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 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: 8FBCU Slow Attachment Speeds If the attachment speed is slower than desired, you can adjust general tuning No.28 (Attachment 1) and No.29 (Attachment 2) up from level 3 (default). Below is the flow rate chart from the FL manual. Please refer to page 3-49 of Repair Manual CU347 for additional information. Flow and Pressure Specifications Chart 36 Volt 48 Volt 8FBCU20 8FBCU25 8FBCHU25 8FBCU30 8FBCU32 Tuning level Max Auxiliary Function Flow gpm (lpm) 3rd / 4th Function 8 11.04 (41.8) 7 8.71 (33.0) 6 6.37 (24.1) 5 4.04 (15.3) 4 3.5 (13.2) 3 3.0 (11.3) 2 2.4 (9.2) 1 1.9 (7.1) Max Auxiliary Function Pressure psi (kg/cm2) 3rd / 4th Function 2580 (181) Class II: 7BPUE15 Change In The Battery State Of Charge Tune-ability There was an improvement made to the 7BPUE15 software in regards to the Battery State Of Charge (BSOC) Tune-ability. This was part of the upgrade in Firmware version 2.3. This new setting called BSOC Calibration, changes what average voltage will be considered zero percent by the software. This allows a technician to better tune the truck to the customer s application, and battery configuration, since there is such a large variety in the field. Version 2.3 firmware was included in the programming of new units starting with unit number 7BPUE15-81059. We recommend this version be uploaded to older units. The firmware and Flashware program are located in the Download section of the Service Support area in Toyota Information System website. For more information on how to program the BSOC, and instructions on loading the firmware, please refer to Service Information Bulletin CC10-002. Class III: Adding Travel Alarm To A 7HBW23 Unit number 7HBW23-31032 and up, have an option of a travel alarm being added. However, if the jack is not ordered with the travel alarm, the necessary parts are not in the harness to allow the alarm to be added easily. 1
Toyota now has part number 00590-49200-71 which includes the sub harness, to add travel alarm to a jack that was not originally ordered with one. If you wish to add travel alarm to a 7HBW23, the SPn (software part number) must be 313959-003 or newer. If a customer has a jack with the old version software, and desires that it be updated to this new version, this can be done by downloading Truck-Comm from the Toyota Information System website. The new software for the 7HBW23 is included in this download. Parameter 16 is the travel alarm parameter and can be set using the following options. 0: Off 1: Travel with forks first 2: Travel with handle first 3: Travel in both directions 4: Lifting 5: Lifting or travel with forks first 6: Lifting or travel with handle first 7: Lifting or travel in both directions 8: Lowering 9: Lowering or travel with forks first 10: Lowering or travel with handle first 11: Lowering or travel in both directions 12: Lifting or lowering 13: Lifting or lowering or travel with forks first 14: Lifting or lowering or travel with handle first 15: Lifting or lowering or travel in both directions Class I, IV & V: Seat Switch Failures On TIEM Produced Lift Trucks In an effort to obtain additional information on seat switch related failures. TMHU is requesting assistance from the dealers. In the event of a confirmed seat switch failure, DO NOT remove the seat switch from the seat, or tamper with the seat or switch. Please contact your TPSM or associated CQE member; they will submit a tech report on the failure. The tech report should include information on the condition that the customer is experiencing, and include specific details needed to duplicate the condition. The tech report should also request a replacement seat assembly, along with referencing Warranty Information Bulletin WD10-004. TIEM will ship out a replacement seat as soon as they receive the tech report. This request is for units that are within the basic warranty period, and this project will expire on April 30 th, 2011. If you have any questions regarding this program, details can be found in Warranty Information Bulletin, WD10-004. Class IV & V: 7 & 8-Series 1DZ Diesel Producing White/Gray Exhaust Smoke Whitish/gray smoke produced by a diesel engine is usually caused by unburned fuel (but not over fueling) leaving the exhaust. This can be differentiated from plain white smoke (coolant) by the smell. Coolant will generally smell sweet, while the gray smoke has a raw fuel smell and usually causes eye irritation. Gray smoke is generally caused by lack of cylinder compression, retarded pump timing, poor fuel quality, and/or failed injectors. Gray Smoke Troubleshooting Check List Check your fuel quality. This is easily done by putting the fuel pump inlet line into a container of known good diesel fuel, and then running the truck. Check the return line going to the tank. Check this by pulling the return fuel line off the injector rail, add a longer line that will dump into a fuel container, and then run the truck to see if the symptom changes. Verify that there is flow coming out of the line. Check injection pump timing using the correct engine repair manual. Note: Make sure that the correct specifications are used when checking pump timing. 1DZ-II and 1DZ-III have different timing specifications. 2
You must use SST 09240-32880-71 along with a dial indicator to perform the pump timing procedure. Check cylinder compression using SST 09992-76002-71. The compression at each cylinder should be within 10% of each other. Refer to the engine repair manual for compression specs. Low compression can be caused by valves and/or piston/cylinder issues. The injectors will need to be pop tested to verify the pop off pressure (1706+/- 71 psi), and the spray pattern. For information on troubleshooting Blue and Black diesel smoke, please refer to the Hotline Tech Tip article from June 2007. Class I, IV & V: What Is A Good Battery Reading? The battery is the primary source of electrical energy in Toyota Forklifts. It stores chemicals, not electricity. Two different types of lead plates in an acid-water mixture react to produce voltage and current. This electrochemical reaction changes chemical energy into electrical energy. In addition, the battery serves as a voltage stabilizer, or large filter, by absorbing abnormal, transient high voltages in the forklifts electrical system. Without this protection, certain electrical or electronic components could be damaged by these high voltage surges. On Internal Combustion forklifts utilizing Electronic Control Units (ECUs), it is necessary to maintain a minimum of 10.2 volts to the ECU, throttle body, ignition coil, etc. while cranking, in order for proper starting. A fully charged battery will have a voltage of 2.2 volts per cell. A fully discharged battery will have a voltage of 2.0 volts per cell. This correlates to the percentage of acid left in the electrolyte mixture. Fully charged, there should be approximately 36% sulfuric acid content mixed with purified water. This equates to a specific gravity of 1.285 at 70 degrees Fahrenheit. The discharged specific gravity will be approximately 1.125 at 70 degrees Fahrenheit. Please see the below chart: Battery Number of cells Charged voltage Discharged Voltage 12V 6 13.2 V 12.0V 24V 12 26.4V 24.0V 36V 18 39.6V 36.0V 48V 24 52.8V 48.0V When diagnosing an electrical or starting problem, always start by confirming the state of battery charge, and condition of the battery. To do this, check the individual cell voltage, both static and under load. Then check the specific gravity using a quality hydrometer with a temperature correction scale. If the battery cannot be tested (sealed), install a known good battery to complete the diagnosis, and charge the customer s battery before load testing. Make sure to follow all safety precautions when working with batteries. When load testing, a minimum of ½ the CCA load must be applied to the battery, which is at least 50% charged. We recommend fully charging the battery and allowing it to cool for at least two hours, before load testing. On an internal combustion forklift 12V battery this requires a load in excess of 150A. On an electric forklift, loading against tilt or lift relief will apply enough load to test the battery. No cell should drop more than 0.3 volts under load, when tested from fully charged. It is helpful to make a chart that has a large square for each cell. Divide each large square into three smaller rectangles that allow you to record static voltage, loaded voltage, and specific gravity. See the example at the end of the article. Compare the readings across all the cells. Normally, if there is a bad cell, it will start drawing down the adjacent cells. 3
If you find a cell (or cells) that are failing, mark the cells and provide this chart to the battery company, to assist them in correctly servicing the battery. If the customer complaint on an electric forklift is related to the battery, ask the customer to equalize charge the battery, and respond to the customer location before they use this charged battery. This provides the best opportunity to deduce if the problem is battery related, or forklift related. If the customer complaint on an internal combustion forklift is related to the battery, ask the customer, if he would like the battery replaced, or if he would prefer the battery be charged, and returned. Explain that in order to diagnose a forklift electrical problem, you have to start with a known good battery. Ultimately, the goal is to fix the customer s complaint. Repairing the forklift is part of the overall fix. Satisfying the customer involves, clearly stating the root cause, and assisting the customer in determining the best course to resolve his issue. Be it offering operator training, charging & battery service instruction, options available to reduce unwanted battery drain (i.e. key off headlights, key off warehouse inventory control systems, etc). Fully explaining the cause, and getting the customer involved in the solution, will help ensure the customer has good battery life. Battery Chart 24V battery 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) 341-3888 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 email, 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 voicemail. If any problems are encountered, please contact the Technical Services Manager, Cary Howie, at (812) 341-3668. 4
8FBCU20, 8FBCU25, 8FBCU30, 8FBCU32 7BPUE15, 7HBW23, 8FGCU15, 8FGCU18, 8FGCSU20, 8FGCU20, 8FGCU25, 8FGCU30, 8FGCU32, 8FDU15, 8FDU18, 8FDU20, 8FDU25, 8FDU30, 8FDU32, 7FDU15, 7FDU18, 7FDU20, 7FDU25, 7FDU30, 7FDU32 5