Schaeff Echo 3000 Service Manual Download Page 59 | Manualshive

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Capacitor Discharge

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

System Controller / Operator Display Box

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.1

Operator Display Board / Memory Board

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.2

Traction Amplifier

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3

Contactor Tips

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

Main Power Contactor

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.4

Lift and Steer Contactors

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

Fuses

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

Horn

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5

Horn Relay

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.5
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

Amplifier Diodes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.6

E

lectric

C

ounterbalance

H

igh

O

utput

Electrical

04/05/00

8.i

TABLE OF CONTENTS

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Summary of Contents for Echo 3000

Page 1: ...al 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 Repla...

Page 2: ...ection If necessary install spacers between the battery and the frame to achieve this specification Overhead Guard NOTE Any modifications to the overhead guard must be approved by the manufacturer Rem...

Page 3: ...he top of the cover is released lift upward on the cover and remove from the truck Replacement 1 Place the lower edge of the front cover into the support channels 2 Gently press the upper portion of t...

Page 4: ...moving the pads use care to avoid detaching the fastener from either the pad or the frame of the truck If the fastener does come loose clean the area with isopropyl alcohol and reattach it with cyanoa...

Page 5: ...1 Remove the top cover refer to TOP COVER Removal procedure in this section 2 Remove the two cap screws and brackets on the bottom of the pad 3 Lift the pad off the upper bracket and remove it from th...

Page 6: ...Tires 2 5 V Ring Seal 2 5 Drive Wheel Spindle Removal 2 6 Replacement 2 6 Drive Unit Rebuild Disassembly 2 7 Drive Unit Rebuild Assembly Pinion Gear to Motor Endbell Assembly 2 7 Gear Housing to Moto...

Page 7: ...on a spindle on the frame of the truck Each drive train is independently controlled by its own traction amplifier This allows the truck to monitor and control the power output from each of the drive...

Page 8: ...e lifting device has adequate capacity to handle the weight of the drive unit approximately 140 lbs a Lubricate the drive pinion and outer bearing use a needle nose grease gun to grease the outer bear...

Page 9: ...E If the unit has brush wear indicators be sure to install the new brush with the indicator wire in the same brush holder and route the indicator wire clear of the rotating armature 8 Rotate the top e...

Page 10: ...drive the truck and inspect for leaks Drive Wheel Assembly Removal Special Tools Drive Wheel Lock nut Tool P N 9650007 1 Disconnect the battery and discharge the capacitors WARNING Park the truck on...

Page 11: ...wheel Seat the bearings by tightening the nut to 60 lb ft 4 Back the lock nut off until a tab of the lock washer can be bent into the lock nut 5 Fasten the wheel cover onto the drive wheel 6 Lower the...

Page 12: ...es and bolts before reassembly 2 Align the cutout in the spindle with the hole in the frame Insert two screws to keep the spindle in place 3 Install the remaining screws and lock washers with a small...

Page 13: ...g from the endbell c To replace the lower seal press both the seal and the upper bearing cup out together Drive Unit Rebuild Assembly Pinion Gear to Motor Endbell Assembly NOTE w w Before assembling t...

Page 14: ...en the motor endbell and gear housing The thickness of the shim package is determined by one of the following formulas Use Procedure 1 when you have both the number on the end of the pinion and the nu...

Page 15: ...e the gear housing to the motor using four 3 8 16 nylon lock nuts torqued to 30 lb ft as either a left or right drive unit as required Carrier to Gear Housing Assembly 1 Place a 6 hole shim package Fi...

Page 16: ...tions 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...

Page 17: ...ft 5 Slide the pinion shaft out of the carrier housing 6 Remove bearings bearing cups and seals as necessary being careful not to damage gear teeth or machined surfaces Carrier Assembly 1 Ensure casti...

Page 18: ...ion shaft end Example Measured Depth 0 010 Add 0 003 0 003 Total Shim Package 0 013 13 Place the cap over the shim package and secure using three 5 16 18 screws Torque to 20 lb ft 14 Again spin housin...

Page 19: ...Removal 3 2 Disassembly 3 2 Assembly 3 2 Replacement 3 3 Brake Pedal Removal 3 3 Replacement 3 4 Brake Adjustments Brake Pedal Height 3 4 Brake Switches 3 4 Braking Force Clamping Pressure 3 5 Electr...

Page 20: ...n plate An electric solenoid coil acts against these springs to release the brakes The friction plate floats on the arbor so that equal pressure is applied to both sides When the operator releases the...

Page 21: ...the air gap is too small or there is no gap the brake may drag If the air gap is too large the clamping pressure may be weak resulting in long stopping distance Removal 1 Unplug the disc brake unit fr...

Page 22: ...iction plate Replacement 1 Install the arbor on the motor shaft using a woodruff key and the same number and thickness of shims noted in step 3 of removal The typical setup is four 0 020 shims under t...

Page 23: ...od end 5 Rotate the rod end to lengthen or shorten the brake rod Rotating the rod end counterclockwise will lower the brake pedal rotating the rod end clockwise will raise the brake pedal 6 Tighten th...

Page 24: ...nt screws in the top of each disc brake unit are used to adjust clamping pressure Before adjusting these verify that the air gap is 0 008 to 0 015 for both brakes see Figure 2 Turn the screws clockwis...

Page 25: ...ontrol Valve Removal 4 2 Replacement 4 2 Hydraulic Motor Removal 4 3 Replacement 4 3 Steer Gear Removal 4 3 Replacement 4 3 Steer Fork Assembly Removal 4 4 Replacement 4 4 Steer Wheel Assembly Removal...

Page 26: ...tor and control valve the hydraulic fluid is returned to the reservoir Steer Pump and Motor Assembly NOTE The steer pump can be removed from the motor without removing the steer pump and motor assembl...

Page 27: ...p Continue to turn the tiller and read the pressure gauge while the pump operates against relief The pressure should reach approximately 900 psi 5 Use a 3 slotted stubby screwdriver to adjust the reli...

Page 28: ...ic motor onto the mounting bracket making sure to use the correct length screws Longer screws may crack the motor case 2 Install the steer pinion gear onto the hydraulic motor shaft Use tool P N 96500...

Page 29: ...assembly must be supported prior to removing the lock nut If the steer fork assembly is not supported serious damage to the lift truck or the steer fork may occur Personal injury is also possible 4 U...

Page 30: ...nut and install the cotter pin 8 Using a grease gun fill the cavity of the steer wheel with grease The grease fitting is in the end of the axle 9 Lower the truck completely connect the battery and te...

Page 31: ...3 Connect the 3 pin plug from the steer position potentiometer Connect the battery and turn on the truck Run Diagnostic Input Test 05 The display will show the steer position potentiometer voltage 4 I...

Page 32: ...al 5 2 Replacement 5 3 Horn Button Spring Removal 5 3 Replacement 5 3 Lift Travel Springs Removal Replacement 5 3 Control Handle Replacement Removal 5 4 Replacement 5 4 Light and Auxiliary Rocker Swit...

Page 33: ...nnect lever mechanically separates the battery connectors cutting power to the truck The truck connector is mounted to the frame When the lever is pushed forward it pushes against the battery connecto...

Page 34: ...control handle harness pull it back and disconnect the potentiometer from the harness 3 Loosen the set screw holding the shaft of the potentiometer in the pivot shaft 4 Remove the screw holding the po...

Page 35: ...ng and other parts of the control handle and mechanism are not damaged during removal and installation of the roll pins 2 Remove and replace one spring at a time A Support the stop block in a vise or...

Page 36: ...hanism and remove the handle from the mechanism Replacement 1 Install the control handle boot on the handle Thread the lower jam nut onto the shaft 2 Feed the handle harness wires through the mechanis...

Page 37: ...on the rocker switch and remove it from the cover Replacement 1 Insert the switch into the cover until the switch locks in place 2 Connect the wires to rocker switches and plug the key switch into th...

Page 38: ...e keyswitch from the cover Replacement 1 Install the keyswitch through the system controller cover 2 Install and tighten the locknut on the keyswitch 3 Plug the keyswitch into the system controller Co...

Page 39: ...oval 6 3 Replacement 6 3 Valve Cartridges Removal 6 3 Replacement 6 4 Hydraulic Oil Filter Removal 6 4 Replacement 6 4 Hydraulic Oil Removal 6 4 Replacement 6 5 Tilt Cylinders Removal 6 5 Replacement...

Page 40: ...The system controller switches to a low voltage signal at J4 Pin 1 opening the lower valve and allowing the hydraulic oil to flow back to the lift lower proportional valve The voltage signal at J4 Pi...

Page 41: ...to the full forward position 2 Disconnect the battery and discharge the capacitors 3 Remove the front cover and top cover refer to FRONT COVER and TOP COVER Removal procedures in the FRAME section 4...

Page 42: ...from the brush 6 Remove the screw securing the brush lead to the brush holder 7 Remove the brush Replacement NOTE If any brush needs replacing replace all the brushes as a set It is recommended to sto...

Page 43: ...battery and discharge the capacitors 3 Remove the front cover refer to FRONT COVER Removal procedure in the FRAME section 4 Use a filter wrench to loosen the filter Unscrew the filter and lift it out...

Page 44: ...ns to the tilt cylinders and disconnect the hoses from the tilt cylinder fittings leave the 90o fittings on the cylinder 7 Disconnect the tilt cylinder from the mast by removing the screw and retainin...

Page 45: ...t cylinders stop at the same time in both the forward and backward tilt and the tilt angle is correct 4 Once proper adjustment is attained tighten the clamp screw to lock the rod end 5 Test the tilt c...

Page 46: ...Center Free Lift Cylinder Repacking 7 8 Removal 7 8 Installation 7 8 Outer Lift Cylinders Repacking 7 9 Removal 7 10 Replacement 7 10 Checks and Adjustments Check for Leaks 7 10 Lift Chain Adjustments...

Page 47: ...ers are installed at the back of the outer rail The base of each lift cylinder sits in a mount at the bottom of the outer rail and is secured with a roll pin The top of each outer lift cylinder cylind...

Page 48: ...4 providing a cushioning effect 1 Cylinder Rod Assembly 2 Cylinder Shell 3 Large Orifice 4 Small Orifice 5 Wear Ring 1 2 3 4 5 s s FIGURE 7 2 CENTER CYLINDER CUSHIONING OUTER CYLINDERS The outer cyli...

Page 49: ...nspecting or working on the mast Additional precautions and procedures can be required when repairing or removing the mast WARNING Mast parts are heavy and can move Distances between parts are small S...

Page 50: ...vating 3 10 00 7 4 1 2 3 4 5 6 LOWERED 7 8 FREE LIFT 1 2 3 4 5 6 7 8 FULLY RAISED 1 Outer Rail 2 Outer Lift Cylinders 3 Middle Rail 4 Center Lift Cylinder 5 Inner Rail 6 Carriage 7 Outer Lift Chains 8...

Page 51: ...ust the clearance of the load rollers refer to Checks and Adjustments in this section 2 Lower the carriage below the center cylinder clevis head Install the chain sheaves and hose sheaves on the cente...

Page 52: ...t of the middle rail until the load rollers on the inner rail are visible in the notches at the top of the middle rail 5 Lift the inner rail out of the middle rail Remove the load rollers at the botto...

Page 53: ...cks and Adjustments 4 Connect the outer cylinder rods to the middle rail using the screws washers spacer sleeves and shims noted during disassembly do not allow the rod to spin If either of the outer...

Page 54: ...center cylinder clevis head out of the cylinder rod and set it aside If oil is present inside the hollow tube there is a leak between the piston and the tube refer to Figure 7 2 3 Use a spanner wrenc...

Page 55: ...t the cylinder from rotating while loosening the gland nut Use the proper gland nut tool to loosen and remove the gland nut from the top of the cylinder 7 Install new seals and lubricate them with cle...

Page 56: ...capacity load on the forks Use a safety chain to hold the load to the carriage Raise and lower the load several times Check the lift cylinders and all hydraulic connections for leaks Leave the mast el...

Page 57: ...he mast tilted forward The brass set screws reduce the front to back movement between the rails The brass set screws are too loose if there is excessive front to back play in the rails when extended O...

Page 58: ...vel 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...

Page 59: ...moval 8 3 Replacement 8 3 Contactor Tips Removal 8 4 Replacement 8 4 Main Power Contactor Removal 8 4 Replacement 8 4 Lift and Steer Contactors Removal 8 5 Replacement 8 5 Fuses Removal 8 5 Replacemen...

Page 60: ...ION To avoid damage to the system controller and operator display follow the CAPACITOR DISCHARGE PROCEDURE at the beginning of this section Removal 1 Disconnect the battery and discharge the capacitor...

Page 61: ...r display remove the four screws securing the operator display pc board to the standoffs on the system controller pc board CAUTION The operator display board and system controller are connected by a s...

Page 62: ...the mounting surface on the truck is clean and free from any foreign materials which might prevent the amplifier base from making full contact Position the amplifier in place and align the mounting h...

Page 63: ...e bus bars of the contactor Over tightening the nuts can cause the bus bars to bend resulting in misalignment of the contactor tips and overheating Use a backup wrench to prevent bending the bus bars...

Page 64: ...Install screws and tighten 2 Connect power cables and wires to contactor in correct locations as noted in Step 3 of Removal 3 Install top cover refer to TOP COVER Replacement procedure in the Frame se...

Page 65: ...rs to the horn and the main harness 3 Install the top cover refer to TOP COVER Replacement procedure in the FRAME section 4 Connect the battery AMPLIFIER DIODES Special Tools Digital Volt Ohm Meter DV...

Page 66: ...e High Output Preventive Maintenance 4 3 00 10 1 FIG 10 1 SCHEDULED MAINTENANCE AND INSPECTION POINTS The numbers in this drawing correspond to the numbers in the first column of the SCHEDULED MAINTEN...

Page 67: ...9 E E X X Inspect for cracks bends and damage Lubricate sideshift carriage Carriage Load Backrest Forks 8 X Locks out travel capability when pedal is up Brake Switches 7 X Check for smooth operation...

Page 68: ...the starting sequence as described above and check the following operations w Operator Display w Horn w Lift tilt sideshift if so equipped and auxiliary functions if equipped w Brakes w Steering syst...

Page 69: ...s specification BRAKES NOTE Release the brake pedal only in an emergency The forklift will stop abruptly which may cause the load to fall The brakes operated by the brake pedal are primarily for use a...

Page 70: ...re can be injected into the skin Never check for leaks by putting hands on a hydraulic line under pressure w Disconnect the battery while servicing w Never operate the pump without oil in the hydrauli...

Page 71: ...ring control TIRES WHEELS Inspect the tires for wire rocks glass pieces of metal holes cuts and other damage Tire wear will vary depending on the operating surface load weight and the method of operat...

Page 72: ...wer the carriage and tilt the mast fully forward Check the hydraulic oil level with the dipstick Make sure the temperature of the oil is at least 90o F 2 If the oil level is low carefully check for le...

Page 73: ...our battery or with your dealer for a suitable battery charger combination and for specific details about the equalizing charge for your battery CONTACTOR TIPS WARNING Disconnect the battery and disch...

Page 74: ...rriage and tilting the upright to a vertical position 4 Press on each chain using moderate pressure Each chain should have equal tension Refer to the ELEVATING section for adjustment procedures MOTOR...

Page 75: ...4 Replace the breather cap Filter 1 Use a filter wrench to remove the oil filter 2 Use hydraulic oil to lubricate the seal on a new filter of the same type as the old one 3 Install the new filter and...

Page 76: ...ndition E01 E01 Replace lift lower potentiometer and calibrate Bad lift lower potentiometer Adjust springs so there is no play in the neutral position Calibrate the control handle Excess play in the c...

Page 77: ...ion E04 E04 Check working voltage of battery It must be within the range listed at left Replace the battery if the voltage is above the maximum or below the minimum listed voltages After charging allo...

Page 78: ...ssible Cause Steer position potentiometer voltage is outside the normal operating range 0 29 V to 4 7 V Note actual voltage supplied to potentiometer is 15V TRACTION system shutdown Criteria Resulting...

Page 79: ...14 FLOORPAD SWITCH Should indicate ON when right foot is on switch Solution Possible Cause Programmable floorpad option is enabled and floorpad switch reading is open while truck is traveling Truck wi...

Page 80: ...heated shorted to supply shorted to ground or disconnected TOTAL shutdown Criteria Resulting Effect MAIN POWER CONTACTOR WIRING FAULT Fault condition E27A E27A Inspect contactor tips and remove foreig...

Page 81: ...n Criteria Resulting Effect MAIN POWER CONTACTOR OPEN Fault condition E27F E27F Replace system controller field fix Malfunction of the coil driver Replace coil Solenoid coil is open or shorted interna...

Page 82: ...Resulting Effect LOWER VALVE WIRING FAULT Fault condition E30 E30 Replace system controller field fix Malfunction of the coil driver Replace coil Solenoid coil is open or shorted internally Check 15...

Page 83: ...ULT Fault condition E32 E32 Replace system controller field fix Malfunction of the coil driver Replace coil Solenoid coil is open or shorted internally Check 15 amp fuse on main harness wiring on all...

Page 84: ...fect TILT REVERSE VALVE WIRING FAULT Fault condition E34 E34 Replace system controller field fix Malfunction of the coil driver Replace coil Solenoid coil is open or shorted internally Check 15 amp fu...

Page 85: ...Resulting Effect SIDESHIFT RIGHT VALVE WIRING FAULT Fault condition E36 E36 Replace system controller field fix Malfunction of the coil driver Replace contactor Contactor coil is open or shorted inte...

Page 86: ...raction motor field resistance greater than 0 9 ohm at room temp Check motor terminals brake clearance operation of drive unit and wheel Loose motor terminals brake drag mechanical binding of drive un...

Page 87: ...ace all left right traction motor brushes Left right traction motor brushes are worn Solution Possible Cause Indicator sensor in brush is worn and has 36 volts from armature SPEED limited Criteria Res...

Page 88: ...ENT NOT PRESENT Fault condition E63L E63L E63R E63R Replace traction motor Bad traction motor shorted winding Replace traction amplifier Bad traction amplifier Test diode and replace if necessary Bad...

Page 89: ...PRESENT Fault condition E65L E65L E65R E65R Replace system controller field fix Damaged or defective system controller Test battery under load and replace if necessary Battery voltage too low especial...

Page 90: ...ct LEFT RIGHT TRACTION CONTROL 15 VOLTAGE OUT OF RANGE Fault condition E72L E72L E72R E72R Replace system controller field fix Bad system controller Solution Possible Cause A D chip failure TOTAL shut...

Page 91: ...m except lower shutdown Criteria Resulting Effect LIFT CUTOUT DUE TO LOW BATTERY STATE OF CHARGE Fault condition E80 E80 LO LO BATT BATT Replace upper control handle Wires shorted in control handle ha...

Page 92: ...ecessary Battery voltage too low especially if error occurs while operating truck Solution Possible Cause TOTAL SYSTEM shutdown and open MAIN POWER CONTACTOR Criteria Resulting Effect LEFT RIGHT AMP H...

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