6847 PDF

TECHNICAL COMMUNICATORS TELECONFERENCE NOTES
September 2006—Revised
INSIDE THIS ISSUE Enclosed are the notes from the Technical
S15G Electronic Control Unit (ECU) 2
Communicators Teleconference Call from September
2006. The Service Engineering group truly appreciate
Sample Readings V259 Picture 01 & Picture 02 3 you taking time out of your busy schedule to partici-
Sample Readings V259 Picture 03 4 pate in this valuable call.
LP Mixer Tier II (EPA) 5
K21/K25 200 Hour Service 6 Several items:
Steer Wheel Hubs 7
1.) We have received information from our transmis-
Large Cushion Truck Radiator Failure Update 8
sion vendor that there are a very limited number of
Serpentine Belt Squeal on the GM 4.3L Engines 9 small IC cushion trucks that will experience a failure of
Serpentine Belt Squeal (cont) 10 the reverse clutch drum. The failure is due to a miss-
ing weld and will occur in less than 200 hours of opera-
TB45 Starter Failure 11 tion. The symptom will be no reverse direction. Please
Delay in Transmission Engagement 12 contact us if you experience one of these failures.
Limit Settings Update 13
EE Settings 14 2.) We are in the process of planning the 2007 TC
Conference. It will be held in Houston in early April.
Code 61 15
More information will be forthcoming . We just want
Reman Controllers 16 you to know so that you can budget accordingly.
Slow Ramp Speed 17
AC3 Controller 18 Please make sure that the following date is marked on
your calendar . The next scheduled TC Teleconference
Code 56 19
Call is scheduled for:
Error Code 016 & E014 20
Vehicle Function Card (VFC) 21 December 6, 2006

Hose Roller Kit 22
Service Manuals for AC Truck 23 Additional information will be sent to you regarding the
topics and contact information as we get closer to this
Miscellaneous Q & A 24
date.
Update Information Form 27
Technical Communicators Teleconference Notes
S15G Electronic Control Unit (ECU)
Reference: TN06-0901
Service Engineer: Lynn Fite
Models:
GC15K-GC30K, GP15K-GP35K TIER I (CARB)
FGC15K-FGC30K, FG15K-FG35K TIER I (CARB)
Problem:
Replacement ECU’s with a vendor model number FCR-1-xxx perform differently than the original S15G
ECU. The symptoms may include a start up idle RPM of less than 500 RPM or a sudden RPM increase.
Cause:
The supplier’s first FCR-1-xxx ECU’s did not adequately control the S15G fuel system.
Solution:
The supplier developed a more robust ECU that replaces the MAP sensor with an actuator
current feedback sensing circuit. This sensing circuit now controls DWELL. The brass nipple is provided
to allow the technician a common point to plug the vacuum line.
MCFA diagnostic software will connect to and read the new ECU’s.
Part Number (s):

91165-15800 ECU FCR---- V257 or higher
Page 2
Sample readings V259: Actual readings may vary.
Picture 01
Picture 02
Idle speed
normal
Page 3
Sample readings V259: Actual readings may vary.
Picture 03
High speed
normal
New S15G ECU and original
ECU 20-FCR-10, S/N: 1123, ECU S15G 2-N039-002

Blocked vacuum port. Active vacuum port.
Page 4
LP Mixer TIER II (EPA)
Models:
GC15K-GC30K TIER II (EPA)
FGC15K-FGC30K TIER II (EPA)
Problem:
Technician’s are installing the SE000071 S15G LP mixer diaphram in TIER II LP mixers. In
addition, the published part numbers for the Pressure Trim Valve (PTV) and the Fuel Trim Valve (FTV)
are incorrect.
Cause:
The SE000071 LP mixer diaphram is designed for the S15G fuel system and is not compatible with
other systems. EPA TIER II certification does not allow the LP mixer or the LP regulator to be rebuilt.
Solution:
Replace the EPA TIER II mixer as a complete assembly.
Part Numbers:
91165-07500 LP Mixer, TIER II (EPA)
93820-04100 Fuel Trim Valve, FTV: V3-30270-277
93820-03600 Pressure Trim Valve, PTV: V3-30272-279
Page 5
K21/K25 200 Hour Service
Models:
C3000-C6500, P3000-P7000
FGC15N-FGC33N, FG15N-FG35N
Problem:
K21/K25 engine break-in and first service procedures are not clearly understood.
Cause:
The O&M guide has a separate page on the first service steps as well as the maintenance chart in
the service manual.
Solution:
The K21/K25 engine has mechanical valve lifters and an aluminum cylinder head.
The first engine service is due after 200 hours of operation. This service consists of:
Torque the cylinder head bolts.
Adjust the intake and exhaust valves.
Change the engine oil and oil filter.
Change the hydraulic return filter.
Lubricating the king pins and tie rod pins.
Cylinder head bolt torque: See engine service manual page EM-12.
a.) 14.5-17.5 ft lb (19.6-23.52 N-m)
b.) 50.76 ft lb (68.6 N-m)
c.) Loosen to zero
d.) 14.5-17.4 ft lb (19.6-23.52 N-m)
e.) Rotate bolt 90-92 degrees
Intake and exhaust valve clearance (hot): 0.38mm
Part Numbers:
91H20-01870 Engine oil filter
91375-23600 Hydraulic return filter
Page 6
Steer Wheel Hubs
Models:
P3000-P7000
FG15N-FG35N
Problem:
Rims with solid pneumatic tires installed may crack around the lug nuts holes.
Cause:
An impact tool or incorrect torque was applied to the lug nut during rim installation. Service
Engineering conducted a rim/lug nut test on 5 lift trucks: 2 in general warehousing,
2 in cotton warehousing, and one in a brick plant. Although other lift trucks at the test site failed
rims (not installed by Service Engineering), there are no reported failures of the rims or lug nuts
when installed with hand tools.
Solution:
Install solid pneumatic rims using hand tools and torque to:
1-2 compact Front 116 ft lb (157 Nm)

Rear 116 ft lb (157 Nm)
2-3T Front 278 ft lb (378 Nm)

3.5T Front 275 ft lb (378 Nm)

Page 7
Large Cushion Truck Radiator Failure Update
Service Engineer: Henry Glover
Models:
GC35k, GC40K, (STR) (SWB), GC45K, GC55K (STR), GC60K, GC70K, (STR)
FGC35K, FGC40K (STC) (KC), FGC45K, FGC55K (STC), FGC60K, (STC)
Problem:
Radiator leaks at top and bottom tank seams.
Cause:
There have been several issues with the frame bulkhead flatness, radiator mounts and
radiator construction that can cause the tank seams to leak.
Solution:
All the issues listed above have been corrected in production some time ago with the last issue being
the radiator construction. The new radiator with the heavier header plates and reinforcement baffle
welded into the upper and lower tanks was put into production on 8/25/06. This is the radiator that
we discussed at the last conference call.
Before this new radiator was developed and released, Service Engineering was instructing dealer to
remove the older radiator and have them repaired locally until the new radiator became available.
The new radiator is now available from spare parts. If you experience a failure within the warranty
period, please DO NOT locally repair the radiator. IF you have a radiator leaking at the upper or lower
tank seam on the previous radiator (93701-40100) within the warranty period, MCFA will no longer
cover local radiator repairs. You must replace the radiator with the new one listed below.
Part Number:
New radiator part number: 93701-50100
Page 8
Serpentine Belt Squeal on GM 4.3L Engines
Models:
GC35K, GC40K (STR) (SWB), GC45K, GC55K (STR), GC60K, GC70K, (STR)
FGC35K, FGC40K, (STC) (KC), FGC45K, FGC55K (STC), FGC60K, FGC70K, (STC)
Problem:
The serpentine belt on the GM 4.3L continues to squeal or the squeal returns shortly after
changing the belt.
Cause:
The root cause may be a bent crankshaft pulley. The crankshaft pulley is being bent from the hub
retaining bolts used to mount the hydraulic pump driveshaft mounting plate to the front of the
engine. Also, check for proper belt and pulley alignments.
Crankshaft pulley
Hydraulic pump driveshaft

mounting plate
Page 9
Solution:
Replace the serpentine crankshaft pulley and make the following modifications:
1: Remove the hydraulic pump driveshaft and serpentine belt.
2: Remove the outer hub plate retaining bolts.
3: Remove the inner hub retaining bolts to replace the crankshaft pulley.
4: Before installing the outer hub plate, you will need to shorten the bolts. Install a nut on each bolt
then use a grinder to remove 2mm from the tip of each bolt. Remove the nuts before installing the
outer hub retaining bolts.
5: Install the outer hub plate and driveshaft. Torque all bolts per service manual specification.
Part Number:
Crankshaft Pulley: 93720-07900
Outer Hub Inner Hub

Retaining Bolts Retaining Bolts
Page 10
TB45 Starter Failures
Models:
GP40K, GP40KL, GP45K, GP50K
FG40K, FG40KL, FG45K, FG50K
Problem:
Premature starter motor and ring gear failures on TB45 engines.
Cause: Service Engineering is investigating a volt drop to the starter solenoid circuit during cranking.
Solution:
The failure is under investigation at this time. Service Engineering is looking for applications that
have failed the TB45 starter and/or ring gear multiple times or at low service hours in order to try a
modification to increase the starting amps and voltage.
If you have a potential application, please submit a HEAT ticket and Service Engineering will provide
the information to you and will set the truck up as a field follow unit.
Part Numbers:
Contact Service Engineering
Page 11
Delay in Transmission Engagement
Models:
GP40K, GP40KL, GP45K, GP50K, DP40K, DPL40K, DP45K, DP50K GC35K, GC40K (STR) (SWB),
GC45K, GC55K (STR), GC60K, GC70K (STR).
FG40K, FG40KL, FG45K, FD40K, FD40KL, FD45K, FD50K FG50K, FGC35K, FGC40K (STC) (KC),
FGC45K, FGC55K (STC), FGC60K, FGC70K (STC)
Problem:
Delay in transmission engagement or a delay going into second speed.
Cause:
Service Engineering is continuing the investigation into the possible cause(s).
One of the areas we are currently looking at is leakage under the control valve due to a tolerance
stack up between the main control valve and sub-plate.
Solution:
Service Engineering is looking for one speed and/or two speed transmissions that have a delay in
engagement in order to test a new control valve gasket.
If you have a customer with a delay problem, please take all pressure readings and the delay time
then report this information via the HEAT system.
Part Numbers:
Contact Service Engineering
Page 12
Limit Settings Update
Service Engineer: Bill Fussell
Model:
FBC15N-FBC30LN
E3000-E6500
Problem:
Limit Settings Update
Cause:
The speed limit option settings are not active within the logic software. The result is that you can not
have additional speed limit settings that may be required for your customers application.
Solution:
The internal logic software must be changed in order to add the speed limit options to the truck. The
Design Change Proposal (DCP) has been written and filed with Design Engineering. The development
of new logic software has started and the initial version is currently in the testing phase.
In applications that demand that the speeds be limited, we can offer new software that enables
Options 11,12 and 13 which can lock the speed of the truck to the speed you set.
Part Number (s):

NA– Card Assembly, Logic
Notes: At this time the logic card must be removed and returned to MCFA to be programmed with the
speed lock software. It is our goal in the near future to be able to download and install this upgrade at
The dealership level with Diagnozer or Up-Time program tool.
One of our dealers has reported that it is possible to lock the Mode buttons with 1/2 inch E clip/snap-
ring or even an o-ring. This would prevent operators from changing the models and defaulting the
settings.
Page 13
EE Settings Update
Models:
FBC15N-FBC30LN
E3000-E6500
Problem:
Type EE Settings update, truck not operating in EE Economy Mode “C”.
Cause:
When a truck is programmed to UL type EE truck parameters, the modes should not be changeable.
We have had two reports that the modes would change when the truck type was set to EE. We have
not been able to verify this problem and in our testing here all trucks did lock the mode to “C”.
Economy when set to EE type truck (option #40).
Solution:
If modes can be changed when the truck is in the EE setting, it will be necessary to disable the right
Mode button by removing the button wire to prevent an operator from changing to an incorrect mode. If
this is not an acceptable method to keep the speeds reduced, we have an optional software package
that allows you to lock the speed of the truck, the modes would still be changeable and the
speed would be limited in all modes.
Part Number (s):

The method of getting different software is to open a HEAT ticket and then
arrange to send your logic cards in for programming.
Notes:
If an EE truck is not kept in Economy Mode “C” with reduced speeds, an overheating
condition could occur.
Page 14
Code 61
Models:
FBC15N-FBC30LN
E3000-E6500
Problem:
Code 61 after installing a new logic
Cause:
Code 61 means that the group three options have not been set correctly. Also a code 61 and code 34
can indicate a failed traction or failed pump controller.
Solution:
For Code 61, set group three options with the Diagnozer or Up-Time software tool.
For code 61 and code 34, following the troubleshooting guide in the service manual leads you to
Group three set up and then to replace the logic. You should remove the cover on the inverters and
visually inspect the inverter for any failed internal components and also for any arcing at motor
terminal connections. Also test the inverters by using the ohm test called out in the service manual.
Part Number (s):

16A68—11320 cable assy.
16A68—00018 cable cover kit, (modification)
Notes:
Please enter HEAT tickets on any unusual failure that is not consistent with the troubleshooting
guides in the service manual.
Page 15
Reman Controllers
Model:
EC15K-EC30K, FBC15K-FBC30K
Problem:
Installed a new or remanufactured controller and now the truck move very slow or not at all.
Cause:
Controller is set up incorrectly.
Solution:
All controllers, both new and remanufactured, have the brake switch option software installed in
them and require different setting and a jumper wire to operate at 100% Armature on-time. Set
function # 11 to 255 and add a jumper wire from positive at the line contactor control wires to P1-12
at the controller.
Part Number (s):

SE000103 - pin connector
Notes:
Please provide this info. to all your technicians due to repeated calls from the field on this problem.
Page 16
Slow Ramp Speed
Model:
FBC15N-FBC30LN
E3000-E6500
Problem:
Slow Ramp Speed Complaint from the customer.
Cause:
The truck logic and controller were designed to provide maximum battery life and are set to a cut
back the amperage when going up ramps. This design limits the speed to about two miles per hour
when going up most ramps.
Solution:
A design change was written and new software is currently being field tested with great success.
If you have an application that demands a faster speed when climbing a ramp, you should advise
the customer that the battery run time may be reduced. If it is determined that a software change
is necessary, open a HEAT ticket and include the customer name, grade of the ramp and additional
information about the application.
Note:
This software is only installed at MCFA and can not be done at the dealership or customer.
Page 17
AC3 Controller
Service Engineer: Peter Kruliczek
Models:
36V Trucks Only
ND3000P, NR400P, & NR4500P
EDR15HN, ESR20HN, & ESR23HN
Problem:
When an AC3 pump controller is replaced in a high performance truck, the truck will not
function.
Solution:
The AC3 controller must be set up as the slave. Use the handset or the PC program with an 8-pin
connector adapter cable to plug directly into the AC3 controller. In the controller, go to Special
Adjustments, find the parameter NODE INDEX and set it to 1.
This only applies to high performance trucks with 2 pump controllers. The AC2 will be the primary
and the AC3 will be the slave.
Part Number (s):

RL462069AC3 - pump controller
RL473177 - 8-pin connector adapter cable
Note:
Node Index parameter setting is “0” for standard performance (default)
Node Index parameter setting is “1” for high performance
In addition, when replacing the SICOS make sure to turn on parameter “AUX Function 1” under Set
Options menu to enable 2nd pump for high performance trucks.
Page 18
Code 56
Models:
24V & 36V Trucks
NS3000-NS4000, NR3000-NR4500P, ND2500-ND-3000P
ESS15N-ESS20N, ESR15N-ESR23N, EDR13N-EDR15N
Problem:
Adjustment of the Operator Presence may cause switch failures.
Solution:
When a code 56 appears, in most cases, it is caused by a misadjusted operator presence switch.
When making the adjustment, check for over travel of the switch plunger. There have been reports
of switch plungers sticking due to over travel.
Part Number (s):

RK468076 (3A) - Operator Presence Switch
RL468077 (5A) - Operator Presence Switch
Page 19
Error Code C016 & E014
Models:
WP6000
PMW30N
Problem:
Error code C016 E014, no travel.
Solution:
In most cases this has been found to be a failed hand controller.
Part Number (s):

Standard: W205010498—new
W205010139—reman
Cold Storage: W205010500—new

W205010140—reman
Page 20
Vehicle Function Card (VFC)
Models:
NOR30 & NOR30P serial number range 1200 to 1999
Problem:
The Vehicle Function Card (VFC) for this serial number range will not be available in the near future.
The logic circuits that are used on the VFC card are no longer in production.
Solution:
Presently there is a good stock available of these VFC cards. The trucks within the 1200 to 1999 se-
rial number range will then have to be modified to accept the Vehicle Managers presently used on
trucks with serial number above 2000. A PSB will be provided to dealers when the modification kit
becomes available to Service Engineering.
Part Number (s):

NA012230—Vehicle Function Card
Service Manual Correction—Orderpicker Potentiometer Voltage Setting
Models:
NOR30 & NOR30P
Notes:
Please revise service manuals # SENB8548 and SENB2735 with the following information.
The neutral position voltage under the A4 test, Lift Lower Pot voltage, should read 2.4-2.6 volts. This
value holds true for all truck serial numbers.
Part Number (s):

NA014981 Lift/Lower Potentiometer
Page 21
Hose Roller Kit
Models:
NS3000-NS4000, NR3000-NR4500P, ND2500-ND3000P
Problem:
Premature deep reach pantograph hose failure due to rubbing on guide pins.
Solution:
Deep reach hose rollers are available to prevent rubbing against the guide pins. Install the rollers to
each guide pin by first cleaning the off all paint and dirt from the pins, apply grease, and install the
washer followed by the roller.
Part Number (s):

RT00294089—Hose Roller Kit
Notes:
Each kit number includes 1 hose roller and 1 washer. Please order 1 kit per guide pin,
4 required.
Service Manual Correction—SUEC Contactor Coils
Models:
EC15KS-EC25KS
FBC15KS-FBC25KS
Notes:
There are four contactor coil resistances incorrectly specified in the service manual as having values
between 93 and 103 ohms. The correct values are 32 ohms +/- 4ohms on page 7-63.
Service Manuals Pub Numbers:

Caterpillar - SENB2740
Mitsubishi - WENB2740
Page 22
Service Manuals for AC Trucks
Models:
NS3000-NS4000, NR3000-NR4500P, ND2500-ND3000P
Notes:
New Service Manuals are available for the AC Reach Truck
Caterpillar— SENB 2900-02
Mitsubishi— WENB 2900-02
Includes:
Default parameters for all versions of controllers
Software/Handset instructions
Keyless Option Programming Instructions
Reach Cylinder Adjustments
Aux. Flushing Procedure
Field Replacement of Triline hose instructions
Coil Resistance checks for troubleshooting code 57
Added additional alarm codes
Better illustrations
Page 23
Miscellaneous Topics
John Jones
New Radiator Large Cushion
Question:
Under warranty we are to install the new part number radiator. What should we do for the trucks
outside of warranty?
Answer:
Well the new radiator can be installed in a truck that is out of standard warranty. You can still repair it
locally If you’d like. But for trucks under warranty that experience the failure we want the new radiator
put in.
Kevin Al-Molky
TN06-0911
Question:
Did you say in regards to 0911 that if there is an adjustment made to inform the customer about the
ramp speed.
Answer:
If you have a customer complaining about the ramp speed be sure to inform them that if you increase
the ramp speed it will reduce the battery run time.
Question:
It’s not so much that it is going to affect any heat build up?
Answer:
No, we have not had any problems like that at this point but we have had good success increasing the
speeds going up the ramp.
Page 24
Kevin Al-Molky
Question:
This question is in regards to the S15G fuel system and also Tier II IMPCO system. My question has to
do with the female to female adapter gray adapter cord. Do you know if that cord is a non
motive cord or a standard DB9 straight through cord? I have run into some issues here with these
female to female cords. What I found is that I can get them to work on Tier I but when you put them on
the Tier II, they will not communicate.
Answer:
I have heard of this before so there is likely a difference in the pin connections of the two RS232
cables. This is an important item since the cables externally look the same. If you have a technician
that calls you and is having a communication issue between the laptop and the truck, this is
something to ask them about.
Response:
And although they look the same that’s the difference between them on the standard cable pin 1 lines
up with pin 1 on both ends. On the non-modem the pin numbers do switch from one end of the cable
to the other so Pin 1 may be Pin 9 on the other end of the cable.
Mike Manus
Serpentine Belt Squeal on GM 4.3L Engine
Comment (s):
I wanted to just make a comment on the serpentine belt squeal on the GM 4.3L. We had four trucks
that shipped into our area and one of the early trucks had a really annoying belt squeal while the rest
of them did not. We tried different belts and I did file a HEAT ticket on it and what we found is that the
alternator and the idler pulley below the alternator was totally out of misalignment and it was bent
from like when it was installed at the factory and that’s what was causing the squeal. We didn't have
any problems with it after we realigned the pulleys up and you can see it when you looked directly
down on it you can see the alternator pulley and there is a small pulley below it I believe and its
not tracking properly and that’s what was causing the squeal.
Page 25
Kevin Al-Molky
TN06-0901
Question:
You said that we were going to see changes in the dwell, the actuator and the 02 readings?
Answer:
Correct.
Question:
And you said the dwell readings we will typically see will be between 80 and 101%?
Answer:
Correct 101. They are fine to run at that because dwell use to be the on time for the fuel control
solenoid which is vacuum activated. Now that we’ve taken away the vacuum activation fuel control
Solenoid it is basically controlled from the rhythmic table contained in the firmware in the ECU so its
very accurate so we don’t use dwell vacuum which is why we left the nipple plugged on the ECU cause
you got to have some place to stick that line that we don’t need anymore. I’ve tested some that came
back from the dealers. My dwell always stayed at 101 when at idle rpm but the magic thing is the oxy
gen sensor voltage stays between .62 and .81 all the time so it is a fine line. You know we use to see
oxygen sensor voltage go to .99 or drop off to 0, then you get your 02 light. Well, since we have that
feedback sensing circuit now, this condition is virtually eliminated.
Page 26
If you are a new Technical Communicator

and you are not receiving TC mail to your
attention, please complete this form and fax it to:
(713) 365-1655
**Please Print**
YOUR NAME: YOUR E-MAIL
____________________________ ______________________________
DEALERSHIP NAME:
_______________________________________
MAILING ADDRESS:
_______________________________________
_______________________________________
_______________________________________
PHONE NUMBER: _______________________
FAX NUMBER: __________________________
BRANCHES YOU COVER:
_________________________________________________________________________
Page 27

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TECHNICAL COMMUNICATORS TELECONFERENCE NOTES

Vehicle Function Card (VFC) 21 December 6, 2006

S15G Electronic Control Unit (ECU)

Part Number (s):

Sample readings V259: Actual readings may vary.

Sample readings V259: Actual readings may vary.

New S15G ECU and original

ECU 20-FCR-10, S/N: 1123, ECU S15G 2-N039-002

LP Mixer TIER II (EPA)

K21/K25 200 Hour Service

Intake and exhaust valve clearance (hot): 0.38mm

Steer Wheel Hubs

1-2 compact Front 116 ft lb (157 Nm)

2-3T Front 278 ft lb (378 Nm)

3.5T Front 275 ft lb (378 Nm)

Large Cushion Truck Radiator Failure Update

Serpentine Belt Squeal on GM 4.3L Engines

Hydraulic pump driveshaft

Outer Hub Inner Hub

TB45 Starter Failures

Delay in Transmission Engagement

Limit Settings Update

Part Number (s):

Part Number (s):

Part Number (s):

Part Number (s):

Slow Ramp Speed

Part Number (s):

Part Number (s):

Error Code C016 & E014

Part Number (s):

Cold Storage: W205010500—new

Vehicle Function Card (VFC)

Part Number (s):

Service Manual Correction—Orderpicker Potentiometer Voltage Setting

Part Number (s):

Hose Roller Kit

Part Number (s):

Service Manual Correction—SUEC Contactor Coils

Service Manuals Pub Numbers:

Service Manuals for AC Trucks

If you are a new Technical Communicator

YOUR NAME: YOUR E-MAIL

PHONE NUMBER: _______________________

FAX NUMBER: __________________________

BRANCHES YOU COVER:

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