Schaeff Echo 3000 Service Manual

Electric Counterbalance High Output Frame

TABLE OF CONTENTS

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

1.i

Electric Counterbalance High Output 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
removed - the battery could slide out of the
compartment and could cause damage and/or
personal injury.

NOTE
The battery must not be able to slide more
than 1/2” in any horizontal direction. If
necessary, install spacers between the battery
and the frame to achieve this specification.

1 Shaft
2 O-Ring
3 Roller

FIGURE 1.1 - Disassembly of Battery Rollers

4 Bushing
5 Flat Washer

Battery Gates

1. To remove a battery gate, slide the gate up so
that the rear tab lines up with the cutout in the
frame. Rotate the rear of the gate away from
the frame, and remove the gate.

2. To install a battery gate, insert the front tab of
the gate into the slot in the frame. Line up the
rear tab of the gate with the cutout in the
frame. Rotate the gate into the cutout and
slide the gate all the way down.

Overhead Guard

NOTE
Any modifications to the overhead guard must
be approved by the manufacturer.

Removal

1. Disconnect the battery and discharge the

capacitors. Remove the front cover and top
cover. Disconnect any accessory wiring on
the overhead guard (such as work lights or
flashing lights).

2. Attach a lifting device to the overhead guard

and take up any slack.

3. Remove the overhead guard mounting screws

from the front crossbar and rear post.

4. Use the lifting device to raise the overhead

guard off the truck. Do not allow the posts to
swing and damage any components of the
truck.

Replacement

1. Use a lifting device to position the overhead

guard directly over the truck.

REV W1 11/02/99 1.1

2. Do not let the overhead guard legs swing and

damage components of the truck. Slowly
lower the overhead guard so that the

Electric Counterbalance High Output Frame

mounting holes in the overhead guard line up
with the mounting holes in the frame. Install
the mounting screws and torque to 120ft.-lbs.
Install the rear post mounting screw and
torque to 120 ft-lbs.

3. Reconnect any accessory wiring. Install the
top cover and front cover.

REAR POST

Removal

1. Disconnect the battery and discharge the
capacitors. Remove the top cover.
Disconnect any accessory wiring through the
rear post (such as flashing light).

2. Attach a lifting device to the rear post and
take up any slack.

3. Remove the mounting screws from the lower
end of the rear post.

4. Remove the mounting screw at the top of the
rear post. Lower the post out of the overhead
guard, the nraise it out of the truck. Do not
allow the post to swing and damage
components in the truck.

Replacement

1. Use a lifting device to position the post in the
truck. Install, but do not tighten the mounting
screw at the top of the post.

2. Install the mounting screws at the bottom of
the rear post. Torque to 120 lb-ft. Torque the
upper screw to 120 lb-ft.

3. Connect any accessory wiring. Install the top
cover and connect the battery.

4. Once the 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 the front
cover into place until the latch clicks into
position.

3. Connect the battery.

TOP COVER

Removal

NOTE
The top cover is held in place with 7 frame
mounted spring-type retaining clips. This
cover does not require any tools to remove.
Care must be used when removing this cover
to avoid possible breakage.

1. Disconnect the battery and discharge the

capacitors.

2. Starting at the corner where the top cover

meets the control cover in the operator
compartment, gently pull up until the first
spring clips release the top cover.

3. As each spring clip on the left side releases

the top cover, move the handhold as close as
possible to the next spring clip. Gently pull up
until the cover is released from all of the
spring clips on the left side.

4. To release the right side of the cover, move

the battery disconnect forward, grasp the rear
edge of the opening, and gently pull upward.

FRONT COVER

Removal

1. Tilt the mast to the full forward position.

2. Disconnect the battery and discharge the
capacitors.

3. The front cover is held by a spring clip that
engages the overhead guard crossbar. Pull
the front cover forward, away from the front of
the truck.

REV W1 11/02/99 1.2

5. Once the top cover is released from the spring
clips, lift the rear edge of the cover up until it
is clear of the rear leg of the overhead guard.
Move the entire cover toward the rear of the
truck until the top cover is free from the front
clip and the overhead guard.

6. Remove the cover from the truck.

Replacement

1. Tilt the top cover so that the front edge of the
cover is lower than the rear edge and slide
into place on the truck.

Electric Counterbalance High Output Frame

2. Align the cutouts on the front edge of the top
cover with the front posts of the overhead
guard. Move the front edge of the top cover
into place. Lower the rear of the top cover
into place.

3. Align the cut-outs in the lip of the cover with
the spring clips on the truck frame.

4. Press downward at each spring clip until the
cover is secured.

5. Connect the battery.

CONTROL COVER

Removal

1. Disconnect the battery and discharge the
capacitors.

2. Remove the top cover (refer to TOP COVER
Removal procedure in this section).

3. Remove the steering tiller.

4. Remove the seven screws securing the
control cover.

5. Lift the control cover over the control handle
and remove it from the truck.

the frame of the truck. If the fastener does
come loose, clean the area with isopropyl
alcohol and reattach it with cyanoacrylate
adhesive (“super glue”).

1. Remove the top cover.

2. Grasp the outside edge of the pad and
carefully separate the pad from the mating
portion of the fastener attached to the frame
of the truck.

3. Rotate the pad outward until the remainder of
the fasteners release.

4. Remove the pad.

Replacement

NOTE
Refer to PADS AND PLASTIC in the FRAME
section of the PARTS Manual for location of
operator compartment pads.

1. Align the pad so the halves of the fasteners

meet.

2. Firmly press the pad into place.

3. Gently pull on the outside edges of the pad to

verify the attachment.

4. Install the top cover.

Replacement

1. Place the control cover into position over the
control handle and start the seven screws - do
not tighten.

2. Install the steering tiller.

3. Position the cover so there is no contact with
the control handle boot or steer tiller, then
tighten the seven screws.

4. Replace the top cover (refer to TOP COVER
Replacement procedure in this section).

5. Connect the battery.

OPERATOR COMPARTMENT PADS

Removal

NOTE
The pads in the operator compartment are
secured in place with dual-lock fasteners.
When removing the pads, use care to avoid
detaching the fastener from either the pad or

FLOOR MAT / BRAKE PEDAL PAD

NOTE
The floor mat in the operator compartment is
not glued down. However, normal servicing of
the truck does not require the removal of the
floor mat.

Removal

NOTE
The brake pedal pad is secured in place with
general purpose RTV silicone adhesive. The
brake pedal pad will be damaged when
removed. It is recommended that a
replacement pad be available prior to removal
of the old pad.

1. Using an appropriate scraper, pry up the

outside edge of the pad.

2. Carefully peel the pad away from the brake

pedal.

REV W1 11/02/99 1.3

Electric Counterbalance High Output 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. (Follow
the manufacturer's instructions on the label of
the adhesive.)

2. Align the brake pedal pad with the brake
pedal.

3. Firmly press the pad into position.

4. Allow the adhesive to cure per the
manufacturer's recommendations.

HIGH BACK PAD

Removal

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 the truck.

Replacement

1. Hook the top of the pad over the bracket at
the top of the frame.

2. Align the brackets with the lower brackets on
the truck frame and install flat washers, lock
washers and cap screws through each bracket
into the pad. Tighten the cap screws.

3. Install the top cover.

DECALS

Make sure all safety decals are in place and
readable. Replace worn or missing decals. Refer
to the PARTS Manual for decal location drawings.

REV W1 11/02/99 1.4

Electric Counterbalance High Output Drive

TABLE OF CONTENTS

Drive Train

Description.................................................2.1

Drive Unit

Removal...................................................2.2

Replacement................................................2.2

Drive Motor

Brush Replacement..........................................2.3

Gearbox

Oil Change.................................................2.3

Drive Wheel Assembly

Removal...................................................2.4

Replacement................................................2.5

Changing Drive 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 Motor Assembly..............................2.8

Carrier to Gear Housing Assembly.............................2.9

Carrier Rebuild

Carrier Disassembly........................................2.11

Carrier Assembly...........................................2.11

04/05/00

2.i

Electric Counterbalance High Output 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. From the gearbox, the
traction drive is transmitted to the drive wheel by
a pinion gear on the output end of the gearbox
which meshes with a ring gear mounted on the
inside of the drive wheel. The drive wheel rotates
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 units, improving the maneuverability of
the truck in tight areas. During turns, the inside
drive motor decreases speed to improve the
turning radius. In addition, each drive motor is
equipped with a disc-type brake to ensure positive
emergency stopping. Normal slowing or
deceleration is accomplished through "plugging"
of the motors.

NOTE
Specialized tools, fixtures, and training are
required to service any part of the drive unit
assembly.

FIGURE 2.1 - DRIVE UNIT

12/20/99 2.1

Electric Counterbalance High Output Drive

Drive Unit

Removal

1.Disconnect the battery and discharge the

capacitors.

2.Remove the mast and front cover (refer to

Mast Removal procedure in the ELEVATING
section).

3.Put the truck on blocks or stands so the drive

wheels are completely off the ground.

4.Disconnect the power cables from the motor,

noting their location for correct replacement.

5.Remove the screws securing the drive unit to

the frame.

6.Tilt the drive unit forward so the motor is

vertical.

7.Remove the disc brake unit from the motor

(refer to Brake Removal in the BRAKES
section).

8.Remove the drive unit:

CAUTION
Ensure the lifting device has adequate
capacity to handle the weight of the drive unit
(approximately 140 lbs).

a)Attach a lifting device to the drive unit

for support and remove the slack.

b)Move the drive unit toward the center

of the truck, being careful not to
damage the hydraulic connection
block in the center of the frame.

c)Rotate the drive unit to clear the

pinion gear from the frame of the
truck. Use caution when rotating the
drive unit to prevent the pinion gear
from striking the frame of the truck.

d)Remove the drive unit from the truck.

a)Lubricate the drive pinion and outer

bearing (use a needle nose grease
gun to grease the outer bearing).

b)Connect a lifting device to the drive

unit.

c)Lift the drive unit into position in front

of the truck.

d)Carefully rotate the gearbox so the

pinion gear enters the opening in the
frame.

e)Rotate the drive wheel to engage the

pinion with the ring gear and slide the
gearbox pilot into the opening until the
flange is against the frame.

2.Install the disc brake unit (refer to Brake
Replacement).

NOTE
The drive unit is mounted to the frame with
four screws. Three screws are 1-1/2" long and
one is 1-1/4" long. The 1-1/4" screw goes in
the lower front hole (refer to DRIVE TRAIN in
the PARTS manual for an illustration).

3.Tilt the drive unit back to line up the mounting

holes. Install the four mounting screws and
torque to 80 lb-ft.

4.Connect the power cables to the correct

terminals on the motor. Plug in the brake unit.

5.Ensure the gearbox is filled with the proper

lubricant (refer to GEARBOX OIL CHANGE
procedure in this section).

6.Before lowering the truck off the blocks or

stands, connect the battery and test the drive
unit in Diagnostic Output Test 17 or 18 to
confirm proper operation.

7.Install the mast (refer to Mast Replacement

procedure in the ELEVATING section).

8.Install the front cover.

9.Place the drive unit on a clean, secure work
surface.

Replacement

1.Install the drive unit into the truck:

CAUTION
Ensure the lifting device has adequate
capacity to handle the weight of the drive unit
(approximately 140 lbs).

12/20/99 2.2

Electric Counterbalance High Output Drive

Drive Motor

NOTE
Specialized tools, fixtures, and training are
required to service the drive motor. Refer to
DRIVE UNIT REBUILD in this section.

Brush Replacement

NOTE
ww Replace all the brushes in one motor as a

set.

ww Units with brush wear indicators will have

one brush with an indicator wire. Note the
position of this brush for reassembly.

1.Tilt the mast to the full forward position.

2.Disconnect the battery and discharge the

capacitors. Remove the top cover and front
cover.

3.Remove the brake unit from one motor (refer

to the BRAKES Section).

4.Remove the armature cables from the motor,

noting their location for correct replacement.

NOTE
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 endbell housing to gain access

to the remaining brushes. When all eight
brushes and springs have been replaced,
return the endbell to its original position
(armature studs forward).

9.Reverse Steps 3 through 6 for reassembly.

10.Install the top cover and front cover. Connect

the battery and test the truck for proper
operation.

5.Disconnect and remove the cooling fan from
the motor.

6.Remove the four 1/4” screws holding the
upper endbell to the drive motor.

7.Replace one brush and spring at a time.
Insert the new brush into the brush holder in
the correct orientation (see Fig. 2.2). Install
the brush spring, insuring it is in the proper
position. Tighten the brush lead screw to 15

-18 in.-lbs.

CORRECT

INCORRECT

COMMUTATOR

FIGURE 2.3 - GEARBOX

Gearbox

NOTE
Specialized tools, fixtures, and training are
required to service any part of the gearbox.
Refer to DRIVE UNIT REBUILD in this section.

Oil Change

1.Disconnect the battery, discharge the

capacitors, and block the wheels of the truck
to prevent movement.

2.Place a clean drain pan under the appropriate

drive unit.

3.Remove the fill plug from the front of the

gearbox.

4.Remove the magnetic drain plug from the

bottom of the gearbox and allow the oil to
drain completely. Inspect the magnetic plug
and the used oil for excessive metal shavings.

FIGURE 2.2 - BRUSH ORIENTATION

12/20/99 2.3

Electric Counterbalance High Output 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
thread sealant to the plug and reinstall the
magnetic drain plug.

6.Remove the fluid level plug from the side of
the gearbox.

7.Fill the gearbox through the fill plug hole, with
Mobil SHC 50 Synthetic Gear Lubricant or
equivalent (SAE 80/90 Gear Oil may be
substituted if the truck is not used in Freezer
applications) until fluid level is even with the
bottom of the fluid level plug hole
(approximately 20 oz. for each gearbox).

8.Clean the old sealant from the threads of the
fluid level plug, apply new pipe thread sealant
to the plug and install the plug.

9.Clean the threads of the fill plug, apply pipe
thread sealant, and install the fill plug.

10.Remove the blocks from the wheels and
connect the battery. Test 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 a level surface. Block the
rear wheel to prevent the truck from rolling.

2.Lift the front of the truck and place it on

blocks.

3.Remove the drive wheel cover.

4.Bend the tabs of the lock washer out of the

slots in the spindle lock nut.

5.Use the lock nut tool to remove the lock nut

from the spindle. Remove the lock washer
with the lock nut.

CAUTION
The drive wheel assembly weighs 85 pounds
or more.

12/20/99 2.4

6.Remove the drive wheel assembly from the

spindle. The outer bearing will come off with
the wheel.

7.With the drive wheel off, the v-ring seal can

be inspected or replaced. Remove the v-ring,

Electric Counterbalance High Output Drive

clean the groove, then apply a thin film of the
same lubricant used for the final drive gears
(Mobilith SHC 007 Synthetic Grease NLGI 00
or equivalent) to the v-ring seal.

Replacement

NOTE
Before installing the drive wheel assembly on
the truck, the outer drive pinion bearing, and
wheel bearings must be lubricated with
Mobilith SHC 220 Synthetic Grease NLGI 2 or
equivalent. Use a needle tipped grease gun to
lube the outer drive pinion bearing with this
same grease. Lubricate the final drive gears
with Mobilith SHC 007 Synthetic Grease NLGI
00 or equivalent.

NOTE
DO NOT remove the ring gear from the inside
of the drive wheel. The ring gear is not
available as a separate part. If the ring gear is
damaged, replace the drive wheel assembly.

1.Pack both wheel bearings and place the inner

bearing on the spindle. Set the drive wheel
onto the spindle. Rotate the drive wheel so
the ring gear teeth mesh with the pinion gear
teeth, then push the drive wheel completely
onto the spindle.

Changing Drive Tires

Special Tools: Tire Changing Fixture (P/N

9650008), Tire Press (40 ton)

NOTE
There is a flange at the back of the drive wheel
that can be broken if the wheel is improperly
pressed.

1.Remove the drive wheel assembly (refer to

procedure in this section).

2.Place the larger ring of the tire changing

fixture on the press table. Place the wheel
and tire, ring gear down, on top of the ring,
making sure the ring does not touch the
wheel. Center the smaller ring on top of the
wheel. Press the wheel out of the tire.

NOTE
When replacing the drive tire, make sure the
composition and size are such that
maneuverability and capacity are maintained.

3.Place the new tire on the press table. Align

the wheel on top of the tire with the ring gear
up. Press the wheel into the tire.

4.Install the drive wheel assembly.

2.Install the outer bearing. Line up the inner tab
of a new lock washer with the slot in the
spindle and install.

3.Carefully thread the lock nut onto the spindle
(beveled side toward the 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 truck off the blocks or stands and
remove the rear wheel blocks. Connect the
battery and test drive the truck for proper
operation.

NOTE
If the wheel bearings are not properly
adjusted, the drive wheel may lock up in one
direction.

V-Ring Seal

See Drive Wheel Removal.

FIGURE 2.5 - CHANGING DRIVE TIRES

12/20/99 2.5

Electric Counterbalance High Output 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.

Replacement

1.Clean old thread locking compound and oil

from the holes 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 amount of thread lock compound.
Tighten to 80 lb-ft.

4.Remove the first two screws, apply thread

lock compound, and reinstall with lock
washers. Tighten to 80 lb-ft.

5.Install the drive wheel.

6.Test drive the truck for proper operation.

12/20/99 2.6

FIGURE 2.6 - DRIVE UNIT ASSEMBLY

Electric Counterbalance High Output 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.Remove the four nylon lock nuts (Figure 2.6

Item 14) and separate the gearbox from the
motor. Note the thickness of the shim
package.

3.Remove the six screws (Figure 2.6 Item 26)

and separate the carrier from the housing.
Note the thickness of the old shim package,
then discard.

4.If necessary, remove the bottom endbell

(including the pinion gear) from the motor.
There may be shim material around the motor
shaft in the pinion gear.

5.Remove the O-ring (Figure 2.6 Item 12) and

discard.

6.To disassemble pinion:

a.Loosen the screw on the side of the clamp

nut (Figure 2.6 Item 2) and remove the
clamp nut using the pinion locknut wrench
(P/N 9660099) and 3/8” drive pinion
wrench (P/N 9660154-01).

b.The spacer (Fig. 2.6 Item 3) and bearings

(Fig. 2.6 Item 5) are pressed onto the
pinion gear. Carefully press the pinion
gear out of the endbell. Press the lower
bearing off the pinion gear. Remove the
upper seal to remove the upper bearing
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

ww Before assembling the drive unit, all

components and machined surfaces must
be thoroughly cleaned of any dirt, grime,
gasket compound, etc. Machined surfaces

Figure 2.7- Pinion Gear to Endbell Assembly

must be cleaned only by using a soft cloth
and mild, non-abrasive cleaning solvent.

1.Refer to Figure 2.7 to assemble the pinion
gear to the motor endbell:

a.Install the lower seal (lip down) and the

lower bearing cup.

b.Pack the upper bearing with Mobilith SHC

220 synthetic grease (or equivalent) and
lubricate the lip of the lower seal. Press
the lower bearing all the way onto the
pinion using the pinion bearing press die
(P/N 9660100).

c. Cover the threads on the pinion to prevent

damaging the seal. Slide the pinion
through the endbell and remove the
thread covering.

d.Use a hand press and the pinion bearing

press die (P/N 9660100) to press the
upper bearing and spacer onto the pinion
shaft. Rotate the endbell housing while
pressing. Stop pressing when slight drag
can be felt. Fill the upper bearing cavity
with Mobilith SHC 220 synthetic grease
(or equivalent), then install the upper seal.

12/20/99 2.7

Electric Counterbalance High Output 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.

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.

e.Measure the turning torque on the pinion

using the 1/4” drive pinion wrench (P/N
9660154-00) and a torque wrench. The
turning torque should be 13-17 in.-lbs. If the
turning torque is greater, loosen the clamp nut
and make slight adjustments with a hand
press on the pinion. If the turning torque is
less, slight adjustment can be made by
tightening the clamp nut, or remove the clamp
nut and make slight adjustment with a hand
press on the spacer.

2.Apply anti-seize compound to the motor shaft

spline. Attach the endbell to the motor. If
shim stock was removed during during
disassembly, replace it only if using the same
motor.

3.Install a new O-ring (Fig 2.6, Item 12) on the

motor pilot flange.

Gear Housing to Motor Assembly

NOTE
Before assembling the gear housing to the
motor, you must first determine whether you
are to build a left or a right drive unit. As an
assembler holds a drive unit with the brake
end of the motor up and the terminal lugs
pointing forward, a right drive unit would be
assembled with the gearbox pointing to the
right; a left drive unit would be assembled
with the gearbox pointing to the left (see Fig.

2.8).

1.Determine the thickness of the 4-hole shim

package required between 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
number on the gearbox housing.

A + B - C = Shim package
Refer to Fig. 2.9 Procedure 1

RIGHT

Figure 2.8 - Drive unit orientation.

Use Procedure 2 when the number on the
end of the pinion is illegible or there is no
number.

D + 2.061 - C = Shim Package
Refer to Fig. 2.9 Procedure 2

A is the distance from the back surface of the

pinion gear to the mounting face of the motor
Measure using the Pinion Height Dial Indicator
(P/N 9650004) zeroed at 1.000”. To get the
correct distance, measure to the top of the
bearing , not to the endbell casting surface.
The number should be around 1.40”

B is the distance from the back face of the
pinion gear to the theoretical center of the
matching ring gear. This number is etched on
the end of the pinion gear. If this number is

not legible or there is no number, use
Procedure 2.

C is the distance from the center of the
gearbox housing to the mounting face of the
motor mounting face. This number is
stamped on the back of the gear housing
casting. The stamped number may or may
not begin with a four. If the number reads

4.611, for example, record this number as
Distance C. If the number reads only .611, for
example, assume a four at the beginning.
Distance C would therefore be 4.611.

D is the distance from the end of the pinion to
the mounting face of the motor. If the number
on the end of the pinion is not legible, then
measure D using the Pinion Height Dial
Indicator zeroed at 2.500” . The number
should be around 2.57”

LEFT

12/20/99 2.8

Electric Counterbalance High Output Drive

Procedure 2

Measure D if there
is no number on
the end of pinion.

Example for Procedure 1:

Measurement A = 1.394
Etched on Pinion B = 3.240
Stamped on Gearbox C = 4.611

1.394 + 3.240 - 4.611 = 0.023

4-Hole Shim Package = 0.023"

Procedure 1

Measure A if there is
a number on the end
of pinion.

Figure 2.9 - CALCULATE 4-HOLE SHIM THICKNESS.

Example for Procedure 2:

Measurement D = 2.573
Add 2.061
Stamped on Gearbox C = 4.611

2.573 + 2.061 - 4.611 = 0.023

4-Hole Shim Package = 0.023

Correct
alignment

Incorrect
alignment

Figure 2.10 - Carrier to Housing Alignment

2.Assemble a 4-hole shim package as
determined in Step 1 (verify thickness with a
micrometer) and install on the motor mounting
face.

3.Remove the carrier assembly from the gear
housing. Apply a thin coat of grease to the
outer diameter of the motor pilot flange and
secure 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 (Fig. 2.6, Item

18) over mounting flange on gear housing.
Initially use 0.022” or the same thickness that
was removed during disassembly.

o

2.Coat an approximately 30

area of the ring
gear with marking compound for checking the
tooth contact pattern.

12/20/99 2.9

Electric Counterbalance High Output Drive

Figure 2.11 - Backlash Tool

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:

a. The correct pattern, as shown in
Example 1, is well centered on the bevel gear
tooth with lengthwise contact clear of the toe.
The length of the pattern in an unloaded
condition is approximately one-half to
two-thirds of the bevel gear tooth. The
backlash (6-hole) and motor to gear box
(4-hole) shims are correct.

NOTE
When installing carrier to gear housing,
ensure alignment of flange mounting holes is
correct (see Fig. 2.10)

3.Place the carrier on the gear housing ensuring

gear teeth are meshed. Temporarily fasten by
tightening at least three of the six screws
supplied with the gearbox. Rotate the pinion
gear to make sure it turns freely.

4.Attach the drive unit backlash tool to the

gearbox as shown in Fig. 2.11. Make sure the
dial indicator is aligned as shown.

5.Install the flag assembly on the spur gear with

the flag in the upright position.

6.Rotate the flag until it moves about halfway

into the dial indicator's range of motion.
Then, rock the flag back and forth (firmly, but
not hard enough to rotate the motor shaft) and
observe the dial indicator readings. The
difference between the highest and lowest
reading is the backlash. Backlash should be

greater than 0.003" but should not exceed

0.013". Check backlash at every other tooth

for a full revolution. If this condition is not
met, disassemble the carrier from the gear
housing and add or remove shims as required
(if backlash is too great, remove shims; if
backlash is too small, add shims). Repeat
these steps as necessary until backlash
conditions are met.

Example 1

b. Example 2 indicates an incorrect 4-hole
shimming package between the motor and the
gear housing. The contact pattern in the left
illustration indicates that the pattern is too
close to the root of the gear tooth or off the
tooth root. If this condition occurs, add some
4-hole shims between the motor and the
gearbox and test again. The illustration to the
right shows a pattern that is too close to the
tooth top land and off center. If this condition
exists, remove some 4-hole shims between
the motor and gearbox and test again.

Example 2

c. Example 3 indicates a backlash error
caused by an incorrect 6-hole shim package
between the carrier and the gear housing. The
illustration to the left shows the pattern too far
off the tooth toe. As was noted in Example 1,
there should be an area between the contact

12/20/99 2.10

Electric Counterbalance High Output Drive

pattern and the tooth toe that is not in contact
with the gear set. To correct for this condition,
remove the carrier from the gear housing, add
additional shims, reassemble and test again.
The illustration to the right however shows the
pattern moving too far along the tooth toward
the tooth heel. To correct for this condition,
remove the carrier, remove some shims,
reassemble and test again.

Example 3

8.Once gear teeth pattern conditions are met,

remove carrier from gear housing and set the
shim package aside. Apply a thin coat of
suitable gasket compound to mounting
surfaces of the carrier and housing then
replace shim package. Reattach carrier to
housing using the six bolts supplied with the
gearbox and a thread locking compound.
Torque to 40 lb-ft.

9.Using grease gun containing Mobilith SHC

220 grease, ensure the cone bearing on gear
shaft is greased.

10.Ensure motor terminal lugs are tight.

11.Reinstall drive unit into the truck.

2.Remove the three cap screws (Fig. 2.6, Item

19) securing the bevel gear to the pinion
shaft.

3.Remove the cap (Fig. 2.6, Item 20) and any
shims underneath.

4.Lift the spiral bevel gear off of the pinion
shaft.

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 castings and machined surfaces are
clean and free of foreign material. Clean only
with a rag and mild non-abrasive solvents.

2.Stand carrier housing on end with large
mounting flange down.

3.Lubricate the outside diameter of the seals
(Fig. 2.6, Item 27), and carefully press into the
housing individually. Ensure that the lip of the
first seal is downward . Ensure that the lip of
the second seal is pointing upward.

4.Lubricate outside diameter of the bearing cup
(Fig. 2.6, Item 28), and press evenly into the
carrier housing until properly seated against
the stop.

5.Turn the carrier housing over so that the large
flange is pointing up. Lubricate bearing cup
(Fig. 2.6, Item 24), and press evenly into the
carrier housing until properly seated against
the stop.

Carrier Rebuild

Carrier Disassembly

NOTE
The bearings on the drive shaft are pressed on
with an interference fit. Disassembly is
recommended only when one of the carrier's
bearings or seals need to be replaced or the
carrier has excessive endplay (greater than

0.002"). Refer to DRIVE UNIT REBUILD ­DISASSEMBLY for disassembly of the drive
unit.

1.Place the carrier assembly with the spiral

bevel gear facing up.

12/20/99 2.11

6.Pack the cone roller bearing (Fig. 2.6, Item

29) with Mobilith SHC 220 grease, or
equivalent. Stand the pinion shaft on end with
the spur gear down. Lubricate the inside
diameter of the packed cone roller bearing
and press evenly onto pinion shaft as shown
until properly seated against the spur gear.

7.Place the bevel gear face down with support
under the center section opposite the bearing
seat preventing the gear teeth from being
damaged (see Fig. 2.12). Lubricate the inside
diameter of the cone roller bearing (Fig. 2.6,
Item 23) and press onto the bevel gear as
shown until properly seated against the stop.
This bearing should not be packed with heavy
grease. It will eventually be lubricated by
gearbox oil in the gear housing.

Electric Counterbalance High Output Drive

Figure 2.12 - Support Spiral Bevel Gear

8. Lubricate the inner diameter of the seals
installed in Step 3 above. Using a twisting
motion, insert the pinion shaft through the
carrier housing.

9. With the spur gear end of the shaft in the
downward position on the table, install the
bevel gear over splined end of the shaft.

10. Apply light pressure to the bevel gear and
shaft. Spin the carrier housing several times
to seat the bearings.

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.

11. Place the cap (Fig. 2.6, Item 20) over the
spiral bevel gear and secure using three
5/16-18 screws (Fig. 2.6, Item 19). Torque
bolts to 20 lb-ft to ensure bearings and
bearing cups are seated properly. Remove
the three bolts and the cap.

12. Using a depth micrometer, measure and
record the depth from the face of the bevel
gear to the end of the pinion shaft (see Fig.

2.13). A carrier shaft shim package (Fig. 2.6,
Item 21) should be assembled 0.003" greater
than the recorded bevel gear to pinion shaft
depth. Verify shim package thickness using a
micrometer; then place the package on pinion
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 housing to seat bearings.

15. Invert the carrier with ring gear down and
place supporting blocks on the mounting
flange at the bolt circle diameter. This will
suspend the ring gear.

Figure 2.13 - Measure Shim Depth

NOTE
If there is no endplay, and the pinion shaft
cannot be turned freely by hand, the bearings
are too tight. Increase the shim thickness
under the cap.

18. Remove retaining bolts and reassemble using

a permanent thread locking compound with a
minimum temperature rating of at least 450

o

F. If there are no wire tie holes in the bolts,
torque to 20 lb-ft.

19. Refer to DRIVE UNIT REBUILD - ASSEMBLY

to reassemble the drive unit.

16. Place a magnetic base indicator on the small
flange end of the carrier with indicator probe
on end of spur gear.

12/20/99 1.12

Electric Counterbalance High Output Brakes

Brake System

Theory of Operation ........................................ 3.1

Disc Brake Unit

Description ............................................... 3.2

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

TABLE OF CONTENTS

04/04/00

3.i

Electric Counterbalance High Output Brakes

Theory of Operation

The brake system of this lift truck is to be used as
a parking brake and for emergency stopping only.
Slowing or stopping the lift truck is normally done
through "plugging" of the traction motors.
Plugging is a method of slowing the rotation of the
drive wheels by changing the direction of current
flow through the traction motor. In an emergency,
the truck can be stopped by lifting the foot off of
the brake pedal.

The brake system is designed to mechanically
apply the brakes when the operator removes his
foot from the pedal. The brakes are electrically
released when the operator depresses the pedal.

The brake system consists of a brake pedal, an
electric brake relay, and two self-contained disc
brake units. The disc brake units are attached to
the commutator end of the drive motors to take
advantage of the increase in torque supplied by
the gearbox.

Internal coil springs in the disc brake units supply
the force which clamps the rotating friction 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.

traveling. For example a fully loaded truck
traveling 6 MPH should stop within about 6.6 feet.

The brakes should hold a fully loaded truck on a
10% grade.

When the operator releases the brake pedal, two
micro-switches are actuated. One signals the
system controller to cut power to the traction
motors. The second signals the brake relay to cut
power to the disc brake units, thus applying the
brakes. The system controller does not monitor
the operation of the disc brake units or the relay.

NOTE
Many of the brake adjustments interact with
one another. When performing any
adjustments on the brake system, please
follow the order of the list below. When
servicing the brakes, check all of the
adjustments listed below (See Brake
Adjustments).

1.Brake Pedal Height

2.Brake Switch Adjustment

3.Disc Brake Air Gap

4.Braking Force (Clamping Pressure)
The brakes should stop a fully loaded truck on a

dry, level floor within 1.1 feet per MPH the truck is

REV W1 12/02/99 3.1

Electric Counterbalance High Output 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. Clamping
pressure is applied by 10 springs (3) inside the
magnet/coil assembly. Three screws on top of the
unit adjust clamping pressure. The magnet/coil
assembly is secured to the mounting plate by
three screws. The air gap between the armature
(upper pressure plate) and the magnet/coil
assembly (see Fig. 2) is set by the shims (6) under
each spacer – 0.008” to 0.015” allowable. When
power is applied to the brake unit, the armature is
retracted, closing the air gap and releasing the
brake. If 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 from the brake

relay harness.

2.Remove the three hex screws (10) securing

the mounting base to the top of the drive
motor. Lift the brake unit off of the arbor.

3.If necessary, remove the arbor from the motor

shaft by removing the upper snap ring (9),
shims (7) and spacer (8). Note the number
and thickness of shims above and below the
arbor and spacer.

Disassembly

1.Place the brake assembly on a clean, dry

work surface with the magnet/coil assembly
up. Loosen the three screws in equal
increments to ensure the spring pressure is
reduced gradually and evenly.

NOTE
Turn the brake unit upside down before

removing the bottom plate. This will prevent
the shims, springs, and discs from falling out
and getting lost.

REV W1 12/02/99 3.2

Figure 1 - Disc Brake Unit

Electric Counterbalance High Output 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.

Assembly

1.Clean all parts thoroughly.

2.Turn the magnet/coil assembly upside down.

Place all springs in the magnet/coil assembly.
Remember to put discs (4) under the three
springs in the adjustment screw holes (see
Figure 3).

3.Assemble the magnet/coil assembly, armature

(upper pressure plate), friction plate, and
mount plate using the three screws, spacers,
and shims. The shims should be placed next
to the mount plate. Try to center the friction
plate during assembly to make installation on
the motor easier. After tightening the three
screws, measure the air gap near each screw.
Add or remove shims as necessary to achieve
an even 0.010” to 0.015” air gap. If the air
gap exceeds 0.015” with no shims, then
replace the friction plate.

Figure 3 - Adjustment Screws

Figure 2 - Air Gap

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
the arbor, one 0.020” shim on top of the arbor,
and six 0.020” shim on top of the spacer.
Verify that the friction plate will slide
completely onto the arbor, and the arbor
cannot move up and down on the motor shaft.

2.Slide the brake unit onto the motor and secure
in position with three screws. The plug lead
should be toward the rear of the truck. If
necessary, release the brake by plugging it in
and holding the pedal down (battery must be
connected).

3.Plug the brake unit into the relay harness.
Perform a braking distance test.

Brake Pedal

Removal

1.Disconnect the battery and discharge the
capacitors.

2.Remove the access panel at the
front-lower-left corner of the operator
compartment.

3.Remove the clevis pin from the brake pedal
rod clevis.

4.Remove the brake pedal pivot shaft, nylon
bushings and machine bushings.

REV W1 12/02/99 3.3

Electric Counterbalance High Output Brakes

5.Remove the brake pedal.

Replacement

1.Position the brake pedal in the pivot bracket.

2.Install the brake pedal pivot shaft with two
nylon bushings, and two machine bushings.

3.Attach the brake pedal rod to the brake pedal.

4.Install the access panel into the opening in the
bottom of the operator compartment.

5.Connect the battery.

Brake Adustments

Brake Pedal Height

Specification:4.75 ± 0.25 inches (see Fig. 4)

1.Disconnect the battery and discharge the
capacitors.

2.Remove the top cover and the control cover.

3.Disconnect the rod end on the brake rod from
the brake lever arm.

4.Loosen the jam nut on the brake rod 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 the jam nut on the rod end.

7.Attach the rod end to the brake lever arm.

8.Check the height of the brake pedal and
repeat steps 3 through 7 if necessary.

9.After the brake pedal height has been
adjusted, verify that the brake switches are
adjusted properly.

10.Install the control cover and the top cover.

11.Connect the battery.

Brake Switches

1.Disconnect the battery and discharge the
capacitors.

2.Remove the top cover and control cover.

3.With the brake pedal released, loosen the
screws securing the brake switch. Move the

Figure 4 - Brake Pedal Height

REV W1 12/02/99 3.4

Electric Counterbalance High Output 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. Readjust as needed, then
tighten the screws securing the brake
switches.

5.Replace the control cover and top cover

6.Connect the battery.

7.Test the brake operation of the lift truck.

Disc Brake Air Gap

See Disc Brake Unit for adjustment procedures.

Braking Force (Clamping Pressure)

NOTE
This adjustment does not affect the air gap.
See Disc Brake Unit Assembly to set the air
gap.

The three adjustment 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 clockwise to increase
clamping pressure; turn the screws
counter-clockwise to decrease clamping pressure.
Adjust all three screws on one brake unit the same
amount. Both brakes should apply equal pressure
so that the truck does not pull to one side during
braking. The brakes should stop a fully loaded
truck on a dry level surface in 1.1 feet per mile per
hour. For example, a truck traveling 6 MPH
should stop in about 6.6 feet when the brakes are
released.

NOTE
Clamping pressure adjustment is for minor
corrections only. If the braking distance is
excessive, check for other problems with the
brake units, such as contamination of the
friction plate.

REV W1 12/02/99 3.5

Electric Counterbalance High Output Steering

TABLE OF CONTENTS

Steering System .................................................4.1

Steer Pump and Motor Assembly

Removal ................................................. 4.1

Replacement .............................................. 4.1

Steer Motor Brushes ............................................. 4.1

Steer Pump

Removal ................................................. 4.2

Replacement .............................................. 4.2

Steer Pressure Adjustment .......................................4.2

Steer Control 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 ................................................. 4.4

Replacement .............................................. 4.5

Changing Steer Tires ............................................ 4.5

Steer Position Potentiometer

Removal ................................................. 4.5

Replacement .............................................. 4.6

04/05/00

4.i

Electric Counterbalance High Output Steering

Steering System

The steering system of this lift truck consists of
the following components: the steer pump motor
and pump, the steer control valve and tiller, the
hydraulic motor, the steering gears and the steer
fork assembly. A potentiometer is attached to the
top of the steering fork which is used by the
system controller to determine the position of the
steer tire. An indicator is incorporated in the
operator's display to show the angle of the steer
wheel(s).

Hydraulic fluid from the reservoir is drawn into the
steering system by the steer pump. This gear
pump is driven by a DC electric motor and is
controlled by a contactor. Included in the pump
assembly is a pressure relief valve. This valve
prevents the buildup of excessive pressure in the
steering system. It is designed to limit the
pressure in this system to 900 PSI.

Pressurized fluid is directed to the steer control
valve. The steer control valve meters the flow
rate and direction of the oil flow to the hydraulic
motor. Speed and direction of hydraulic motor
rotation is dependent on the amount of oil the
steer control valve passes and the direction of the
flow.

The hydraulic motor converts the hydraulic flow
into rotational movement. Fluid is directed to the
motor in proportion to the amount of movement of
the steering tiller. As the tiller is moved, a
metered amount of hydraulic fluid is directed to
the hydraulic motor. As this fluid enters the
motor, the output shaft of the motor is rotated. A
pinion gear attached to the output shaft of the
motor rotates the spur gear, which is attached to
the steer fork assembly.

Removal

1.Disconnect and remove the battery and
discharge the capacitors.

2.Tilt the left drive unit (the drive unit in front of
the steer pump and motor assembly) (refer to
DRIVE UNIT Removal procedure in the
DRIVE section).

3.Label and disconnect the electrical cables
from the steer pump motor.

4.Clean the area around the hydraulic
connections to the steer pump. Disconnect
and cap the hydraulic lines from the steer
pump.

5.Attach a lifting device to the steer pump and
motor assembly for support.

6.Remove the screws securing the steer pump
and motor assembly to the front frame of the
truck. Remove the steer pump and motor
assembly from the truck.

Replacement

1.Align the steer pump and motor assembly with
the mounting holes in the front frame of the
truck.

2.Attach the steer pump and motor assembly to
the front frame of the truck.

3.Attach the hydraulic lines to the steer pump.

4.Reattach the electrical cables on the steer
pump motor. (Ensure the electrical cables are
returned to the correct terminals.)

5.Replace the left drive unit (refer to DRIVE
UNIT Replacement procedure in the DRIVE
section).

6.Install and reconnect the battery.

After the hydraulic motor 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 assembly from the truck. Refer to
STEER PUMP Removal procedure in this
section.

REV W1 11/02/99 4.1

Steer Motor Brushes

1.Remove the steer pump motor from the truck
(refer to Steer Pump and Motor Removal
procedure in this section).

2.Remove the endbell from the motor.

3.Replace brushes and brush springs. Push the
brushes into the holders and insert a pin in the
holes to retain them.

4.Install the endbell. Remove the pins holding
the brushes.

Electric Counterbalance High Output Steering

5.Install the steer pump and motor on the truck
(refer to Steer Pump and Motor Assembly
Replacement procedure in this section).

Steer Pump

Removal

NOTE
If the steer pump and motor assembly has
already been removed from the truck, proceed
to Step 6.

1.Tilt the mast to the full forward position.

2.Disconnect the battery and discharge the

capacitors.

3.Remove the front cover.

4.Clean the area around the hydraulic

connections to the steer pump.

5.Disconnect and cap the hydraulic lines from

the steer pump.

6.Remove the hex screws securing the steer

pump to the steer pump motor.

7.Separate the steer pump from the steer pump

motor. Remove the steer pump.

Replacement

1.Position the steer pump on the steer pump

motor shaft.

2.Attach the steer pump to the steer pump

motor and tighten the screws to 17 lb-ft.

3.Attach the hydraulic lines to the steer pump in

the correct locations.

4.Reinstall the front cover and connect the

battery.

4.Turn the steer tiller until the fork reaches
either stop. 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 relief pressure. Turn the screw clockwise
to increase pressure, and counter-clockwise to
decrease pressure.

6.When relief pressure is set, install the hex cap
over the adjustment screw. Remove the
pressure check hose and gauge.

Steer Control Valve

Removal

1.Disconnect the battery and discharge the
capacitors.

2.Remove the tiller, top cover and the control
cover.

3.Remove the pad on the left side of the
operator compartment.

4.Place identifying tags on all of the hydraulic
hoses. Note the orientation of the steer
control valve to the mounting bracket.

CAUTION
Before loosening any hydraulic hose, allow
the truck to sit for 1 to 2 minutes to relieve
pressure. When removing hydraulic hoses,
use care to avoid contaminating electrical
components with oil.

5.Disconnect and cap the hydraulic hoses from

the steer control valve.

6.Remove the steer control valve mounting

bracket from the truck.

Steer Pressure Adjustment

1.Attach a pressure gauge to the test port on the
outlet fitting of the steer pump using the
pressure check hose kit 9650041.

2.Remove the hex cap covering the relief
pressure adjustment screw on the bottom of
the pump.

3.Turn the steer pump motor on using Output
Test 02 (refer to Programming and
Diagnostics section).

REV W1 11/02/99 4.2

7.Place the steer control valve and bracket on a
clean work surface. Remove the mounting
screws. The steering column will separate
from the bracket and valve.

Replacement

1.Attach the steer control valve and the steering
column to the mounting bracket in the same
orientation noted in Step 4 of Removal.

2.Install the steer control valve and mounting
bracket assembly to the truck.

Electric Counterbalance High Output Steering

3.Install the hydraulic hoses in the correct
locations.

4.Install the steering tiller.

5.Connect the battery.

6.Check the operation of the steering system.

7.Check all hydraulic connections for leaks.

8.Disconnect the battery and remove the
steering tiller.

9.Install the left hip pad in the operator
compartment.

10.Install the control cover and the top cover.

11.Connect the battery.

Hydraulic Motor

Removal

1.Disconnect the battery and discharge the
capacitors.

2.Remove the top cover.

3.Remove the steer position potentiometer
(refer to STEER POSITION
POTENTIOMETER Removal procedure in
this section).

NOTE
The hydraulic lines must be removed before
removing the mounting screws from the
hydraulic motor. Hoses should be labeled to
help install them correctly.

4.Remove the hex screws securing the

mounting bracket.

5.Remove the hydraulic motor mounting plate

by threading two 3/8" x 3" screws through the
threaded holes (Item 1 in Fig. 4.1).
Alternately tighten the screws until the
mounting plate is free.

6.Loosen the lock nut from the hydraulic motor

shaft. Use tool P/N 9650029 to hold the
pinion gear.

7.Remove the screws securing the hydraulic

motor to the mounting bracket.

8.The motor shaft is tapered. Use a suitable

puller to remove the pinion gear from the
shaft utilizing the mounting bracket as part of
the puller.

Replacement

1.Install the hydraulic 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 9650029 to hold
the pinion gear and torque the nut to 115 lb-ft.
Install a cotter pin.

3.Lower the hydraulic motor and bracket into
position and align the mounting holes with the
studs.

4.Install the mounting screws until finger tight.
Gradually tighten the mounting screws in an
alternating pattern. Torque to 23 lb-ft.

5.Install the steer position potentiometer (refer
to STEER POSITION POTENTIOMETER
Replacement procedure in this section).

6.Install the hydraulic hoses in the correct
locations.

7.Connect the battery and test the steering
system for proper operation. Inspect all of the
hydraulic hoses and fittings for leaks.

8.Install the top cover.

Steer Gear

Removal

1.Disconnect the battery and discharge the
capacitors.

2.Remove the top cover and the control cover
(it is not necessary to remove the tiller for this
procedure).

3.Remove the steer control valve bracket
screws and move it aside. Remove the
hydraulic motor and steer position
potentiometer. It is not necessary to remove
the hydraulic hoses.

4.Remove the lock nut securing the steering
gear to the steer fork assembly.

5.Lift the steering gear off the steer fork shaft
and out of the truck.

Replacement

1.Before installing the steering gear, make sure
the steer fork is properly positioned with the
stop pin toward the forks.

REV W1 11/02/99 4.3

Electric Counterbalance High Output Steering

2.Install the steering gear on the splined portion
of the steer fork shaft with the proper machine
bushing above and below.

3.Install the lock nut on the steer fork and
tighten to 60 lb-ft.

NOTE
Over tightening or under tightening of this nut
can cause excessive wear on the bearings and
steer fork shaft.

4.Install the hydraulic motor and the steer

position potentiometer (refer to procedures in
this section).

5.Install the steer control valve.

6.Check all hydraulic lines on the steering

components for tightness.

7.Install the control cover and top cover.

8.Connect the battery and test the truck for

proper operation.

Steer Fork Assembly

CAUTION
The steer fork 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.Use a 5/16” eyebolt and chain that will fit

through the lock nut to support the steer fork.
Remove the lock nut and lower the fork out of
the truck.

NOTE
During the removal and installation of the
steer fork, use care to avoid damaging the
bearing seals or the threads and splines on
the steer fork shaft.

5.Lower the steer fork assembly to the floor and

remove it.

Replacement

NOTE
The steer fork must be installed with the stop
pin toward the forks.

Removal

NOTE
To allow for the removal of the steer fork from
the lift truck, the entire lift truck must be at
least 27" off the floor. The steer fork assembly
is 36" long. If the truck is not 27" off the floor,
there is not enough clearance to remove the
steer fork from the truck.

1.Disconnect and remove the battery.

Discharge the capacitors.

2.Remove the control cover and the control

cover mount bracket. Remove the hydraulic
motor (it is not necessary to remove the
hoses) and steer position potentiometer.

CAUTION
The lift truck, without a battery weighs from
6,000 to 8,000 pounds. Use a lift or stands
with adequate capacity.

3.Raise and safely support the entire lift truck at

least 27" off the floor.

1.Put the lower bearing in place and drive the
lower seal into position with the lip facing
down.

2.Put the upper bearing in place and drive the
upper seal into position with the lip facing up.
Stack the lower machine bushing, steer gear,
upper machine bushing and lock nut in
position.

3.Thread the eyebolt and chain through the
stacked parts and screw it into the steer fork.

4.Carefully raise the steer fork into position.
Tighten the lock nut to 60 lb-ft. Make sure the
steer fork can rotate freely.

5.Lower the lift truck to the ground. Install the
hydraulic motor and steer position
potentiometer (refer to procedures in this
section). Install the control cover bracket and
the control cover.

6.Install and connect the battery. Test the truck
for proper operation.

Steer Wheel Assembly

Removal

1.Disconnect the battery and discharge the
capacitors.

REV W1 11/02/99 4.4

Electric Counterbalance High Output Steering

2.Jack the rear of the truck just until the steer
wheel can turn. Rotate the steer fork so the
axle nut is visible.

3.Remove the axle nut. Rotate the steer fork
180° and remove the axle.

4.Raise the truck until the wheel can be
removed.

NOTE
Inspect the steering axle, bearings, and seals
for wear or damage. Replace all worn or
damaged parts prior to replacing the steer
wheel assembly into the steer fork.

Replacement

1.Rotate the steer fork so that the larger hole

with the lock bar above is visible.

2.Position the steer wheel assembly in the steer

fork. Lower the truck to align the center hole
of the steer wheel assembly with the axle
holes in the steer fork.

3.Install the steer axle through the steer fork

and the steer wheel assembly.

4.Rotate the steer fork 180° to install the axle

nut.

NOTE
Do not over tighten the axle nut on the
steering axle. This nut serves as a bearing
tightening adjustment. The nut should be
tightened enough to remove any lateral play
yet allow the steer wheel assembly to turn
freely. If the nut is over tightened or under
tightened, the bearings and the steer axle may
be damaged.

2.Remove the seals and bearings.

3.Align the old wheel and tire on top of the new
tire. Press the wheel out of the old rim and
tire into the new one.

4.Install the bearings and seals.

5.Install the steer wheel assembly.

Steer Position Potentiometer

Removal

1.Go into Diagnostic Output Test 05 (refer to
Programming & Diagnostics). Rotate the tiller
so that the voltage reading decreases until the
steer fork hits the stop.

2.Disconnect the battery and discharge the
capacitors.

3.Remove the top cover.

4.Disconnect the 3-pin connector between the
steer position potentiometer and the wiring
harness.

5.Loosen the nut (Item 23 Fig 4.1) and remove
the hex screw holding the potentiometer
mounting bracket to the hydraulic motor
mounting bracket.

6.Loosen the hex nut (Item 44 Fig 4.1) on the
steer fork insert, and unscrew the insert to
remove the steer position potentiometer
assembly.

7.Tighten the axle 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 test the truck for proper operation.

Changing Steer Tires

1.Remove the steer wheel assembly.

NOTE
The capacity of the press must be
approximately 40 tons.

REV W1 11/02/99 4.5

Figure 4.1 - Steer Position Potentiometer

Electric Counterbalance High Output 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. Insert the hex screw
through the torque arm and thread the hex nut
onto the screw.

2.Screw the steer fork insert into the steer fork

and the hex screw into the hydraulic motor
mount plate. Leave an 1/8” gap between the
torque arm and the hex screw head to allow
the torque arm to float, then tighten the hex
nut down to the hydraulic motor mount plate.

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.If Step 1 of the Removal procedure was

performed, the steer wheel is in the full left
position. If not, rotate the tiller until the steer
wheel is in the full left position (visually
verify). Turn the steer fork insert so that the
voltage display is around 0.50V.

5.Hold the steer fork insert so that the voltage

reading does not change, and tighten the hex
nut onto the steer fork shaft. Verify that the
voltage display did not change.

6.Calibrate the steer position potentiometer (see

PROGRAMMING & DIAGNOSTICS).

7.Install the top cover.

8.Test the truck for proper operation.

REV W1 11/02/99 4.6

Electric Counterbalance High Output Operator Controls

TABLE OF CONTENTS

Description ..................................................... 5.1

Control Handle Assembly

Removal ................................................. 5.2

Replacement .............................................. 5.2

Control Handle Potentiometer

Removal ................................................. 5.2

Replacement .............................................. 5.2

Battery Disconnect Lever

Removal ................................................. 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 Switches

Removal ................................................. 5.5

Replacement .............................................. 5.5

Keyswitch

Removal ................................................. 5.5

Replacement .............................................. 5.6

01/17/96

5.i

Electric Counterbalance High Output Operator Controls

OPERATOR CONTROLS

DESCRIPTION

The operator controls of the ECHO 3000™ lift
truck consist of the control handle, the battery
disconnect lever, the steering tiller, the brake
pedal, the key switch, and the light and auxiliary
selector switches (if so equipped).

The control handle is a molded plastic handle
used to control travel, lift, tilt, sideshift and
auxiliary functions (if so equipped), and the horn.
Travel and lift are proportionally controlled by
moving the control handle forward or backward,
and left or right. Tilt and sideshift are single
speed functions controlled by a four way rocker
on the top of the handle. Auxiliary functions are
controlled by the sideshift switches and a rocker
switch on the display. The horn switch is located
on the edge of the handle, under the thumb.

The control handle is mounted to a dual-axle
mechanism with a potentiometer on both axes for
the travel and lift proportional controls. Return
springs keep the handle centered, and stop
blocks limit the movement of the handle.

The battery disconnect 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 connector and
separates it from the truck connector.

The steering tiller controls the direction of the
steer fork and wheels. The steering tiller is
covered in the STEERING section.

The brake pedal releases the parking brakes of
the lift truck and enables traction functions. The
brake pedal is covered in the BRAKES section.

The key switch is located on the operator display.
It has three positions, O, I, II. In position O, no
truck functions are available. In the I position, the
system controller is powered up. When rotated to
the II position, power is available to all systems.
For more information, refer to the ELECTRICAL
section.

The light and auxiliary selector switches are
rocker switches on the operator display. On
trucks without lights or auxiliary equipment, there
are blank panels inserted in their place. These
switches are covered in the ELECTRICAL
section.

3/30/00

Refer to OPERATOR CONTROLS in the PARTS Manual for illustrations.

5.1

Electric Counterbalance High Output Operator Controls

CONTROL HANDLE ASSEMBLY

Removal

1.Disconnect the battery and discharge the

capacitors (refer to ELECTRICAL).

2.Remove the top cover.

3.Disconnect the control handle harness from

the system controller at connector J8 (refer to
decal on back of system controller).

4.Pull the control handle boot up through the

opening in the control cover.

5.Remove the screws securing the control

handle to the frame and remove the control
handle assembly.

Replacement

1.Place the four mounting screws in the control

handle mechanism. Thread the handle
harness through the opening in the control
cover.

2.Position the control handle assembly in the

unit and secure in place. Ensure the handle
angle is correct for a forward or side stance
unit.

3.Tuck the boot into the control cover opening.

Make sure the boot does not drag and the
control handle operates smoothly through its
full range.

4.Connect the control handle harness to J8

(refer to decal on back of system controller).

5.Install the top cover (refer to TOP COVER

Replacement procedure in the FRAME
section).

6.Connect the battery and calibrate the traction

and lift potentiometers (refer to
PROGRAMMING AND DIAGNOSTICS
section).

2.Remove the electrical tape around the
sleeving on the 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 potentiometer
bracket to the dual-axle mechanism.

5.Remove the potentiometer assembly from the
dual-axle mechanism.

6.Remove the lock nut on the collar of the
potentiometer and remove the potentiometer
from the mounting bracket. Remove the nylon
washer from the potentiometer.

Replacement

1.Place a nylon washer and mount bracket over

the collar of the potentiometer and secure
with the lock nut (make sure the
potentiometer is oriented so that the wires exit
toward the bend in the bracket).

2.Slide the potentiometer shaft into the hole in

the end of the axle shaft.

3.Attach the bracket to the dual-axle

mechanism.

4.Make sure the flat on the potentiometer shaft

is facing the set screw then tighten the set
screw.

5.Wire-tie the potentiometer wires to the mount

bracket and route the wires through the
standoff guide. Plug the connector in to the
control handle harness.

6.Slide the sleeving back over the connectors

and seal the end with electrical tape.

7.Install the control handle in the truck (refer to

CONTROL HANDLE Replacement procedure
in this section).

CONTROL HANDLE

POTENTIOMETER

Removal

1.Remove the control handle (refer to
CONTROL HANDLE Removal procedure in
this section).

3/30/00

BATTERY DISCONNECT LEVER

Removal

1.Disconnect the battery and discharge the
capacitors.

2.Remove the top cover (refer to TOP COVER
Removal procedure in the FRAME section).

3.Disconnect the return spring from the handle.

5.2

Electric Counterbalance High Output Operator Controls

4. Remove the retaining ring and flat washer
from the shaft.

5. Remove the battery disconnect lever.

Replacement

NOTE
When replacing the battery disconnect lever,
ensure the flange side of the bushing is
toward the frame.

1. Slide the battery disconnect lever over the

shaft.

2. Install the flat washer and the retaining ring.

3. Connect the return spring.

4. Install the top cover (refer to TOP COVER

Replacement procedure in the FRAME
section).

5. Make sure the screw is installed in the battery

connector. Connect the battery and test the
disconnect for proper operation.

HORN BUTTON SPRING

Removal

1. Disconnect the battery and discharge the

capacitors.

2. Remove the control handle bezel.

3. Carefully lift the horn button out of the handle

and remove the horn button spring.

Replacement

1. Install the new horn button spring in the

correct orientation (see Fig. 5.2)

2. Engage the horn switch to prevent damaging

the arm and install the horn button.

3. Install the bezel and test the horn button for

proper operation (listen for a click when the
switch closes and opens).

4. Connect the battery and test the horn, tilt and

sideshift switches.

LIFT AND TRAVEL SPRINGS

Removal & Replacement

Refer to Fig. 5.3.

1. Remove the control handle from the truck
and place it on a clean flat work surface (refer
to CONTROL HANDLE Removal procedure
in this section).

CAUTION
Position the control handle so that the
potentiometers, wiring, 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 against
a solid surface or use the roll pin removal
tool, Part # 9660146. Use an appropriate
size pin punch to drive the roll pins out of the
stop block. Slide the stop block and nylon
washer off the cross shaft.
B: Grasp the outer leg of the spring with
pliers and move it to the other side of the
bracket arm to release tension, then remove
the spring.
C: Slide the correct spring onto the shaft so
that the inner leg falls into the notch in the
bracket arm. Grasp the outer leg of the
spring with pliers and pull it to the other side
of the bracket arm until it snaps into the
notch.
D: Slide the nylon washer onto the shaft.
Slide the stop block onto the shaft so that the
leg of the stop block fits between the legs of
the spring.
E: Support the stop block in a vise or against
a solid surface. Drive a 1/4” x 1¼” roll pin
approximately half way into the stop block.
Insert a 5/32” x 3/4” roll pin into the first roll
pin with the open sides 180° apart. Drive the
smaller pin into the larger pin until flush, drive
the assembly the rest of the way in. Insert a
piece of the stainless steel wire through the
roll pin assembly, wrap it around the back of
the stop and twist it together to prevent the
pins from coming out. See Figure 2 for wire
location. Bend the twisted ends back toward
the roll pin to prevent them from catching on
the boot.

3/30/00

5.3

Electric Counterbalance High Output 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. Make sure there is no play in the neutral
position. Adjust the set screws in the
brackets so that there is no play and the
upper bracket is level when the control
handle is released.

4. Test the control handle for binding and full
movement. Ensure that the control handle
returns to neutral when released.

5. Install the control handle on the truck,
calibrate traction and lift, and test for proper
operation.

CONTROL HANDLE REPLACEMENT

Removal

1. Remove the control handle assembly from
the truck (refer to Control Handle Removal
procedure in this section).

2. Slide back the mesh over the control handle
harness connectors. Separate the two control
handle (five-pin) connectors. Note the
harness routing, then remove the loom clip
and wire tie to remove the wires from the
mechanism.

3. Loosen the lower jam nut and unscrew the
control handle from the mechanism. Rotate
the wires while unscrewing the handle. Pull

3/30/00

the wires through the mechanism 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
mechanism. Make sure the wires will not rub
against any moving parts.

3. Screw the control handle onto the
mechanism. The bottom of the threaded
shaft should be flush with the bottom surface
of the bracket. Make sure the control handle
is oriented correctly for a forward or side
stance truck, then tighten the lower jam nut
against the bracket.

4. Secure the control handle harness wires to
the mechanism with the loom clip and wire
tie. Route the wires through the standoff
guide. Connect the five-pin plugs, cover with
the mesh, and secure with electrical tape.

5. Install the control handle assembly in the
truck (refer to Control Handle Replacement
procedure in this section).

5.4

Electric Counterbalance High Output Operator Controls

Figure 5.3 - Mechanism and Springs

Light and Auxiliary Rocker Switches

Removal

1. Disconnect the battery and discharge the
capacitors (refer to Capacitor Discharge
procedure in the Electrical section). Remove
the top cover.

2. Remove the system controller from the
bracket (leave all harnesses connected).
Remove the cover from the system controller.
Avoid straining the wires connected to the
switches.

3. Unplug the key switch from the system
controller and disconnect all wires from the
rocker switches.

4. Release the retaining catches on the rocker
switch and remove it from the cover.

3/30/00

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 the system controller.

3. Install the system controller cover. Install the
system controller in the bracket.

4. Install the top cover and connect the battery.

Keyswitch

Removal

1. Disconnect the battery and discharge the
capacitors (refer to Capacitor Discharge
procedure in the Electrical section).

2. Remove the top cover and remove the
system controller from the bracket (leave the
harnesses connected).

5.5

Electric Counterbalance High Output 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.

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.
Connect the wires to the rocker switches.

4. Install the cover on the system controller.

5. Install the system controller in the mount
bracket.

6. Install the top cover and connect the battery.

3/30/00

5.6

Electric Counterbalance High Output Lift & Auxiliary

TABLE OF CONTENTS

Theory of Operation .............................................6.1

Lift Pump

Removal ................................................. 6.2

Replacement .............................................. 6.2

Lift Pump & Motor Assembly

Removal ................................................. 6.2

Replacement .............................................. 6.3

Lift Pump Motor Brushes

Removal ................................................. 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 .............................................. 6.5

Tilt Angle Adjustment ............................................ 6.6

Relief Pressure Adjustment ....................................... 6.6

04/05/00

6.i

Electric Counterbalance High Output Lift & Auxiliary

LIFT AND AUXILIARY HYDRAULICS

THEORY OF OPERATION

Hydraulic power is provided by a gear pump
directly driven by a series-wound DC motor. This
motor/pump assembly provides fluid forces
distributed by an electrically controlled valving
manifold system. Pump motor speed is fixed and
is controlled by a contactor and the valves are
controlled by the system controller.

The truck uses two independent valves to control
the lifting and lowering of the mast and carriage.
Since the pump runs at a fixed speed, lift speed
is varied by the lift/lower proportional valve,
which allows some of the fluid to return to the
reservoir. Lowering speed is controlled by the
lift/lower proportional valve, and limited by the
flow regulator element.

LIFT SEQUENCE

To lift, the control handle is moved to the right.
The voltage output from the lift/lower
potentiometer increases at J8 pin 1 signaling the
system controller to start the lifting sequence
(Note: the truck may be programmed such that

the lift sequence will not begin unless the brakes
are engaged, and/or the truck is not moving in
reverse). The lift pump motor is turned on. The

system controller switches to a low-voltage signal
at J4 pin 2, opening the lift valve and allowing oil
to flow from the pump to the lift cylinders. The
voltage signal at J4 Pin 6 is varied to operate the
lift/lower proportional valve which controls the
lifting speed by varying the amount of fluid
returned to the reservoir. A check valve is
installed in the manifold ahead of the lift valve to
prevent the load from dropping prior to the
build-up of hydraulic pressure in the system. An
adjustable relief valve in the manifold limits the
maximum pressure of the hydraulic system.
When the voltage signal at J8 Pin 1 returns to the
neutral range, the pump motor is turned off and
the lift and lift/lower proportional valves are
closed.

LOWER SEQUENCE

To lower, the control handle is moved to the left.
The voltage output from the lift/lower
potentiometer decreases at J8 Pin 1, signaling
the system controller to start the lowering
sequence. 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 Pin 6 is varied to operate the
lift/lower proportional valve which controls the
amount of fluid returned to the reservoir and,
therefore, the lowering speed. A flow regulator
element is placed in-line with the lift/lower
proportional valve to further control the oil flow.
The flow regulator element monitors the pressure
on both sides of the lift/lower proportional valve
and maintains the pressure on the outlet side of
the proportional valve. In case of electrical
failure, a manual lowering valve on the manifold
will allow the mast to be lowered.

Each of the hydraulic cylinders in the lift system
has flow fuses installed in the hose connections.
If there is an out-rush of oil exceeding 25 gallons
per minute from the center cylinder or 15 gallons
per minute for the outer cylinders, the fuse closes
off the opening, stopping the flow of oil and the
descent of the carriage. The flow fuses can be
reset once the failure is repaired by applying
pressure to the system. A pressure-compensated
flow control with reverse flow bypass is also
installed in the lift circuit at the mast. This device
limits the maximum lowering speed under normal
conditions without affecting lift speed.

TILT AND SIDESHIFT

The tilt and sideshift/auxiliary functions share a
common supply circuit. Hydraulic oil is supplied
from the lift pump prior to the lift valve. The
same check valve mentioned in LIFT
SEQUENCE prevents oil from flowing back
through the pump. The same relief valve which
limits lift pressure also prevents the pressure in
the tilt and auxiliary systems from becoming too
great.

IT IS IMPORTANT TO NOTE THAT TILT AND
SIDESHIFT/AUXILIARY RELIEF PRESSURE
ARE THE SAME AS MAIN (LIFT) RELIEF
PRESSURE.

To tilt the mast forward, press the top of the
tilt/sideshift disk. This provides a voltage signal
at J8 Pin 6. The lift pump is started, and the
system controller then switches to a low-voltage
signal at J4 Pin 4, energizing the tilt-forward

03/21/00

6.1

Electric Counterbalance High Output Lift & Auxiliary

solenoid. To tilt the mast back, press the bottom
of the tilt/sideshift disk. This provides a voltage
signal at J8 Pin 13. The lift pump motor is
started, and the system controller then switches
to a low-voltage signal at J4 Pin 7, energizing the
tilt-back solenoid. During forward and back tilt
operation, the proportional valve is partially
opened to remove excess fluid. The
counterbalance valve maintains back pressure on
the tilt cylinders for steady forward tilt speed
when loaded. An orifice disc under the tilt
cylinder front port fitting on the manifold controls
the backward tilt speed.

To sideshift left, press the left side of the
tilt/sideshift disk. This provides a voltage signal
at J8 Pin 14. The lift pump motor is started, and
the system controller then switches to a
low-voltage signal at J4 Pin 5, energizing the
sideshift-left solenoid. To sideshift right, press
the right side of the tilt/sideshift disk. This
provides a voltage signal at J8 Pin 7. The lift
pump motor is started, and the system controller
then switches to a low-voltage signal at J4 Pin 8,
energizing the sideshift-right solenoid. During
sideshift operation, the proportional valve is
partially opened to remove excess fluid. There is
an orifice disc under the sideshift valve cartridge
to reduce the speed of operation of the sideshift
cylinders.

LIFT PUMP

Removal

NOTE
If the pump is replaced due to failure, also
replace the hydraulic oil filter element.

NOTE
If the lift pump and motor assembly has been
removed from the truck, skip to Step 6.

1.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.Clean the area around the hydraulic

connections to the lift pump.

5.Disconnect the hydraulic lines from the lift

pump and cap them.

6.Remove the screws securing the lift pump to
the lift pump motor. [2 cap screws & lock
washers]

7.Separate the lift pump from the lift pump
motor and remove from the truck.

Replacement

1.Position the lift pump on the lift pump motor
shaft.

2.Attach the lift pump to the lift pump motor and
tighten the bolts to 30 lb-ft. [2 cap screws &
lock washers]

3.Attach the hydraulic lines to the lift pump.

4.Reinstall the top cover and front cover (refer
to TOP COVER and FRONT COVER
Replacement procedures in the FRAME
section).

5.Connect the battery.

LIFT PUMP & MOTOR ASSEMBLY

Removal

NOTE
The lift pump can be removed from the motor
without removing the motor from the truck
(refer to LIFT PUMP Removal procedure in
this section).

1.Disconnect and remove the battery, and

discharge the capacitors (refer to APPENDIX
A: INDUSTRIAL BATTERY, and the
ELECTRICAL section).

2.Remove the overhead guard (refer to

OVERHEAD GUARD Removal procedure in
the FRAME section).

3.Label and disconnect the power cables to the

lift pump motor.

4.Clean the area around the hydraulic

connections to the lift pump.

5.Disconnect the hydraulic lines from the lift

pump and cap them.

6.Attach a lifting device to the lift pump and

motor assembly for support.

7.Remove the bolts securing the lift pump and

motor assembly to the frame of the truck. [4
hex bolts, 4 flat washers, 4 flange lock nuts]

03/21/00

6.2

Electric Counterbalance High Output Lift & Auxiliary

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

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.

MINNEWTABLE 6

0.62 in.1.35 in.Brush Length
40 oz.65 oz.Spring Tension

2.80 in.2.92 in.Commutator Dia.*

* Replace at 2.75 in. Diameter

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.

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.

03/21/00

6.3

Electric Counterbalance High Output Lift & Auxiliary

6.Place a shop towel over the top of the valve
cartridge and loosen 1/4 turn. Allow any
internal pressure to equalize. Remove the
valve cartridge.

Replacement

1.Make sure the O-ring on the valve cartridge is
in place and in good condition. Insert the
cartridge into the opening and hand tighten.

2.Tighten the valve cartridge to the correct
torque as listed in Table 6.2. If installing the
sideshift valve, make sure the restrictor is
installed under the valve with the beveled side
down.

3. Close the manual lowering valve if it was
opened during removal.

4.If applicable, install the coil(s) in the correct
position and install the retaining nut. Tighten
to the torque listed in Table 6.2.

5. Connect the battery and test for leaks and
proper operation.

6.Install the top cover and front cover (refer to
TOP COVER and FRONT COVER
Replacement procedure in the FRAME
section).

TABLE 6.2

Valve Cartridge

(Tilt, Sideshift)

Torque

Valve to

25 lb-ftManual Lowering
25 lb-ftRelief Valve
25 lb-ftCheck Valve
35 lb-ftFlow Regulator

Torque Coil

Retaining

Nut to

5 lb-ft25 lb-ftDouble-Coil

5 lb-ft25 lb-ftSingle-Coil (Lift, Lower)

17 lb-ft35 lb-ftProportional

N/A
N/A
N/A
N/A

HYDRAULIC OIL FILTER

Removal

1.Lower the carriage to the ground and 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.Use a filter wrench to loosen the filter.
Unscrew the filter and lift it out.

Replacement

1.Lubricate the seal of the new filter with
hydraulic fluid.

2.Screw the filter onto the filter housing until the
gasket seats and then turn another ¼ turn.

3.Connect the battery and operate the hydraulic
system.

4.Check the hydraulic oil level and fill to the
proper level using the correct type of hydraulic
oil (refer to the Scheduled Maintenance and
Inspection Table in the PREVENTIVE
MAINTENANCE Section.

5.Install the front cover (refer to FRONT
COVER Replacement procedure in the
FRAME section).

HYDRAULIC OIL

Removal

1.Lower the carriage to the ground (collapse all
lift cylinders).

2.Tilt the mast to the full forward position.

3.Disconnect the battery and discharge the
capacitors.

4.Remove the front cover (refer to FRONT
COVER Removal procedure in the FRAME
section).

5.Place the lift truck on blocks to access the
drain plug in the bottom of the hydraulic oil
tank (refer to PUTTING THE LIFT TRUCK ON
BLOCKS in the GENERAL section).

6.Remove the breather cap from the filler tube
of the hydraulic reservoir.

7.Place a pan of adequate size, minimum 10
gallon capacity, underneath the drain plug.

8.Remove the drain plug from the bottom of the
hydraulic reservoir.

9.Allow the oil to completely drain from the
reservoir.

03/21/00

6.4

Electric Counterbalance High Output Lift & Auxiliary

10.Remove the hydraulic oil filter (refer to
HYDRAULIC OIL FILTER Removal procedure
in this section).

Replacement

1.Install a new hydraulic oil filter (refer to
HYDRAULIC OIL FILTER Replacement
procedure in this section).

2.Use pipe thread sealant (Loctite 545 or
equivalent) on the threads of the drain plug
and install it in the opening of the hydraulic
reservoir and tighten.

3.Insert a funnel into the filler neck of the
hydraulic reservoir and pour the new hydraulic
oil into the reservoir.

4.Using the markings on the front of the
reservoir, check the level of the hydraulic oil.
Add oil until the proper level is attained.

5.Install the front cover (refer to FRONT
COVER Replacement procedure in the
FRAME section).

6.Connect the battery and operate the lift
system. Check oil level and fill as needed.

TILT CYLINDERS

Removal

1.Lower the carriage to the floor and tilt the mast
to the vertical position.

2.Disconnect the battery and discharge the
capacitors.

3.Wrap a chain around the top cross members
of the mast and attach it to a lifting device.

4.Remove the slack from the chain so the lifting
device will support the weight of the mast. DO
NOT lift the front of the truck off the floor.

5.Remove the front cover (refer to FRONT
COVER Removal procedure in the FRAME
section).

WARNING
Before disconnecting any hydraulic lines,
relieve the pressure in the lines. Allow the
truck to sit for approximately five minutes.

6.Loosen the hydraulic connections to the tilt

cylinders and disconnect the hoses from the
tilt cylinder fittings (leave the 90
cylinder).

o

fittings on the

7.Disconnect the tilt cylinder from the mast by
removing the screw and retaining washer and
pulling the tilt cylinder pin out of the mount.

WARNING

w DO NOT use fingers to remove the tilt

cylinder pins.

w Support the tilt cylinder when removing

the pin so that it does not drop and
damage the truck or the tilt cylinder.

8.Remove the plastic plug from the hole in the
side of the truck.

9.Remove the cotter pin from the tilt cylinder
pin.

10.Using a 1/2" x 12" drift pin, drive the tilt
cylinder pin from the frame mount and remove
the tilt cylinder from the truck.

Replacement

1.Make sure the rear bushing is in place in the
frame mount. Insert the base of the tilt
cylinder into the mount in the frame of the
truck.

2.Insert the pin into the mount from the inner
side.

3.Install the cotter pin into the end of the tilt
cylinder pin and replace the plastic plug in the
frame hole.

4.Connect the hydraulic hoses to the tilt cylinder
and tighten all fittings.

5.Align the rod end of the tilt cylinder with the
mounting bracket on the mast. Make sure the
front bushing is in place in the mast mount.

6.Insert the tilt cylinder pin through the tilt
cylinder and mast mount.

7.Install the retaining washer and screw.

8.Remove the lifting device supporting the mast
assembly.

9.Connect the battery.

10.Operate the tilt function to test for proper
operation and to check for leaks.

11.Install the front cover (refer to FRONT
COVER Replacement procedure in the
FRAME section).

03/21/00

6.5

Electric Counterbalance High Output Lift & Auxiliary

TILT ANGLE ADJUSTMENT

Test Procedure

The following conditions mean the tilt cylinders

need to be adjusted:

a.Tilt the mast fully forward. As the mast is

tilted forward, watch both tilt cylinder
ends. If one end stops before the other,
adjustment is required.

b.Tilt the mast to the full back position. As

the mast is tilted back, watch both of the
tilt cylinder ends. If one cylinder stops
before the other, adjustment is required.

c.Tilt the mast to the full forward position.

Use an angle protractor to measure the
angle of the mast. If the tilt angle does
not match the specifications listed on the
serial plate, both tilt cylinders need
adjustment.

Adjustment

1.Disconnect the rod end from the mast (refer to
TILT CYLINDER Removal procedure in this
section).

2.Loosen the rod end clamp screw (Item 8
Figure 6.1).

RELIEF PRESSURE ADJUSTMENT

Special Tools:P/N 9650041 Pressure Check

Adapter & Hose Kit

1.Locate the pressure check port for the lift
system. This port is on the lift pump outlet
fitting.

2.Connect an appropriate pressure gauge to the
port using the adapter and hose kit.

3.Place a maximum capacity load on the

carriage. Read the pressure gauge while
lifting in the second stage and record the
highest pressure observed. Continue lifting to
the stops. Record the pressure while lifting
against the stops. DO NOT lift against the
stops for more than 5 seconds.

4.The relief pressure should be approximately
200 psi above the lifting pressure (for a triplex
mast, approximately 2400 psi). Relief
pressure may be adjusted at the relief valve
on top of the manifold. Loosen the lock nut on
the valve and turn the internal screw clockwise
to increase pressure or counter-clockwise to
decrease pressure. When the relief pressure
is correct, tighten the lock nut.

3.Rotate the tilt cylinder rod end to adjust the
length of the cylinder.

NOTE
Connect the rod end to the mast and test both
forward and backward tilt after each change
in tilt cylinder length to verify proper
adjustment. Continue adjusting as necessary
until both tilt 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 cylinder adjustment per the Test

Procedure above.

Figure 6.1

03/21/00

6.6

Electric Counterbalance High Output Elevating

TABLE OF CONTENTS

Mast Description ................................................7.1

Carriage

Removal ................................................. 7.5

Replacement .............................................. 7.5

Mast

Removal ................................................. 7.5

Disassembly .............................................. 7.6

Cleaning and Inspection .................................... 7.6

Assembly ................................................. 7.7

Installation ................................................ 7.7

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 ..................................... 7.10

Load Rollers ............................................. 7.10

Brass Set Screws .........................................7.11

Outer Cylinder Shims ...................................... 7.11

04/05/00

7.i

Electric Counterbalance High Output 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. It is called a full free-lift mast because the
carriage can travel to the top of the inner rail
without extending the inner rail.

Load rollers are installed at the top inside of the
outer and middle rails. Load rollers are also
installed at the bottom outside of the middle and
inner rails. The load rollers travel along the
flanges of the rails. The angle of the load rollers
permits them to control the forces from the front,
back, and sides of the mast. The load rollers are
adjustable with shims.

The brass set screws are installed at the top rear
of the outer and middle rails and help keep the
correct clearance between the rails. The brass set
screws at the top of the outer rail are adjustable
and are locked in place by stainless steel set
screws. The brass set screws at the top of the
middle rail are adjustable and are locked in place
by jam nuts.

3

2

1

6

4

5

The two outer (main) lift cylinders 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 (cylinder rod) is bolted to the top
crossbar of the middle rail. The center (free-lift)
cylinder is mounted in the inner rail and is held in
place with a snap ring and strap. All three lift
cylinders are displacement-type cylinders
equipped with internal hydraulic cushioning (see
Figs. 7.2 and 7.3).

One pair of lift chains is connected to adjustable
anchor bolts near the top of the outer rail. These
chains go over sheaves (pulleys) at the top of the
middle rail and fasten at the bottom of the inner
rail. The free-lift chains are connected to
adjustable anchor bolts at the middle crossbar of
the inner rail. These chains go over sheaves on
the head of the center cylinder and fasten to the
carriage.

The three hydraulic cylinders are connected by
hoses and tubes as shown in Fig. 7.4. To extend
the mast, oil from the main control valve flows to
all cylinders at the same time. The center cylinder
extends first because it lifts the least amount of
weight and has the larger area. The center

1. Outer Rail

2. Middle Rail

3. Inner Rail

4. Outer Lift Cylinder

FIGURE 7.1 - TRIPLEX MAST

7

5. Center Lift Cylinder

6. Free-Lift Chain

7. Carriage

3/10/00 7.1

Electric Counterbalance High Output Elevating

s s

CENTER CYLINDER

2

The center cylinder is cushioned at the top of its
stroke. There is hydraulic oil on the rod side of

1

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

3

forced underneath the rod through the large
orifice (3). When the rod extends near the end
of its stroke, the gland nut at the top of the
cylinder closes the large orifice (3). The
remainder of the hydraulic oil must flow through
the small orifice (4) providing a cushioning
effect.

4

1. Cylinder Rod Assembly

2. Cylinder Shell

3. Large Orifice

5

4. Small Orifice

5. Wear Ring

FIGURE 7.2 - CENTER CYLINDER CUSHIONING

1

OUTER CYLINDERS
The outer cylinders are cushioned at the bottom
of their stroke. As the rod retracts, the hydraulic

2

3

oil flows out of the cylinder through the port (3).
When the rod is retracted near the end of its
stroke, the piston ring (6) is below the port
opening. The hydraulic oil below the rod must
flow through the small orifice (4). This cushion
effect prevents a sudden stop at the end of the
lowering sequence, making a smoother lowering
operation.

5

4

6

FIGURE 7.3 - OUTER CYLINDER CUSHIONING

3/10/00 7.2

1. Cylinder Rod Assembly

2. Cylinder Shell

3. Port

4. Small Orifice

5. Wear Ring

6. Piston Ring

Electric Counterbalance High Output Elevating

cylinder raises the carriage to the top of the inner
rail. After the center cylinder reaches the end of
its stroke, the outer lift cylinders begin to extend.
As the outer cylinders extend, the middle rail is
raised. The inner rail is raised by the lift chains.
During lowering, the outer lift cylinders retract first
because they have the greater load and the
smaller area. After the outer cylinders have
retracted, the center cylinder lowers. All oil from
the lift cylinders flows through the lowering control
valve which limits the lowering speed. Flow fuses
at each cylinder port close to prevent the mast
from dropping in the event of a sudden outrush of
oil from a broken hose or tube. Once the problem
has been repaired, raise the mast to reset the flow
fuses.

Safety Procedures When Working on
the Mast

The following procedures must be used when
inspecting 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. Serious
injury or death can result if part of the body is
hit by parts of the mast or carriage.

Ÿ Never put any part of the body into or

under the mast or carriage unless all parts
are completely lowered or safety chains
are installed. Also make sure the power is
off and the key is removed. Put a “DO
NOT OPERATE” tag in the operator
compartment.

Ÿ Be careful of the forks. When the mast is

raised, the forks can be at a height to
cause injury.

Ÿ DO NOT climb the mast or lift truck at any

time. Use a ladder or personnel lift to
work on the mast.

Ÿ DO NOT use blocks to support the mast

rails or to restrain their movement.

Ÿ Mast repairs require disassembly and

removal of parts and can require removal
of the mast or carriage. Follow the repair
procedures in this manual.

FIGURE 7.4 - HYDRAULIC SCHEMATIC

3/10/00 7.3

Electric Counterbalance High Output Elevating

1

2

7

3 4 5

LOWERED

6

8

5

6

8

7

4

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

3

FULLY RAISED

2

1

FIGURE 7.5 - OPERATION

3/10/00 7.4

Electric Counterbalance High Output Elevating

Carriage

Removal

1.Tilt the mast to vertical. Remove the forks
and load backrest. Disconnect any hydraulic
connections to the carriage. Remove the two
carriage stop bolts at the top of the inner rail.

2.Connect a lifting device to the carriage. Use
the lifting device to raise the carriage so there
is slack in the free-lift chains.

WARNING
When disconnecting the lift chains, keep
control of the ends to prevent them from
falling and causing injury or damage.

3.Remove the pin from each chain anchor at

the carriage. Disconnect the chains from the
carriage. Remove the chain sheaves and
hose sheave from the center cylinder. NOTE:
if the mast is to be disassembled, disconnect
the free lift chains at the inner rail middle
crossbar and remove them.

4.Use the lifting device to raise the carriage out

of the top of the inner rail. Lower the carriage
to the floor so that it lays face down.

5.If any of the load rollers must be replaced,

make a note of the number and location of
shims. See Checks and Adjustments for
correct adjustment of load rollers.

Replacement

4.Route auxiliary (sideshift) hoses over the hose
sheave on the center cylinder and connect
them to the carriage.

5.Install the carriage stop bolts at the top of the
inner rail.

Mast

Removal

NOTE
If the mast must be disassembled, remove the
forks and carriage before removing the mast.
Make sure rails are completely lowered and
open the manual lowering valve to relieve
pressure in the hydraulic lines.

1.Before removing the mast, check the length of

the lift chains to see if they need replacing
(refer to Cleaning and Inspection).

2.Fully lower all of the rails and the carriage.

Use chains to fasten all the rails together and
connect a lifting device to the mast. Make
sure the chains will not damage the sheaves,
tubing, hoses, or other parts of the mast.
Make sure the lifting device has a capacity of
at least 2500 lb (1150kg).

3.Put a drain pan under the area of the

hydraulic fittings. Disconnect the hydraulic
lines from the truck to the mast. Cap the
hydraulic lines from the truck.

CAUTION
The carriage bearings could fall off while
lifting the carriage above the mast.

1.Install the load rollers and shims on the

carriage. Use a lifting device to raise the
carriage directly above the inner rail. Check
and adjust 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 center cylinder clevis
head.

3.Route the free-lift chains over the chain

sheaves and connect them to the chain
anchors on the carriage. Make sure the lift
chains are adjusted correctly as described in
Checks and Adjustments.

3/10/00 7.5

FIGURE 7.6 - TILT CYLINDER

Electric Counterbalance High Output Elevating

4.Make sure there is no slack in the lifting

device or chains. Remove the metric screw,
lock washer, and retainer washer (Item 12, Fig

7.6) from the tilt cylinder rod end.

5.Support the tilt cylinder while removing the

front cylinder pin. Rest the tilt cylinder on the
frame of the truck being careful not to
damage the cylinder rods.

6.Repeat Steps 4 and 5 for the other tilt

cylinder.

7.Make sure the mast is vertical. Remove the

mast mount plates and use the lifting device
to raise the mast and separate it from the
truck. Put the mast on the floor so that the
back of the mast is down.

Disassembly

NOTE
If the carriage has already been removed, start
with Step 3.
Hoses are installed under tension.

1.Disconnect all hydraulic connections from the

carriage. Loosen chain anchor bolts and
disconnect the chains from the carriage and
middle crossbar of the inner rail and remove.
Remove the chain and hose sheaves from the
center cylinder.

2.Remove the two carriage stop bolts at the top

of the inner rail. Attach a lifting device to the
carriage. Slide the carriage out the top of the
inner rail. Lay the carriage on the floor face
down. Remove the load rollers, noting the
number and location of shims at each load
roller. The shim arrangement will be
approximately the same during reassembly.

3.Disconnect and remove the hydraulic hoses

for the center cylinder and auxiliary (sideshift)
attachment back to the outer rail. Remove
the tube connecting the center cylinder to the
distributor block. Remove the snap ring at the
bottom of the center cylinder and the center
cylinder strap. Remove the center cylinder.

4.Loosen the chain anchor bolts and disconnect

the lift chains at the bottom of the inner rail
and the top of the outer rail and remove.
Remove the chain sheaves at the top of the
middle rail. Push the inner rail half way out
the top of the middle rail and connect a lifting
device to the inner rail. Now push the inner
rail out 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 bottom of the
inner rail and the top of the middle rail. Make
a note of the shim arrangement at each load
roller location. The shim arrangement will be
approximately the same during assembly.

6.Remove the screws, washers, and spacer
sleeves at the top of the outer cylinders (do
not allow the cylinder rod to spin). Make a
note of all shims at the top of either cylinder
rod.

7.Push the middle rail half way out of the outer
rail and connect a lifting device to it. Now
push the middle rail out until the load rollers at
the bottom of the middle rail are visible in the
notches at the top of the outer rail.

8.Lift the middle rail out of the outer rail.
Remove the load rollers at the bottom of the
middle rail and the top of the outer rail. Make
a note of the shim arrangement at each load
roller location. The shim arrangement will be
approximately the same during assembly.

9.If the outer cylinders need repair, disconnect
the hydraulic tubes at the bottom of the outer
cylinders, remove the roll pin from the base,
remove them from the outer rail and mark
them as right and left. Retain any shims
noted in Step 6 with the cylinder. Remove
hydraulic tubes, manifold and fittings from the
rails as necessary.

Cleaning and Inspection

1.Inspect the chain sheaves and load rollers for
wear or damage. DO NOT use steam to
clean the lift chains, sheaves, or load rollers.
The bearings in the sheaves and load rollers
are lubricated and sealed.

WARNING
When using cleaning solvents, always follow
the manufacturer’s recommended safety
precautions.

2.Clean the lift chains with solvent. Remove all

dirt and grease. Inspect the lift chains for
wear or damage. The lift chains must be
installed on the mast before they can be
checked for length. A lift chain becomes
longer when it is worn. Most wear occurs in
the section that goes over a sheave. If a
chain is 3% longer than a new lift chain, a new

3/10/00 7.6

Electric Counterbalance High Output Elevating

PAIR of lift chains must be installed. Use a
chain scale if one is available to check the lift
chains. If you do not have a chain scale,
measure 20 links of the chain. For ¾ inch
pitch chain, the length of 20 links of new chain
is 15 inches. The wear limit, or maximum
allowable length of 20 links of ¾ inch pitch
chain is 15.45 inches. Replace the pair of
chains if the length of 20 links reaches the
wear limit. Lubricate the chains with clean
SAE 40 motor oil. The best procedure is to
soak the lift chains in motor oil.

WARNING
Never replace just the worn section of a chain;
replace the complete chain. Never replace just
one chain of a pair; install new chains in pairs.

3.Inspect the chain anchors and pins. Replace

worn or damaged parts.

WARNING
Be careful when cleaning with steam. Steam
can cause serious burns. Wear protective
clothing and gloves. Never expose your skin
to steam.

4.Clean the mast rails with steam or solvent.

5.Inspect the load roller contact surfaces for

wear or damage. Inspect all welds for cracks.

Assembly

the load rollers as described in Checks 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 cylinders was replaced, see Checks and
Adjustments to determine if shims are
needed. If removed, connect the hydraulic
tubes and fittings between the lift distributor
block and the outer cylinders. Make sure the
arrows on the flow fuses point away from the
cylinder ports.

5.Connect a lifting device to the inner rail.
Install the load rollers and shims at the bottom
of the inner rail and the top of the middle rail.

6.Fit the load rollers on the inner middle rail into
the notches at the top of the middle rail. Slide
the inner rail into the middle rail. Adjust the
load rollers as described in Checks and
Adjustments.

7.Connect the lift chains to the chain anchors at
the top of the outer rail and bottom of the
inner rail. Install the chain and hose sheaves
at the top of the middle rail.

8.Connect the center cylinder feed hoses and
auxiliary (sideshift) attachment feed hoses to
the outer rail. Route the hoses over the hose
sheaves on the middle rail and connect them
to the inner rail.

NOTE
The shims for the load rollers keep the rails
parallel and give correct clearance. During
assembly, the shim arrangement will be
approximately the same as before
disassembly. Check the clearance and adjust
the shims for wear or changes caused by
repairs. See Checks and Adjustments for the
correct procedures.

1.Put the outer rail on the floor with the back

side down. If removed, install both outer
cylinders in their original locations using spiral
roll pins in the mounts at the bottom of the
outer rail.

2.Connect a lifting device to the middle rail.

Install the load rollers and shims at the bottom
of the middle rail and top of the outer rail.

3.Fit the load rollers at the bottom of the middle

rail into the notches at the top of the outer rail.
Slide the middle rail into the outer rail. Adjust

3/10/00 7.7

9.Install the center cylinder in the mount on the
inner rail. Install the cylinder strap and the
snap ring. Install the tube between the center
cylinder and the distributor block. Make sure
the arrow on the flow fuse points away from
the cylinder port.

10.Connect the free-lift chains to the anchors at
the middle crossbar of the inner rail.

11.The carriage may be installed at this time
(refer to Carriage installation procedure).

Installation

1.Connect a lifting device to the top of the mast
using chains. Make sure all the rails are
fastened together and that the chains will not
damage the sheaves, hoses, or other parts of
the mast. The lifting device must have a
capacity of at least 2500 lb (1150 kg).

2.Use the lifting device to set the mast on the
pivot points. Install the mast mount caps and
grease the bearings.

Electric Counterbalance High Output 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. Repeat for opposite
side.

4.Connect the hydraulic lines to the mast. Make
sure the arrow on the lowering control points
down. Close the manual lowering valve on
the manifold.

5.Install the carriage if it was not installed during
mast assembly.

6.Check for proper tilt angle. Operate the mast
and check for leaks and proper operation.
Check the lift chains as described in Checks
and Adjustments. Adjust the brass set screws
as described in Checks and Adjustments.

Center (Free-Lift) Cylinder

Repacking

1.Place a pallet or blocks under the forks and
lower the carriage completely. Disconnect the
free-lift chains and auxiliary attachment
(sideshift) hoses from the carriage.

1

2

8

3

4

5

6

2.Lift the 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 wrench to remove the gland
nut. Replace the O-rings, back-up rings,
wiper, and seal.

4.Install the gland nut on the cylinder and torque
to 350 to 400 lb-ft.

5.Place the clevis head into the center cylinder
rod. Connect the chains and hoses to the
carriage.

6.Bleed the center cylinder.

Removal

1.Raise and support the carriage.

2.Put a drain pan under the area of the
hydraulic fittings. Disconnect the tube from
the cylinder.

3.Remove the snap ring at the bottom of the
cylinder and the cylinder strap. Remove the
cylinder.

1. Wiper

2. Rod Seal

3. Gland

4. Back-up Ring

5. O-Ring

6. Rod Assembly

7. Wear Ring

7

8. Cylinder Shell

FIGURE 7.6 - CENTER CYLINDER

Installation

1.Set the cylinder in the mount bracket in the
inner rail. Install the cylinder strap and the
snap ring.

2.Connect the tube to the cylinder port.

3.Lower the carriage.

3/10/00 7.8

Electric Counterbalance High Output 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.For this procedure, use a chain with a
capacity that is greater than the weight of the
mast. Do not use blocks to support the
elevated mast sections. Use the chain to
secure the top crossbar of the outer rail to the
bottom crossbar of the middle rail.

3.Slowly lower the mast so that the chain
supports the weight of the elevated sections.
The carriage will be completely lowered.

4.Remove the screw securing the outer cylinder
rod to the top crossbar (do not allow the rod to
spin). If resealing both cylinders, remove both
screws at this time.

1

4

2

3

7

5

4

5

9

6

10

5.Open the manual lowering valve so that the
cylinder rods retract into the cylinder. Be
careful not to lose any shims on the top of the
rods. Note their location for reinstallation
(typically, only one side will be shimmed).

6.Use a prybar or a large wrench on the port at
the base of the cylinder to prevent 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 clean
hydraulic fluid. Carefully slide the gland nut
over the cylinder rod and thread it into the
cylinder. Make sure the cylinder does not
rotate while tightening the gland nut. The
gland nut should be torqued in excess of 100
lb-ft.

8.Close the manual lowering valve. Operate
the lift control to extend the cylinder rods to
the top crossbar. Make sure any shims that
were found on top of the rods in Step 5 are in
place. Install and tighten the hardware
removed in Step 4.

1. Wiper

2. Rod Seal

3. Gland

4. Back-up Ring

5. O-Ring

6. Rod Assembly

7
8

7. Wear Ring

8. Piston Ring

9. Spacer

10. Cylinder Shell

FIGURE 7.7 - OUTER CYLINDER

9.Slowly raise the mast just enough to take the
tension off the chain. Remove the chain from
the mast and lower it completely.

10.Check for leaks as described in the Checks
and Adjustments section. If the mast leans to
one side at full extension, the cylinder rods
are not properly shimmed (refer to Checks
and Adjustments for shimming instructions).

3/10/00 7.9

Electric Counterbalance High Output Elevating

Removal

NOTE
Most repairs to the outer cylinders, such as
repacking the gland nut, can be made without
removing the cylinder from the mast. The
outer cylinders can be removed with the mast
on or off the truck; the procedures are similar.
The mast must be completely extended to
remove the outer cylinders.

1.Attach a lifting device to the top crossbar of

the middle rail only. Remove the screws and
spacer sleeves at the top of both outer
cylinders (do not allow the rod to spin).
Disconnect the hydraulic tubes from both
cylinders. Remove the roll pin from the
cylinder to be removed.

2.Use the lifting device to raise the mast near

full extension. Make a note of the shims
between the cylinder rod and the middle rail
crossbar. Lift the cylinder up and out of the
top of the mast.

Replacement

1.Install the outer cylinder through the top of the

mast. Place the bottom of the cylinder in the
mount and install a spiral roll pin.

NOTE
If a different cylinder is being installed, shims
may need to be added. Refer to Checks and
Adjustments for proper procedures.

2.Lower the rails and extend the cylinder rod

until they contact. Place the shims noted
during removal between the cylinder rod and
the middle rail crossbar. Install the screws
and spacer sleeves to secure the rods to the
middle rail. Lower the mast completely.
Connect the hydraulic tubes to the cylinder
ports.

3.Bleed the lift cylinders.

Checks and Adjustments

pressure. Hydraulic oil can be injected into
the body by the pressure.

Operate the hydraulic system. Put a 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 elevated
for several minutes to check for drift.

Lift Chain Adjustments

When the lift chains are correctly adjusted:

Ÿ The tension will be the same on each chain of

the pair. Check tension by pushing on both
chains at the same time.

Ÿ The chain length will be correct.
Ÿ The chains must travel freely through the

complete cycle.

1.Lower the mast completely. Adjust the lift
chains at the top of the outer rail so that the
top of the inner rail is even with the top of the
middle rail within 0.060”

2.Adjust the free-lift chains at the middle
crossbar of the inner rail so that the heel of
the forks are 1/4” to 3/8” off the floor when the
mast is vertical (bottom of the carriage will be
3” - 3½“ off the ground).

3.When the chain adjustments are complete,
tighten the second nut on each chain anchor
and make sure the cotter pin is in place.

4.Check the clearance of the carriage when
center cylinder is at full extension. The
carriage stop blocks must not touch the stop
bolts at the top of the inner rail.

Load Rollers

During assembly, the shim arrangement will be
approximately the same as before disassembly.
Check the clearance and adjust for wear or
changes because of repairs.

The load rollers control the alignment of the rails.
The alignment conditions are listed below in order
of importance:

a)The rails must be parallel to each other.

Check for Leaks

WARNING
DO NOT try to find hydraulic leaks by putting
your hand on hydraulic components under

3/10/00 7.10

b)Use shims to adjust the load rollers so that

there is 0.001 to 0.010 in. clearance between
the load roller and the channel at the point of
tightest fit.

c)The number and thickness of shims under a

load roller must be approximately the same as

Electric Counterbalance High Output 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.

2.Separate the rails and add or remove shims

as required. Slide the rail all the way from top
to bottom and find the tightest fit.

3.Repeat Steps 1 and 2 until there is 0.001 to

0.010 in. clearance at the point of tightest fit.
DO NOT shim the load rollers too tight.
Check for free movement by sliding rail
through full extension by hand.

4.Measure the distance between the channels of

the rails on the top and bottom. Change
shims to keep the distance equal at the top
and bottom so that the rails are parallel within

0.060 in.

A

B

1

1

C

UPPER
LOAD
ROLLERS

2

2

Brass Set Screws

NOTE
The brass set screws can only be adjusted
with the mast installed on the truck and the
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. On the
triplex mast, there are two pairs of brass set
screws. One pair is located at the top of the outer
rail, secured by smaller set screws. The other pair
is located at the top of the middle rail, secured by
jam nuts.

1.Tilt the mast fully forward. Loosen the small

set screw or jam nut.

2.Turn the brass set screw through the rail so it

is tight against the next rail. Back the screw
off by ¼ turn.

3.Tighten the small set screw or jam nut to lock

the brass set screw.

4.Operate the mast and check the adjustment.

A

±0.060

C

B

±0.060

±0.060

1. Shim load rollers to 0.000 -

0.010 in. at tightest point.

2. Brass set screws.

1

1

LOWER
LOAD
ROLLERS

Outer Cylinder Shims

Shims between the outer cylinder rods and the
middle rail keep the mast from being cocked to
one side at full extension. If one cylinder extends

3/10/00 7.11

FIGURE 7.8 - MAST ADJUSTMENTS

Electric Counterbalance High Output 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
the opposite side.

3/10/00 7.12

Electric Counterbalance High Output Electrical

TABLE OF CONTENTS

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

04/05/00

8.i

Electric Counterbalance High Output Electrical

CAPACITOR DISCHARGE

WARNING
Discharge the capacitor bank prior to
performing any service on the lift truck.
Failure to 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
is:

1. Turn the key switch OFF (Position '0').

2. Disconnect the battery.

3. Turn the key switch ON (Position 'I'). The
operator display will light then slowly dim.
Once the operator display goes black, the
capacitors are fully discharged.

FIG. 8.1 - SYSTEM CONTROLLER DECAL

4. Turn the key switch OFF.

The above method cannot be used if the 15 amp
fuse for the System Controller is open. In this
event, the capacitors can be discharged by the
following method:

1. Turn the key switch OFF.

2. Disconnect the battery.

3. Use an INSULATED electrical cable or
wire to short the Positive and Negative
bus bars at the capacitors.

SYSTEM CONTROLLER /

OPERATOR DISPLAY BOX

WARNING

ww Tampering with the System Controller

may void warranty.

ww Switching System Controller from truck to

truck will void warranty.

CAUTION
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
capacitors (refer to CAPACITOR
DISCHARGE procedure in this section).

2. Remove the top cover (refer to TOP COVER
Removal procedure in the FRAME section).

3. Scribe lines on the mounting bracket to mark
the position of the display box. Loosen (do
not remove) the four mounting screws
securing the system controller/operator
display box to the bracket.

4. Rotate the top of the system controller/
operator display box upward until the
connectors on the back are accessible.

5. Unplug all connectors from the back of the
system controller (make sure they are labeled
for correct replacement).

6. Lift the system controller/operator display box
from the mounting bracket.

Replacement

NOTE
The System Controller must be electrically
isolated from the frame of the truck. The back
plate of the system controller is B-.

1. Line up the lower mounting screws on the

system controller/operator display box with
the slots in the mounting bracket and slide
the box into the bracket.

4/3/00

8.1

Electric Counterbalance High Output Electrical

2. Plug all connectors into the correct ports in
the back of the system controller (refer to
Figure 8.1).

3. Rotate the top of the system
controller/operator display box down until the
upper mounting screws are in the slots in the
bracket. Align the display box with the lines
scribed in Step 3 of Removal. Tighten all four
screws.

4. Install the top cover (refer to TOP COVER
Replacement procedure in the FRAME
section). Check for proper alignment of the
display with the cutout in the top cover; adjust
if necessary.

5. Connect the battery.

OPERATOR DISPLAY BOARD /
MEMORY BOARD

Removal

CAUTION
To avoid damage to the system controller and
operator display, follow the CAPACITOR
DISCHARGE PROCEDURE at the beginning of
this section.

1. Disconnect the battery and discharge the

capacitors (refer to CAPACITOR
DISCHARGE procedure in this section).

2. Remove the system controller/operator

display box from the mount bracket (leave all
harnesses attached).

NOTE
When removing the cover from the system
controller/operator display box, be careful not
to break the wires from the key switch and
light or auxiliary selector switches (if so
equipped).

3. Remove the 8 screws that attach the plastic

cover and lift the cover off the system
controller.

CAUTION
Refer to the procedures for handling
static-sensitive assemblies in the GENERAL

INFORMATION section.

board to the standoffs on the system
controller pc board.

CAUTION
The operator display board and system
controller are connected by a single 32-pin
connector. The memory board and system
controller are connected by two connectors.
Be careful not to damage the pins or
connectors when removing the operator
display board or memory board.

6. Gently lift the operator display board or the

memory board off of the system controller.

Replacement

CAUTION
w Be careful not to damage the pins or

connector when installing the operator
display board or memory board.

w Refer to the procedures for handling

static-sensitive assemblies in the
GENERAL INFORMATION section

1. Line up the connectors on the operator

display pc board or memory board with the
mating connectors on the system controller
pc board.

2. If replacing the operator display board, mount

it onto the standoffs on the system controller
and secure it with four screws. If replacing
the memory board, make sure it is fully
seated on the system controller and the foam
block is in place on the memory board.

3. Plug in the key switch and light or auxiliary

selector switches (if so equipped). Make sure
the key switch is plugged in correctly (not off
by one pin).

4. Install the plastic cover over the system

controller/operator display.

NOTE
If the cover is too high, the LED display will
appear fuzzy. Ensure the cover is seated
against the display board, but does not
distort the overlay.

5. Reinstall the system controller/operator

display box in the mount bracket.

4. Unplug the key switch and light or aux.
selector switches (if so equipped).

5. If replacing the operator display, remove the
four screws securing the operator display pc

4/3/00

8.2

Electric Counterbalance High Output Electrical

TRACTION AMPLIFIER

WARNING
Tampering with the amplifier may void
warranty.

CAUTION
To avoid damage to the system controller and
amplifiers, follow the CAPACITOR
DISCHARGE procedure at the beginning of
this section.

Replacement

1. Apply an even film of heat-sink compound to
the bottom of the amplifier before installation.

2. Make sure 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 holes in the
amplifier base with the holes in the truck
frame. Install the 6 mounting screws, lock
washers, and flat washers. Torque the
screws to 13 lb-ft. in the pattern shown in
Figure 8.3. Tighten all screws to
approximately ½ the final torque, then repeat
the sequence, tightening all screws to the full

FIG. 8.2 - TRACTION AMPLIFIER DECAL

Removal

1. Disconnect the battery and discharge the
capacitors (refer to CAPACITOR
DISCHARGE procedure in this section).
Remove the top cover.

2. Disconnect the system controller-to-amplifier
harness at P2 on the amplifier.

3. Disconnect the jumper cable from the B­terminal at the back of the amplifier.

4. Disconnect the FB+ cable from the amplifier
to be removed.

5. Label and disconnect the two field cables (F1
and F2) from the front of the amplifier.

6. Disconnect the short bus bar and cable from
the A2 terminal of the amplifier.

7. Remove the battery. Remove the six screws,
lock washers, and flat washers securing the
amplifier assembly to the frame of the truck
and remove the amplifier.

FIG. 8.3 - AMPLIFIER TORQUE SEQUENCE

torque.

3. Connect the FB+ cable from the 80-amp fuse
to the FB+ terminal on the rear of the
amplifier.

4. Connect the B- jumper cable to the B­terminal at the back of the amplifier.

5. Attach the diode module bus bar and motor
A2 cable to the A2 terminal of the amplifier.

6. Connect the field cables from the motor to
the proper terminals on the amplifier.

7. Plug the system controller-to-amplifier
harness into P2 on the amplifier.

8. Install the TOP COVER (refer to TOP
COVER Replacement procedure in the
FRAME section).

9. Install and connect the battery and test the
truck for proper operation.

4/3/00

8.3

Electric Counterbalance High Output Electrical

CONTACTOR TIPS

CAUTION
NEVER manually close the main power
contactor. Damage to the system controller
and/or the amplifiers may occur.

CAUTION
To avoid damage to the system controller and
amplifiers, follow the CAPACITOR
DISCHARGE PROCEDURE at the beginning of
this section.

Removal

1. Disconnect the battery and discharge the

capacitors (refer to CAPACITOR
DISCHARGE PROCEDURE in this section).

2. Remove the top cover (refer to TOP COVER

Removal procedure in the FRAME section).

3. Note the location of all power cables and

wires for correct replacement. Disconnect the
cables and wires from the bus bars on the
contactor. Use a backup wrench to prevent
bending the bus bars.

4. Remove the nylon lock nuts securing the

upper contactor tips in place.

5. Remove the insulators and springs from the

armature. Remove the contactor tips.

6. Remove the lock nuts securing the insulator

block to the contactor body. Remove the
insulator and the bus bars.

Replacement

1. Install the bus bars on the insulating base.

Be sure the holes in the bus bars engage the
locators on the insulating base.

2. Install the insulator on the bus bars and

secure with the lock nuts.

3. Install the upper tips over the insulators

attached to the armature.

4. Install the springs and insulating washers

and secure with the lock nuts.

NOTE
DO NOT over-tighten the nuts securing the
cables and wires to the 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.

5. Connect the power cables and wires as noted
during Step 3 of Removal.

6. Install the top cover (refer to TOP COVER
Replacement procedure in the FRAME
section).

7. Connect the battery.

MAIN POWER CONTACTOR

CAUTION
NEVER manually close the main power
contactor. Damage to the system controller
and/or the amplifiers may occur.

CAUTION
To avoid damage to the system controller and
amplifiers, follow the CAPACITOR
DISCHARGE PROCEDURE at the beginning of
this section.

Removal

1. Disconnect the battery and discharge the

capacitors (refer to CAPACITOR
DISCHARGE PROCEDURE in this section).

2. Remove the top cover (refer to TOP COVER

Removal procedure in the FRAME section).

3. Disconnect the B+ and capacitor supply

cables from the bus bar of the main power
contactor (the bus bar toward the front of the
truck).

4. Remove the bus bar between the contactor

and the fuses.

5. Label and disconnect the wires from the main

power contactor.

6. Remove the bus bar between the contactor

and the lift (600 amp) fuse.

7. Remove the nuts securing the panel to the

frame of the truck and rotate the panel to
access the contactor mount screws.

8. Remove the screws holding the contactor to

the bracket and remove the contactor.

Replacement

1. Align the mounting holes in the contactor with

the holes in the panel and install the screws.

4/3/00

8.4

Electric Counterbalance High Output Electrical

2. Install the contactor-fuse panel assembly to
the frame.

3. Install the bus bar between the contactor and
the lift (600 amp) fuse.

4. Connect the power cables to the fuses,
starting with the lowest fuse.

5. Connect the wires to the main power
contactor in the correct locations noted during
Step 5 of Removal.

6. Connect the B+ and capacitor bank supply
cables to the contactor bus bar.

7. Install the top cover (refer to TOP COVER
Replacement procedure in the FRAME
section).

8. Connect the battery.

LIFT AND STEER CONTACTORS

Removal

1. Disconnect the battery and discharge the

capacitors (refer to CAPACITOR
DISCHARGE Procedure in this section).

2. Remove the top cover (refer to TOP COVER

Removal procedure in the Frame section).

3. Label and disconnect the power cables and

wires from the contactor bus bars and coil.
Use a backup wrench to prevent bending the
bus bars.

4. Remove the screws securing the contactor to

the top plate. Remove the contactor.

FUSES

Removal

1. Disconnect the battery and discharge the
capacitors (refer to CAPACITOR
DISCHARGE procedure in this section).

2. Remove the top cover (refer to TOP COVER
Removal procedure in the FRAME section).

3. Remove fuse.

Replacement

1. Install the proper fuse and tighten the screws.

2. Install the top cover (refer to TOP COVER
Replacement procedure in the FRAME
section).

3. Connect the battery.

HORN

Removal

1. Disconnect the battery.

2. Remove the top cover (refer to TOP COVER
Removal procedure in the FRAME section).

3. Disconnect the 2-pin connector.

4. Remove the two screws securing the horn to
the frame.

Replacement

Replacement

1. Align contactor with mounting holes in top
plate. 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
section).

4. Connect the battery.

4/3/00

1. Install the horn with two screws.

2. Connect the 2-pin connector.

3. Install the top cover (refer to TOP COVER
Replacement procedure in the FRAME
section).

4. Connect the battery.

HORN RELAY

Removal

1. Disconnect the battery.

2. Remove the top cover (refer to TOP COVER
Removal procedure in the FRAME section).

8.5

Electric Counterbalance High Output 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.

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 (DVOM)

with diode test function.

Test for both forward and reverse bias at room
temperature and at 180° F following the diode
test instructions in the meter manual.

4/3/00

8.6

Electric Counterbalance High Output Preventive Maintenance

The numbers in this drawing correspond to the
numbers in the first column of the SCHEDULED
MAINTENANCE & INSPECTIONS TABLE.

4/3/00

FIG. 10.1 - SCHEDULED MAINTENANCE AND INSPECTION POINTS

10.1

Electric Counterbalance High Output Preventive Maintenance

SCHEDULED MAINTENANCE AND INSPECTION TABLE

8
1

X

X
X

X

XCheck that they are securely in placeBattery Gates3

X

X

XLocks out travel capability when pedal is upBrake Switches7
XInspect for cracks, bends, and damage

X

XCheck operational, safety, and warning decals

XCheck operation

XCheck for leaks

XFunction when switched onLights15
X

X

XTurns without binding - no excess playSteering18
XInspect tires for cracks, gouges, and wearTires19

XTouch the floor.Static Straps21

6

8

COMPONENT

Battery1

Battery Disconnect2

Brakes5

Brake Pedal /
Brake Linkage

Carriage / Load
Backrest / Forks

Contactor Tips9

Control Handle10

Decals11

Gearbox12

Hydraulic System13

Lift Chains14

Mast16

Motor Brushes17

Wheels20

CHECK/ACTION HOURS

DAYS

Charge - Normal
Charge - Equalizing
Check water level and cleanliness
Connector in good condition, bolt installed

Check for free movement of the lever
Check that the lever disconnects the battery
Do Not Lubricate

Released when brake pedal is depressed and stops the
unit within the specified distance when pedal is returned to
up position
Brake pads - inspect and replace (as needed)

Check for smooth operation, no binding, and the pedal
comes up when foot is removed
Do Not Lubricate

Lubricate sideshift carriage
Check condition, inspect for pitting, adequate tip contact

surface, signs of burning
Check for smooth and full movement forward, reverse, lift,

and lower; check horn, tilt, and all auxiliary functions for
operation
Do Not Lubricate

Replace if missing or unreadable

Check fluid level and fill (as needed)
Change fluid at first 100 hours, then:

Check level and fill (as needed)
Change hydraulic oil and filter
Breather cap - check and clean

Check for wear, damage, and cotter pins in place on
connector pins at anchor bolts
Lubricate and adjust

Inspect for damage
Check for cotter pins in place on tilt cylinder pins

Replace (as needed)

Lubricate wheel and final drive pinion bearings
Lubricate final drive gears

LUBRICATION

to

32oF

C
CX

B
BX

E
H

32oF

to

120oF

GFLubricate (as needed)Battery Rollers4

EEX

C
C

A
A

GFX

E
H

40

5

X

X

X

360

60

X

X

X

X

X

XCheck for wear and proper seating

X
X

-40oF

2000

350

LUBRICATION REFERENCE TABLE

4/3/00

Mobilith SHC 220 Synthetic Grease NLGI 2 or equivalentETexaco 32 / Tellus 32 / Mobil DTE 24A
SAE 20W Motor OilFMcCollister Arctic Blue Hydraulic Oil 3028B
SAE 40W Motor OilGMobil SHC 50 Synthetic Gear Lubricant or equivalentC
Mobilith SHC 007 Synthetic Grease NLGI 00 or equivalentH

10.2

Electric Counterbalance High Output Preventive Maintenance

8-HOUR / DAILY INSPECTION

GENERAL

STARTUP SEQUENCE

The lift truck is equipped with a "Static Return to
Off" circuit that prevents operation of the truck if
the starting sequence is not correct. The function
of this circuit is to make sure the operator is in the
correct position to operate the controls before the
lift truck will travel. The following is the starting
sequence:

1. Turn the key switch to the "I" (ON) position.
After the system controller performs internal
checks, the display will read "b-100".

2. With the brake pedal released, turn the key
switch to the "II" (RUN) position and release
it. If the internal self-tests are passed, the
truck will enter run mode. If errors are
detected, the code number will be displayed.
E-82 indicates that the brake pedal is not
released.

3. Use only one foot to depress and hold down
the brake pedal. Traction functions are now
enabled.

4. Move the control handle forward or backward
to initiate travel.

If the control handle is moved forward or
backward before the brake pedal is depressed,
the truck will not travel in either direction. The
control handle must be completely released to
enable travel functions.

The lift truck must not be operated if this circuit
does not function correctly.

GENERAL FUNCTIONS

Perform 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 system
w Direction and speed control

WARNING
If repairs are required, install a "DO NOT
OPERATE" tag on the control handle.
Remove the key and disconnect the battery.
DO NOT operate a damaged or defective lift
truck until it has been repaired.

BATTERY

WARNING
w Read the battery charger manual before

charging batteries.

w DO NOT smoke or use spark producing

devices near batteries.

w DO NOT expose the batteries to open

flames.

w Always charge batteries in a well

ventilated area to avoid hydrogen gas
concentration.

w Clean batteries regularly; corrosion

causes grounds and the possibility of
sparks.

w Keep plugs, terminals, cables, and

receptacles in good condition to avoid
shorts and sparks.

w Charge batteries at the indicated rates.
w DO NOT lay tools, chains, or other metal

objects on top of batteries.

w Always wear protective clothing and eye

protection when handling, checking, or
filling batteries.

w DO NOT overcharge batteries.
w DO NOT connect the battery charger to the

lift truck.

w Ensure charger voltage is correct for the

battery being charged.

Refer to APPENDIX A: INDUSTRIAL BATTERY
for detailed battery safety precautions.

9/1/99

10.3

Electric Counterbalance High Output Preventive Maintenance

CHARGING THE BATTERY

WARNING
DO NOT connect the battery charger to the lift
truck.

NOTE
See APPENDIX A: INDUSTRIAL BATTERY for
detailed information about charging and
maintaining batteries.

Never discharge a battery below the limits listed
in APPENDIX A. Discharging a battery below the
design limits will decrease the service life of the
battery.
Make sure the battery voltage and the weight are
correct as shown on the nameplate.

Give the battery a DAILY CHARGE using a
charger designed for the battery. Check with
the manufacturer of your battery or your
dealer for a suitable battery/charger
combination. The DAILY CHARGE is
normally 8 hours in length and will keep the
battery fully charged if it has not been
discharged below the limit.

Changing the Battery

necessary, install spacers to achieve this
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 as a parking brake and for
emergency stopping. When the brakes are
applied (pedal released), a microswitch informs
the system controller to disable traction.

Verify that the brakes disengage when the brake
pedal is depressed, and that they engage when
the brake pedal is released. The brakes should
hold the truck with a capacity load on a 15%
grade ( a drop of 1.5 feet in a 10 foot run). If the
brakes do not hold the truck on the grade, refer to
the BRAKE ADJUSTMENT procedures in the
BRAKES section of MAINTENANCE.

Refer to APPENDIX A: INDUSTRIAL BATTERY
for detailed information and procedures for
changing the battery.

BATTERY CONNECTOR

1. Operate the battery disconnect lever. The
lever should move freely, and return to the
original position. Check to see that the
battery connectors are separated. The
battery disconnect lever does not require
lubrication.

2. Check the battery connectors and cables for
damage, cracks, breaks, or corrosion.
Ensure the connector from the battery has the
bolt and lock nut correctly installed for the
battery disconnect.

BATTERY GATES

1. Ensure the battery gates are securely in place
and have not shifted.

2. The battery should not be able to shift more
than 1/2" in any horizontal direction. If

BRAKE PEDAL / BRAKE LINKAGE

Check the operation of the brake pedal.
Operation should be smooth with no binding or
dragging. The return spring should easily raise
the pedal to its mechanical stop. The brake pedal
does not require lubrication.

BRAKE SWITCHES

The function of the brake switch is to prevent
operation of the travel functions of the lift truck
when an operator is not properly positioned in the
operator compartment. To test the switch,
release the brake pedal so that it returns fully to
its mechanical stop (brakes fully applied). With
the key switched to "II" (RUN) and while standing
in the operator compartment, operate the control
handle in both the forward and reverse directions.
The traction motors should not engage, and the
truck should not move. If the brake switch does
not work properly, refer to the BRAKES section in
MAINTENANCE. The second brake switch is
used to control the electric brake units through a
relay.

9/1/99

10.4

Electric Counterbalance High Output Preventive Maintenance

CARRIAGE / LOAD BACKREST /
FORKS

Inspect the carriage, load backrest, and forks for
cracks bends and damage. Never repair forks by
heating them; replace worn or damaged forks.

CONTROL HANDLE

WARNING
If any function does not operate correctly,
repair the fault immediately. DO NOT operate
the lift truck until the problem is corrected.
Put a "DO NOT OPERATE" tag on the control
handle, remove the key, and disconnect the
battery.

Test all operations of the control handle (travel,
lift/lower, tilt, sideshift, aux, horn). Movement of
the handle should be smooth and full.

DECALS

Check to see that none of the operational, safety,
or warning decals are missing or unreadable.
Each of these decals serves a vital function; to
protect the operator, those around the truck, or
the truck itself. Replace any decal that is missing
or unreadable. Refer to the FRAME section of
the PARTS manual for type and placement of
decals on your model lift truck.

GEARBOX

1. Inspect the gearboxes for fluid leaks and

loose mounting bolts.

2. Drive the truck forward and reverse in a

straight line. Drive the truck in a tight circle
to the left and right. Operation should be
smooth and free of any unusual noise.

w Hydraulic oil under pressure 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

hydraulic system. Doing so will damage
the pump.

Check the hydraulic system for leaks and
damaged or loose components. Report damage
immediately. DO NOT operate the lift truck until
problems are corrected. If repair is required, put
a "DO NOT OPERATE" tag on the control handle.

LIGHTS (OPTIONAL)

If your unit is equipped with overhead
guard-mounted work lights, a flashing light, or
stop/tail lights, ensure they function correctly and
are tight.

MAST

WARNING
DO NOT work under a raised carriage. Lower
the carriage and forks to the ground or use a
suitable locking device to prevent the carriage
and inner rails from lowering when
performing maintenance on the mast.

1. Inspect the welds on the rails of the mast for

cracks. Make sure all nuts and bolts are tight,
and that the cotter pins are in place on the tilt
cylinder pins.

2. Check the channels for wear in the areas of

roller contact. Check the rollers for wear or
damage.

3. Check that the chain and hose sheaves

operate smoothly and are not damaged.

HYDRAULIC SYSTEM

CAUTION

w The operating temperature of the

hydraulic oil is 90oF - 160oF.

w Before disconnecting any hydraulic lines,

relieve the pressure in the lines.

9/1/99

4. Raise the carriage slowly without a load.

Check for smooth operation and the correct
sequence when the carriage and rails make
their telescoping movements within the
channels. A wrong sequence when the mast
is raised and lowered indicates that
adjustment is necessary. Refer to the
ELEVATING section.

10.5

Electric Counterbalance High Output 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.

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 operation.

STATIC STRAPS

Check that the static straps (attached to the
frame under the brake pedal and at the hydraulic
tube clamp) are in place and are touching the
floor. Replace a worn or missing static strap.

9/1/99

10.6

Electric Counterbalance High Output Preventive Maintenance

40-HOUR / 5-DAY INSPECTION

BATTERY

Keep the battery case and the battery
compartment clean and painted. Leaks and
corrosion from the battery can cause a
malfunction in the electrical controls of the lift
truck. Use a water and soda solution to clean the
battery and the battery compartment. Keep the
top of the battery clean, dry, and free of
corrosion. Refer to APPENDIX A: INDUSTRIAL
BATTERY for more detailed procedures for
cleaning the battery.

Where applicable, check the level of the
electrolyte on all cells. Refer to the instructions
from the manufacturer of your battery for the
correct operating level of the electrolyte.

HYDRAULIC SYSTEM

WARNING

w The operating temperature of the hydraulic

oil is 90oF - 160oF.

w Disconnect the battery while servicing.
w Before disconnecting any hydraulic lines,

relieve the pressure in the lines.

w Hydraulic oil under pressure can be

injected into the skin. Never check for
leaks by putting hands on a hydraulic line
under pressure.

CAUTION

w DO NOT permit dirt to enter the hydraulic

system when checking the oil level.

w Never operate the steer or lift pump

without oil in the hydraulic system. Doing
so will damage the pump.

LIFT CHAINS

WARNING
DO NOT work under a raised carriage. Lower
the carriage and forks to the ground or use a
suitable locking device to prevent the carriage
and rails from lowering when performing
maintenance on the lift chains.

1. Visually inspect the lift chains for cracks or

broken links and pins. Check for corrosion or
worn holes in the links. As the links and pins
wear, the chain will become longer.

2. Use a chain scale to check the lift chains. If a

chain scale is not available, measure 20 links
of chain. Replace the chain if the length of 20
links of the worn chain is more than 15.45”.

WARNING
w Replace a worn chain - DO NOT try to

repair it.

w If one chain in a pair has a defect, replace

both chains.

3. Inspect the chain anchors and pins. Replace

the chain anchors if there are cracks or worn
holes. Replace chain anchor pins that are
worn or damaged. Replace broken or missing
cotter pins.

4. Check the lift chains for dryness. If needed,

lubricate them as described in the 350-HOUR
/ 60-DAY INSPECTION section.

1. Lower 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 90oF.

2. If the oil level is low, carefully check for leaks
and damaged or loose components.

9/1/99

10.7

Electric Counterbalance High Output Preventive Maintenance

350-HOUR / 60-DAY INSPECTION

BATTERY

WARNING

w DO NOT connect the battery charger plug

to the lift truck.

w Read the battery charger manual before

charging batteries.

w DO NOT smoke or use spark-producing

devices near the battery.

w DO NOT expose the battery to open flames.
w Always change batteries in a well-ventilated

area to avoid hydrogen gas concentration.

w Clean batteries regularly; corrosion causes

grounds and the possibility of sparks.

w Keep plugs, terminals, cables, and recep-

tacles in good condition to avoid shorts and
sparks.

w Charge batteries at the indicated rates.
w DO NOT lay tools, chains, or other metal

objects on top of the battery.

w Always wear protective clothing and eye

protection when handling, checking, or
filling batteries.

w DO NOT overcharge the battery.
wEnsure charger voltage is correct for the

battery being charged.

Refer to APPENDIX A: INDUSTRIAL BATTERY
for detailed battery safety precautions.

1. Give the battery an EQUALIZING CHARGE,
using a charger designed for the battery.
This charge is at a low rate and balances the
charge in all of the cells. The equalizing
charge is usually for 3 hours at a low rate, in
addition to the regular charging cycle. The
most accurate specific gravity measurements
for a charged battery will be after an
equalizing charge.

2. Check with the manufacturer of your 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 discharge the
capacitor bank (refer to the ELECTRICAL
section) before making any inspections or
repairs to the contactor.

In normal operation, the contact surfaces become
rough and turn a dark color. Cleaning is usually
not necessary as this does not interfere with
proper operation. The contact surfaces are silver
alloy on a copper base. Replace the contacts
when the silver surface wears through to the
copper base. Always replace the contacts in sets.
Refer to CONTACTOR TIP Removal /
Replacement procedures in the ELECTRICAL
section.

GEARBOX

Park the lift truck on a level surface. Check the
oil level in the gearbox by removing the fluid level
plug on the side of the gearbox. The fluid level
should be even with the bottom of the hole.

CAUTION

DO NOT permit dirt to enter the gearbox.

HYDRAULIC SYSTEM

Check the breather cap for accumulation of
material that could prevent the easy passage of
air.

LIFT CHAINS

WARNING
DO NOT work under a raised carriage. Lower
the carriage and forks to the ground or use a
suitable locking device to prevent the carriage
and rails from lowering when performing
maintenance.

9/1/99

1. Inspect the chains for accumulation of dirt,

especially if the lift truck is operated in dusty

10.8

Electric Counterbalance High Output 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

-40oF to 32oF. Use SAE 40W for operating
temperatures above 32oF.

3. Check the chain tension by fully lowering the
carriage 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 BRUSHES

WARNING
Disconnect the battery before making any
inspections or repairs.

Drive Motors
Check the condition of the brushes in the drive

motors. Brushes must be replaced if they
measure less than 0.7".

Inspect and clean the commutator.

9/1/99

10.9

Electric Counterbalance High Output Preventive Maintenance

2000-HOUR / 360-DAY INSPECTION

BRAKES

The brakes need adjusting when the lift truck wil
not stop within 1.1 ft./mph after applying the
brakes, running at full speed, with a full load. If
after adjustment, the brakes do not meet these
specifications, replace the disc brake unit (refer to
DISC BRAKE UNIT Removal / Replacement
procedures in the BRAKES section).

GEARBOX

1. Park the truck on a level surface, and

completely lower the carriage and mast.

2. Disconnect the battery.

3. Change the oil in both gearboxes as

described in GEARBOX Oil Change in the
DRIVE section.

HYDRAULIC SYSTEM

NOTE
This procedure is best done with the lift truck
positioned approximately one foot off of the
floor on a level surface. Make sure the lift
truck is securely blocked (refer to Putting the
Lift Truck on Blocks in the GENERAL
MAINTENANCE section).

Oil

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 tighten it by hand.
DO NOT overtighten.

4. Fully cycle the tilt function one time.

5. Check the hydraulic oil level and check the
filter for leaks around the seal.

SIDESHIFT CARRIAGE

Lubricate the sideshift carriage with the lubricant
recommended in the chart on Page 1.

TIRES / WHEELS

Lubricate the steer wheel at the grease fitting,
using the correct lubricant as specified in the
Scheduled Maintenance and Inspections Table at
the beginning of this section.

1. Remove the drive wheel (refer to DRIVE
WHEEL Removal in the DRIVE section).

2. Clean the old grease from the drive wheel
bearings, the ring gear, the pinion, and pinion
bearings.

1. The drain plug is accessed through a hole in
the underside of the chassis. Put a pan under
the drain hole.

2. Remove and clean the drain plug. When the
oil has drained, install the drain plug.

3. Fill the hydraulic reservoir with oil as
specified in the Scheduled Maintenance and
Inspection Table at the beginning of this
section.

4. Replace the breather cap.

9/1/99

3. Inspect the drive wheel V-ring seal and
replace if damaged.

4. Repack and install the wheel bearings. Apply
enough grease to the ring gear and pinion (as
specified in the Scheduled Maintenance and
Inspections Table) to fill all the teeth.

5. Use a needle-nose grease gun to apply
grease to the pinion gear shaft bearing. Use
grease as specified in the Scheduled
Maintenance and Inspection Table.

10.10

E02E02

Electric Counterbalance High Output Troubleshooting

ELECTRONIC FAULT ISOLATION PROCEDURE

SOFTWARE VERSION 6.08

Fault condition

E01E01

TRACTION system shutdown until condition is
cleared.

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

brake pedal is depressed.

Excess “play” in the control handle.

RELEASE THROTTLE TO RESUME OPERATION

CriteriaResulting Effect

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

SolutionPossible Cause

Return control handle to neutral.The control handle is not in neutral when the

Perform travel potentiometer calibration procedure.Travel potentiometer out of calibration.
Adjust springs so there is no play in the neutral

position. Calibrate the control handle.
Replace travel potentiometer and calibrate.Bad travel potentiometer.

Fault condition

LIFT system shutdown until condition is cleared.

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

brake pedal is depressed.

Excess “play” in the control handle.

BRAKE LIFT INTERLOCK WARNING

CriteriaResulting Effect

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.

SolutionPossible Cause

Return control handle to neutral.The control handle is not in neutral when the

Perform lift potentiometer calibration procedure.Lift/lower potentiometer out of calibration.
Adjust springs so there is no play in the neutral

position. Calibrate the control handle.
Replace lift/lower potentiometer and calibrate.Bad lift/lower potentiometer.

REV 12/5/99

TS.1

E05E05

E06E06

Electric Counterbalance High Output Troubleshooting

Fault condition

E04E04

LIFT system shutdown until condition is cleared.
NOTE: if rE Lf is enabled in programming and
traveling in reverse, this is normal.

PERFORM INPUT TESTS 03 & 04 - TRAVEL & LIFT/LOWER POTENTIOMETER VOLTAGE. Look
for constant repeatable voltage readings in neutral.

brake pedal is depressed.

Excess “play” in the control handle.

REVERSE LIFT INTERLOCK WARNING

CriteriaResulting Effect

Programmable reverse-lift interlock is enabled. Lift
potentiometer voltage is in the lift range (more than

0.14V above calibrated center) and travel
potentiometer voltage is in the reverse range (more
than 0.12V below calibrated center) while brake
pedal is depressed.

SolutionPossible Cause

Return control handle to neutral.The control handle is not in neutral when the

Perform lift potentiometer calibration procedure.Lift/lower potentiometer out of calibration.
Adjust spring set screws so there is no play in the

neutral position. Calibrate the control handle.
Replace lift/lower potentiometer and calibrate.Bad lift/lower potentiometer.

Fault condition

TOTAL shutdown.

Battery voltage outside of normal working range:
Maximum Minimum

41.2 V 29.5 V
A freshly charged battery which has not been
allowed to sit for the recommended time may
exceed the voltage range.

TRACTION system shutdown.

PERFORM INPUT TEST 03 - TRAVEL POTENTIOMETER VOLTAGE. Look for “dead spots”, sudden
voltage jumps, etc.

BATTERY VOLTAGE OUT OF RANGE

Battery voltage is out of the normal operating
range.

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, allow the
battery to sit for the time period recommended by
the manufacturer.

Fault condition

TRAVEL POTENTIOMETER VOLTAGE OUT OF RANGE

Travel potentiometer voltage is outside the normal
operating range (0.39V to 4.63V). Note: actual
voltage supplied to potentiometer is 15V.

Inspect and repair wiring as necessary.Wiring to travel potentiometer broken or shorted.
Replace travel potentiometer.Bad potentiometer.

CriteriaResulting Effect

SolutionPossible Cause

CriteriaResulting Effect

SolutionPossible Cause

REV 12/5/99

TS.2

E13LE13L

Electric Counterbalance High Output Troubleshooting

Fault condition

E07E07

LIFT system shutdown.

PERFORM INPUT TEST 04 - LIFT/LOWER POTENTIOMETER VOLTAGE. Look for “dead spots”,
sudden voltage jumps, etc.

E09E09

TRACTION system shutdown.

PERFORM INPUT TEST 05 - STEER POSITION POTENTIOMETER VOLTAGE. Look for “dead
spots”, sudden voltage jumps, etc.

Steer position potentiometer out of adjustment.

LIFT/LOWER POTENTIOMETER VOLTAGE OUT OF RANGE

CriteriaResulting Effect

Lift potentiometer voltage is outside the normal
operating range (0.39V to 4.63V). Note: actual
voltage supplied to potentiometer is 15V.

SolutionPossible Cause

Inspect and repair wiring as necessary.Wiring to lift potentiometer broken or shorted.
Replace lift potentiometer.Bad potentiometer.

Fault condition

STEER POSITION POTENTIOMETER VOLTAGE OUT OF RANGE

CriteriaResulting Effect

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.

SolutionPossible Cause

Adjust steer position potentiometer or replace if
necessary.

Inspect and repair wiring as necessary.Wiring to steer potentiometer broken or shorted.
Replace steer position potentiometer.Bad potentiometer.

Fault condition

LEFT/RIGHT TRACTION CONTROL TEMPERATURE SENSE VOLTAGE OUT OF

E13RE13R

TRACTION shutdown.

Bad amplifier harness or amplifier.

Warning: Tampering with traction amplifier may void warranty.

REV 12/5/99

RANGE

Left/right traction amplifier temperature sensor
voltage is outside the normal operating range.

Swap amplifier harness connections at J2 and J6 on
the controller. If the error code changes sides, then
the controller is good. If the code does not change
sides, the controller is bad. Now swap the harness
connections at the amplifiers. If the code changes
back to the original side, then the amplifier is bad.
If the code does not change back, the harness is
bad.

TS.3

CriteriaResulting Effect

SolutionPossible Cause

E17E17

Electric Counterbalance High Output Troubleshooting

Fault condition

E15E15

TRACTION SYSTEM shutdown.

PERFORM INPUT TEST 14 - FLOORPAD SWITCH.

disconnected.
Bad floorpad switch.

e16e16

Truck will coast to a stop.

PERFORM INPUT TEST 14 - FLOORPAD SWITCH. Should indicate “ON” when right foot is on
switch.

during travel.

disconnected.

FLOORPAD SWITCH VOLTAGE OUT OF RANGE

CriteriaResulting Effect

Programmable floorpad option is enabled and
system controller sensing improper input from the
floorpad switch.

SolutionPossible Cause

Inspect harness and repair as necessary.Harness to floorpad switch broken, shorted, or

Test the resistor on the floorpad switch connector.
Replace floorpad switch.

Fault condition

REPOSITION RIGHT FOOT TO RESUME OPERATION

CriteriaResulting Effect

Programmable floorpad option is enabled, and
floorpad switch reading is open while truck is
traveling.

SolutionPossible Cause

Keep right foot on floorpad switch during travel.Operator’s right foot not properly positioned

Inspect harness and repair as necessary.Harness to floorpad switch broken, shorted, or

Replace floorpad switch. Bad floorpad switch.

Fault condition

BRAKE FAILURE

CriteriaResulting Effect

TOTAL shutdown.

PERFORM INPUT TEST 02 - BRAKE LIMIT SWITCH. Should indicate “DN” when brake pedal is
depressed and “UP” when released.

Wiring to the brake limit switch broken, shorted,
or disconnected.

REV 12/5/99

System controller sensing improper input from the
brake switch (greater than 2K ohm resistance).

SolutionPossible Cause

Check for defects in the wiring harness to the brake
limit switch and replace if necessary. Resistance
with pedal down should be 1.5K ohm ± 200 ohms.

Replace brake limit switch.Bad brake limit switch.

TS.4

E27EE27E

Electric Counterbalance High Output Troubleshooting

Fault condition

E27AE27A

TOTAL shutdown.

PERFORM OUTPUT TEST 01 - MAIN POWER CONTACTOR.
Broken or shorted wiring to the contactor.

driver.
If error codes 29-42 occur at the same time; J4

pin 3 not connected to switched B+.

TOTAL shutdown.

PERFORM OUTPUT TEST 01 - MAIN POWER CONTACTOR.

causing them to become welded. Check for
movement of contactor tips.

MAIN POWER CONTACTOR WIRING FAULT

The main power contactor coil circuit is overheated,
shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the contactor.
Test resistance from B+ to J4 pin 9 for 28 ohms.
Measure B+ and B- on coil.

Replace main power contactor.Main contactor coil is open or shorted internally.
Replace system controller field fix.Malfunction of the main power contactor coil

Check 15 amp fuse on main harness, wiring on all
hydraulic valve coils, repair or replace.

Fault condition

MAIN POWER CONTACTOR WELDED

System controller senses current at both amplifier
fields during POST indicating that Main Power
Contactor is closed.

Replace contactor tips.Contactor tips have been allowed to deteriorate,

Replace main power contactor.Binding of the contactor solenoid shaft.
Inspect contactor tips and remove foreign material.Conductive material between contactor tips.

CriteriaResulting Effect

SolutionPossible Cause

CriteriaResulting Effect

SolutionPossible Cause

REV 12/5/99

TS.5

E29E29

Electric Counterbalance High Output Troubleshooting

Fault condition

E27FE27F

TOTAL shutdown.

Contactor tips are not passing battery voltage
when the coil is activated.

No battery voltage is supplied to the main power
contactor tips.

No field currrent at both traction amplifiers.

LIFT system shutdown.

PERFORM OUTPUT TEST 14 - LIFT/LOWER PROPORTIONAL SOLENOID.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

MAIN POWER CONTACTOR OPEN

CriteriaResulting Effect

No field current at both traction amplifiers when the
coil driver for the main power contactor is
energized.

SolutionPossible Cause

Check for foreign material between the contactor
tips. Replace the contactor tips if necessary.

Check the condition of the cables to the main power
contactor and repair as necessary.

Check the power cables to the traction amplifiers
and perform Diagnotic Output Tests 17 and 18.

Test fuse and replace if necessary.80 amp fuse is blown.

Fault condition

LIFT/LOWER PROPORTIONAL VALVE WIRING FAULT

CriteriaResulting Effect

The lift/lower proportional valve solenoid coil circuit
is overheated, shorted to supply, shorted to ground,
or disconnected.

SolutionPossible Cause

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace coil.Solenoid coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

REV 12/5/99

TS.6

E31E31

Electric Counterbalance High Output Troubleshooting

Fault condition

E30E30

LIFT system shutdown.

PERFORM OUTPUT TEST 03 - LOWER SOLENOID.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

LIFT system shutdown.

PERFORM OUTPUT TEST 04 - LIFT SOLENOID.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

LOWER VALVE WIRING FAULT

The lower valve solenoid coil circuit is overheated,
shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace coil.Solenoid coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

Fault condition

LIFT VALVE WIRING FAULT

The lift valve solenoid coil circuit is overheated,
shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace coil.Solenoid coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

CriteriaResulting Effect

SolutionPossible Cause

CriteriaResulting Effect

SolutionPossible Cause

REV 12/5/99

TS.7

E33E33

Electric Counterbalance High Output Troubleshooting

Fault condition

E32E32

DISPLAY code.

PERFORM OUTPUT TEST 15 - HORN.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

LIFT system shutdown.

PERFORM OUTPUT TEST 06 - TILT FORWARD SOLENOID.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

HORN WIRING FAULT

The horn circuit is overheated, shorted to supply,
shorted to ground, or disconnected.

Check and repair damaged wires to the horn.Broken or shorted wiring to the horn.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace horn.Horn is open or shorted internally.
Replace system controller field fix.Malfunction of the horn driver.

Fault condition

TILT FORWARD VALVE WIRING FAULT

The tilt forward valve solenoid coil circuit is
overheated, shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace coil.Solenoid coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

CriteriaResulting Effect

SolutionPossible Cause

CriteriaResulting Effect

SolutionPossible Cause

REV 12/5/99

TS.8

E35E35

Electric Counterbalance High Output Troubleshooting

Fault condition

E34E34

LIFT system shutdown.

PERFORM OUTPUT TEST 07 - TILT BACK SOLENOID.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

LIFT system shutdown.

PERFORM OUTPUT TEST 08 - SIDESHIFT LEFT SOLENOID.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

TILT REVERSE VALVE WIRING FAULT

The tilt reverse valve solenoid coil circuit is
overheated, shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace coil.Solenoid coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

Fault condition

SIDESHIFT LEFT VALVE WIRING FAULT

The sideshift left valve solenoid coil circuit is
overheated, shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace coil.Solenoid coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

CriteriaResulting Effect

SolutionPossible Cause

CriteriaResulting Effect

SolutionPossible Cause

REV 12/5/99

TS.9

E41E41

Electric Counterbalance High Output Troubleshooting

Fault condition

E36E36

LIFT system shutdown.

PERFORM OUTPUT TEST 09 - SIDESHIFT RIGHT SOLENOID.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

TRACTION system shutdown.

PERFORM OUTPUT TEST 02 - STEER MOTOR.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

SIDESHIFT RIGHT VALVE WIRING FAULT

The sideshift right valve solenoid coil circuit is
overheated, shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace coil.Solenoid coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

Fault condition

STEER CONTACTOR WIRING FAULT

The steer contactor coil circuit is overheated,
shorted to supply, shorted to ground, or
disconnected.

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace contactor.Contactor coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

CriteriaResulting Effect

SolutionPossible Cause

CriteriaResulting Effect

SolutionPossible Cause

REV 12/5/99

TS.10

E51LE51L

Electric Counterbalance High Output Troubleshooting

Fault condition

E42E42

LIFT system, except lower shutdown.

PERFORM OUTPUT TEST 19 - LIFT MOTOR.

If error codes 29-42 occur at the same time; 15
Amp fuse in main harness is bad.

LIFT CONTACTOR WIRING FAULT

CriteriaResulting Effect

The lift contactor coil circuit is overheated, shorted
to supply, shorted to ground, or disconnected.

SolutionPossible Cause

Check and repair damaged wires to the coil.Broken or shorted wiring to the coil.
Check 15 amp fuse on main harness, wiring on all

hydraulic valve coils, repair or replace. Check for
B+ at J4 Pin 3.

Replace contactor.Contactor coil is open or shorted internally.
Replace system controller field fix.Malfunction of the coil driver.

Fault condition

LEFT/RIGHT TRACTION MOTOR OVERHEATED

E51RE51R

CriteriaResulting Effect

TRACTION system shutdown.

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should
see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.
Left and right field current should not differ by more than 5 amps.

Steer not properly calibrated.

runs, hard acceleration / plugging.
Loose motor terminals, brake drag, mechanical

binding of drive unit or wheel.

0.9 ohm at room temp).

The temperature of the traction motor (based on
field resistance) has reached a point at which
damage may occur.

SolutionPossible Cause

Calibrate steer position potentiometer.
Change style of operation. Continuous low speed travel operation, short

Check motor terminals, brake clearance, operation
of drive unit and wheel.

Replace traction motor.Bad traction motor (field resistance greater than

Replace traction amplifier.Bad traction amplifier.

REV 12/5/99

TS.11

E61LE61L

Electric Counterbalance High Output Troubleshooting

Fault condition

E55LE55L

LEFT/RIGHT TRACTION CONTROL OVERHEATED

E55RE55R

TRACTION system shutdown.

acceleration / plugging.
Loose motor terminals, brake drag, mechanical

binding of drive unit or wheel.

Inadequate heat sink.

Warning: Tampering with traction amplifier may void warranty.

The temperature sensor in the traction amplifier
indicates that the temperature has reached a level
which may damage components.

Reduce operation.Continuous travel operation, short runs, hard

Check motor terminals, brake clearance, operation
of drive unit and wheel.

Test diode and replace if necessary.Open or shorted diode.
Check amplifier base for full contact and heat sink

grease.
Replace traction amplifier.Bad traction amplifier temperature sensor.

CriteriaResulting Effect

SolutionPossible Cause

Fault condition

LEFT/RIGHT MOTOR BRUSH WEAR FAILURE

E61RE61R

CriteriaResulting Effect

SPEED limited.

E62LE62L

LEFT/RIGHT TRACTION MOTOR FIELD CURRENT HIGH

Indicator sensor in brush is worn and has 36 volts
from armature.

SolutionPossible Cause

Replace all left/right traction motor brushes.Left/right traction motor brushes are worn.
Inspect brush indicator wire and repair.Brush indicator wire shorted to 36V.

Fault condition

E62rE62r

CriteriaResulting Effect

TRACTION system shutdown. Will not pass
POST.

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should
see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.
Left and right field current should not differ by more than 5 amps.

traction motor.

The traction motor field current draw is greater than
the system controller expects.

SolutionPossible Cause

Check cables, repair or replace.Shorted F1 or F2 cable from traction amplifier to

Replace traction amplifier.Bad traction amplifier.
Replace traction motor.Bad traction motor (shorted winding).

REV 12/5/99

TS.12

E64LE64L

Electric Counterbalance High Output Troubleshooting

Fault condition

E63LE63L

LEFT/RIGHT TRACTION MOTOR FIELD CURRENT NOT PRESENT

E63RE63R

CriteriaResulting Effect

TRACTION system shutdown. Will not pass
POST.

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should
see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.
Left and right field current should not differ by more than 5 amps.

amplifier to traction motor.

LEFT/RIGHT TRACTION MOTOR ARMATURE HIGH

The system controller detects no current to the
traction motor field when there should be.

SolutionPossible Cause

Check cables, repair or replace.Broken or loose F1 or F2 cable from traction

Replace traction amplifier.Bad traction amplifier.
Replace traction motor.Bad traction motor (open winding).

Fault condition

E64RE64R

CriteriaResulting Effect

TRACTION system shutdown. Will not Pass
POST.

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should
see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.
Left and right field current should not differ by more than 5 amps.

traction motor.

The traction motor armature current draw is greater
than the system controller expects.

SolutionPossible Cause

Check cables, repair or replace.Shorted A1 or A2 cable from traction amplifier to

Test diode and replace if necessary.Bad diode.
Replace traction amplifier.Bad traction amplifier.
Replace traction motor.Bad traction motor (shorted winding).

REV 12/5/99

TS.13

Electric Counterbalance High Output Troubleshooting

Fault condition

E65LE65L

LEFT/RIGHT TRACTION MOTOR ARMATURE CURRENT NOT PRESENT

E65RE65R

CriteriaResulting Effect

TRACTION system shutdown. Will not pass
POST.

PERFORM OUTPUT TEST 17 or 18 - TRACTION MOTOR FIELD & ARMATURE CURRENT. Should
see Field amps 25-36 and armature amps 40-70 with truck jacked up. Test both forward and reverse.
Left and right field current should not differ by more than 5 amps.

Open armature fuse (400 Amp).

amplifier to traction motor.

Bad traction motor (open winding).

The system controller detects no current to the
traction motor armature when there should be.

SolutionPossible Cause

Replace fuse.
Check cables, repair or replace.Broken or loose A1 or A2 cable from traction

Test diode and replace if necessary.Diode failure.
Replace traction amplifier.Bad traction amplifier.
Stone the commutator, clean or replace brushes;

replace traction motor if necessary.

E69E69

while operating truck.

E70E70

while operating truck.

Bad amplifier.

SYSTEM CONTROL +5 VOLTAGE OUT OF RANGE

SYSTEM CONTROL +15 VOLTAGE OUT OF RANGE

Fault condition

CriteriaResulting Effect

The internal 5V power supply is out of range.TOTAL shutdown.

SolutionPossible Cause

Test battery under load and replace if necessary.Battery voltage too low, especially if error occurs

Replace system controller field fix.Damaged or defective system controller.

Fault condition

CriteriaResulting Effect

The internal 15V power supply is out of range.TOTAL shutdown.

SolutionPossible Cause

Test battery under load and replace if necessary.Battery voltage too low, especially if error occurs

Locate and eliminate any shorts to chassis.Electrical shorts to chassis.
Disconnect amplifier harnesses one at a time until

fault changes. (Turn truck off while unplugging
harnesses)

Replace system controller field fix.Bad system controller.

REV 12/5/99

TS.14

E77E77

E78AE78A

E78DE78D

Electric Counterbalance High Output Troubleshooting

E72LE72L

LEFT/RIGHT TRACTION CONTROL +15 VOLTAGE OUT OF RANGE

E72RE72R

TOTAL shutdown.

while operating truck.

amplifier harnesses and see if fault follows.
Bad amplifier harness.

Bad system controller.

SYSTEM CONTROL HARDWARE FAILURE

Fault condition

CriteriaResulting Effect

SolutionPossible Cause

Test battery under load and replace if necessary.Battery voltage too low, especially if error occurs

Replace traction amplifier.Bad traction amplifier. To check, switch

Check amplifier harness for shorts or broken wires
and replace if necessary.

Test by swapping left and right amplifier harness
connections. Replace system controller field fix.

Fault condition

CriteriaResulting Effect

A/D chip failure.TOTAL shutdown.

SolutionPossible Cause

Replace system controller field fix.Bad system controller.

TOTAL shutdown.

TOTAL shutdown.

Fault condition

SYSTEM CONTROL SOFTWARE FAILURE

CriteriaResulting Effect

SolutionPossible Cause

Replace software board.Software corrupted in memory.

Fault condition

DISPLAY CONFIGURATION DATA LOST

CriteriaResulting Effect

SolutionPossible Cause

Replace operator display board.Bad operator display board.

REV 12/5/99

TS.15

E79cE79c

E81E81

TOTAL shutdown.

E79dE79d

TOTAL shutdown.

E80E80

LOLO

Electric Counterbalance High Output Troubleshooting

Fault condition

SYSTEM CONTROL CONFIGURATION ERROR

CriteriaResulting Effect

SolutionPossible Cause

Replace system controller field fix.Bad system controller.

Fault condition

DISPLAY CONFIGURATION FAILURE

CriteriaResulting Effect

SolutionPossible Cause

Replace display board.Bad operator display board.

Fault condition

LIFT CUTOUT DUE TO LOW BATTERY STATE OF CHARGE

BATTBATT

LIFT system, except lower, shutdown.

EACH BUTTON STUCK

LIFT system, except lower, shutdown.

tilt/sideshift disk at once or too fast.

in control handle.

CriteriaResulting Effect

The battery state of charge (BSOC) reading has
reached the programmed limit.

SolutionPossible Cause

Replace with fully charged battery.Discharged battery.

Fault condition

CriteriaResulting Effect

Both tilt switches or both sideshift switches closed
at the same time.

SolutionPossible Cause

Cycle keyswitch.Operator pressing opposite sides of the

Disassemble and clean.Foreign material in keypad switch.
Replace upper control handle.Damaged or defective keypad switch and/or pcb

Replace upper control handle.Wires shorted in control handle harness.

REV 12/5/99

TS.16

E99E99

Electric Counterbalance High Output Troubleshooting

E82E82

POST will not continue.

E89LE89L

ENGAGE BRAKE TO CONTINUE POST

LEFT/RIGHT AMP HARDWARE FAILURE

E89rE89r

TOTAL SYSTEM shutdown and open MAIN
POWER CONTACTOR.

while operating truck.

Fault condition

CriteriaResulting Effect

The brake pedal is depressed during the Power On
Self-Test (POST).

SolutionPossible Cause

Raise brake pedal.Brake pedal is depressed during POST.
Replace brake limit switch.Bad brake limit switch.

Fault condition

CriteriaResulting Effect

SolutionPossible Cause

Test battery under load and replace if necessary.Battery voltage too low, especially if error occurs

Replace amplifier.Bad traction amplifier.

LOST ERROR HISTORY

Display message (only in error history).

Operator display was replaced, or error history
was reset by factory.

Fault condition

CriteriaResulting Effect

SolutionPossible Cause

No action necessary. This error code for
information only.

REV 12/5/99

TS.17