Schaeff Echo 3000 User manual

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
ElectricCounterbalance High Output Frame
04/05/00 1.i
TABLE OF CONTENTS

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.
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.
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.
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.
2.Do not let the overhead guard legs swing and
damage components of the truck. Slowly
lower the overhead guard so that the
ElectricCounterbalance High Output Frame
REV W1 11/02/99 1.1
FIGURE 1.2 - Placement of Battery Rollers
1 Shaft
2 O-Ring
3 Roller
4 Bushing
5 Flat Washer
FIGURE 1.1 - Disassembly of Battery Rollers

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.
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.
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 7frame
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.
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.
ElectricCounterbalance High Output Frame
REV W1 11/02/99 1.2

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.
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
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.
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.
ElectricCounterbalance High Output Frame
REV W1 11/02/99 1.3

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.
ElectricCounterbalance High Output Frame
REV W1 11/02/99 1.4

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
ElectricCounterbalance High Output Drive
04/05/00 2.i
TABLE OF CONTENTS

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.
ElectricCounterbalance High Output Drive
12/20/99 2.1
FIGURE 2.1 - DRIVE UNIT

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.
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).
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.
ElectricCounterbalance High Output Drive
12/20/99 2.2

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
wwReplace all the brushes in one motor as a
set.
wwUnits 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.
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.
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 endbellhousing 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.
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.
ElectricCounterbalance High Output Drive
12/20/99 2.3
FIGURE 2.2 - BRUSH ORIENTATION
CORRECT INCORRECT
COMMUTATOR
FIGURE 2.3 - GEARBOX

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.
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-ringseal can
be inspected or replaced. Remove the v-ring,
ElectricCounterbalance High Output Drive
12/20/99 2.4
15 V-Ring Seal
16 Bearing
17 Tab Lock Washer
18 Lock Nut
19 Wheel Cover
20 Screw
FIGURE 2.4 - DRIVE WHEEL INSTALLATION