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Battery Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Battery Gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Overhead Guard
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
Rear Post
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Front Cover
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Top Cover
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
Control Cover
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Operator Compartment Pads
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Floor Mat / Brake Pedal Pad
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
High Back Pad
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
04/05/00
C
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ounterbalance
TABLE OF CONTENTS
H
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1.i
Frame
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Table of Contents
Summary of Contents for Schaeff Echo 3000
- Page 1 lectric ounterbalance utput Frame TABLE OF CONTENTS Battery Rollers ..........1.1 Battery Gates .
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Page 2: Battery Rollers
lectric ounterbalance utput Frame Battery Rollers There are five battery rollers in the battery compartment. They can be removed and disassembled for cleaning or repair as shown in Figure 1.1. The battery rollers must be installed in the compartment in the pattern shown in Figure 1.2. FIGURE 1.2 - Placement of Battery Rollers WARNING Do not operate the truck with a battery gate... - Page 3 lectric ounterbalance utput Frame mounting holes in the overhead guard line up 4. Once the top of the cover is released, lift with the mounting holes in the frame. Install upward on the cover and remove from the the mounting screws and torque to 120ft.-lbs. truck.
- Page 4 lectric ounterbalance utput Frame 2. Align the cutouts on the front edge of the top the frame of the truck. If the fastener does cover with the front posts of the overhead come loose, clean the area with isopropyl guard. Move the front edge of the top cover alcohol and reattach it with cyanoacrylate into place.
- Page 5 lectric ounterbalance utput Frame 3. Scrape the pedal surface to remove as much of the old pad material as possible. 4. Clean any remaining residue from the pedal with an appropriate solvent. Replacement 1. On a properly prepared surface, apply a thin film of adhesive to the brake pedal.
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Page 6: Table Of Contents
lectric ounterbalance utput Drive TABLE OF CONTENTS Drive Train Description ..........2.1 Drive Unit Removal . -
Page 7: Drive Train
lectric ounterbalance utput Drive Drive Train Description This lift truck is equipped with dual independent drive trains. Each drive train consists of a drive unit (drive motor and gearbox), and a drive wheel. Traction drive is transmitted from the drive motor to the gearbox through a pinion gear driven by the motor armature shaft. -
Page 8: Drive Unit
lectric ounterbalance utput Drive a) Lubricate the drive pinion and outer Drive Unit bearing (use a needle nose grease gun to grease the outer bearing). Removal b) Connect a lifting device to the drive 1. Disconnect the battery and discharge the unit. -
Page 9: Drive Motor
lectric ounterbalance utput Drive NOTE Drive Motor If the unit has brush wear indicators, be sure to install the new brush with the indicator wire NOTE in the same brush holder and route the Specialized tools, fixtures, and training are indicator wire clear of the rotating armature. -
Page 10: Drive Wheel Assembly
lectric ounterbalance utput Drive 15 V-Ring Seal 16 Bearing 17 Tab Lock Washer 18 Lock Nut 19 Wheel Cover 20 Screw FIGURE 2.4 - DRIVE WHEEL INSTALLATION 5. Clean the threads of the drain plug, apply pipe Drive Wheel Assembly thread sealant to the plug and reinstall the magnetic drain plug. -
Page 11: Replacement
lectric ounterbalance utput Drive clean the groove, then apply a thin film of the Changing Drive Tires same lubricant used for the final drive gears (Mobilith SHC 007 Synthetic Grease NLGI 00 Special Tools: Tire Changing Fixture (P/N or equivalent) to the v-ring seal. 9650008), Tire Press (40 ton) Replacement NOTE... -
Page 12: Drive Wheel Spindle
lectric ounterbalance utput Drive Drive Wheel Spindle Removal 1. Remove the drive wheel (refer to the procedure in this section). 2. Remove the screws attaching the spindle to the frame. The spindle is very heavy. DO NOT let the spindle drop and damage the threads or the bearing surfaces. -
Page 13: Drive Unit Rebuild - Disassembly
lectric ounterbalance utput Drive Drive Unit Rebuild - Disassembly 1. Remove the drive unit from the truck. CAUTION DO NOT pry the sections apart - this may damage the machined surfaces. If necessary, use a rubber mallet to separate the sections. 2. -
Page 14: Gear Housing To Motor Assembly
lectric ounterbalance utput Drive Install the clamp nut (Fig. 2.7, Item 2) and torque the screw in the side of the clamp nut to 70 in-lb. RIGHT LEFT NOTE Tightening the screw in the clamp nut will increase the turning torque on the pinion. Always measure the turning torque with the clamp nut installed and the locking screw on the side tightened. -
Page 15: Carrier To Gear Housing Assembly
lectric ounterbalance utput Drive Procedure 2 Procedure 1 Measure D if there Measure A if there is is no number on a number on the end the end of pinion. of pinion. Figure 2.9 - CALCULATE 4-HOLE SHIM THICKNESS. Example for Procedure 1: Example for Procedure 2: Measurement A = 1.394 Measurement D = 2.573... - Page 16 lectric ounterbalance utput Drive 7. Once backlash conditions are met, remove the flag assembly and backlash tool. Rotate the motor shaft several revolutions both forward and reverse. Remove the carrier from the gear housing and observe the contact pattern on the gear: The correct pattern, as shown in Example 1, is well centered on the bevel gear tooth with lengthwise contact clear of the toe.
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Page 17: Carrier Rebuild
lectric ounterbalance utput Drive pattern and the tooth toe that is not in contact 2. Remove the three cap screws (Fig. 2.6, Item with the gear set. To correct for this condition, 19) securing the bevel gear to the pinion remove the carrier from the gear housing, add shaft. - Page 18 lectric ounterbalance utput Drive 17. Pry upward on the cap to observe the endplay. Add or remove shims as necessary until an endplay of 0.000" to 0.002" is obtained. Figure 2.12 - Support Spiral Bevel Gear 8. Lubricate the inner diameter of the seals installed in Step 3 above.
- Page 19 lectric ounterbalance utput Brakes TABLE OF CONTENTS Brake System Theory of Operation ........3.1 Disc Brake Unit Description .
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Page 20: Theory Of Operation
lectric ounterbalance utput Brakes traveling. For example a fully loaded truck Theory of Operation traveling 6 MPH should stop within about 6.6 feet. The brake system of this lift truck is to be used as The brakes should hold a fully loaded truck on a a parking brake and for emergency stopping only. -
Page 21: Disc Brake Unit
lectric ounterbalance utput Brakes Disc Brake Unit Description The brake unit is an electrically released, spring applied disc brake. The friction plate (2) fits onto splines on the arbor (1), which is keyed to the motor shaft. Shims (7) are used to position the arbor on the shaft, while the friction plate is free to move up and down on the arbor. -
Page 22: Replacement
lectric ounterbalance utput Brakes 2. The brake assembly can now be fully dismantled and the parts examined. Note the number and thickness of shims (6) at each hole. Do not lose the three discs (4) used under the springs in the adjustment screw holes. -
Page 23: Replacement
lectric ounterbalance utput Brakes 5. Remove the brake pedal. 4. Loosen the jam nut on the brake rod end. 5. Rotate the rod end to lengthen or shorten the Replacement brake rod. (Rotating the rod end counterclockwise will lower the brake pedal, 1. -
Page 24: Braking Force (Clamping Pressure)
lectric ounterbalance utput Brakes brake switches toward the brake lever arm until they actuate (click). 4. Slowly depress the brake pedal while watching the brake lever arm. The brake switches must de-actuate after the pedal moves about one inch. The contacts on the brake switches should not be pressed all the way in when the brake pedal is up. - Page 25 lectric ounterbalance utput Steering TABLE OF CONTENTS Steering System ..........4.1 Steer Pump and Motor Assembly Removal .
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Page 26: Steering System
lectric ounterbalance utput Steering Removal Steering System 1. Disconnect and remove the battery and The steering system of this lift truck consists of discharge the capacitors. the following components: the steer pump motor 2. Tilt the left drive unit (the drive unit in front of and pump, the steer control valve and tiller, the the steer pump and motor assembly) (refer to hydraulic motor, the steering gears and the steer... -
Page 27: Steer Pump
lectric ounterbalance utput Steering 5. Install the steer pump and motor on the truck 4. Turn the steer tiller until the fork reaches (refer to Steer Pump and Motor Assembly either stop. Continue to turn the tiller and Replacement procedure in this section). read the pressure gauge while the pump operates against relief. -
Page 28: Hydraulic Motor
lectric ounterbalance utput Steering 3. Install the hydraulic hoses in the correct Replacement locations. 1. Install the hydraulic motor onto the mounting 4. Install the steering tiller. bracket, making sure to use the correct length screws. Longer screws may crack the motor 5. -
Page 29: Steer Fork Assembly
lectric ounterbalance utput Steering 2. Install the steering gear on the splined portion CAUTION of the steer fork shaft with the proper machine The steer fork assembly must be supported bushing above and below. prior to removing the lock nut. If the steer fork assembly is not supported, serious damage to 3. -
Page 30: Replacement
lectric ounterbalance utput Steering 2. Jack the rear of the truck just until the steer 2. Remove the seals and bearings. wheel can turn. Rotate the steer fork so the 3. Align the old wheel and tire on top of the new axle nut is visible. -
Page 31: Replacement
lectric ounterbalance utput Steering NOTE The potentiometer, torque arm, and steer fork insert cannot be disassembled. The potentiometer shaft is permanently attached to the steer fork insert. Replacement 1. Make sure the potentiometer is tight on the torque arm. Thread the hex nut all the way on the steer fork insert. - Page 32 lectric ounterbalance utput Operator Controls TABLE OF CONTENTS Description ........... . . 5.1 Control Handle Assembly Removal .
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Page 33: Description
The steering tiller is covered in the STEERING section. The operator controls of the ECHO 3000™ lift truck consist of the control handle, the battery The brake pedal releases the parking brakes of disconnect lever, the steering tiller, the brake the lift truck and enables traction functions. -
Page 34: Control Handle Assembly
lectric ounterbalance utput Operator Controls 2. Remove the electrical tape around the CONTROL HANDLE ASSEMBLY sleeving on the control handle harness, pull it back, and disconnect the potentiometer from Removal the harness. 1. Disconnect the battery and discharge the 3. Loosen the set screw holding the shaft of the capacitors (refer to ELECTRICAL). -
Page 35: Replacement
lectric ounterbalance utput Operator Controls 4. Remove the retaining ring and flat washer LIFT AND TRAVEL SPRINGS from the shaft. Removal & Replacement 5. Remove the battery disconnect lever. Refer to Fig. 5.3. Replacement 1. Remove the control handle from the truck NOTE and place it on a clean flat work surface (refer When replacing the battery disconnect lever,... -
Page 36: Control Handle Replacement
lectric ounterbalance utput Operator Controls Horn Switch - when installing horn button, engage switch to avoid damaging arm. Horn Button Horn Button Spring - note that bent end of spring goes in horn button. FIGURE 5.2 - HORN BUTTON SPRING REPLACEMENT 3. -
Page 37: Light And Auxiliary Rocker Switches
lectric ounterbalance utput Operator Controls Figure 5.3 - Mechanism and Springs Replacement Light and Auxiliary Rocker Switches 1. Insert the switch into the cover until the switch Removal locks in place. 1. Disconnect the battery and discharge the 2. Connect the wires to rocker switches and plug capacitors (refer to Capacitor Discharge the key switch into the system controller. -
Page 38: Replacement
lectric ounterbalance utput Operator Controls 3. Remove the system controller cover. Avoid straining the wires connected to the switches. 4. Unplug the key switch from the system controller. Disconnect the wires to the rocker switches. 5. Remove the lock nut from the back of the keyswitch and remove the keyswitch from the cover. - Page 39 lectric ounterbalance utput Lift & Auxiliary TABLE OF CONTENTS Theory of Operation ..........6.1 Lift Pump Removal .
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Page 40: Theory Of Operation
lectric ounterbalance utput Lift & Auxiliary LIFT AND AUXILIARY HYDRAULICS low-voltage signal at J4 Pin 1, opening the lower THEORY OF OPERATION valve and allowing the hydraulic oil to flow back to the lift/lower proportional valve. The voltage Hydraulic power is provided by a gear pump signal at J4 Pin 6 is varied to operate the directly driven by a series-wound DC motor. -
Page 41: Lift Pump
lectric ounterbalance utput Lift & Auxiliary solenoid. To tilt the mast back, press the bottom 6. Remove the screws securing the lift pump to of the tilt/sideshift disk. This provides a voltage the lift pump motor. [2 cap screws & lock signal at J8 Pin 13. -
Page 42: Replacement
lectric ounterbalance utput Lift & Auxiliary 8. Remove the lift pump and motor assembly 7. Remove the brush. from the truck. Replacement Replacement NOTE 1. Align the lift pump and motor assembly with If any brush needs replacing, replace all the the holes in the front frame of the truck. -
Page 43: Replacement
lectric ounterbalance utput Lift & Auxiliary 6. Place a shop towel over the top of the valve 3. Remove the front cover (refer to FRONT cartridge and loosen 1/4 turn. Allow any COVER Removal procedure in the FRAME internal pressure to equalize. Remove the section). -
Page 44: Replacement
lectric ounterbalance utput Lift & Auxiliary 10.Remove the hydraulic oil filter (refer to 7. Disconnect the tilt cylinder from the mast by HYDRAULIC OIL FILTER Removal procedure removing the screw and retaining washer and in this section). pulling the tilt cylinder pin out of the mount. Replacement WARNING DO NOT use fingers to remove the tilt... -
Page 45: Tilt Angle Adjustment
lectric ounterbalance utput Lift & Auxiliary TILT ANGLE ADJUSTMENT RELIEF PRESSURE ADJUSTMENT Test Procedure Special Tools: P/N 9650041 Pressure Check Adapter & Hose Kit The following conditions mean the tilt cylinders need to be adjusted: 1. Locate the pressure check port for the lift a. - Page 46 lectric ounterbalance utput Elevating TABLE OF CONTENTS Mast Description ..........7.1 Carriage Removal .
- Page 47 lectric ounterbalance utput Elevating Description The Triplex Mast has three rails; outer, middle, and inner. The rails are telescopic and use load rollers (bearings) and brass set screws to keep them in alignment. Two single-stage outer (main) lift cylinders and a center (free-lift) cylinder are used to raise the carriage and extend the mast rails.
- Page 48 lectric ounterbalance utput Elevating CENTER CYLINDER The center cylinder is cushioned at the top of its stroke. There is hydraulic oil on the rod side of the piston. There are two orifices in the rod, one larger than the other (Items 3 and 4). As the rod extends, the hydraulic oil on the rod side is forced underneath the rod through the large orifice (3).
- Page 49 lectric ounterbalance utput Elevating cylinder raises the carriage to the top of the inner Safety Procedures When Working on rail. After the center cylinder reaches the end of the Mast its stroke, the outer lift cylinders begin to extend. As the outer cylinders extend, the middle rail is The following procedures must be used when raised.
- Page 50 lectric ounterbalance utput Elevating LOWERED FULLY RAISED FREE-LIFT 1. Outer Rail 2. Outer Lift Cylinders 3. Middle Rail 4. Center Lift Cylinder 5. Inner Rail 6. Carriage 7. Outer Lift Chains 8. Free-Lift Chains FIGURE 7.5 - OPERATION 3/10/00...
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Page 51: Removal
lectric ounterbalance utput Elevating 4. Route auxiliary (sideshift) hoses over the hose Carriage sheave on the center cylinder and connect them to the carriage. Removal 5. Install the carriage stop bolts at the top of the 1. Tilt the mast to vertical. Remove the forks inner rail. -
Page 52: Disassembly
lectric ounterbalance utput Elevating 4. Make sure there is no slack in the lifting on the inner rail are visible in the notches at device or chains. Remove the metric screw, the top of the middle rail. lock washer, and retainer washer (Item 12, Fig 5. -
Page 53: Assembly
lectric ounterbalance utput Elevating PAIR of lift chains must be installed. Use a the load rollers as described in Checks and chain scale if one is available to check the lift Adjustments. chains. If you do not have a chain scale, 4. -
Page 54: Center (Free-Lift) Cylinder
lectric ounterbalance utput Elevating 3. Make sure that the bushing is in place in the tilt cylinder mount on the mast. Line up the tilt cylinder rod end and insert the front tilt cylinder pin. Install the retainer washer, lock washer and metric screw. -
Page 55: Outer Lift Cylinders
lectric ounterbalance utput Elevating 4. Bleed the air out of the lift system. Outer Lift Cylinders Repacking Tools: 9650080 - Triplex Gland Nut Tool 1. Operate the lift function so that the outer cylinders are extended about 12 to 24 inches. 2. -
Page 56: Removal
lectric ounterbalance utput Elevating Removal pressure. Hydraulic oil can be injected into the body by the pressure. NOTE Operate the hydraulic system. Put a capacity load Most repairs to the outer cylinders, such as on the forks. Use a safety chain to hold the load repacking the gland nut, can be made without to the carriage. -
Page 57: Brass Set Screws
lectric ounterbalance utput Elevating that under the load roller on the opposite side of the rail. Perform the following procedure to adjust the mast load rollers. 1. Use a pry bar to move the rails from side to side while measuring the movement. Measure the movement in a minimum of three different positions of the rails. - Page 58 lectric ounterbalance utput Elevating slightly longer than the other, or if one cylinder mount is slightly higher than the other, shims must be used to keep the mast level. Raise the mast to full extension. If the middle rail cocks to one side when it reaches full extension, add shims at the top of the cylinder rod on the short side, or remove shims from the top of the cylinder rod on the low side to bring it level with...
- Page 59 lectric ounterbalance utput Electrical TABLE OF CONTENTS Capacitor Discharge ..........8.1 System Controller / Operator Display Box Removal .
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Page 60: Capacitor Discharge
lectric ounterbalance utput Electrical CAPACITOR DISCHARGE WARNING Discharge capacitor bank prior performing any service on the lift truck. Failure follow proper discharging procedures can result in personal injury or damage to the electronic circuitry of the truck. The normal method of discharging the capacitors 1. -
Page 61: Operator Display Board / Memory Board
lectric ounterbalance utput Electrical 2. Plug all connectors into the correct ports in board to the standoffs on the system the back of the system controller (refer to controller pc board. Figure 8.1). CAUTION 3. Rotate the top of the system The operator display board and system controller/operator display box down until the controller are connected by a single 32-pin... -
Page 62: Traction Amplifier
lectric ounterbalance utput Electrical TRACTION AMPLIFIER Replacement WARNING 1. Apply an even film of heat-sink compound to Tampering with the amplifier may void the bottom of the amplifier before installation. warranty. 2. Make sure the mounting surface on the truck CAUTION is clean and free from any foreign materials To avoid damage to the system controller and... -
Page 63: Contactor Tips
lectric ounterbalance utput Electrical overheating. Use a backup wrench to prevent CONTACTOR TIPS bending the bus bars. CAUTION 5. Connect the power cables and wires as noted NEVER manually close the main power during Step 3 of Removal. contactor. Damage to the system controller 6. -
Page 64: Lift And Steer Contactors
lectric ounterbalance utput Electrical 2. Install the contactor-fuse panel assembly to FUSES the frame. Removal 3. Install the bus bar between the contactor and the lift (600 amp) fuse. 1. Disconnect the battery and discharge the 4. Connect the power cables to the fuses, capacitors (refer to CAPACITOR starting with the lowest fuse. -
Page 65: Replacement
lectric ounterbalance utput Electrical 3. Disconnect the 2-pin connectors from the horn and from the main harness. 4. Remove the two screws securing the horn relay to the frame. Replacement 1. Install the horn relay with two screws. 2. Connect the 2-pin connectors to the horn and the main harness. - Page 66 lectric ounterbalance utput Preventive Maintenance The numbers in this drawing correspond to the numbers in the first column of the SCHEDULED MAINTENANCE & INSPECTIONS TABLE. FIG. 10.1 - SCHEDULED MAINTENANCE AND INSPECTION POINTS 4/3/00 10.1...
- Page 67 lectric ounterbalance utput Preventive Maintenance SCHEDULED MAINTENANCE AND INSPECTION TABLE LUBRICATION COMPONENT CHECK/ACTION HOURS 2000 DAYS Battery Charge - Normal Charge - Equalizing Check water level and cleanliness Connector in good condition, bolt installed Battery Disconnect Check for free movement of the lever Check that the lever disconnects the battery Do Not Lubricate Battery Gates...
- Page 68 lectric ounterbalance utput Preventive Maintenance 8-HOUR / DAILY INSPECTION GENERAL WARNING If repairs are required, install a "DO NOT STARTUP SEQUENCE OPERATE" control handle. Remove the key and disconnect the battery. The lift truck is equipped with a "Static Return to DO NOT operate a damaged or defective lift Off"...
- Page 69 lectric ounterbalance utput Preventive Maintenance necessary, install spacers to achieve this CHARGING THE BATTERY specification. WARNING DO NOT connect the battery charger to the lift BRAKES truck. NOTE NOTE See APPENDIX A: INDUSTRIAL BATTERY for Release brake pedal only detailed information about charging and emergency.
- Page 70 lectric ounterbalance utput Preventive Maintenance Hydraulic oil under pressure can be CARRIAGE / LOAD BACKREST / injected into the skin. Never check for FORKS leaks by putting hands on a hydraulic line under pressure. Inspect the carriage, load backrest, and forks for Disconnect the battery while servicing.
- Page 71 lectric ounterbalance utput Preventive Maintenance 5. Operate the mast and check visually for equal tension of the chains through the complete cycle. If the chains do not have equal tension, adjustment is necessary; refer to the ELEVATING section. STEERING Check that the steering system operates smoothly and provides good steering control.
- Page 72 lectric ounterbalance utput Preventive Maintenance 40-HOUR / 5-DAY INSPECTION BATTERY LIFT CHAINS Keep battery case battery WARNING compartment clean and painted. Leaks and DO NOT work under a raised carriage. Lower corrosion from battery cause the carriage and forks to the ground or use a malfunction in the electrical controls of the lift suitable locking device to prevent the carriage truck.
- Page 73 lectric ounterbalance utput Preventive Maintenance 350-HOUR / 60-DAY INSPECTION BATTERY CONTACTOR TIPS WARNING WARNING w DO NOT connect the battery charger plug Disconnect the battery and discharge the capacitor bank (refer to the ELECTRICAL to the lift truck. section) before making any inspections or w Read the battery charger manual before repairs to the contactor.
- Page 74 lectric ounterbalance utput Preventive Maintenance conditions. Wipe the chains to remove any surface dirt. 2. Use a thin paint brush to liberally coat the full length of the lift chains with motor oil. Use SAE 20W for operating temperatures from F to 32 F.
- Page 75 lectric ounterbalance utput Preventive Maintenance 2000-HOUR / 360-DAY INSPECTION Filter BRAKES 1. Use a filter wrench to remove the oil filter. The brakes need adjusting when the lift truck wil not stop within 1.1 ft./mph after applying the 2. Use hydraulic oil to lubricate the seal on a brakes, running at full speed, with a full load.
- Page 76 lectric ounterbalance utput Troubleshooting ELECTRONIC F AULT ISOLATION PROCEDURE SOFTWARE VERSION 6.08 Fault condition RELEASE THROTTLE TO RESUME OPERATION Resulting Effect Criteria TRACTION system shutdown until condition is Travel potentiometer voltage is not in the neutral cleared. range (±0.12V from calibrated center) when the brake pedal is depressed.
- Page 77 lectric ounterbalance utput Troubleshooting Fault condition REVERSE LIFT INTERLOCK WARNING Resulting Effect Criteria LIFT system shutdown until condition is cleared. Programmable reverse-lift interlock is enabled. Lift NOTE: if rE Lf is enabled in programming and potentiometer voltage is in the lift range (more than traveling in reverse, this is normal.
- Page 78 lectric ounterbalance utput Troubleshooting Fault condition LIFT/LOWER POTENTIOMETER VOLTAGE OUT OF RANGE Resulting Effect Criteria LIFT system shutdown. Lift potentiometer voltage is outside the normal operating range (0.39V to 4.63V). Note: actual voltage supplied to potentiometer is 15V. Possible Cause Solution PERFORM INPUT TEST 04 - LIFT/LOWER POTENTIOMETER VOLTAGE.
- Page 79 lectric ounterbalance utput Troubleshooting Fault condition FLOORPAD SWITCH VOLTAGE OUT OF RANGE Resulting Effect Criteria TRACTION SYSTEM shutdown. Programmable floorpad option is enabled and system controller sensing improper input from the floorpad switch. Possible Cause Solution PERFORM INPUT TEST 14 - FLOORPAD SWITCH. Harness to floorpad switch broken, shorted, or Inspect harness and repair as necessary.
- Page 80 lectric ounterbalance utput Troubleshooting E27A E27A Fault condition MAIN POWER CONTACTOR WIRING FAULT Resulting Effect Criteria TOTAL shutdown. The main power contactor coil circuit is overheated, shorted to supply, shorted to ground, or disconnected. Possible Cause Solution PERFORM OUTPUT TEST 01 - MAIN POWER CONTACTOR. Broken or shorted wiring to the contactor.
- Page 81 lectric ounterbalance utput Troubleshooting E27F E27F Fault condition MAIN POWER CONTACTOR OPEN Resulting Effect Criteria TOTAL shutdown. No field current at both traction amplifiers when the coil driver for the main power contactor is energized. Possible Cause Solution Contactor tips are not passing battery voltage Check for foreign material between the contactor when the coil is activated.
- Page 82 lectric ounterbalance utput Troubleshooting Fault condition LOWER VALVE WIRING FAULT Resulting Effect Criteria LIFT system shutdown. The lower valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected. Possible Cause Solution PERFORM OUTPUT TEST 03 - LOWER SOLENOID. Broken or shorted wiring to the coil.
- Page 83 lectric ounterbalance utput Troubleshooting Fault condition HORN WIRING FAULT Resulting Effect Criteria DISPLAY code. The horn circuit is overheated, shorted to supply, shorted to ground, or disconnected. Possible Cause Solution PERFORM OUTPUT TEST 15 - HORN. Broken or shorted wiring to the horn. Check and repair damaged wires to the horn.
- Page 84 lectric ounterbalance utput Troubleshooting Fault condition TILT REVERSE VALVE WIRING FAULT Resulting Effect Criteria LIFT system shutdown. The tilt reverse valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected. Possible Cause Solution PERFORM OUTPUT TEST 07 - TILT BACK SOLENOID. Broken or shorted wiring to the coil.
- Page 85 lectric ounterbalance utput Troubleshooting Fault condition SIDESHIFT RIGHT VALVE WIRING FAULT Resulting Effect Criteria LIFT system shutdown. The sideshift right valve solenoid coil circuit is overheated, shorted to supply, shorted to ground, or disconnected. Possible Cause Solution PERFORM OUTPUT TEST 09 - SIDESHIFT RIGHT SOLENOID. Broken or shorted wiring to the coil.
- Page 86 lectric ounterbalance utput Troubleshooting Fault condition LIFT CONTACTOR WIRING FAULT Resulting Effect Criteria LIFT system, except lower shutdown. The lift contactor coil circuit is overheated, shorted to supply, shorted to ground, or disconnected. Possible Cause Solution PERFORM OUTPUT TEST 19 - LIFT MOTOR. Broken or shorted wiring to the coil.
- Page 87 lectric ounterbalance utput Troubleshooting E55L E55L Fault condition LEFT/RIGHT TRACTION CONTROL OVERHEATED E55R E55R Resulting Effect Criteria TRACTION system shutdown. The temperature sensor in the traction amplifier indicates that the temperature has reached a level which may damage components. Possible Cause Solution Continuous travel operation, short runs, hard Reduce operation.
- Page 88 lectric ounterbalance utput Troubleshooting E63L E63L Fault condition LEFT/RIGHT TRACTION MOTOR FIELD CURRENT NOT PRESENT E63R E63R Resulting Effect Criteria TRACTION system shutdown. Will not pass The system controller detects no current to the POST. traction motor field when there should be. Possible Cause Solution PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD &...
- Page 89 lectric ounterbalance utput Troubleshooting E65L E65L Fault condition LEFT/RIGHT TRACTION MOTOR ARMATURE CURRENT NOT PRESENT E65R E65R Resulting Effect Criteria TRACTION system shutdown. Will not pass The system controller detects no current to the POST. traction motor armature when there should be. Possible Cause Solution PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD &...
- Page 90 lectric ounterbalance utput Troubleshooting E72L E72L Fault condition LEFT/RIGHT TRACTION CONTROL +15 VOLTAGE OUT OF RANGE E72R E72R Resulting Effect Criteria TOTAL shutdown. Possible Cause Solution Battery voltage too low, especially if error occurs Test battery under load and replace if necessary. while operating truck.
- Page 91 lectric ounterbalance utput Troubleshooting E79c E79c Fault condition SYSTEM CONTROL CONFIGURATION ERROR Resulting Effect Criteria TOTAL shutdown. Possible Cause Solution Bad system controller. Replace system controller field fix. E79d E79d Fault condition DISPLAY CONFIGURATION FAILURE Resulting Effect Criteria TOTAL shutdown. Possible Cause Solution Bad operator display board.
- Page 92 lectric ounterbalance utput Troubleshooting Fault condition ENGAGE BRAKE TO CONTINUE POST Resulting Effect Criteria POST will not continue. The brake pedal is depressed during the Power On Self-Test (POST). Possible Cause Solution Brake pedal is depressed during POST. Raise brake pedal. Bad brake limit switch.
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