YOUR TECHNICAL NEWSLETTER January 2011

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Gary Ferguson
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1 YOUR TECHNICAL NEWSLETTER January 2011 Purpose: The purpose of this monthly newsletter is to provide tips proactively to enable our dealers to resolve customer issues promptly and efficiently. This information should enable the technician to diagnose and repair issues in a timelier manner. A copy of this news letter is posted in the Service Support section of the TIS website. 15 Year Anniversary Of The Technical Hotline January 2011 marks the 15 Year Anniversary of the Technical Hotline. The Hotline was developed to provide technical assistance to service departments of Toyota Industrial Equipment dealers. It originally started out with one person providing technical assistance. The requests for assistance were faxed to the Hotline. We averaged 79 cases a month the first year. 15 years later, we now have 6 Field Technical Specialists providing technical assistance for more than 2,000 technicians. Requests for technical assistance are now received via live phone calls, voice mail, e- mail and faxes. We try to answer all phone calls live. More than 85 percent of the calls we receive are answered live. In 2010 we averaged 452 new cases per month. Class I: Adjusting The Speed Limit On 8FBCU Models If a customer requests the top speed to be lower than the factory default, information to accomplish this can be found in the Travel Setting Mode (page 3-13 in repair manual CU347). This setting is located in the Manager s Function/Administrator Menu, and not the Mask Function/Service (different passwords and files). The default is set to 30 MPH, and you simply use the left arrow button to decrease the speed. Class II: 8BRU Adding A Travel Alarm In many cases it is found that a customer may want to add a travel alarm to a truck, after the fact. If the truck was not ordered with the travel alarm, it is possible to add this feature at a later time. If the reach truck does not have work lights, operator compartment lights, operator fan or a strobe light, the truck may not have the options harness (part number ), which runs through the rear over head guard post. While installation is significantly easier with the options harness, you can still add the travel alarm option without it. After swinging open the rear compartment door, you will find 2 connectors near and below the horn assembly. One is a 10 pin Black Connector, and the other is a 6 pin Grey Connector (see picture on page 2). This is where the options harness would plug into. (Continued on the next page) 1

2 To add the alarm without the options harness, you will need to find wire 22 (B+ fused) in the 10 pin connector, and wire 53 (backup -) in the 6 pin connector. Wire 22 will be your B+ connection for the travel alarm, and wire 53 will be your B- connection for the travel alarm. After connecting the alarm to these wire connections, it will be necessary to go into configure mode, and turn on the option. First you will need to determine if the customer wants the travel alarm to function in forward and reverse, or just reverse only. Set C4 to Yes for the alarm to function in forward and reverse. Set C5 to Yes for the alarm to function in reverse only. Remember, to permanently save these changes you must exit configure mode by pressing the hour meter select switch. Please note that this modification voids the UL listing. Connectors for the Options Harness Class II & III: AC Motor Temperature Sensor Installation The repair manuals for the Class II and Class III models with AC drive motors ( CL and CL398-07) indicate in the Component Procedures section, that high temperature silicone is supplied with the new temperature sensor when it is ordered. This information is incorrect. The high temperature silicone must be ordered separately (PN ). The repair procedures have been updated, and are included with SIB MA Please print a copy of SIB MA Then remove the old pages from your manual, and replace them with the updated pages included with this SIB. Repair Manual Replace Page Number CL CL Class IV & V: How To Read The Oxygen (O2) Sensor The oxygen (O2) sensor can be a useful tool when troubleshooting a fuel system issue on 7 and 8-Series I.C. trucks. When a good running truck is warmed up to operating temperature (180 deg F) the O2 sensor reading should be bouncing between Rich (greater than 0.5 volts) and Lean (less than 0.5 volts). The readings will normally jump between about 0.2 volts and 0.8 volts, more than 10 times a minute. When monitoring the OX value with the Analyzer, if the reading stays on the lean or rich side and does not move, then this tells you that the sensor has failed, the engine controller is not receiving the signal, or the fuel system is out of adjustment. Generally the cause of the O2 sensor sticking on the rich or lean side is that the fuel system is out of adjustment. On LP/CNG trucks this will require either the adjustment of the regulator, or the replacement of a fuel system component. A gasoline truck will usually require the replacement of a component, since most of the gasoline trucks do not have fuel system adjustments. Here is a quick tip to see if an O2 sensor is working properly. If the throttle is pressed quickly when the O2 sensor reading is showing lean, this will normally cause the O2 sensor to read rich for a moment, because of the sudden influx of fuel introduced into the system. If the O2 sensor is showing rich, then induce a large vacuum leak to see if the O2 sensor will go to lean. (Continued on the next page) 2

you may receive a complaint of an error code 154 coming up at low hours. DTC 154 is set when a failure is found in the EGO2 circuit.

3 This will tell you if the O2 sensor is reading, and if the controller is getting the reading from the O2 sensor while using the analyzer. Dash Display showing O2 sensor voltage (OX) O2 Sensor (7 & 8 Series with 4Y engine) Class IV & V: 7-Series With PSI GM-V6 Engine, DTC 154 (EGO 2 Open Or Lazy) On 2011 PSI GM-V6 equipped forklifts, you may receive a complaint of an error code 154 coming up at low hours. DTC 154 is set when a failure is found in the EGO2 circuit. The EGO2 sensor is used to monitor the efficiency of the catalytic converter. The ECM compares the EGO1 and EGO2 voltage signals to determine this. This fault is set if EGO2 is cold, non-responsive, or inactive for more than 120 seconds. When troubleshooting this error code you will see the EGO2 voltage on the DST software stay at.1 to 0.1 volts. It has been found the sensor may crack due to moisture in the exhaust system. When the sensor cracks, the heated portion of the sensor quits functioning. When the heater in the sensor quits working, the signal voltage back to the ECM will not change. At this time the only repair is to replace the sensor. Class IV & V: Oil Pressure Switch Failure On 8-Series Forklifts With 4Y Engine. Oil pressure switch failures have been traced back to spilled engine oil entering the vent hole on the oil pressure switch when the engine oil filter is being changed. Oil entering the vent hole on the switch clogs the filter, and prevents the oil pressure switch from operating correctly. It is recommended that care be taken when changing the oil filter on the 4Y engine. If engine oil is spilled on the oil pressure switch, it should be wiped off immediately. Please review SIB MA for further information. 3

4 Important ASE Testing Information According to the website, 2011 will be the last time ASE offers pencil and paper testing. There will be written tests available in May, and in November of Computer based testing will be available starting in the July/August time frame. Computer based testing (CBT) will be available four times per year, and the schedule of testing will be both days, and evenings. All computer based testing will be done at test sites. There are no options for home testing. There will be 360 test sites nationwide initially, with more added over time. These test sites will be different from the test sites where written tests were offered. All Computer Based Testing will be done in English, with an on-screen English/Spanish glossary of automotive terms. ASE has previously offered computer based testing, but this is the first time they will completely transition away from the paper testing format. According to information on the web site, the person taking the ASE test will know before leaving the test center if they have passed or failed. The format of multiple choice will carry over, and the content will be similar to the written tests. Costs for the CBT tests will remain similar to what the written test costs have been. According to the website, regular certification and re-certifications will be $30 each (re-certs max out at $90 regardless of the number of re-cert tests taken). L1 and L2 will be $60. There is a registration fee applicable to each testing window. This is the same fee structure as the 2011 written tests. If you have not taken Computer Based Tests, this is a good opportunity to test the waters, so to speak. You might try taking one or two of the tests that are easiest for you, in order to get comfortable with the format. As always, TMHU wishes all ASE participants great success. TECHNICAL CONTACTS Technical Services operating hours are 8:30 a.m. 5:00 p.m. Monday Friday Eastern time. Contacting The Technical Support Group Technical Hotline number: (812) In response to dealer concerns of unauthorized access to the Technical Assistance Hotline, by non-toyota technicians, the system has been enhanced. This will require more information to be provided by the technician before the technician is provided with assistance. When calling, faxing, sending , etc., please provide the Model, Serial Number, Dealer code, TMHU Portal I.D. and last name spelling. We will not be able to provide assistance without all the above information. Please make sure to have all the information outlined above, along with the hour meter reading, available at time of call. After the dealer prompt, you will be given eight choices for assistance: Press 1 for sit down counterbalanced electric lift trucks (class I) Press 2 for Reach Trucks and Order Pickers (class II) Press 3 for electric pallet jacks and electric tow tractors (class III) Press 4 for cushion tired internal combustion forklift models 15 to 32 (class IV) Press 5 for pneumatic tired internal combustion forklift models 15 to 32 (class V) Press 6 for internal combustion Forklift models 35 and up. Press 7 for internal combustion tow tractors and skid loaders (class VI) Press 8 for AICHI Scissor & Boom Lifts (Authorized Dealers only). After 2 minutes on hold, you will be given the option to continue to hold or go to voic . If any problems are encountered, please contact the Technical Services Manager, Cary Howie, at (812)

5 8FBCU20, 8FBCU25, 8FBCU30, 8FBCU32, 8BRU18, 8BDRU15, 8BRU23, 8HBW30, 8HBC30, 8HBC40, 8HBE30, 8HBE40, 8TB50, 7BPUE15, 7HBW23, 8FGCU15, 8FGCU18, 8FGCSU20, 8FGCU20, 8FGCU25, 8FGCU30, 8FGCU32, 8FDU15, 8FDU18, 8FDU20, 8FDU25, 8FDU30, 8FDU32, 7FDU15, 7FDU18, 7FDU20, 7FDU25, 7FDU30, 7FDU32, 7FGCU35, 7FGCU445, 7FGCU60, 7FGCU70, 7FGCU80, 7FGU35, 7FGU45, 7FGU60, 7FGU70, 7FGU80. 7FGKU40, 7FGAU50 5

YOUR TECHNICAL NEWSLETTER November 2010

YOUR TECHNICAL NEWSLETTER November 2010 Purpose: The purpose of this monthly newsletter is to provide tips proactively to enable our dealers to resolve customer issues promptly and efficiently. This information