure.
2. Engage the master cylinder with the pedal linkage
and bolt it in place.
3. Add brake fluid to the reservoir and pump the pedal
slightly until fluid begins to come out of the outlet.
4. Connect the brake line, top the reservoir up with
clean, fresh brake fluid and bleed the system.
Master Cylinder Backing Plate Assemblies
Rear backing plate assemblies contain identical features
except for the backing plate itself. The same service
procedures apply to all plates.
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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Service the brake linings after the wheel is removed. 4. Using the brake drum gauge (at the drum diameter
Remove the wheel cylinder from the backing plate after setting), adjust the brakes to fit into the drum. See
the plate is removed on the drive axle. After aligning the Figure 3-14.
brake, overhaul or replace the wheel cylinder. On most
hydraulic brakes, piston and cup appear pushed inward
after insalling a new lining.

Brake Adjustment
The bakes contain automatic adjusters and do not
require adjustment during normal truck operation.
Readjust the brakes after performing the following
services:
1. Replace or remove the automatic adjustment device.
2. Replace or repair brake shoes or brake drums.

NOTE
Perform adjustment to brake shoes and drums on cold
brakes only.
The brake adjustment procedure is as follows:
1. Using a suitable lifting device, raise the truck off the
floor and support the truck with approved devices of
sufficient load bearing capacity.
! WARNING
When lifting or supporting the truck, ensure all
lifting devices, jacks or safety stands comply with
weight restrictions. Do not crawl beneath the
truck. Keep unauthorized personnel away from
the truck service area.
2. Remove the wheel.
3. Measure the diameter of the wheel hub/brake drum
with a brake drum gauge. See Figure 3-13 on
page 3-19.
Figure 3-14: Fitting the Drum
! CAUTION
Accurate adjustment of the brakes is critical to
the performance of the automatic adjustment
device. An adjustment made too small damages
the adjustment device.
5. Re-install the wheel.
6. Loosen the self-locking hex head screw, securing the
automatic adjustment device.
7. Actuate the brake several times, allowing the brake
shoes and the adjustment device to center inside of
the brake drum.
8. Torque the self-locking hex head screw to 85 lbs.
9. The wheels should turn with an equal amount of
resistance. Lower the vehicle and perform a road
test.
10. At an empty travel speed of 5-1/2 to 6 MPH, apply
the brakes ten times in forward and reverse. Observe
the braking behavior of the vehicle.
The automatic adjustment device is now set for optimal
performance. This adjustment is required on all brakes
on the vehicle.

Figure 3-13: Measuring the Brake Drum

3-19
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Bleeding the Brakes

Perform the following when bleeding the brakes:
1. If the pedal becomes spongy, indicating air in the
lines, bleed the brake system. Also, bleed the brakes
if the fluid in the master cylinder dropped to low,
leaks appear in the brake lines, or any brake line is
disconnected.
2. When bleeding the entire system, start with the
wheel farthest from the master cylinder (right rear)
and work toward the closest.
3. Use clean, new brake fluid from a sealed container.
Do not add fluid from an old or unsealed container --
impurities may contaminate the fluid.
4. Check the fluid level in the master cylinder by
removing the access plate, cleaning off the top of the
Figure 3-15: Axle Adjustment
master cylinder around the filler cap, ad removing the
cap. The proper fluid level is 3/4” below the cap hole. 4. Remove the obstruction parts
If necessary, top up with fresh brake fluid. Refit the 5. Loosen the fitting nuts and horizontally remove the
cap upon completion. axle housing. See Figure 3-16.
5. Locate the bleed screws on the wheel being bled.
Turn the steer wheels in either direction to ease
access.
6. Fit a short length of plastic tubing to the bleed nipple,
immersing the other end of the tube in a container
with a couple of inches of new brake fluid. Ensure the
tube is a snug fit on the nipple.
7. With an assistant applying the brakes hard several
times and holding down the pedal, loosen the bleed
nipple. Push the pedal to the floor. Close the bleed
nipple before the pedal bottoms and before the
assistant releases it. Repeat the procedure until the
Figure 3-16: Axle Housing Removal
fluid coming out of the nipple is free of air bubbles.
8. Re-check the master cylinder fluid level and top up to
the proper level, if necessary. Removal of Drive Disc Brakes
9. Check the pedal action. If it is not firmer, repeat the Perform the following when removing the brake discs:
procedure. Repeat the operation with the other 1. When disassembling parts, note the direction of the
brakes. installation.
2. If the brake discs do not need replacing, remove the
Drive Brakes complete pack without changing the position of the
discs. See Figure 3-17 on page 3-21.
Perform the following when servicing the brakes:
1. Check, adjust or torque dimensions, pressures, etc.
Adjust until a minimum thickness of S=4,5 mm is
achieved.
2. Renew brakes if necessary.
3. Tighten dimensions if necessary. See Figure 3-15.

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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

4. When adjusting the brake disc’s gap, adjust the bolts

counter clockwise and turn them a half revolution
clockwise. This corresponds to a gap of 0.5 mm
between the brake disc. See Figure 3-20.

Figure 3-17: Disc Brake Removal

3. When assembling, perform the opposite. Align the
lubrication holes. See Figures 3-18 & 3-20.

Figure 3-20: Adjust Brake Disc’s Gap

5. Applying pressure into the hydraulic circuit, remove
the brake pistons using air pressure at 45psi. See
Figure 3-21.

Figure 3-18: Aligning Lubrication Holes (1)

Figure 3-21: Removal of Brake Pistons

6. When installing o-rings and brake pistons, ensure
that either the pistons or the cylinders contain
scratches or indentations. Scratches or indentations
will cause leaks. See Figure 3-22 on page 3-22.

Figure 3-19: Aligning Lubrication Holes (2)

3-21
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Figure 3-22: Install O-Rings
7. Applying pressure into the hydraulic circuit, check
tightness with compressed air at 15psi for 10 minutes
on each side. See Figure 3-23.
Figure 3-23: Checking Tightness
3-22
Hydraulic
Hydraulic Pump Motor
Hydraulic Pump Motor Removal and
Installation
Perform the following when removing/installing the
hydraulic pump motor:
1. Loosen and remove the hydraulic reservoir retaining
bolts. Remove the hydraulic reservoir to gain working
clearance.
2. Remove the suction line hose from the hydraulic
pump suction fitting.
3. Remove the 2 pressure lines from the pump outlet
fitting.
4. Tag and remove the 2 power cables from the pump
motor terminals.
5. Back-off the 2 nuts at the upper end of the pump
motor mounting bracket. Back-off a minimum of three
turns.
6. Attach a sling by means of an overhead crane to the
pump motor assembly. Remove the 2 nuts at the
base of the pump motor mounting brackets.
7. Allow the pump motor assembly to fall slightly
forward until the pump motor bracket is free of the
studs at the upper end of the pump motor mounting
bracket.
8. Raise the pump motor assembly slowly out of the
truck chassis. Install the pump motor assembly by
reversing the procedure outlined above.
Hydraulic Pump Motor Brush Replacement
Perform the following when replacing the hydraulic pump
motor brush:
1. Disconnect both of the battery connectors.
2. Remove the access plate on the right side of the
truck. The plate contains a “top” and “bottom.” Ensure
it is correctly positioned when installing.
3. Remove the brush end motor cover.
4. Remove the brush holder clips. Unscrew the brush
pigtails to remove the brushes.
5. Check the brushes for wear and replace them as a
set if wear is excessive or if contact surface damage
occurs. Replace brushes if they show wear within
3/8” of the pigtail.
6. When fitting new brushes, sand each brush into the
curvature of the commutator. A minimum of 85%
surface contact with 100% brush arc is
recommended. Replace brushes with the same
grade size as the original.
F-602-R1 Edition
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
7. Check the commutator for excessive wear, Cracks or
burnt spots. Commutator run out should not exceed
0.002” total indicated reading, with a bar-to-bar
variation of 0.0002”. Keep the mica bar-to-bar
insulation below the copper surface. When
commutator wear results in flush or protruding mica,
undercut the mica to a depth equal to the thickness
of the mica, or approximately 0.025.
! WARNING
Wear a dust mask when cleaning the commutator.
8. Clean the commutator thoroughly before installing
the brushes. After installation, run the motor to
ensure brushes seat properly.
NOTE
If the brushes show signs of arcing, seat them using a
brush seater and commutator cleaner.
9. When seating the brush, run the motor and press
down hard on the brush. Apply the brush seater at
the heel of the brush. Friction of the turning
commutator releases the brush seater material and
carries it under the brush.
10. When cleaning the commutator, run the motor, hold
the cleaner against the commutator and slowly move
it back and forth across the face.
11. Wearing a dust mask, use compressed air to clean
out matter generated by the seating and cleaning
operations.
12. Re-fit the covers.
Hydraulic Control
Hydraulic Control Valve Removal and
Disassembly
Perform the following when removing/disassembling the
hydraulic control valves:
1. Disconnect, tag and plug all hydraulic lines at the
control valves. Remove the mounting hardware and
lift the assembly out.
2. Disassemble the valves only as far as necessary to
correct the malfunction. Re-install parts removed
from one section to the same section. Replace all
seals whenever the valve assembly is over-hauled. If
the sections separate, replace the seals and o-rings
in-between.
3. Remove the two 2 c-clips from the rod and slide it
out. Remove the control levers.
4. Remove the nuts holding the valve sections together
and separate the sections. Discard the o-rings and
seals.
5. Remove the relief valve plug, o-ring and spring from
the inlet section. Remove the control valve with the
relief valve. Install this assembly with the hex nut up.
6. Remove the pin from the end of the spool. Remove
the screws securing the retainer, sleeve and switch
brackets. Slide out the spool. Discard the o-ring,
quad rings and back-up ring. Remove c-washers and
spring.
7. If a cam is removed from the spool, install a new one
when assembling.
8. To disassemble the check valve, grip the stem of the
plug with suitable pliers and pull it out. Remove the
rings. Remove the spring and ball.
Hydraulic Control Valve Inspection
Perform the following when inspecting the hydraulic
valves:
1. Discard all old seals.
2. Wash all parts in clean mineral oil solvent.
3. Remove burrs by light stoning or lapping. Ensure
there is no paint or burring on mating surfaces of the
valve bodies.
4. Inspect the valve spools for burrs and scoring. Check
the spool bores. If scoring is not deep enough to
cause objectionable leakage, stone the surface or
polish with a crocus cloth. If scoring is deep, replace
the spool and valve body.
5. Ensure the spool in the valve body moves freely.
6. Ensure the relief valve moves smoothly in its bore.
The valve should move from its own weight.
Hydraulic Control Valve Assembly
Perform the following when assembling the hydraulic
control valve:
1. Use all new o-rings and seals.
2. When assembling the check valve, install a new
back-up ring and o-ring on the plug with the o-ring
towards the spring and ball.
3. Insert the ball, then the spring. Insert the plug into
the body, ensuring the hole in the plug lines up with
the stud hole in the body.
4. When fitting c-washers to the spools, install the
c-washers so the flat sides face away from the
springs.
5. Install the relief valve with the hex nut up.
6. Use petroleum jelly to hold seals in position when
joining the sections.
7. Torque the nuts holding the sections together
gradually and evenly to 15 feet. When fitting the
sections, place all seals in their grooves.
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TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

U-Cup Seal

Seal
Retainer
U-Cup Seal
Plug
O-Ring
Seal
Spring Center Sections

Control Valve
Sub Assembly

Inlet Section

C Washer
Outlet
Section

Centering Spring
Quad Ring
O-Ring
Sleeve Stud
Ball
Retainer
Spring Nut
Dustcover O-Ring
Screw Back-Up Ring
Plug
Figure 3-24: Hydraulic Control Valve

Lift Control Valve Lift Control Valve Inspection

A special tool, T-9, is required to replace the u-cup seal in Perform the following when inspecting the lift control
the lift control valve. A T-9 tool is contained in Drexel’s valve:
Seal Kit Part Number 28205 1. Clean all metal parts in clean mineral oil solvent.
2. Clean seal grooves thoroughly.
Lift Control Valve Disassembly
3. Replace all rubber parts (seals, o-rings, etc.) with
The following procedures, the control handle side of the new ones.
valve is the “front,” and the other side is the “back.” See
4. Check the spool and its groove for signs of wear or
Figure 3-24 as an aid to disassembly.
damage. If worn or damaged, replace as an
1. At the back of the valve, remove the bonnet assembly assembly
by removing the snap ring and the spring assembly
screw. Lay parts out in the order of removal for easy
reassembly.
2. At the front of the valve, remove the handle
assembly.
3. Push the spool into the housing from the front
(handle side) until the front seal in the body is
exposed. Remove the front seat.
4. Pull the spool out of the housing from the front of the
valve. Ensure the spool and bore do not become
scratched during this operation.
5. Remove the back seal.

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 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Lift Control Valve Assembly
Perform the following when assembling the lift control
valve:
1. Replace the spool through the front (handle side) of
the housing, ensuring the end with the bolt holes
enters the housing first. Push the spool into the valve
until the spool end touches the back seat groove.
Insert a new seal in the back groove, ensuring the
u-cup of the seal is placed toward the valve body.
Pinch one side of the seal, causing the seal to bend
into a shape slightly smaller than the seal groove,
straighten the seal by running a smooth rod around
the exposed surface of the seal until a perfect fit
occurs. To check, run a finger around the exposed
edge of the seat. The result is a smooth, perfect ridge
with no kinks.
2. Insert the T-9 tool into the housing from the back of
the valve and through the new seal until the shoulder
of the T-9 touches the valve housing.
3. Push the spool into the housing from the front,
keeping a firm grip on the T-9 in back until the front of
the spool is forced into the housing and the front
groove is visible. In pushing the spool through the
housing, a slight twisting of the spool and the T-9
assists the movement. Do not push the spool too far.
Pushing the spool too far allows the back seal to
enter the grooves of the spool and cut the new seal.
4. Install a new front seal, ensuring the u-cup side of the
seal in toward the valve housing. When the seal is
properly placed in the groove, straighten the seal by
running a rod around the exposed edge of the seal
until a perfect fit occurs. The result is a smooth, even
ridge with no kinks.
5. Insert the T-9 into the spool bore (front) and with a
twisting motion; carefully push the tool through the
new seal until the spool shoulder stops progress.
With a twisting action, push the spool back against
the T-9 until 1/4” of the polished surface of the spool
remains exposed at the front of the valve. Remove
the T-9 from the front of the valve.
6. The remainder of the procedure is the reverse of
disassembly.
7. Tighten the spring assembly screw to 10 ft. lbs.
Drive System
Traction Motor
Traction Motor Brush Replacement
! WARNING
Ensure the truck is properly supported with
approved devices of sufficient load bearing
capacity.
Perform the following when replacing the traction motor
brushes.
1. Remove the batteries and plywood liner at the
bottom of the battery compartment. Raise the truck
from the floor a minimum of 18 inches or more. Place
a minimum of 4 support jacks beneath the frame. A
cut-out in the front of the battery compartment is
provided for maintenance.
2. Remove the brush covers from the traction motor.
3. The traction motor contains 12 brushes. Bend the
retainer spring(s) back and take out the brush(es).
See Figure 3-25. Unscrew the brush pigtail(s) to
remove the brush(es). See Figure 3-26.
4. Check the brushes for wear and replace them as a
set if wear is excessive or if the contact surfaces
appear damaged. Replace brushes if they are worn
to within 3/8 inch of the pigtail rivet.
5. When fitting new brushes, sand each brush into the
curvature of the commutator. Use a minimum of 85%
surface contact with 100% brush arc. Use exactly the
same brush grade as the original. See Figure 3-27.
Figure 3-25: Traction Motor Retainer Springs
3-25
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Figure 3-26: Traction Motor Brush Removal
Figure 3-27: Replacement Brushes
6. Check the commutator for excessive wear, cracks or
burnt spots. Commutator run-out will not exceed
0.002 inches in total indicated reading, below the
copper surface. When commutator wear results in
flush or protruding mica, undercut the mica to a
depth equal to the thickness of the mica, or about
0.025 inches.
! WARNING
Wear a dust mask when cleaning the commutator.
7. Clean the commutator thoroughly before installing
the brushes. After installation, inspect the brushes for
proper seating and check by running the motor.
NOTE
If the brushes show signs of arcing, seat them using a
brush seater and commutator cleaner. The procedure is
outlined in Items 8, 9, 10, and 11 below.
8. To seat the brushes, with the motor running, press
down hard on the brush and apply the brush seater
at the heel of the brush. Friction of the turning
commutator releases the brush seater material and
carries it under the brush.
3-26
9. To clean the commutator, with the motor running,
hold the cleaner against the commutator and slowly
move it back and forth across the face.
10. Wearing a dust mask, use compressed air to clean
out matter generated by the seating and cleaning
operations.
11. Refit the covers. Replace the cover gaskets if worn or
damaged.
Traction Motor Disassembly
Perform the following when disassembling the traction
motor:
1. Remove the mounting brackets and end covers.
2. Remove the brush springs and brushes.
3. With the drive end of the motor pointing up, remove
the drive end bearing bracket bolts.
4. Lift the armature and drive end tapping the bracket
loose from the mainframe as it is lifted.
5. Disconnect all connections between the frame and
the commutator end bearing bracket. Remove all
bolts holding the commutator end bracket to the
magnet frame. Remove the bracket from the frame
by tapping it loose.
6. Assembly is the reverse of disassembly.
Traction Motor Cleaning
Perform the following when cleaning the traction motor:
1. Keep both the inside and outside of the motor clean
and free of dirt and grease.
2. Remove loose dirt by vacuum cleaning or dry
compressed air. Vacuum cleaning is recommended.
Compressed air drives dirt deeper into cracks.
3. Remove loose dirt with a cleaning rag or a soft bristly
brush. Clean clogged air openings without damaging
insulated parts.
! CAUTION
Do not use solvents. Solvents carry electrical
conducting dirt into the insulation system.
4. If the insulation resistance is low after cleaning, bake
the armature at 90°C (194°F) to remove moisture or
to varnish treat and bake for reliable repair.
F-602-R1 Edition
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Traction Motor Bearings 3. Remove the wheel bearing lock nut after bending
back the locking tab on the lockwasher. See
Standard bearings contain double shielding and
Figure 3-28.
pre-lubrication. Normally, standard bearings do not
require lubrication. 4. Pull the wheel off the spindle enough to allow
removal of the wheel bearing. Take out the bearing
Under normal conditions, the bearings fail after several
and place it in a clean place. Remove the wheel. See
years of service due to a lack of proper lubrication, either
Figure 3-29.
from dirty contaminants or insufficient oil in the grease.
New grease consists of about 80% oil, 20% soap. When 5. To remove the inner bearing, pry out the grease seal.
bleeding results in a reduction of oil to about 60%, bleed
rate reduces to a level that cannot supply sufficient
lubrication. As a routing practice during maintenance
overhauls, replace the bearings.
When replacing bearings, replace with exact
replacements or bearings with interchangeable features.
Also, bearings must contain high temperature grease.

Traction Motor Insulation

Perform the following for traction motor insulation:
1. Check insulation resistance during each
maintenance inspection.
2. Excessive dirt, moisture, or impending failure causes
low resistance.
3. Although motors run with insulation resistance as low
as 1/4 megohm, any resistance below 1 megohm Figure 3-28: Wheel Bearing Locknut Removal
leads closer to inspection to determine the cause.
4. Correct low resistance values due to dirt by cleaning,
followed by a varnish dip and bake.
5. Correct low resistance due to moisture by baking the
motor in a 90°C (194°F) oven until the insulation
resistance rises above this value and stabilizes to a
nearly constant value.

Steer Axle
Steer Axle Wheel Removal
Perform the following when removing the steer axle
wheel:
1. Raise and safely support the rear of the truck using a
suitable lifting device. Lift the rear wheel
approximately one inch off the ground. Figure 3-29: Wheel Spindle Removal

! WARNING Steer Axle Wheel Inspection

Ensure that the truck is properly supported with
approved devices of sufficient load bearing
capacity.
2. Remove the four (4) screws holding the hub cover.
Secure the screws with a non-permanent
thread-locking compound.
Perform the following when inspecting the steer axle
wheel:
1. Clean the wheel bearings in solvent. Check the
bearing rollers for pitting, flat spots, or the other
obvious damage. Replace damaged or questionable
wheel bearings in sets.

3-27
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

2. Check the wheel bearing inner races while still in
place in the hub. The races appear pressed in and
removal damages them. If races are not smooth,
rough or cracking, drive them out. Press new races
straight into the hub, ensuring against tilting.
3. Check the condition of the brake shoes. Inspect the
wheel drum. If the surface is scored, grooved or
worn, replace the hub and the brake shoes.
! WARNING
Wear a dust mask when using compressed air to
clean equipment and parts.
2. Disconnect the tie rods from the spindles and bell
crank by removing the cotter pins and washers. Note
the number of washers at each point and save them
for reassembly.
3. Break the tack welds at the grease cap and remove
the caps. See Figure 3-30.
4. Remove the steer cylinder by taking out the lock bolt,
mounting pin, and cotter pin on the other end.
5. Remove the locknuts, securing the king pin locking
bolts. Tap out the bolts. Tap out the king pins.
Figure 3-31 on page 3-28.

4. Check for fluid leakage. Blow out the brake

assemblies using compressed air.
5. Check the condition of the grease seal. Replace
grease seals with worn or damaged lips.

Steer Axle Bearing Installation

Perform the following when installing bearings:
1. Pack the bearing with the type of grease
recommended in the preventive Maintenance
section.
2. Slide the wheel straight onto the spindle to avoid
damage to the grease seal lips.
3. Support the wheel while installing the outer wheel
bearing. Install the lockwasher. Tighten the locknut to
30 ft. lbs.; then back it off and tighten to 15 ft. lbs.
Check for free rotation of the wheel. Bend up the tab Figure 3-30: Grease Cap Disassembly
on the lockwasher.
4. Replace the cover and secure the screws with a
non-permanent thread-locking compound.

Steer Axle Removal

Perform the following when removing the steer axle:
1. Position the truck beneath a crane or other suitable
lifting device of sufficient capacity to safely support it
when removing the steer axle.
2. Disconnect the brake lines at the rear wheels and
plug the lines in order to prevent fluid loss.
3. Disconnect the lines at the steer cylinders and plug
the ends. Remove the trunnion bolts at both ends of
the steer axle. Self-locking nuts hold the bolts.
Remove and save any thrust bearings.
4. To allow pushing out of the steer axle, raise the rear
of the truck sufficiently.

Steer Axle Disassembly Figure 3-31: King Pin Removal

Perform the following when disassembling the steer axle: 6. Remove the thrust bearings.
1. Remove the wheel and brake assemblies as 7. Remove the bell crank in the same manner as
previously outlined. described for the wheel spindles. Note the thrust
bearings at the top and bottom of the bell crank.

3-28 F-602-R1 Edition

 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Steer Axle Bearing Inspection
Inspect the bearings as follows:
1. Check the condition of all the bearings. Replace any
damaged bearings. Drive in new bearings.
2. Carefully check the condition of all welds in the
assembly.
Steer Axle Assembly
Assembly is the reverse of disassembly. Note the
following points:
1. If removal of the steer cylinder clevis took place,
ensure it is threaded on a distance equal to the
diameter of the cylinder rod.
2. Put all thrust bearings and washers back in place.
Install enough thrust washers on the tie rod ends so
play is minimal.
3. Install tie rods so the end with the left-hand threads is
closest to the center of the assembly.
4. When installing kingpins, ensure the flat is aligned
with the cross hole in the spindle. Tap the kingpins in
carefully after lubrication. Ensure the kingpins do not
go straight through the spindles.
5. After completion of assembly, align the wheels.
Steer Axle Wheel Alignment
Perform the following when aligning the wheels:
1. Loosen the lock nuts on the left-hand tie rod and turn
the rod until it is in the middle of the adjustment
range.
2. Use a straight-edge to align the left wheel or spindle
relative to the rear of the weldment.
3. Turn the right side tie rod in or out to align the right
wheel or spindle, relative to the left side tie rod.
When alignment occurs, tighten the locknuts on the
tie rods.
Steer Axle Installation
Installation is the reversal of removal. Note the following
points:
1. Put trunnion thrust bearings in place. Lubricate the
trunnions before assembly.
2. Torque the trunnion bolts to 150 ft. lbs.
Electrical
Line and Pump
Line and Pump Disassembly
Perform the following when disassembling the line and
pump:
1. Loosen the 4 long bolts in each corner and remove
the 2 contact spacers.
2. Remove the 2 stationary contacts.
3. Remove armature and moveable contact assembly.
4. Remove the magnet frame and coil from the base
5. Loosen and remove the nut from the armature and
moveable contact assembly. When moving the parts
from the stud, note the order.
Line and Pump Assembly
Before assembling, clean all parts and inspect for wear.
Replace parts if required. The assembly process is the
reverse of disassembly. Perform the following
precautions:
1. Force the small end of the spiral over the small
diameter on the armature assembly.
2. Reassemble the armature parts and tighten the nut
with 14 to 18 inch pounds torque.
3. Locate the projections on the magnet frame in the
indentations on top of the coil with the frame.
4. Add the armature and movable contact assembly.
5. Properly seat the stationary contacts in the slots of
the molded stationary contact support and add the 2
contact spacers.
6. Tighten the 4 long bolts with 14 to 18 in. lbs. torque.
Forward and Reverse
Forward and Reverse Disassembly
Perform the following when disassembling forward and
reverse:
1. Loosen the 4 long bolts in each corner. Remove the
top contact retainer and the long bolts.
2. Remove the 2 top stationary, normally closed
contacts.
3. Remove the 2 contact spacers.
4. Remove the 2 bottom stationary contacts.
5. Remove armature and the movable contact
assembly.
6. Remove the magnet frame and coil from the base.
7. Loosen and remove the nut from the armature and
movable contact assembly. When moving the parts
from the stud, note the order.
Forward and Reverse Assembly
Before assembling, clean all parts and inspect for wear.
Replace parts if required. The assembly process is the
reverse of disassembly. Perform the following
procedures:
1. Force the small end of the spiral over the small
diameter on the armature assembly.
3-29
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
2. Reassemble the armature parts and tighten the nut
with 14 to 18 inch-pounds torque.
3. Locate the projections on the magnet frame in the
indentations on top of the coil with the frame.
4. Add the armature and movable contact assembly.
5. Properly seat the stationary contacts in the slots of
the molded stationary contact support and add the 2
contact spacers.
6. Add the 2 top stationary contacts and top contact
retainer. Insert the bus connector before proceeding.
7. Tighten the 4 long bolts in a uniform manner using a
diagonal tightening sequence. Tighten the bolts with
14-18 in. lbs. torque.
Dash Panel
Dash Panel Module Removal
Perform the following when removing the dash panel
module:
! WARNING
Before servicing the dash panel, disconnect both
of the battery connectors.
1. Remove the console front cover.
2. Unscrew the 4 locking screws, one from each corner
of the dash panel.
3. Lift up the panel to free the nylon pins from the
console.
4. Mark the electrical connectors for proper mating.
Disconnect the wiring and take off the dash panel.
Dash Panel Disassembly
Perform the following when disassembling the dash
panel:
1. Mark all electrical connections before removing any
of the dash panel switches or gauges.
2. To remove the directional control levers assembly,
remove the snap ring accessible through the
mounting bracket. Take off the handle and housing.
Remove the bolts holding the bracket to the panel.
Reach through the bracket to loosen the screws
securing the switch.
3. To remove the battery capacity indicator, mark and
then disconnect the 3 leads. Loosen the clamp
screws and take the gauge out from the front of the
panel.
4. Remove key and light switches after marking their
leads for position and unscrewing the switch knobs
and locknuts.
3-30
Dash Panel Module Assembly and
Installation
Assembly is the reverse of the disassembly procedure.
Ensure proper electrical connections. Ensure clean and
tight electrical connection points.
Battery
Battery Removal
Perform the following when removing the battery:
1. Drive the vehicle to an area having an overhead
lifting device with a lifting capacity of at least 4000
lbs.
2. Clean the area around the truck.
3. Lower the forks to the floor. Turn the Keyswitch off.
4. Apply the parking break.
5. Raise the operator’s seat.
6. Disconnect the battery from the truck.
7. Open the battery compartment cover.
8. Remove the battery compartment side cover.
9. Attach a spreader bar with chains and hooks to the
overhead crane.
! WARNING
A short circuit occurs when a lifting hook
contacts an exposed battery cell link.
10. Attach the spreader bar chain hooks to the lifting
eyes at the side of the battery. Remove only 1 battery
at a time.
11. Raise the battery enough to clear the battery and
remove it from the right side.
12. Installation is the reverse of the removal procedure.
Replacement batteries must meet the capacity and
weight specifications shown on the vehicle
nameplate.
F-602-R1 Edition
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Battery Service
! WARNING
Adhere to safety precautions in eve aspect of
battery service. Read and comply with all warning
and caution notes relating to the batteries in the
safety precautions section at the front of this
manual.
Checking Battery State-of-Charge
Check the individual cells daily with a hydrometer. When
checking the cells, disconnect the battery. Check at least
three cells -- different ones every day.
Use a high quality hydrometer in good condition. Wear
rubber gloves, safety goggles and face shield during the
procedure. The hydrometer glass syringe is breakable.
Carefully wash the syringe to remove impurities before
the cell check
Do not use a hydrometer in lead-acid batteries previously
used in alkaline batteries.
Ensure the rubber tip of the hydrometer is fully immersed
in the electrolyte and remains so throughout the check,
otherwise air squeezes out and a false reading occurs.
Squeeze and release the rubber bulb slowly. Draw
sufficient electrolyte so the float is midway in the barrel.
The float must not touch either top or bottom. Hold the
hydrometer vertically so the float is free. Tilting the float
causes it to stick to the sides of the barrel. Shake the
hydrometer slightly to ensure the float is not sticking.
Hold the hydrometer at eye level. The electrolyte curves
upward slightly where is meets the glass of the barrel and
the float. Do not confuse the electrolyte curve with the
true level reading.
Correct specific gravity readings for electrolyte
temperature. Add 0.003 to the actual specific gravity for
each 10°F. above 77°F. This is electrolyte temperature,
not air temperature.
After the check, return the electrolyte to the same cell
before removal.
Do not continue to discharge a battery beyond the point
where the specific gravity is less than 1.125.
Watering the Battery
Check the electrolyte level daily. Electrolyte level is one of
the most important factors in battery life.
• Check every cell.
• Do not allow the level to fall below the top of the
battery plates. If the batteries are charging, add just
enough water to cover the tops of the cells. Adding too
much water causes loss due to expansion and
splashing during the charging process. After charging
is complete, re-check the level of each cell and top-up
to the proper level.
• Do not fill the cells above the bottom of the vent well.
• Wear rubber gloves when adding water to the battery.
• Use an automatic cell-filler or plastic container. Do not
use metal or glass containers. Glass may break and
metal causes a short circuit between inter-cell
connectors if handled carelessly.
• Do not add acid to the batteries during routing
maintenance. Add water only
• Ensure the water is approved for battery use and free
of impurities. Impurities in the water remain in the
battery and increase with each filling, shortening
battery life.
• Excessive water requirements indicate the batteries
are overcharged.
After watering the battery, replace all vent plugs and
tighten to prevent loss of electrolyte.
Charging the Battery
Before removing the batteries from the truck, tag the
cables for polarity to prevent possible reversal of
connections. If doubt exists, check the polarity with a
meter.
The vehicle is equipped with battery restraints to prevent
vertical movement of the batteries. When exchanging
batteries, reinstall the restraints for safe operation of the
truck.
Perform battery charging in a well-ventilated area
removed from flames, sparks, and naked lights. Provide
an emergency eye-wash bottle or fountain near the
battery charging area. Do not permit smoking in the
battery changing area.
Check the electrolyte level in each cell before charging.
Charge a storage battery at any current rate that does
not produce excessive gas or bubbling of the electrolyte
or result in temperatures above 110°F (125°F for short
periods). During a normal recharge, the temperature will
not rise more than 15° - 20°F. Excessive temperature
rising decreases the battery voltage on the charge. A
higher current flows, further raising the temperature and
compounding the effect.
3-31
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Ensure the batteries receive the proper amount of
charge. Consistent undercharge or failing to recharge the
batteries completely at the reasonable intervals causes
gradual sulfation of the negative plates, loss of capacity
and shortened life. Over charging higher than proper
current rates or failure to stop the charge when complete
causes high electrolyte temperatures, loss of material
from positive plates and corrosion of the opposite grid
structure.
Do not “boost charge” the batteries during lunch periods
or rest breaks.
During the last hour of charging, cell voltages will not
vary more than +0.002/-0.000. If the measurements
show more of a variation, ensure battery charge is the
proper length of time, the charger is the right size for the
battery, all connections are clean and tight and the AC
supply voltage does not vary more than 10%.
If variations remain, equalize the battery. To equalize, set
the charger timer to 11 hours instead of 8 hours. Equalize
charge the battery every month, not every week. The
Equalizing charge is a continuation of the regular charge
at the finish rate until no further rise in voltage or specific
gravity occurs over a one hour period. Equalizing
ensures a full charge and balances any minor differences
between cells.
A large quantity of explosive gas is given off during
battery charging. This gassing continues after charging is
complete.
Remove water spilled on the batteries during charging.
Also, remove electrolyte splashed from the cells.
Neutralize any acid or electrolyte spillage immediately. If
acid contacts any part of the skin, wash it off with water
immediately and consult a physician.
Cleaning the Battery
Keep the battery, including tray and connectors, clean
and dry. Grease, oil, dirt or moisture cause a current path
grounding the batteries. Grease and oils disintegrate the
battery sealing compound and cause leakage.
Electrolyte spilled on batteries and surrounding areas
does not evaporate. Electrolyte corrodes metals subject
to attack by sulfuric acid and increases the possibility of a
voltage leak.
Post and enforce battery cleaning schedules. Wipe off
grease and oil with a cloth dampened with a chlorinated
hydrocarbon solvent or a similar cleaner. Do not use
ammonia products to clean a battery.
3-32
Neutralize electrolyte on the battery top or tray by
applying a warm solution of bicarbonate of soda (one
pound of soda to one gallon of water). Ensure the vent
caps remain firmly in place before applying the solution;
the solution neutralizes the electrolyte if it gets into the
cells. Allow the solution to fizz for a a few minutes, then
wash off thoroughly with clear water. Perform the above
procedure twice a year.
Examine the gas escape holes in the vent plugs for
clogging. Wash all vent plugs yearly.
If corrosion exists on metal parts of the tray or
compartment, clean with a bicarbonate of soda solution
and refinish with acid-resistant paint.
Remove accumulated dust and dirt on the batteries and
battery tray with plain water, compressed air or a cloth.
Battery Records
To obtain the best results in battery operation, record
essential data.
When more than one battery is in use, identify each one
by assigning a permanent number, painted on the
battery.
Each battery received, after its freshening charge,
records the specific gravity of each cell. The recording
serves as a reference for the comparison of later
readings.
In a new application, check the amount of discharge for
several weeks to determine if it is in the expected range.
By reading the specific gravity of a cell at the beginning
and end of discharge, compare the difference with the
specific gravity drop.
For best operation, the daily discharge should not exceed
80% of the rated gravity drop. Change the pivot cells at
monthly intervals. Otherwise, the frequent hydrometer
reedings will noticeably reduce their specific gravity.
Where batteries interchange among different trucks, a
record immediately indicates where the load is heaviest.
Control Panel
EVT-1000 Panel Replacement
Perform the following when replacing the SCR EV-100
panel:
1. Disconnect the battery connectors.
2. Open the control door assembly. Disconnect the
PS-2 and PA-1 power cables.
3. Tag and disconnect the 5 control wires. Unplug the
quick disconnect connector from P2 terminal.
4. Remove the 4 heavy bus bars.
F-602-R1 Edition
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
! CAUTION
Protect the transistor assembly from dropping off
the door unexpectedly.
5. Remove the 3 bolts mounting the transistor control to
the door.
6. Remove the control off of the door.
7. Clean the heat transfer grease from the door and the
control heat sink with a petroleum distillate,
Chlorinated hydrocarbon solvent or Dupont freon TF
greaser or equivalent.
8. Do not steam clean the control or electric door
assemblies. In dusty areas use low-pressure air to
blow off the control or door assembly. In oily or
greasy areas, use a mild solution of detergent to
wash the control and electric door assembly. Blow
completely dry with low-pressure air.
Installing a New or Re-built SCR Unit
Perform the following when installing a new or re-built
transistor unit:
1. Ensure the mounting area is smooth, clean and flat.
2. Apply heat transfer grease to the rear heat sink of the
transistor control. Use Dow Corning 340, Wakefield
Engineering Type 120 or the equivalent. Apply the
compound evenly to a thickness of 1/32 - 3/64 inches
over the complete surface of the heat sink. Use a
hard rubber squeegee to distribute the grease evenly
to the required thickness.
3. Align the control mounting holes with the tapped
mounting holes in the control door assembly. Place
the control directly into position and fasten with the
appropriate hardware.
4. Clean excess heat transfer grease from around the
sides of the control heat sink with a clean, dry cloth.
5. Assemble a new or re-built SCR unit by reversing
steps 1 through 5.
Replacement of EVT-1000 Components
When replacing stud semi-conductors like 3 or 4 REC, it
is not necessary to torque these devices to a specific
value. Screw the device into the heat sink and tighten to a
snug fit. SCR gates, not screw connected, terminate
inside the card plug. Remove the card connector for
access to thestab terminals.
! WARNING
Before replacing EV-100 SCR components
discharge the main capacitor by placing at least
2.7k ohm load across the terminals.
Use a heat transfer grease (GE Versilube G-350-M or
equivalent) when installing the SCR assembly. When
replacing module semi-conductors, perform the following:
1. Remove all module connections.
2. Remove module by backing out the 2 screws at the
device sides.
3. Remove snubber assemblies and the buss bar.
4. Remove and tag all the wires. Tagging the wires
makes re-installation easier.
5. Remove the thermal protector.
6. Remove the PS-2 and PA-2 REC cables.
7. Remove the positive battery cable from No. 1 REC.
8. Clean the insulator surface with a clean rag and
isopropyl alcohol.
9. Inspect the insulator surface for tears or cracks.
Replace the insulator if it appears defective. Wipe a
light layer of machine oil on the base and smooth the
insulator into position.
10. Coat the insulator with a light coat of heat transfer
grease similar to GE-350.
11. Install the thermal protector in the new module.
Tighten the thermal protector until snug.
12. Set the new module on the insulation and start the
screws back into the base. Use original screws and
washers. Run the screws in until their finger tight.
Replacement of the EV100 Card
Perform the following when replacing the EV100 card:
1. Disconnect the battery connector.
2. Open the SCR control door assembly.
3. Discharge the main capacitor. See Figure 3-32.
4. Unplug the wiring harness connector.
5. Remove the 2 oscillator card retaining screws.
6. Carefully remove the EV100 card box from the
controller panel.
7. Installation is the reverse of the removal procedure.
3-33
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Lift Wire Harness

Retaining Controller Connector Retaining
Screws Thermal Screws
Protector

Commutating
Capacitor

Figure 3-32: Discharging the Main Capacitor

Adjustment Procedure for a New or

Mis-adjusted Card
With a new card, turn all pots fully CCW to “1.” Then set
each pot to the setting for the particular truck. See
Figure 3-33. Turning pots CW increases the particular Tilt Speed Control
function (i.e., CW adjustment increases tilt, pivot and shift
speeds, control acceleration and 1A contactor pick-up Pivot Speed Control
delay time).

Current Limiting for EVT-1000 Shift Speed Control

The current limit (C/L) circuit monitors motor current by
using a sensor in the series with the armature. If heavy Control Acceleration
load current is detected, the current overrides the To Full Motor Volts
oscillator to limit average current. The C/L is adjusted by
1A Contactor
the P3 trimpot on the control panel printed circuit card.
Delay Pick-Up
CW rotation of the trimpot increases the current limit.
Because the pump and motor are difficult to install, the
current limit was preset at the factory and no adjustment
is recommended.

Figure 3-33: EV100 Box Dial Setting

Motor Speed Control

The first speed is obtained by closing speed 1 switch
connecting TB2 to SCR control negative.
Speed 1 is adjusted by the speed 1 trimpot with
clockwise rotation to increase motor voltage (adjusted
from “0” to full control motor volts). The specified motor
volts become regulated, the magnitude of the motor
current varies, but the motor volts remain constant.
Speed 2 is obtained by closing the speed switch
connecting TB3 to SCR battery control negative. Speed 2
is adjusted by speed 2 trimpot with clockwise rotation to
increase motor voltage (adjustable from “0” to full control
motor volts).

3-34 F-602-R1 Edition

 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Speed 3 is obtained by closing the speed switch
connecting TB5 to the SCR battery control negative and
is adjusted with speed 3 trimpot. Clockwise rotation
increases the motor volts (adjustable from “0” to full
control motor volts).
Speed 4 is obtained by closing the speed switch
connecting TB6 to the SCR battery control negative.
Speed 4 is non-adjustable and provides full control motor
volts. Bypass speed 4 to activate the contactors.
If more than one speed is actuated, the selected speed
with the highest motor volts overrides the low motor volt
speed.
Control of Motor Acceleration
Control acceleration varies the rate the oscillator
increases its percentage on-time -- the minimum time
required to go to full control motor volts. The point of full
motor volt varies by adjusting the C/A trimpot from
approximately .06 - 4.0 seconds.
Control of 1A Contactor Pick-Up
The 1A bypass contactor activates by closing the speed
switch. Connecting TB6 to the SCR control battery
negative enables the time delay pick-up of the 1A bypass
contactor. This time delay adjusts by means of the 1A
timer trimpot. Clockwise rotation increases the 1A time
delay (1A time varies .8 to 4.0 seconds).
Steering and Pedals
Pedal Travel
Perform the following regarding pedal travel:
1. The brakes are self adjusting. Pedal travel should
remain the same until the linings become worn to the
wear limit. A sudden increase in pedal travel
indicates air in the system.
2. The pedal needs approximately 1/32” of free-play
before feeling pressure. If necessary, make this
adjustment at the master cylinder rod. Insufficient
Free-play causes the linings to drag after several
applications.
• Remove the floor plate covering the master cylinder.
• Loosen the locknut of the brake linkage clevis and
turn the adjusting rod in either direction to adjust
pedal travel. Screwing the adjusting rod into the
clevis increases free play and vice-versa.
• If correct free play does not occur, check the fluid
level and brake lining wear. Also, check for air or
leaks in the system.
3. The brake pedal should feel firm when applied. A
spongy feel indicates air in the lines. If a spongy
feeling occurs, bleed the system.
4. The brake pedal contains at least 1/2 of the travel
remaining after the brakes are fully applied. If the
pedal contains less than 1/2 travel, remove the
wheels and check the linings for wear.
5. If brake pedal travel increases, check the brake fluid
level in the master cylinder. Remove the floor plate
and clean off the top of the master cylinder. Remove
the master cylinder filler cap. Proper fluid level is 3/4”
below the filler cap hole.
6. Refer to the “Recommended Lubricants” chart on
page 1-8 for the correct brake fluid.
7. The master cylinder fluid level rises after fitting new
linings. If repeated topping-off of the master cylinder
becomes necessary, check the entire system and
determine the cause of the fluid loss.
Power Steering pump
Power Steering Pump and Motor
Replacement
Perform the following when removing/installing the power
steering pump and motor:
1. Remove the right side cover retaining bolts. Remove
the right side cover.
2. Turn the Keyswitch OFF. Turn the steering wheel in
both directions to relieve any residual pressure in the
system.
3. Disconnect the 2 main battery connectors.
Disconnect the 2 electrical cables at the steering
pump motor. Tape the ends of the cables to prevent
accidental shorts while the pump motor is out of the
truck.
4. Disconnect the 2 hydraulic lines from the pump. Cap
all open ends to prevent fluid leakage.
5. Remove the motor mounting nuts and lift out the
pump and motor assembly.
Power Steering Pump and Motor Brush
Replacement
Perform the following when replacing the power steering
pump and motor brush:
1. Remove the pump and motor assembly from the
truck as outlined above.
2. Remove the brush cover screw from the end of the
motor and use a slot-head screwdriver to pry the
pinned covers from the motor.
3. Use a thin slot-head screwdriver to move the spring
off the top of the brush. Pull the brush out of its
holder. Using a screwdriver, unscrew and remove the
brush pigtail from the commutator end shield.
4. Repeat the procedure with the remaining brushes.
3-35
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
5. Check the brushes for wear and replace as a set if
excessive wear exists.
6. Wipe the commutator with a clean lint-free rag
soaked in gasoline.
7. Check the commutator for excessive wear, cracks or
burnt spots. Check the mica undercut. The mica
should undercut the commutator segments by
approximately 0.025”. If the wear of the commutator
results in flush or protruding mica bars, disassemble
the motor and undercut the mica to specification.
! WARNING
Wear a dust mask when cleaning the
commutators.
8. Clean the commutator thoroughly before installing
the brushes. After installation, run the motor to
ensure proper seating of the brushes.
NOTE
If the brushes show signs of arcing, seat them using a
brush seater and commutator cleaner. The procedure is
outlined in steps 9-12 below.
9. To seat the brush with the motor running, press down
hard on the brush and apply the brush seater at the
heal of the brush. Friction of the turning commutator
releases the brush seater material and carries it
under the brush.
10. To clean the commutator, with the motor running,
hold the cleaner against the commutator and slowly
move it back and forth across the face.
11. Wearing a dust mask, use compressed air to clean
out matter generated by the seating and cleaning
operations.
12. Refit the covers
Power Steering Pump
Foreign matter entering the unit causes power steering
pump problems. Damage also occurs to the gear shaft
needle bearings (often herd as a “whine” when the unit is
in operation), gear teeth break, or the gears jam,
shearing the shaft keys.
Power Steering Pump Removal
Perform the following when removing the power steering
pump:
1. Remove the steering pump and motor from the truck
as outlined above.
2. Plug the inlet and outlet fittings, reducing fluid
spillage.
3. Mark the location of the pump relative to the motor
for assembly.
3-36
4. Remove the 4 bolts securing the pump to the motor.
5. Remove the pump from the motor. Remove the
coupling, which remains on the motor shaft.
6. Inspect the o-ring for any signs of deterioration or
damage. Replace the o-ring if it is not in perfect
condition.
Power Steering Pump
Inspection/Disassembly
Perform the following when inspecting/disassembling the
power steering pump:
1. Check the condition of the coupling. Replace
deformed or worn couplings.
2. Turn the pump drive shaft by hand. Rotation should
be smooth and easy.
3. Before disassembling, mark the two halves of the
housing for position.
4. Remove the 8 screws securing the housing halves.
Carefully separate the housing halves drive shaft
upward. Keeping a finger on the protruding drive
shaft keeps both gears in the other half.
5. Take out the gears on their shafts.
6. Remove the pressure relief valve cover. With a
slot-headed screwdriver, turn the pressure relief
valve screw in until it is lightly seated, counting the
turns so the same setting is obtained during the
assembly. Unscrew the relief valve assembly,
consisting of a screw
7. Clean all metal parts in a safe solvent.
8. Inspect the gear areas in the housing. Ensure walls
are smooth and featureless. Remove foreign matter
from the housing with a solvent. Ensure clearance of
all oil passages.
9. Check bearing condition. If dented or flattened rollers
appear, replace the bearings. Replace bearings as a
set. Before assembly, clean and lubricate the
bearings. Check bearings while in place -- removing
them from their holes destroys the bearings.
10. Check the gear teeth for chips or pitting near the
base. If one gear is damaged in any way, replace
both gears.
11. Ensure the gears are locked on their shafts. Shearing
of the keys is possible. To remove a gear from its
shaft, remove the snapping from one side and take
off the gear. Ensure the key is in good condition. If
available, use a new snap ring on the assembly.
12. Check the condition of the housing drive shaft oil
seat. If leakage occurs, replace it by prying it out.
Drive the new seal straight in, ensuring it is not
cocked. Lubricate the lips of the seal before
assembly.
F-602-R1 Edition
 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Steer Orbital
Orbital Unit Removal and Installation
Perform the following when removing/installing the orbital
unit:
! WARNING
Disconnect both of the battery connectors and
discharge the steering system by turning the
steering wheel back and forth several times
before attempting to remove the orbital unit.
1. Remove the console cover.
2. Remove the dash panel assembly if additional
access space is needed to remove the orbital
mounting hardware.
NOTE
Cleanliness is important when repairing this unit. Work in
a clean area. Before disconnecting the lines, clean the
port area of the orbital unit thoroughly. Use a wire brush
to remove foreign matter around the outside joints of the
unit.
Figure 3-34: Clamping and Removal of End Cap
3. Mark the positions of the 4 hydraulic lines to
reconnect the correct fittings. Proper connection is
critical to operation.
4. Disconnect the hydraulic lines at the orbital unit.
5. Remove the 2 bolts securing the orbital to the
bracket. Lower the unit to free it from the steering
column.
6. installation is the reverse of removal. Ensure proper
connection of the hydraulic lines.
Orbital Unit Disassembly
Keep the orbitrol unit in a soft-faced vise during the
disassembly procedure. Reference mark all parts before
removal.
Meter (Gerotor) End
Perform the following when disassembling the meter
(gerotor) end:
1. Clamp the unit in a soft-faced vise, meter end up.
Clamp the unit at the mounting area. Do not over
tighten the vise jaws. See Figure 3-34.
2. Remove the 5/16” cap screws.
3. Remove the end cap.
4. Remove the end cap seal. See Figure 3-34.
Cap Screw
End Cap
Seal
3-37
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Spacer
Plate
Seal

Meter Drive
(Gerotor)
Spacer(s) Seal

Figure 3-35: Removing the Drive Spacers

5. Remove the meter. Do not drop the star. Install the
star with the same side outward in which it is found.
Mark the sides of the meter for position. See
Figure 3-35
6. Remove the seal from the meter.
7. Remove the drive spacer(s), if fitted. See Figure 3-35
8. Remove the drive and the spacer plate.
9. Take the seal out of the housing.

Seal
Gland
Bushing

Figure 3-36: Retain Ring and Control End Bushing Removal

Control End 3. Rotate the spool and sleeve until the pin is horizontal.
Push the spool and sleeve assembly forward, far
Perform the following when disassembling the control
enough to free the gland bushing from the housing.
end:
Remove the bushing. See Figure 3-36.
1. Remove the unit from the vise. Place the housing on
a clean, soft cloth.
2. Use a thin slot-headed screwdriver to pry the
retaining ring from the housing. See Figure 3-36.

3-38 F-602-R1 Edition

 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Quad
Dust Ring
Seal Seal

Seal
Gland
Bushing
Figure 3-37: Removal of Quad Ring Seal

Needle
Thrust
Bearing

Pin

Bearing
Races
Figure 3-38: Removal of Bearings and Pin
4. Remove the quad ring seal from the seal gland 9. Push the spool partially out of the control end of the
bushing. See Figure 3-37. sleeve. Remove the 6 centering springs from the
5. Use a thin slot-head screwdriver to pry the dust seal spool by hand. See Figure 3-39.
from the seal gland bushing. Do not damage the 10. Push the spool back through and out of the sleeve.
bushing. Rotate the spool slowly when removing the sleeve.
6. Remove the two bearing races and the needle thrust 11. Remove the seal from the housing.
bearing from the spool and sleeve assembly. See 12. Remove the set screw from the housing.
Figure 3-38.
13. Thread a 1/8”-24 machine screw into the end of the
7. Remove the spool and sleeve assembly from the check ball seat. Pull the screw and seat out of the
14-hole end of the housing. housing with pliers.
8. Push the pin from the spool and sleeve assembly. 14. Remove the 2 seals from the check valve seat.
See Figure 3-38.
15. Tilt the housing to remove the check ball and check
ball retainer. See Figure 3-40 on page 3-40.
! CAUTION
Do not bind the spool and sleeve in the housing.
Rotate the spool and sleeve assembly slowly
when removing.

3-39
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

Orbital Assembly
Perform the following when inspecting the orbital unit:
1. Lubricate all the seals, except the quad ring seal,
with petroleum jelly. Do not use excessive lubricant
amounts, particularly on meter-end seals.
2. Use needle-nose pliers to lower the check ball
retainer into the housing’s check valve hole. Ensure
the retainer is straight in the housing, not tilted on
edge. See Figure 3-40.
3. Install the check ball in the housing.
4. Lubricate the 5/8” and 7/16” diameter seals for the
check ball seat and install them on the seat.
5. Lubricate the check ball seat and seals thoroughly
before installing the seat in the housing. When
installing, do not twist or damage the seals. Insert the
open end of the seat into the housing first. Push the
seat in until it bottoms.
Figure 3-39: Pushing the Spool
6. Install the set screw and torque it to 100” lbs.
(approximately 8.3 ft. lbs.). Ensure the top of the set
screw is slightly below the housing mounting surface.
Seal
7. Carefully assemble the spool and sleeve so the
spring slots line up at the same end. Rotate the spool
while sliding the parts together. Some spool and
sleeve sets contain identification marks; align these
marks. See Figure 3-41.
8. Test for free rotation. Ensure the spool rotates
smoothly in the sleeve when finger-tip force is
Check applied at the spined end.
Ball
5/8” Seal 9. Align the spring slots. Insert the spring installation
Retainer
tool. Position 3 pairs of centering springs on a bench
Check so the extended edge faces down and the arched
Ball
Check 7/16” Seal center sections touch. In this position, insert one end
Set Ball of the entire spring set into the spring installation tool.
Screw Seat 10. Compress the extended end of the centering spring
Figure 3-40: Removing Check Ball and Retainer set and push it into the spool sleeve assembly
withdrawing the installation tool at the same time.
Orbital Inspection See Figure 3-42.
Perform the following when inspecting the orbital unit:
1. Check the condition of all mating surfaces. Replace Spring
all parts with scratches or burrs, causing potential
Control Slot
leakage.
2. Clean all metal parts in a safe solvent. Blow dry. Do Spring Sleeve
not wipe the solvent from the unit with rags or paper Slot
towels. Rags or paper towels leave foreign matter in
the unit, causing damage.
3. Replace all damaged parts. Do not remedy damaged Control
parts with abrasives, files or grinders.
Spool
4. Replace all of the seals in the unit.

Identification
Marks
Figure 3-41: Aligning Identification Marks

3-40 F-602-R1 Edition

 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Figure 3-42: Centering Spring
11. Center the spring set in the assembly so they push
down evenly and flush with the upper surface of the
spool and sleeve.
12. Install the pin through the spool and sleeve assembly
until the pin is flush at both sides of the sleeve. See
Figure 3-38.
13. Insert the spool and sleeve assembly into the 14-hole
end of the housing, splined end first. See
Figure 3-43.
Figure 3-43: Spool and Sleeve Insertion
! CAUTION
• When inserting parts, ensure they do not get
tilted out of position.
• Push the parts gently into place with a slight
rotating action.
• Keep the pin clearly horizontal.
• Push the spool assembly into the housing
bore until the parts flush at the meter end
(14-hole end) of the housing.
• Do not pull the spool assembly beyond this
point to prevent the cross pin from dropping
into the discharge groove of the housing.
• With the spool assembly in this flush
position, check for free rotation within the
housing by turning with light fingertip force at
the splined end.
14. Place the housing on a clean, lint-free cloth. Install
the 2-1/8” diameter seal into the housing. See
Figure 3-38 on page 3-39.
15. Install the 2 bearing races and the needle thrust
bearing in the order shown in Figure 3-38 on
page 3-39 (race, bearing, race).
16. Install the 1-1/4” diameter dust seal in the seal gland
bushing; the flat or smooth side of the dust seal must
face the bushing.
17. Install the dry quad ring seal in the seal gland
bushing. Smooth the seal in place with a finger. Do
not use any seal that falls freely into the pocket of the
bushing. See Figure 3-44.
18. Install the seal gland bushing over the spool end with
a twisting motion. Tap the bushing into place with a
rubber or soft-faced mallet. Ensure the bushing is
flush against the bearing race. See Figure 3-36 on
page 3-38.
Screwdriver
Dust
Seal
Retaining Ring
Seal Gland Bushing
Quad Ring Seal
Seal
Figure 3-44: Quad Ring Installation
3-41
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE

19. Install the retaining ring in the housing. After
installing the ring, tap on the ring end or run a thin
screwdriver around the entire circumference of the
ring to properly seat the ring in the groove.
20. Clamp the housing in a soft-faced vise.
21. Ensure the spool and sleeve flush with or slightly
below the 14-hole surface of the housing. Clean the
upper surface of the housing by wiping it with the
palm of a clean hand. When assembling, clean each
of the flat surfaces of the meter section parts in a
similar manner. Do not use rags or papertowels due
to the risk of leaving foreign matter on the unit.
22. Install the 3” diameter seal in the housing.
23. Install the spacer plate. Align the bolt holes in the
spacer plate with the tapped holes in the housing.
See Figure 3-45.
24. Rotate the spool and sleeve assembly until the pin is
parallel with the port face. Install the drive, ensuring it
is properly engaged with the pin. Mark the position of
the drive. See Figure 3-45.

Port
Face

Drive

Pin Parallel
with Port Face

Pin

Figure 3-45: Installing the Drive

25. With the seal side of the meter toward the spacer 29. Install the end cap on the gerotor; align the holes.
plate, Align the star valleys with the drive. See 30. Install the 7 cap screws, threads dry, and tighten
Figure 3-35 on page 3-38. them in a cross pattern to 150 in. lbs.
26. Note the parallel relationship of the reference lines A, 31. Tighten the cap screws to 275 in. lbs final torque.
B, C and D. Align the bolt holes without disengaging
the meter from the drive. Figure 3-46 on page 3-42.
27. Install the drive spacer(s), if used.
28. Install the 3” diameter seal in the end cap.

Meter A
(Gerotor)
Star
Valley B

Drive C

Pin

Port
Face
Figure 3-46: Aligning Bolt Holes

3-42 F-602-R1 Edition

 TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Figure 3-47: Lifting the Floor Plate
Figure 3-48: Disconnecting the Wiring
Accelerator Module
Perform the following when removing/installing the
accelerator module:
1. Disconnect both battery connectors.
2. Remove the retaining screws securing the
accelerator module floor plate and lift the plate as far
as possible. See Figure 3-47.
3. Pull out the switch and floor plate and disconnect the
wiring at the plastic connector. See Figure 3-48.
4. Installation is the reverse of the removal procedure.
Attach the battery connectors and check the vehicle
operation.
Potentiometer (Pot) Replacement
Perform the following when replacing the potentiometer:
1. Loosen the screw securing the potentiometer to the
shaft. Take out the pot.
2. Note the wire connections and tag them for
reassembly. Disconnect the wires.
3. Connect the wires to the new pot, ensuring proper
electrical connections.
4. Install the new unit, seating the tab on the pot in the
notch in the casting.
5. Insert a long, thin, slot-headed screw driver into the
shaft hole to adjust the potentiometer.
6. Connect an ohmmeter set to a suitable range across
the pot leads.
7. When the accelerator lever is at rest, adjust the pot
so the meter reads approximately 6200 ohms.
When the lever is rotated, resistance decreases
immediately. If resistance rises at all, adjust the pot to
obtain the correct performance. Resistance at rest should
read 6200 ohms. At full lever travel, resistance should
measure less than 200 ohms.
8. When the adjustment gives the correct performance,
tighten the screw and re-check the operation.
Switch Replacement and Adjustment
Perform the following when replacing/adjusting the
switch:
1. Mark the wires for connection before removal of the
switches.
2. When replacing the switches, properly connect the
wires. Ensure the insulating blocks are in place.
3. To adjust the switch position, activate the start switch
by no more than 2° of lever travel. The final switch
must come on approximately 2° before the end of
lever travel. After proper switch position is found,
tighten the mounting screws.
4. If the above procedure does not occur, set the
switches in the middle of their adjusting range and
adjust the cams by loosening the set screws and
moving the cams around the shaft.
Safety Features
Seat Switch Removal and Installation
Perform the following when removing/installing the seat
switch:
1. Disconnect both of the battery connectors.
2. Remove the 2 seat switch bracket retaining bolts
located at the bottom of the seat switch.
3. Disconnect the seat switch wiring connector.
4. Remove the seat switch.
5. Installation is the reverse of removal. Check for any
pinched wires after installation. Correct as
necessary.
3-43
TROUBLESHOOTING AND CORRECTIVE MAINTENANCE
Pivot/Shift Interlock System
A combination of mechanical, hydraulic and electrical
components provide a safety interlock system, preventing
the truck operator from positioning their load in an unsafe
position. The system provides increased vehicle capacity
and utility while maintaining vehicle stability and operator
safety.
The system consists of pivot and shift interlock electrical
switches, and pivot/shift cams or levers, which activate
the switches and the pivot/shift hydraulic solenoids.
The simplified block diagram shows the relationship of
the electrical and hydraulic components which make up
the system. See Figure 3-49 on page 3-44.
The first section of the system gives the position of the
pivot arm and the lateral position of the masts. The
second section, when signaled by the first, limits travel or
the pivot and shift functions.
Figure 3-49: Block Diagram of Components
Function of Circuit Components
The pivot switch is mechanically cammed open when the
mast assembly is in the front loading position. The switch
remains cammed open up to 45° of clockwise mast
rotation. Figure 3-50 on page 3-44.
Figure 3-50: Circuit Components
3-44
The pivot switch actuating cam is located at the rod end
clevis of the pivot cylinder which rotates along with the
pivot arm. The pivot switch is mounted to the uppermost
plate of the sideshift crosshead and remains stationary.
Closing of the pivot switch (45° - 90° clockwise mast
rotation) actuates the pivot hydraulic solenoid valve and
also the shift hydraulic solenoid valve which permits full
left shift.
The action of the pivot hydraulic solenoid valve, when
de-energized, is to close off hydraulic flow to the pivot
cylinder, stopping counter clockwise rotation of the mast
(between 45° and 0°). Valve design permits reverse
hydraulic flow under any condition so that pivoting
clockwise, to a side carry position, is always possible.
Opening of the shift interlock switch de-energizes the
shift and pivot solenoids. The left shift function stops just
after the telescoping slide allows the lever to release,
providing the mast is in the 0° - 45° pivot zone.
The action of the shift hydraulic solenoid valve, when not
energized, is to close off hydraulic flow to the shift
cylinder.
Valve design permits reverse hydraulic flow under any
conditions so that shift travel to the right is always
possible.
! WARNING
• Proper operation of the pivot/shift interlock system
is essential for safe operation of this vehicle.
• Do not begin any maintenance or repair of these
interlocks until the operating characteristics and
check-out procedures are understood.
F-602-R1 Edition
 Chapter 4

Supplier Provided Documentation

Disclaimer:
The documentation provided here within
Chapter 4, “Supplier Provided
Documentation”, has been appended to
this Landoll Maintenance Manual for
reference only.
The specific contents of this information
is not the responsibility of Landoll
Corporation or any of it’s affiliates.

Lift Technologies Mast Service

Manual
1200 Series

Table of Contents - page 5

Proceed to the above “Table of Contents” starting on
page 5, to the Mast Installation, Periodic Maintenance,
Troubleshooting and Service instructions as required.

4-1
SUPPLIER PROVIDED DOCUMENTATION

4-2 F-602-R1 Edition

Document Control Revision Log:
Date Revision Improvement(s) Description and Comments
08/09/11 F-602-R1 Initial Release
nn/nn/nn F-
nn/nn/nn F-
 Equipment from Landoll Corporation is built to exacting
standards ensured by ISO 9001:2008 registration at all
Landoll manufacturing facilities.

Drexel Model SL120

Maintenance Manual

Re-Order Part Number F-602-R1

LANDOLL CORPORATION
1900 North Street
Marysville, Kansas 66508
(785) 562-5381
800-428-5655 ~ WWW.LANDOLL.COM

Copyright 2011. Landoll Corporation - Author Tech Comm Joshua

"All rights reserved, including the right to reproduce this material or portions thereof in any form."

F-602-R1