Toyota DHU4 - Installation Instructions

Date: 10th of December 2021

Model Name: DHU4

Model: RRE160

Introduction

This document provides installation instructions for the Toyota DHU4 telematic node and its associated antenna. The DHU4 is a telematic node intended for stationary installation within Toyota forklifts. It features wired connections for power and CAN buses, and communicates wirelessly via LTE, WiFi, and Bluetooth technologies, utilizing an external antenna.

Image shows the Toyota DHU4 unit on the left, connected via a four-port mini-fakra to a Smarteq antenna on the right. The DHU4 is a telematic node designed for stationary installation in a Toyota forklift, featuring wired connections for power and CAN buses, and wireless communication via LTE, WiFi, and Bluetooth.

The following pages detail a typical forklift installation of the DHU4 and antenna. While specific forklift variants may differ, the general procedure and application remain consistent.

Revision History

Date	Revision Notes	PIC	Approved	Revision
9/24/2021	Initial Draft	VP		1.0

Installation Instructions

1. Purpose

This document describes the DHU4 and antenna installation performed on RRE 160 truck models.

2. Scope

This document applies to DHU4 and antenna installation used by TOYOTA Material Handling Manufacturing Sweden AB (TMHMS).

IMPORTANT: These installation instructions are for RRE160 models only. Installation instructions for other forklift truck models may be similar.

3. General Safety Precautions

WARNING! Wear safety glasses, safety shoes, and gloves at all times. Failure to do so may result in serious injury or death.

WARNING! Watch hand placement for pinch points. Failure to do so may result in serious injury.

CAUTION! Do not handle the DHU4 assembly roughly or drop it. If the DHU4 is handled roughly or dropped, it will need to be replaced due to damage and functioning issues.

CAUTION! Do not handle the cable assembly roughly or drop it. If the cable assembly is dropped, it will need to be replaced due to damage and functioning issues.

3.1 Antenna and DHU Installation Location Overview

The DHU4 unit and antenna are installed in specific locations on the forklift. The exact placement may vary slightly between Cabin and STD models.

Diagrams show the installation locations for the antenna and DHU unit on both a Cabin model forklift (left) and a STD model forklift (right). The antenna is typically mounted on the roof, and the DHU unit is mounted within the forklift structure.

3.2 DHU4 Assembly Installation and Cables Connection

This section details the mounting of the DHU4 unit onto its bracket and the initial cable connections.

3.2.1 Mounting the DHU4 Unit

Mount the DHU4 onto the bracket as shown in the illustrations. Align the DHU4 holes to the bracket holes and hand-start the screws, then tighten.

Illustrations depict the mounting of the Sub Assembly DHU4 Controller onto a green bracket. The process involves aligning the DHU4 holes with bracket holes and using four screws (part number 22338 x4) for attachment.

3.2.2 Tightening Screws

Use an electric impact tool to tighten the screws to a torque of TT = 4.5 Nm C.

3.3 DHU4 Assembly Installation to Drive Motor

Install the DHU4 assembly with the bracket to the right-hand side of the drive motor.

Illustration shows the Sub Assembly DHU4 Controller mounted on its bracket, positioned on the right-hand side of the drive motor assembly. A connector (part number 7683721) is visible on the DHU4 unit.

3.4 Antenna Installation

Instructions for installing the external antenna.

WARNING! The antenna should not be installed within 200 mm (8 inches) of the operator.

3.4.1 Antenna Placement

For Cabin and STD models, install the antenna on the roof.

3.4.2 Securing the Antenna

Align the antenna on the roof in the dedicated hole. Hand-start the bolt from below, then tighten.

Illustrations show the antenna being installed on the roof of a forklift. A red circle highlights the mounting area on the roof. A close-up view shows the antenna bolt being secured from below.

3.5 Antenna Cable Installation

This section covers the routing and securing of the antenna cable.

3.5.1 Cable Location Overview

Applicable for both Cabin and STD models. The antenna cable installation is routed along the Main Roof Cabling and Main Driver Cab Cabling.

A diagram shows a forklift with the DHU4 and antenna system installed. Orange lines indicate the intended routing path for the antenna cable, following the main roof cabling and the main driver cab cabling.

3.5.2 Routing along Main Roof and Driver Cab Cabling

The antenna cable is routed along with the Main Roof Cabling and Driver Cab Cabling. First, press a clamp into the roof bracket, then place the cable into it. Ensure the clamp is secure in the bracket and the cable is secure within the clamp.

3.5.3 Securing to Roof Post Bracket

Secondly, press a clamp into the roof post bracket, then place the cable into it. Ensure the clamp is secure in the bracket and the cable is secure within the clamp.

Diagrams illustrate the antenna cable routing. One diagram shows the antenna and antenna cabling on the roof. Another shows the Main Roof Cabling. The process involves using clamps to secure the antenna cabling along the roof and post structures.

3.5.4 Connecting Main Roof and Driver Cab Cabling

For both Cabin and STD models, the Main Roof Cabling is connected to the Main Driver Cab Cabling using connectors X60 and X61. Ensure the connectors are secured in their tabs and that the cable is also securely installed to the clamps.

Illustrations show close-ups of the connectors X60 and X61, used to connect the Main Roof Cabling to the Main Driver Cab Cabling.

3.5.5 Securing Main Driver Cab Cabling

Ensure the Main Driver Cab Cabling is secured to the clamps and that the clamps are secured into the chassis.

An illustration shows the Main Driver Cab Cabling secured to clamps within the forklift chassis.

3.5.6 Final Antenna Cabling and Connection to DHU4

Make sure the antenna cabling is secured to the clamps and that the antenna connectors are securely installed into the DHU4 unit.

An illustration shows the final antenna cabling and its connection to the DHU4 unit. Labels indicate 'Antenna connector to DHU', 'Antenna cabling', and the 'DHU' unit (part number 7683721).

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