MCFA Document # 000050-08C

Issue Date 06/16/2008

®
Lift
Trucks

TITLE: Cat® Lift Trucks June 2008 Technical Communicator Webcast Presentation

MODEL AND SERIAL NUMBER:

N/A

SUBJECT: To download a copy of the webcast presentation from the June 12, 2008 TC Webcast copy
and paste this link: http://download.mcfa.com/. You will need to use your HSS (HEAT Self
Service) login and password to access the site. The presentation is located in the Diagnostics
Software section.

CAUSE: N/A

The information provided on this web site is considered to be confidential information and is intended to assist you in resolving product issues. In addition, the information
on this web site is not to be considered as an authorization for any financial claim against MCFA.
Always follow all Safety, Warning, Caution and Precaution information that is provided in the appropriate Service Manual and Operation and Maintenance Manual(s).

RESOLUTION
Items in the presentation with a solution are already installed in the HEAT® Plus Knowledge (HPK)
database. Refer to those documents for the most up to date information on that topic. This
presentation material will not be updated.
 2008 Technical Communicator
Teleconference (via webex)-June

Welcome to the June 12th

TC Teleconference / Webcast!
 A Few Quick Items….
Service Engineering Reorganization

• Ada Ekhaese, Service Manager, IC Products is no longer working at MCFA.

• Brian Rose assumes a dual role as the Interim, Service Manager, IC Products until a

replacement is named.

• Marc Gonzales, Service Engineer, Electric Products, moved to the MCFA CSM

group; a replacement will be named at a later date.

• Chad Munger joins Service Engineering working with Troy Martin on the Warehouse

products.

• Steven Devecchio, Lone Star Lift, will be joining Service Engineering working with

Steve Logsdon on the Small IC products.

 A Few Quick Items….
2008 Technical Communicator Conference

• Plans have been finalized for this year’s TC Conference. It will be held August 5th – 7th, in

Houston, at the InterContinental Hotel.

• Technical Communicators are required to bring their laptops with them for the meetings,

as this year’s conference notes will be handed out in Portable USB Flash drives on the day

of registration.

• Registration and important meeting details can be found in the information letter on the

respective CAT® & Mitsubishi dealer portals by searching “2008 Technical”.

• Your registration must be received no later than July 7, 2008. Due to other events in the

area, we urge you to register by June 30, 2008 to guarantee hotel availability.

We have a lot of information to share with you today, so let’s get started with Steve Logsdon of
the Small IC team.
2008 Technical Communicator
Teleconference-June

Steve Logsdon
Small IC Products
 Cracking Torque Converter Flex-plates or Leaking Torque
Converter Seal leaks on P3000 - P70001-D and the
FG15N - FD35N1 Pneumatic Transmissions Trucks

Models:
P30001 – P70001, P40001-D – P70001-D
FGC15N1 – FGC33N1, FG15N1 – FG35N1, FD20N1 – FD35N1

Problem:
The main cause of cracking torque convertor flex-plates or torque converter seal leak in the powershift
transmissions.

Cause / Discussion:
The flex - plate cracking or toque converter seal leaks will occur when the two dowel pins from the bell
housing to the engine adaptor plate are missing. When the transmissions are removed and replaced
with a remanufactured or new transmission assembly the dowel pins have not been transferred from
the problem transmission to the replacement transmission.

This will cause axial loading of the torque converter pilot stub and pump drive stub of the torque
converter. Side loading of the pump gear, bushing and seal causes premature wear.
The flex - plate cracks from reverse bending fatigue. Torque converter pilot stub can break off.

Solution:
Be sure to transfer the two dowel pins from the old transmission bell housing and onto the new
transmission bell housing to be able to keep a critical alignment.

If the dowel pins are missing or damaged, replace them with dowel pin P/N - F2846-12000, Qty.2
required.

1
Developed a leaking
torque converter seal
 Pilot stub shaft is broken off

Cracks have developed

Both dowel pins are missing. This
causes mis-alignment.
 New Control Power Relay (P/N 91A04-11700) for the
C3000 - C65001 and P3000 - P70001-D, and the
FGC15N1 - FGC33N1 and FG15N1 - FD35N1 Trucks
Models:
C30001 – C65001, P30001 – P70001, P40001-D – P70001-D
FGC15N1 – FGC33N1, FG15N1 – FG35N1, FD20N1 – FD35N1

Problem:
Availability of a an improved power relay (P/N 91A04-11700) and description of the improvement. This
article covers all serial number ranges for the listed serial number prefix's.

Cause / Discussion:
The current power relay used in the electronic controlled gasoline/LPG trucks generates gases when
heated during it's duty cycle. This creates early failures due to contamination of the contact tips.

Solution:
This is a further improvement of reliability. The previous change was made to the relay box, providing
a vent in order to release gas generated inside the relay. The new relay is now made with gasless
wire. This will eliminate contamination failures.

The new relay P/N 91A04-11700 is currently in stock and available for purchase.

Previous part no. 91A05 - 01800 Color: Black

Current part no. 91A04 - 01700 Color: Green
New part no. 91A04 - 11700 Color: Green

Coil specification: (CURRENT) (NEW)

Paraffin wire Gasless wire
Flux-tight Plaseal

Sealing method: (perforated type) (sealed type)

Identification: Part number is located on the top of relay body

1
 NEW CURRENT
Interchange-
Ref. No. Parts name
ability
Part No. Qt. Part No. Qt.

1 BOX ASSY, RELAY 91A05-31070 1 3 91A05-21073 1

2 RELAY 91A04-11700 5 3 91A04-01700 5

3 BASE 91A05-21081 1 — 91A05-21081 1

4 CASE ASSY 91A05-02071 1 — 91A05-02071 1

 Corrosion of Terminals at Diagnostic Connectors in 2007
and 2008 Wiring Harnesses for the C30001 - C65001 and
P30001 - P70001-D and the FGC15N1 - FGC33N1 and
FG15N1 - FD35N1 Trucks
Models:
C30001 – C65001, P30001 – P70001, P40001-D – P70001-D
FGC15N1 – FGC33N1, FG15N1 – FG35N1, FD20N1 – FD35N1

Problem:
There has been a limited number of reports of corrosion of the terminals at the diagnostic connector on
build year 2007 and 2008 wiring harnesses on the listed model numbers. This article will detail how to
reduce or eliminate corrosion of the two diagnostic connector terminals.

Cause / Discussion:
For convenience a round utility holder (somewhat known in the field as a cup holder) was added to the
right side dashboard plastic covers. To allow for spillage or water accumulation a drain hole was placed
in the bottom of this holder. The hole allows for drainage. The liquids when draining drip onto the
harness branch below and travels along the harness and collects in the diagnostic connectors that
have been covered with a rubber cover attached to the harness. With the connectors placed upside
down the covers can collect liquid and corrode the terminals

Usual codes associated are communication codes E03,E04,F03,F04,F07,P03,P04,P07.

Solution:
Remove rubber cover. Clean the pins in the connectors with terminal cleaner kit P/N SE000003. Clean
and then dry completely. Add a LIGHT coat of die-electric grease to the connector pins. Wipe off
excess grease. Re-install the rubber cover.

NOTE: This is a case where too much grease is not good.

Move the harness branch away from the drain hole. Position the diagnostic connectors with the rubber
cover facing up.

1
2008 Technical Communicator
Teleconference-June

Henry Glover
Large IC Products
 Diagnostic Trouble Code (DTC) 2121 FPP1. Lower than
FPP2 (update) for the GC35K – GC70K-STR and the
FGC35K – FGC70K-STR Trucks

Models:
GC35K – GC70K-STR
FGC35K – FGC70K-STR

Problem:
DCT-2121 (FPP1 Lower then FPP2)

Cause / Discussion:
DTC- 2121 will set if FPP1 voltage is 20% or greater then FPP2 voltage. The MIL light will illuminate
and reduce engine RPM’s to idle until the problem is corrected.

Tolerance issue between the ECM and foot pedal sensor is causing this diagnostic code to set shortly
after delivering the unit.

Solution:
Field fix: Order and install the following jumper harness in between the foot pedal sensor and wiring
harness connected to the foot pedal sensor. See attached installation instructions.

A PSB will be released shortly with detailed warranty instructions.

Part Number: SE000181

Production Fix: We are currently testing a pull up resistor change in the ECM on FPP2 to correct the
compatibility issue between the ECM and Foot pedal sensor.

1
 Jumper Harness Installation Instructions

1: Turn ignition key off and wait one full minute for
ECM to power down.

2: Disconnect the
truck harness
from the foot
pedal sensor.
Part number: SE000181 Jumper Harness

Connect to foot pedal sensor.

Connect original foot pedal harness to

new jumper harness.
 3: Connect jumper harness to the foot pedal
sensor.

4: Connect
original truck
harness to the
jumper
harness.

4: Secure the new jumper harness to the main

harness using tie raps.
• Clear all diagnostic trouble codes from
history file.

• Test drive the Lift Truck before returning it

to service to insure no diagnostic codes
return.
 Fuel Cap on 6M60 Causes Engine to Stall

Models:
P17500 – P36000

Problem:
6M60 Engine stalls and will not restart.

Cause / Discussion:
The Fuel tank cap is not venting properly to allow air to be pulled into the fuel tank. This causes a
vacuum lock on the fuel tank and may cause the engine to stall.

Solution:
Service engineering is working with our supplier to correct the fuel cap venting.

As a short term solution: Remove the fuel cap to invert the internal fuel cap vent. this will prevent the
fuel tank from building a positive or negative pressure in the fuel tank. (See attached photos)

P / N: Fuel Cap: 91364-10600

1
 P17,500 – P36,000 Standard Fuel Cap

Atmosphere
vent
passages

Inside tank
Vent
passages
 Standard Fuel Cap Inside View

Inside vent to atmosphere Atmosphere vent passages

Inside edge to prevent

gasket from closing to
atmosphere
View shows standard fuel cap vent
Remove and invert the fuel cap atmosphere vent, this
will prevent the fuel tank from building positive or
negative pressures in the fuel tank.

View shows inverted fuel cap vent

Diagnostic Trouble Code (DTC) 0650. Mil light on No Fault
Codes for the GC35K – GC70KSTR and the
FGC35K – FGC70K-STR Trucks
Models:
GC35K – GC70K-STR
FGC35K – FGC70K-STR, FG40K – FG50K

Problem:
The MIL light mounted on the overhead guard stays on with the engine running and turns off when the
transmission is shifted into forward or reverse. No codes in the ECM.

The Neutral light stays on all the time.

Cause / Discussion:
The wires to the MIL light and the Neutral light were not being connected correctly by manufacturing.

Solution:
1- Remove the switch box sub assembly (right OHG leg) and check the wiring connections:
Neutral lamp - Green
Green wire marked N connects to the Green wire on the N lamp.
Black wire marked N connects to the black wire on the N lamp.
Engine lamp - Yellow
Yellow wire with white stripe marked E connects to the Green wire on the E lamp.
Green wire marked E connects to the Black wire on the E lamp.

2- Re-install the switch box and Clear all codes.

3- Operate the truck at normal conditions.

1
Neutral Lamp

MIL Lamp
 2007 GM4.3L Diagnostic Cable for the
GC35K – GC70K-STR and the FGC35K – FGC70K-STC
Trucks
Models:
GC35K – GC70K-STR
FGC35K – FGC70K-STC

Problem:
Diagnostic cable part number for GC35K ~ GC70K.

Cause / Discussion:
The part number for the diagnostic cable is not listed the service manual. The diagnostic cable is used
on 2004 ~ 2009 EPA compliant GM 4.3 liter engines. This cable is required to read all diagnostic
trouble codes set by the IMPCO Spectrum fuel systems.

2004 – 2007 uses the Impco PSI software

2007 – 2009 uses the Impco DCP software

Solution:
Order the cable through the MCFNet part system.

P/N: 93768-01100 - Diagnostic Cable

1
2008 Technical Communicator
Teleconference-June

Bill Fussell
Electric Products
 Chat Timer Now Installed on E3000 - E6500, EC4000, and
EX5000 and the FBC15N-30N, FBC18LN-30LN, and
FBC25EN Trucks

Models:
E3000 – E6500, EC4000 and EX5000
FBC15N – FBC30N, FBC18LN – FBC30LN, and FBC25EN

Problem:
The Chat Timer is now included in the software 043 and higher

Cause / Discussion:
The Chat Timer was not originally included in the earlier software packages

Solution:
You can adjust the Chat Timer using the option and ranges listed below. The setting is listed in
seconds increasing by number.

Option 24 - Steer Timer Range 0 to 40; Default Setting is at 20

1
 Additional Changes to the Version 043 Software for the
E3000 - E6500, EC4000, and EX5000 and the FBC15N -
FBC30N, FBC18LN - FBC30LN, and FBC25EN Trucks

Models:
E3000 – E6500, EC4000 and EX5000
FBC15N – FBC30N, FBC18LN – FBC30LN and FBC25EN

Problem:
Additional software changes are now included in the software 043 and higher.

Cause / Discussion:
This Software was not originally included in the earlier software packages 002b, 0031 and 0041.

Solution:
Software that has been added listed below:

ƒ Steering turn off control

ƒ Electromagnetic Brake coil control
ƒ Adjustable Chat Timer
ƒ Options 11 to 19 and 19 to 32
ƒ BLDC Brush-less DC Steering motor control
ƒ Improvement of grade ability
ƒ Enable Lowering of Mast after a Error Code
ƒ Pre-Set Options Adjustments (Modes)

1
 PN 97L20-00500 Brush-less BLDC Steer Motor Now
Available for the E3000-E6500, EC4000, and EX5000 and
the FBC15N-30N, FBC18LN-30LN, and FBC25EN Trucks

Models:
E3000 – E6500
FBC15N - FBC30LN

Problem:
We now are installing the brush-less BLDC steer motor in these trucks.

Cause / Discussion:
This design change brings a more efficient steer motor to production.

Solution:
The current production trucks have the new BLDC motor installed. Connections to the motor are the
power cables positive, negative and one error code control wire 20 connected. The motor is polarity
sensitive so be sure to connect properly or damage will occur. If the motor does not start running with
positive and negative applied you will get a code 41. You can power the motor up with positive and
negative to test the operation of the motor as needed. There is a red and green LED to indicate
correct operation or not.

1
 Additional Steer Wheel Motor Torque Required for the
ES3000 - ES5500 and the FBC15NS -FBC20NS Trucks

Models:
ES3000 – ES5500
FBC15NS – FBC20NS

Problem:
Some application may require additional steer wheel torque to hold it straight when hitting dock plates
or in other diverse operations and applications.

Cause / Discussion:
The trucks are shipped with standard steer wheel torque settings.

Customers driving the truck over dock plate at 3 to 4 miles per hour, may experience the steer wheels
turning almost 90 degrees instead going straight.

The problem occurs while operating the steering wheel.

Solution:
Set to increase steer motor and wheel torque.

Using either the Zapi Steering Control Handset (RL199256) or the Laptop software program
(RL471429), go into the options and follow the instructions below.

Customer is driving the truck over dock plate with 3 to 4 miles per hour. Each time they drive over the
dock plate, steer wheel instead going straight is turning almost 90 degree, adjust the following:
1) Increase ANTIROLLBACK, release the steering wheel and drive the truck onto the dock plate.
2) Increase the ANTIROLLBACK value until the problem is fixed.

If the problem occurs while the driver is operating the steering wheel, adjust the following:
1) Increase steering CREEP SPEED and drive the truck on to the dock plate.
2) Increase the steering CREEP SPEED value until the problem will be fixed.

1
2008 Technical Communicator
Teleconference-June

Troy Martin
Narrow Aisle Products
 97E04-09900 Ferrite Bead Clamps Are Now Available to
Help Reduce the Occurrence of Error Codes 80 and 81 on
the NOR30 and NOR30P and Error Codes 6 and 7 on the
EOP15, EOP15P, EOP24, and EOP24P Trucks

Models:
NOR30 and NOR30P
EOP15, EOP15P, EOP24 and EOP24P

Problem:
We have received a higher than expected volume of calls regarding lift and traction potentiometer
failures. When the failure occurs, error codes 80 and 81 on the NOR30 and NOR30P and error codes 6
and 7 on the EOP15, EOP15P, EOP24, and EOP24P trucks are displayed; the fault alarm sounds and
lift, lower and traction are disabled.

Cause / Discussion:
These codes are caused by either and open or short in the pot or related wiring or electrical noise in
the control system. Electrical noise has been found to be the main cause of these codes.

Solution:
There are ferrite bead clamps available for installation on the following wires. By reducing electrical
noise in the control system, this has significantly extended the life of the pot and reduced the
occurrence of error codes 80 and 81. Seven ferrite beads are required per unit.
JPS25-1, JPS25-7, JPS25-8
JPC9-5, JPC9-6
JPC9-7, JPC9-8

The ferrite bead part number is 97E04-09900. Refer to the schematic in the service manual, or the
next page, for connections JPS25 and JPC9.

Note: This is a Product Improvement and is not covered by warranty.

1
JPS25 connection
on the interface
card.
JPC9 Connector
on the carriage
wiring board.
Here are the wires, JPC9-5,
6, 7, and 8. These are the
wires that you install the
ferrite bead clamps.
 The Forks are Hanging-Up When Exiting Pallets for the
2WP4500 - 2WP6000 & 2WPL4500 - 2WPL6000 and the
PW23 - PW30 and PWL23 - PWL30 Walkie Pallet Trucks

Models:
2WP4500 – 2WP6000, 2WPL4500 - 2WPL6000
PW23 – PW30, PWL23 - PWL30

Problem:
The new generation walkie pallet trucks forks may hang-on some pallets when exiting.

Cause / Discussion:
The new generation walkie pallet trucks has a new design fork. In some applications, the new
generation walkie pallets are dragging pallets when exiting.

Solution:
Please open a HEAT Ticket and contact Service Engineering prior to making any repairs. Grinding
down the corner of the fork without intruding into the weld seam provides the best solution.

1
 WP4500 (old style)

Gradual Slope
2WP4500 (New style)

Pallets catching on this location

 PMW23N (older style)

Gradual Slop

PW23 (new style)

Grind off this area
 The Retainer Clip are Shearing Off the Control Arm Pin for
the WR6000 and WR8000 and the PMWR30N and
PMWR40N Walkie Rider Trucks

Models:
WR6000 and WR8000
PMWR30N and PMWR40N

Problem:
The retainer ring for the control arm pins are being sheared off causing the arm to drop off.

Cause / Discussion:
Over a period of time the control arm pin retainer clip gets sheared off due to excessive vibration while
traveling. In some trucks, there is a longer pin (74mm) with no retainer clip to hold the pin in place.

Solution:
Service Engineering recommend one of the following solutions:

1. Drill a counter-bore into the material which has the thread (preferred)
2. Use a cylinder-head screw and a thick and wide washer instead of the counter-sunk screw
3. Change the pin with the shorter one and to use a secure clip
(use the 54mm pin and retainer clip listed in parts manual)

W205012496 - Bolt (54mm)

W205012829 - Shim
W205010412 - Retainer Clip

NOTE: In all cases it is recommended to use Blue Loctite®.

1
Control Arm Pins
 Clarification of the Brake Adjustment Procedures in the
Service Manuals for the 2WP4500 and 2WPL4500, and
WP4500 and WP4500L and the PW23 and PWL30, and the
PMW23N and PMW23NL Trucks.
Models:
2WP4500 and 2WPL4500, WP4500, WP4500L
PW23 and PWL30, PMW23N and PMW23NL

Problem:
To clarify the proper the brake adjustment information in service manual #99759-8E100 and
and SENB6620, and service manual #99759-7E100 and WENB6620 for the walkie pallet trucks.

Cause / Discussion:
Service manuals 99759-8E100 and 99759-7E100 has two different brake service information and
technicians need to know which procedure to use. Service manuals SENB6620 and WENB6620 have
the older brake service information and not the newest brake service information. Dealers are not sure
which information is correct for the WP4500 and 2WP4500, and for the PMW23N and PW23 Trucks.

Solution:
WP4500 and WP4500L trucks with the build date of April 2006 and earlier will use the brake
adjustment used in the service manual SENB6620. WP4500 and WP4500L trucks built in May 2006
and later will use the brake service information provide in service manual 99759-8E100 pages 2-6 and
2-7. PMW23N and PMW23NL trucks with the build date of April 2006 and earlier will use the brake
adjustment used in the service manual WENB6620. PMW23N and PMW23NL trucks built in May 2006
and later will use the brake service information provide in service manual 99759-7E100 pages 2-6 and
2-7.

2WP4500 and 2WPL4500 trucks must use the brake service information in service manual 99759-
8E100 on pages 2-6 and 2-7. PW23 and PWL23 trucks must use the brake service information in
service manual 99759-7E100 on pages 2-6 and 2-7.

Please reference the brake service information below. The WP4500, WP4500L, 2WP4500 &
2WPL4500 and the PMW23N, PMW23NL, PW23 & PWL23 trucks built May 2006 and later must use
the brake service information below on pages 2-6 and 2-7. Refer to iWarranty, Product Details, for the
build date of the serial number of the truck you are looking for.

1
2 — Common Maintenance Practices

Drive Brake
Measure the gap (L) between armature plate (5) and the magnet body (7) using a feeler gauge. Gap
should be between 0.2 to 0.5 mm (0.008 to 0.020 in.).
If the gap (L) between armature plate (5) and magnet body (7) is greater than 0.5mm, the brake disk (4)
must be replaced.

3
4

L
5
6

Item Description
Service Notes
1-8 Complete brake unit
1 Friction plate
Torque Item 2: Mounting screws 5.5 Nm (4.05 ft.
lbs.)
2 Mounting screws
3 Hub After emergency operation has been terminated
4 Brake disk
and the truck has been parked, the screws (7)
must be turned in the clockwise direction until
5 Armature plate
they stop to ensure that the braking effect is
6 Air screws (emergency operation) restored.
Allen head M5x35mm
7 Magnetic body Check the air gap.
8 Brake electrical connector

2-6
 2 — Common Maintenance Practices

Disassembly Sequence Magnetic Brake Adjustment

1. Turn the key switch OFF or press the (O)- Instructions
key on the keypad (keyless entry option) to
turn power off. Adjusting Braking Deceleration
2. Press down on battery disconnect. Depending on the design and total weight of the
3. Disconnect the brake electrical connector. truck, the spring load must be adjusted in order
to achieve the required braking deceleration.
4. Screw the air screws (emergency operation)
into the brake so that the armature plate (5)
rests against the magnetic body (7). ! WARNING

5. Loosen and unscrew mounting screws (2), When replacing the brakes, the number
but do not pull them from magnetic body (7). and thickness of the inserted springs in
6. Remove magnetic body (7) together with the the removed brake must be checked
mounting screws (2). and the new brake adapted accordingly.
7. Remove the brake disk (4) from the hub (3)
and replace it.
Replacing Compression Spring
8. Check friction plate (1) and replace if neces-
sary. 1. Remove magnetic brake.
2. Back out screws and remove friction sur-
face.
Assembly Sequence
3. Insert compression springs in accordance
1. Place friction plate (1) on bearing plate. with removed brakes.
2. Slide the brake disk (4) onto the hub (3). It 4. Place friction surface on brake and fasten
should be possible to move the brake disk with screws.
manually.
5. Install magnetic brake.
3. Mount the magnetic body complete with
mounting screws (2) and spacer sleeves
onto the bearing shield and slightly tighten
screws.
4. Tighten mounting screws (2) uniformly with
a torque of 5.5 Nm (4.05 ft. lbs.)
5. Remove Allen head screws from brake so
that the armature plate can move freely in an
axial direction.
6. Plug the brake cable (8) into the wire har-
ness.
7. Plug the battery in and turn the truck on.
8. Check braking function.

2-7
 WP4500 and WP4500L trucks built April 2006 and earlier uses the brake adjustment below.

2 — Common Maintenance Practices

Adjusting Air Gap “a”

1. Install magnetic brake.

2. Air gap “a” is changed by backing out or
turning in the three screws (1) by equal
amounts.
• By turning screws counter clockwise “a”
(gap) becomes smaller.
• By turning screws clockwise “a” (gap)
becomes larger.
3. Use feeler gauge (4) to adjust air gap “a” to
between 0.3 and 0.8 mm (0.012 and 0.032
inches).

NOTE

Check air gap “a” in several locations

with feeler gauge (4) to ensure a uni-
form clearance. If clearances are
uneven, adjust air gap “a” by turning
one or more screws (1) as described in
item 2.

2-8
 WP4500 and WP4500L trucks built April 2006 and earlier uses the brake adjustment below.

2 — Common Maintenance Practices

Adjusting Spring Compression

• To reduce spring compression:

Use spanner wrench (5) to turn set screw (6)
to the left.
• To increase spring compression:
Use spanner wrench (5) to turn set screw (6)
to the right.

Special Tools
Spanner Wrench 90–155 mm (3.54–6.1 inches),
Din 1804 Feeler gauge 0.05–1 mm (0.002–0.04
inches)

NOTE

The spanner wrench or any other tools

required for adjusting the brake should
be sourced at your local tool supplier
store. MCFA does not offer this tool.

2-9
2 — Common Maintenance Practices

Drive Brake
Measure the gap (L) between armature plate (5) and the magnet body (7) using a feeler gauge. Gap
should be between 0.2 to 0.5 mm (0.008 to 0.020 in.).
If the gap (L) between armature plate (5) and magnet body (7) is greater than 0.5mm, the brake disk (4)
must be replaced.

3
4

L
5
6

Item Description
Service Notes
1-8 Complete brake unit
1 Friction plate
Torque Item 2: Mounting screws 5.5 Nm (4.05 ft.
lbs.)
2 Mounting screws
3 Hub After emergency operation has been terminated
4 Brake disk
and the truck has been parked, the screws (7)
must be turned in the clockwise direction until
5 Armature plate
they stop to ensure that the braking effect is
6 Air screws (emergency operation) restored.
Allen head M5x35mm
7 Magnetic body Check the air gap.
8 Brake electrical connector

2-6
 2 — Common Maintenance Practices

Disassembly Sequence Magnetic Brake Adjustment

1. Turn the key switch OFF or press the (O)- Instructions
key on the keypad (keyless entry option) to
turn power off. Adjusting Braking Deceleration
2. Press down on battery disconnect. Depending on the design and total weight of the
3. Disconnect the brake electrical connector. truck, the spring load must be adjusted in order
to achieve the required braking deceleration.
4. Screw the air screws (emergency operation)
into the brake so that the armature plate (5)
rests against the magnetic body (7). ! WARNING

5. Loosen and unscrew mounting screws (2), When replacing the brakes, the number
but do not pull them from magnetic body (7). and thickness of the inserted springs in
6. Remove magnetic body (7) together with the the removed brake must be checked
mounting screws (2). and the new brake adapted accordingly.
7. Remove the brake disk (4) from the hub (3)
and replace it.
Replacing Compression Spring
8. Check friction plate (1) and replace if neces-
sary. 1. Remove magnetic brake.
2. Back out screws and remove friction sur-
face.
Assembly Sequence
3. Insert compression springs in accordance
1. Place friction plate (1) on bearing plate. with removed brakes.
2. Slide the brake disk (4) onto the hub (3). It 4. Place friction surface on brake and fasten
should be possible to move the brake disk with screws.
manually.
5. Install magnetic brake.
3. Mount the magnetic body complete with
mounting screws (2) and spacer sleeves
onto the bearing shield and slightly tighten
screws.
4. Tighten mounting screws (2) uniformly with
a torque of 5.5 Nm (4.05 ft. lbs.)
5. Remove Allen head screws from brake so
that the armature plate can move freely in an
axial direction.
6. Plug the brake cable (8) into the wire har-
ness.
7. Plug the battery in and turn the truck on.
8. Check braking function.

2-7
 PMW23N and PMW23NL trucks built April 2006 and earlier uses the brake adjustment below.

2 — Common Maintenance Practices

Adjusting Air Gap “a”

1. Install magnetic brake.

2. Air gap “a” is changed by backing out or
turning in the three screws (1) by equal
amounts.
• By turning screws counter clockwise “a”
(gap) becomes smaller.
• By turning screws clockwise “a” (gap)
becomes larger.
3. Use feeler gauge (4) to adjust air gap “a” to
between 0.3 and 0.8 mm (0.012 and 0.032
inches).

NOTE

Check air gap “a” in several locations

with feeler gauge (4) to ensure a uni-
form clearance. If clearances are
uneven, adjust air gap “a” by turning
one or more screws (1) as described in
item 2.

2-8
PMW23N and PMW23NL trucks built April 2006 and earlier uses the brake adjustment below.

2 — Common Maintenance Practices

Adjusting Spring Compression

• To reduce spring compression:

Use spanner wrench (5) to turn set screw (6)
to the left.
• To increase spring compression:
Use spanner wrench (5) to turn set screw (6)
to the right.

Special Tools
Spanner Wrench 90–155 mm (3.54–6.1 inches),
Din 1804 Feeler gauge 0.05–1 mm (0.002–0.04
inches)

NOTE

The spanner wrench or any other tools

required for adjusting the brake should
be sourced at your local tool supplier
store. MCFA does not offer this tool.

2-9
 The New AC Reach Truck Service Manual 99759-8D100
are Available for NR3000 - NR4500, NR4000P - NR4500P,
ND2500 - ND3000, ND3000P and NS3000 - NS4000 and
the Service Manual 99759-7D100 are Available for ESR15N
- ESR23N, EDR13N - EDR15N & ESS15N - ESS20N
36 Volt Reach Trucks
Models:
NR3000 - NR4500, NR4000P – NR4500P, ND2500 - ND3000, ND3000P, NS3000 - NS4000
ESR15N - ESR23N, EDR13N - EDR15N & ESS15N - ESS20N

Problem:
Inform our dealer network of the new 36V AC Reach truck published material and how to identify the
new 36V AC Reach Truck from the ZAPI control system 36V AC Reach Truck.

Cause / Discussion:
Dealers are receiving the new 36V AC Reach Truck Model.

Solution:
The new 36V AC reach truck service manuals 99759-8D100 and 99759-7D100 are available in book
format. The electronic service manual will be posted online in June 2008. The new 36V AC reach truck
is referred to as Orion TC (Technical Change).

Contact Service Engineering for the wiring schematic and programming information until the online
service manual are available.

There are two ways to quickly identify the new 36V AC Reach Truck:

1. The serial number

2. The console display/buttons

1
 ®
Lift
Trucks

Service Manual
Chassis, Mast & Options
NR3000-36V 2NR3800900-up

NR3500-36V 4NR3800900-up

NR4000-36V 5NR3800900-up

NR4000P-36V 6NR3800900-up

NR4500-36V 7NR3800900-up

NR4500P-36V 8NR3800900-up

ND2500-36V 1ND3800900-up

ND3000-36V 2ND3800900-up

ND3000P-36V 3ND3800900-up

NS3000-36V 2NS3800900-up

NS4000-36V 5NS3800900-up

99759-8D100
 Service Manual
Chassis, Mast & Options
ESR15N-36V 2SR3800900-up

ESR18N-36V 4SR3800900-up

ESR20N-36V 5SR3800900-up

ESR23N-36V 7SR3800900-up

EDR13N-36V 1DR3800900-up

EDR15N-36V 2DR3800900-up

ESS15N-36V 2SS3800900-up

ESS20N-36V 5SS3800900-up

99759-7D100
 Castor Adjustment Chart for the WR6000 and WR8000 and
the PMWR30N & PMWR40N Walkie Rider Pallet Jack
Trucks

Models:
WR6000 and WR8000
PMWR30N and PMWR40N

Problem:
This article addresses unclear castor adjustment procedure and missing battery information in service
manual # SENB6650-01 and service manual WENB6650-01.

Cause / Discussion:
The castor adjustment procedure and chart in service manual SENB6650-01and WENB6650-01 is
unclear and the 750 Ah battery information is missing.

Solution:
Reference the following pages for the complete procedure and updated chart detailing which nuts
need to be removed during the adjustment. When referencing the chart on page three, if the square is
blank the nut should not be removed. Remove the nut only if there is an X in the corresponding square
of the chart. The 750 Ah battery is now shown in the chart.

1
2008 Technical Communicator
Teleconference-June

QUESTIONS & ANSWERS

2008 Technical Communicator
Teleconference-June

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