YOUR TECHNICAL NEWSLETTER May 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 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. Class I: 7FBEU Front Axle Repair Kits Below are 2 kits that are available which include many parts for the 7FBEU front axles. Neither kit includes the drive motor rotor gear, so please inspect it first for damage before ordering kits. Please also use SIB FA07-001R for correct assembly and hub preload. Also, please reference Parts Bulletin IO- 2010003 dated April 19, 2010 for further information on how to identify old and new style front axles. Kit # 04099-03869-71 Contains parts pictured (boxed) below. Kit # 04099-03870-71 Contains parts pictured (boxed) above. Class III: Parameter 24 Explained For 8 Series Pallet Jacks And 8TB50 There has been some confusion about the function of Parameter 24 on the 8-Series AC powered Class III units. This parameter refers to how far the battery has to discharge before the battery will reset. This function is in place to prevent an operator from simply unplugging and plugging back in a discharged battery, which has recovered some surface charge. In some cases, a customer s application may require the BDI to reset with less of a discharge level, due to light usage between charging cycles. In a situation like this, it would be necessary to increase the setting of Parameter 24. For example, let s look at a scenario with this parameter setting at the default of 75%. Now the customer takes a fully charged battery and uses the unit for a couple of hours, depleting the battery to 80% of a full charge. (Continued on next page) 1
Then they fully charge the battery and plug it into the truck the next morning. To their frustration, the BDI didn t reset! This is because the battery was not pulled down BELOW the 75% setting that Parameter 24 is set at. In most cases, this may only happen for one cycle, and will be cleared during the next usage, once the battery is depleted below 75%. In rare cases where the customer does not use the unit enough between charges to cause a reset, the value of parameter 24 may need to be increased. In our example above, parameter 24 would need to be increased above 80%. For more information please reference Service Information Bulletin CC10-003 Class IV & V: Retrieving Error Codes on 2004 Compliant TWC system The error codes on the 2004 Compliant Three Way Catalyst System (1/2004 to 12/2006 production range) can be retrieved without using any special tools. The only tool required is a basic jumper wire that can be plugged into the six pin diagnostic connector. The jumper wire needs to be installed into the TE1 and E1 terminals of the six pin diagnostic connector. TE1 can be identified by the G-B color code of the wire. E1 can be identified by the W-B color code of the wire. An illustration of the connector and location of the TE1 and E1 terminals can be found on page 2-6 of the TWC Supplemental Repair Manual, Publication Number CU643-2. Once the jumper wire is installed correctly and the key switch turned on, the Check Engine Light will flash any stored error codes. Error codes will be displayed by the light flashing the same number of times as the error code. Example: Error Code 3 will be displayed by 3 consecutive flashes with a 1.5 second pause in between the error being displayed again. Multiple error codes will be displayed in ascending numerical order, with a 1.5 second pause between error codes. If an error code is not stored, the Check Engine Light will display a Normal Code, the light will flash quickly every 0.25 seconds. There are several key points to remember when checking for error codes. When the Check Engine Light is illuminated, one or more error codes may have been set and stored in the TWC controller memory. The error codes need to be retrieved prior to turning the Check Engine Light off. Turning the Check Engine Light off by either removing the TWC fuse, or disconnecting the negative battery cable for 30 seconds, clears stored error codes. The second method for retrieving diagnostic information can be completed by using the TWC analyzer, p/n 09240-13381-71. By checking and recording the Out Signal, Diagnostic 1 and Diagnostic 2 information. This information can be used to determine the error code and possible cause of the condition. This diagnostic troubleshooting information can also be found in the supplemental repair manual CU643-2. REMEMBER, turning the Check Engine Light off clears the diagnostic information, which can be helpful in diagnosing and repairing the TWC system. DO NOT turn off the Check Engine Light until this information has been recorded. Once the source of trouble has been repaired, clear the codes before leaving the customer site. Class IV & V: Error Code AD-7 After Replacing The Main Wiring Harness On 8 Series I.C. Forklifts If an AD-7 error code is displayed after replacing the main wiring harness on a truck equipped with a Multi-function display, then the connections under the Multi-Function display need to be checked. (Continued on next page) 2
There are two connectors located under the Multi-Function display that are the same color (Dark Gray) and are capable of being switched. These are connectors AQ1, which supplies power and ground to the Multi- Function display, and A14, which is the connector for the lift switch. If these two connectors are swapped, then the truck will show an AD-7 error code, because the Multi-Function display will not power up, which causes the CAN communication signal to be lost. Page E6-2 Page E6-8 Page E2-6 Class IV & V: Troubleshooting Overheat Complaints When troubleshooting an IC truck for an overheat condition, please remember to check the basics. The following is a simple check list to help determine the actual failure, when troubleshooting an overheat complaint. Start by defining the customer s actual complaint: Engine temperature gauge reads in the red Coolant is boiling over or leaking Engine shut down feature is activating Transmission gauge reads in the red Other Once the items above have been reviewed, check these items: Confirm coolant level at reservoir tank Check radiator to ensure it is free of debris (to include the corners) Bleed air out of the cooling system Make sure the minimum and maximum engine rpm are set to factory specifications Verify the cooling fan belt is not slipping Check ignition timing, fuel mixture, & TWC settings If all of these items check OK, and there is still an overheating complaint, please record the following information below and provide it to technical services: Ambient Temperature: Transmission: Oil filter Upper transmission cooler fitting @ radiator Lower transmission cooler fitting @ radiator Hydraulic Side of tank (below fluid level) Fluid inside tank Upper cooler hose @ radiator Lower cooler hose @ radiator Return hose fitting @ hydraulic tank Differential drive hubs Right Left Engine: Engine oil filter Exhaust manifold Thermostat housing Oil pan Water pump inlet (metal portion where hose from radiator connects) (Continued on the next page) 3
Radiator: Upper radiator hose fitting Lower radiator hose fitting Upper radiator tank Mast: R, outer lift cylinder L, outer lift cylinder Free lift cylinder Attachment: Cylinders: Hoses: Note the working pattern: cycles per minute, distance traveled, turns, direction of travel, etc. Once this information is gathered and documented, contact the appropriate FTS if troubleshooting and failure analysis assistance is required. Class I through VI: Using A Non- Contact Thermometer To Aid Troubleshooting Overheat Conditions To aid in troubleshooting an overheat condition, we will look at a tool for collecting temperature readings, which is non-contact by design. This tool is also known as a Temp-gun. Sample of a quality non-contact thermometer (aka Temp-gun). A Temp-gun works by emitting a signal that is reflected back by the surface it is aimed at. This is a tool where buying cheap is a bad idea. At a minimum the gun should have temperature hold function, and a low battery indicator. A laser pointer is also a good feature to have. When using the Temp-gun, if at all possible, place the gun between three to five inches from the surface to be measured. The closer to the surface you can get (within 3-5 ), the more accurate and confined an area you can take a reading from. The signal emitted from the Temp-gun spreads out in a conical pattern, like a paint spray gun. If you need to get a broad signal (i.e. entire hydraulic tank), move away from the surface an appropriate distance. Aim straight on, at the center of the target. The instructions that come with the Temp-gun will give approximate distances for the diameter of the circle of influence. Pull and release the trigger quickly, then move the gun away to a safe point where you can read the display. It is important not to hold the trigger down while moving the gun. Log each measurement as it is taken. *Tip, utilize a second person with a clipboard who calls out the surfaces to shoot, and records the data that you call back* The Temp-gun does not work accurately on polished or shiny surfaces, or in smoky, dusty, or windy conditions. If you need to check the temperature of a shiny or polished object, smudge the area with a bit of flat black paint or masking tape. Allow the paint or tape to reach the same temperature as the surface. Keep the gun as close to the target as possible to avoid picking up stray heat signals. In order to get a temperature reading in a windy area (i.e. behind the radiator fan), shield the area around the target and the Temp-gun with a piece of cardboard. Pay attention to safety! Follow instructions for your particular model, and attention to detail. A quality non-contact thermometer when used correctly is an excellent tool for pin-pointing hot spots. 4
TECHNICAL CONTACTS Technical Services operating hours are 8:30 a.m. 5:00 p.m. Monday Friday Eastern time. Class VI: Large Capacity Tow tractors Contacting The Technical Support Group Technical Hotline number: (812) 341-3888 Please make sure to have your dealer code, the model and serial number and hour meter reading of the unit, available at time of call. When you dial this number you will be answered with a request to enter your 5 digit dealer number (this is to prevent non Toyota technicians from accessing this hotline). 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 forklifts 1.5t - 3.2t (class IV) Press 5 for pneumatic tired internal combustion forklifts 1.5t - 3.2t (class V) Press 6 for internal combustion Forklifts greater than 3.2t Press 7 for internal combustion tow tractors and skid loaders (class VI) Press 8 for AICHI Scissor & Boom Lifts (Authorized Dealers only). If for some reason, all FTSs are busy on the phone you will be prompted to hold. After 2 minutes on hold, you will be given the option to continue to hold or go to voicemail. If any problems are encountered, please contact the Technical Services Manager, Cary Howie, at (812) 341-3668. 02-2TDU25 tow capacity is 72,750 pounds with a single trailer or 108,000 pounds when pulling more than one trailer. It uses the 1DZ-III Diesel engine, which is EPA Tier 4 compliant, and an Aisin Automatic transmission. The unit also comes standard with front disc / rear drum brakes and hydraulic power steering. 2TE15/18 Electric AC drive Tow tractor. The 2TE15 is capable of towing 44,100 pounds, while the 2TE18 is capable of towing 55,100 pounds. Both are capable of speeds in excess of 15 mph. Both units come with Hydraulic power steering; front disc / rear drum brakes. They both use an 80V DC battery system, to generate the AC voltage. Both have on board diagnostics similar to the 7FBCU series Forklifts. 5
7FBE15, 7FBE18, 7FBE20, 8HBE30, 8HBC30, 8TB50, 8FGCU15, 8FGCU18, 8FGCSU20, 8FGCU20, 8FGCU25, 8FGCU30, 8FGCU32, 8FGU15, 8FGU18, 8FGU20, 8FGU25, 8FGU30, 8FGU32, 8FDU15, 8FDU18, 8FDU20, 8FDU25, 8FDU30, 8FDU32, 7FGU35, 7FGCU15, 7FGCU20, 7FGCU25, 7FGCU30, 7FGU15, 7FGU18, 7FGU20, 7FGU25, 7FGU30, 7FGU32, 02-2TDU25, 2TE15, 2TE18 6