8. Remove the lift pump and motor assembly
from the truck.
Replacement
1. Align the lift pump and motor assembly with
the holes in the front frame of the truck.
2. Attach the lift pump and motor assembly to the
frame of the truck. [4 hex bolts, 4 flat
washers, 4 flange lock nuts]
3. Attach the hydraulic lines to the lift pump in
the correct locations.
4. Install the power cables to the proper terminals
on the lift pump motor.
5. Install the overhead guard (refer to Overhead
Guard Replacement procedures in the FRAME
section).
6. Install and connect the battery (refer to
APPENDIX A: INDUSTRIAL BATTERY).
LIFT PUMP MOTOR BRUSHES
* Replace at 2.75 in. Diameter
2.80 in.
2.92 in.
Commutator Dia.*
40 oz.
65 oz.
Spring Tension
0.62 in.
1.35 in.
Brush Length
MIN
NEW
TABLE 6
Removal
NOTE
Two of the lift pump motor brushes may be
inspected without removing the lift pump
motor from the truck.
1. Tilt the mast to the full forward position.
2. Disconnect the battery and discharge the
capacitors.
3. Remove the front cover (refer to FRONT
COVER Removal procedure in the FRAME
section).
4. Remove the lift pump and motor assembly
(refer to LIFT PUMP AND MOTOR
ASSEMBLY Removal procedure in this
section).
5. Remove the brush covers. Release the spring
tension on the brush by rotating the brush
holder spring away 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 stone
the commutator when replacing brushes.
1. Insert the brush assembly into the brush
holder.
2. Reposition the end of the brush spring on the
brush.
3. Attach the brush lead to the brush terminal
and tighten the screw.
4. Reinstall the lift pump and motor assembly
(refer to LIFT PUMP AND MOTOR
ASSEMBLY Replacement procedure in this
section).
5. Replace the front cover (refer to FRONT
COVER Replacement procedure in the
FRAME section).
6. Connect the battery.
VALVE
CARTRIDGES
Refer to the LIFT & AUX section of the PARTS
Manual for an illustration of the components
of the manifold.
WARNING
Before disconnecting any hydraulic lines,
relieve the pressure in the lines. Allow the
truck to sit for approximately five minutes.
Removal
1. Lower the mast completely and tilt the mast 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. When working on any of the valves in the
lift/lower circuit, open the manual lowering
valve to relieve pressure.
5. If applicable, mark the coil connections for
correct replacement. Remove the coil
retaining nut and slide the coil(s) off the valve.
E
lectric
C
ounterbalance
H
igh
O
utput
Lift & Auxiliary
03/21/00
6.3
