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Replace travel potentiometer and calibrate.

Bad travel potentiometer.

Adjust springs so there is no play in the neutral
position. Calibrate the control handle.

Excess “play” in the control handle.

Perform travel potentiometer calibration procedure.

Travel potentiometer out of calibration.

Return control handle to neutral.

The control handle is not in neutral when the
brake pedal is depressed.

PERFORM INPUT TEST 03 - TRAVEL POTENTIOMETER VOLTAGE. Look for constant repeatable
voltage reading in neutral.

Solution

Possible Cause

Travel potentiometer voltage is not in the neutral
range (±0.12V from calibrated center) when the
brake pedal is depressed.

TRACTION system shutdown until condition is
cleared.

Criteria

Resulting Effect

RELEASE THROTTLE TO RESUME OPERATION

Fault condition

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 control handle.

Perform lift potentiometer calibration procedure.

Lift/lower potentiometer out of calibration.

Return control handle to neutral.

The control handle is not in neutral when the
brake pedal is depressed.

PERFORM INPUT TEST 04 - LIFT/LOWER POTENTIOMETER VOLTAGE. Look for constant
repeatable voltage reading in neutral.

Solution

Possible Cause

Programmable brake-lift interlock is enabled. Lift
potentiometer voltage is not in the neutral range
(±0.14V from calibrated center) when brake pedal is
depressed.

LIFT system shutdown until condition is cleared.

Criteria

Resulting Effect

BRAKE LIFT INTERLOCK WARNING

Fault condition

E02

lectric

ounterbalance

igh

utput

Troubleshooting

REV 12/5/99

TS.1

ELECTRONIC F

AULT

ISOLATION PROCEDURE

SOFTWARE VERSION 6.08

Содержание Echo 3000

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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