Toyota 02-8FGF15 User manual

Operator’s Manual en
Manual del operador es
Manuel de l’opérateur fr
Fahrerhanduch de
Gebruikershandleiding nl
Publication No A5028-0EA05 PRINTED IN FRANCE
English
Spanish
French
German
Dutch
013010-G
02-8FGF15,18,20,25,30
02-8FDF15,18,20,25,30
32-8FGF15,18,20,25,30
62-8FDF15,18,20,25,30
52-8FDF20,25,30
02-8FGKF20
02-8FDKF20
02-8FGJF35
02-8FDJF35
52-8FDJF35
32-8FGJF35
TOYOTA Material Handling Europe

Operator’s Manual
(Original)
Manual del operador
(Traducción del manual original)
Fahrerhanduch
(Übersetzung des Originalhandbuchs)
en (English)
es (Español)
de (Deutsch)
Manuel de l’opérateur
(Traduction du manuel original)
fr (Français)
Gebruikershandleiding
(Vertaling van de originele handleiding)
nl (Nederlands)
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en-2
ENGLISH
CONTENTS
Note to Operators and Supervisors ....................................................................................................... 2
Before Initial Operation ........................................................................................................................ 2
Caution Plates ....................................................................................................................................... 6
Main Components............................................................................................................................... 10
Driving Controls and Instrument Panel .............................................................................................. 10
Instruments.......................................................................................................................................... 11
Multifunction Display (Option) .......................................................................................................... 15
Switches and Levers ........................................................................................................................... 21
Body Components............................................................................................................................... 32
Handling the Toyota DPF-II System (Option).................................................................................... 42
Pre-Operation Check........................................................................................................................... 45
Before Garaging the Vehicle............................................................................................................... 51
Weekly Maintenance........................................................................................................................... 51
Self Servicing...................................................................................................................................... 53
Fuel Tank Check ................................................................................................................................. 56
Frame Serial Number.......................................................................................................................... 56
How to Read the Name Plate.............................................................................................................. 57
Lubrication Chart ................................................................................................................................ 57
Periodic Maintenance ......................................................................................................................... 58
Periodic Replacement Table ............................................................................................................... 58
Protect Your Investment with Toyota Genuine Parts.......................................................................... 58
Periodic Maintenance Table................................................................................................................ 59
Service Data........................................................................................................................................ 63
LPG Device (Option).......................................................................................................................... 65
Wheel & Tire ...................................................................................................................................... 73
Vehicle Dimensions ............................................................................................................................ 74
NOTE TO OPERATORS AND SUPERVISORS
This manual explains the correct operation and maintenance of Toyota Industrial vehicles as well as
daily lubrication and periodic inspection procedures.
Please read this manual thoroughly even though you may already be familiar with other Toyota
Industrial vehicles because it contains information which is exclusive to this series of vehicles. The
manual has been produced based on a standard vehicle. However, if you have questions on other
types, please contact your Toyota Industrial vehicle dealer (Toyota dealer).
In addition to this manual, it is essential that you review the separate publication entitled
“Operator’s Manual for Safety Operation” for forklift vehicle operators. It contains important
information about the safe operation of forklift vehicles. Toyota reserves the right to make any
changes or modifications of specifications in this manual without giving previous notice and without
incurring any obligation.
BEFORE INITIAL OPERATION
•Please read this manual thoroughly. This
will give you a complete understanding of
Toyota industrial vehicles and permit you to
operate them correctly and safely.
Correct handling of new vehicles promotes
performance and extends service life. Drive
with special caution while becoming famil-
iar with a new vehicle.
In addition to the standard operating proce-
dures, pay attention to the following safety
items.
•Please acquire thorough knowledge of the
Toyota Industrial vehicle. Read the opera-
tor’s manual thoroughly prior to operating
the vehicle. Get to know its operation and
components. Learn about the safety devices
and accessory equipment and their limits and
precautions. Be sure to read the caution plate
attached to the vehicle.
•Please learn safe driving points and safety
management. Understand and maintain
working area traffic rules. Ask the work area
supervisor about any special working pre-
cautions.
•Wear neat clothing for operation.
Improper clothing for vehicle operation may
interfere with smooth operation and cause an
unexpected accident. Always wear appropri-
ate clothing for easy operation.
•Please keep away from live electric power
lines. Know the locations of inside and out-
side power lines and maintain sufficient dis-
tance.
•Be sure to perform pre-operation checks
and periodic maintenance. This will pre-
vent sudden malfunctions, improve work
efficiency, save money and insure safe work-
ing operation.
• Always warm up the engine before start-
ing operation.
•Be sure to avoid forward tilt when the
forks are elevated with a load. In the worst
case, this will cause overturning due to poor
stability resulting from forward shifting of
the center of gravity.
•Never attempt traveling when the forks
are elevated with a load beyond the speci-
fied height. Traveling with a load on the
forks elevated beyond the specified height
may cause overturning due to the upward
shift of the center of gravity. Keep the forks
weight at 10-20cm (6-8in) above the ground
when traveling.
•Please avoid overloading or uneven load-
ing. Overloading or an uneven load is dan-
gerous. If the center of gravity is not evenly
distributed, i.e. nearer to the front side of the
load and the load is below the maximum,
limit the load weight according to the load
rating table.
• If you hear any unusual noise or sense
anything unusual, stop, inspect and repair
immediately.
• Be sure to observe the correct operating
procedures and precautions for the opera-
tion of vehicles equipped with power
steering and power brakes.
•If the engine stops during traveling, this
will affect the operation. Stop the vehicle
in a safe place as described below. Steering
operation becomes heavy because the power
steering becomes ineffective. Operate the
steering wheel more firmly than usual.
•Please use only the recommended types of
fuel and lubricants. Low-grade fuel and
lubricants will shorten service life.
Diesel fuel
Recommendation
Use diesel fuel with a cetane index of 46 or
more and a sulfur content of not more than
10 ppm that is based on European diesel fuel
standard EN590/2009.
Caution
Caution
In winter, use winter diesel fuel to prevent
clogging of the fuel filter caused by paraffin
precipitation.
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• Flammable and/or combustible materials
can be damaged and in some cases ignited
by a hot exhaust system or hot exhaust
gases. To minimize the possibility for such
damage or fire, the operator must obey
the following recommended practices:
• Do not operate the lift vehicle over or near
flammable and/or combustible materials,
including dried grass and paper scraps.
• Park the lift vehicle with rear end at least
30 cm (12 in) away from lumber, veneer
board, paper products and other similar
materials to avoid discoloration, deforma-
tion or combustion of those materials.
• For the vehicles using color tires, a static
strap must be fixed.
Safety requirements
• Trucks equipped with a load bearing clamp
(e.g. paper clamp) shall feature control(s)
with a secondary action to prevent uninten-
tional release of the load. When any “load
bearing clamp” is used on a lift truck, the
control (hydraulic hand lever for example)
must be configured to conform to the
ISO3691-1.
Precautions to be taken when using
SAS models
(SAS: System of Active Stability)
Note:
Some models are not equipped with the SAS
system. Regarding SAS models, contact a
Toyota dealer.
Caution
Caution
• Whenever you get on an SAS models,
please check the caution plate, which will
inform you what functional features are
provided on the vehicle. Do not proceed to
operate the vehicle before making certain
that each of the features is operating cor-
rectly.
• For those models fitted with double/dual
wheels, there is no rear tire swing lock
control cylinder/stabilizer.
• While driving the vehicle, be alert about
any warning lamp that may appear.
Should an error code be indicated by a
warning lamp or the hour-meter, park the
vehicle at a safe location and ask a Toyota
dealer for an inspection.
• The SAS, which is electronically con-
trolled, may need to be initialized after
completion of a maintenance operation. Do
not remove or modify any SAS features.
Whenever an inspection may be necessary,
make contact with a Toyota dealer.
• When washing the vehicle, carefully pre-
vent water from spraying directly over
the electronics (controller, sensor and
switches) employed in the SAS.
Description of features available in
SAS models
Active control rear stabilizer:
When the vehicle makes a turn on the spot, a
centrifugal force will be generated in the lateral
direction of the vehicle. In such an event, this
feature will operate so that the rear axle will be
locked from pivoting to support the vehicle on
four wheels. Thus, the vehicular stability will be
enhanced in both right and left directions.
Caution
Caution
With the rear axle locked from pivoting, the
stability will be increased. Nevertheless, it
does not signify that the vehicle would never
tipover. Operate the vehicle as outlined in
this manual.
Automatic forks leveling control
• With tilting the mast forward while pressing
the tilt lever knob switch will cause the fork
to automatically stop at its horizontal posi-
tion (the mast vertically positioned).
• After stopping the forks at its horizontal
position with the tilt lever knob switch
pressed, you may want to tilt the forks fur-
ther forward. To do this, return the tilt lever
to the neutral position once. Then, after
releasing the tilt lever knob switch, operate
the tilt lever.
When the tilt lever is operated from the back-
ward to forward position with the knob switch
depressed, the mast will perform as follows:
Caution
Caution
• With the mast titled forward with a load
on the forks and elevated, pressing the tilt
lever knob switch will cause the mast to
stop moving. Absolutely avoid such oper-
ation because this automatic forks level-
ing control, if operated while handling a
load, may cause the vehicle to tipover.
• In case of the vehicle with an attachment,
do not allow the forks to be automatically
positioned horizontally, with a load on the
elevated while the engine is running at
high rev. This will lead to a hazard.
• Some specialty models onto which a heavy
attachment is mounted may not be
equipped with the automatic forks level-
ing control. Confirm with a Toyota dealer
in advance.
Note:
• The mast will not move if it is tilted forward
by pressing the tilt lever knob switch with a
load at an elevated height (more than 2 m).
• When the mast is tilted forward from its ver-
tical position, it will not be possible to tilt
forward even if the tilt lever knob switch is
pressed.
• While it is tilting backward, the forks will
not stop at the horizontal position (mast ver-
tical) even if the tilt lever knob switch is
pressed. (except vehicles equipped with mini
lever or joy stick)
Active mast front tilt angle control
According to the lift and to the load, the angle at
which the mast can be tilted forward is automat-
ically controllable within a range of angles illus-
trated below.
Caution
Caution
• If a load is tilted forward at a low lift
height, and then the load is elevated there
is a fear that the vehicle may tip forward
when the load stops at a height having a
tilt angle beyond the specified angle
range. Always ensure the mast is vertical
when elevating the load or forks and only
tilt forward when the height required has
been reached.
• With a load at a high lift height, never
match the load (mast angle) by controlling
the mast forward tilt angle, since it
involves the fear that the vehicle may tip
forward.
• Even with a load positioned within the
allowable angle range, never tilt the mast
beyond its vertical position, or the vehicle
may tip over, losing its stability forward
or backward. Never tilt the mast forward,
with an elevated load.
Not load Loaded
High lift
height Stops with forks level (mast vertical) No forward tilt
Low lift
height Stops with forks level (mast vertical)
Light load
(no load) Intermediate load Heavy load
High lift
height No restriction for front tilt
angle
Anglerestricted
between 1°and
5°forward tilt
angle
Forward tilt
angle
restricted to 1°
Low lift
height No restriction for front tilt angle
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Caution
Caution
• Some specialty models onto which a heavy
attachment is mounted may not be
equipped with the mast forward tilt con-
trol. Confirm with a Toyota dealer in
advance.
• Once you have mounted or replaced any
attachment on a forklift, ask a Toyota
dealer for an inspection.
• If you use two or more removable attach-
ments alternately, the heaviest one should
be used to carry out matching (SAS set-
ting). Contact your Toyota dealer to
request compatibility matching.
• When attaching an attachment to a model
without forks, the attachment must be
compatible with the model. Contact your
Toyota a dealer to request compatibility
matching.
Note:
When the forks are elevated to the maximum
height, a high pressure (relief pressure) may
remain in the lift cylinder. This high pressure
causes the vehicle to judge that it has a high load
even if there is no load. As a result, the mast will
be stopped from tilting forward. In this case,
lower the forks slightly (to release the pressure)
and the mast may be tilted forward.
Active mast rear tilt speed control
• At a high lift height, the mast has a back-
ward tilt speed controller (slow down) irre-
spective of the load. When lowering from a
high lift height to a lower lift height while
tilting the mast backward, the control speed
will not change.
• At a low lift height, the mast can be tilted at
full speed even if there is a load. If the mast
is tilted backward at a low lift height with
the tilt knob switch pressed, the mast has the
backward tilt speed controlled (slowed
down) as long as the tilt lever knob switch is
pressed. (Except mini lever/joy stick mod-
els)
• If the low lift height is then changed to a
high lift height while tilting the mast back-
ward, the control speed will not change as
long as the tilt lever knob switch is pressed.
The mast may be tilted backward at the full
speed so long as the tilt lever knob switch is
not pressed.
Key-lift interlock
When the ignition switch is turned to OFF and
lowering the lift lever, the forks will not lower.
However, by sitting on the normal seated posi-
tion and turning the ignition switch to ON, the
forks will lower even when the engine is off.
(Except mini lever/joy stick models)
Active steering synchronizer
If the steering wheel knob is not angularly
matched with the steer tires, such out-of-posi-
tion will be automatically corrected while turn-
ing the steering wheel. Thus, the knob is kept at
a constant position relative to the steer tires.
If SAS feature should fail:
The SAS models are equipped with a controller,
sensors and various actuators. If any of these are
found not to be operating normally, it will tell
you that:
• Steering wheel knob is out-of-position may
not be corrected.
• Functions such as Automatic forks levelling
control, Active mast front tilt angle control,
Active mast rear tilt speed control may not
be operated.
• Swing lock cylinder may not be unlocked.
If any of the phenomena referred to above
should take place.
• Diagnosis lamp will light up or blink.
• Error code will be displayed in the hour
meter.
Thus, the operator will be informed. In such
an event, move the vehicle to a safe location
and ask a Toyota dealer to inspect and repair.
Action to be taken in emergency
Move the vehicle to a safe location and ask a
Toyota dealer for a repair.
If any phenomenon different from normal oper-
ations (failure to run or the like), among others,
should take place, ask a Toyota dealer for an
inspection.
Note:
Once a torque converter model has its control
lever abnormal, it is impossible to manually
operate the vehicle, which need be towed,
accordingly.
OPS System
The OPS (Operator Presence Sensing) System
prevents traveling and load handling operations
when the operator is not seated in the operator’s
seat.
If the operator leaves the operator’s seat while
the vehicle is operating, the OPS lamp will light
up, and a buzzer will sound for one second to
warn the operator that the OPS System will be
activated. If the operator leaves the operator’s
seat for longer than two seconds, the OPS Sys-
tem will be activated and traveling and load
handling operations will be stopped. However,
if the operator returns to the normal seating
position within two seconds, the OPS System
will not activate and will allow travel and load
handling operations to continue.
Again, if an abnormality occurs to the OPS Sys-
tem, the diagnosis lamp will blink to warn the
operator. In this case, the OPS System may have
malfunctioned. Contact your Toyota dealer to
request an inspection.
This forklift is equipped with an OPS (Operator
Presence Sensing) System. Before operating the
forklift, check that each of the System’s func-
tions is working correctly.
Travel OPS Functions
If the operator leaves the seat while the vehicle
is traveling, the OPS lamp will light up, and two
seconds later, traveling will be stopped. How-
ever, this does not apply the brakes to stop
travel. (If the operator returns to the normal
seating position within 2 seconds, traveling can
be continued.)
If the OPS System is activated while driving up
a slope or incline, the drive to the front wheels is
stopped and consequently the vehicle will roll
back down the slope incline. To avoid this prob-
lem, make sure to sit on the seat at all times.
If more than 2 seconds has elapsed, apply the
brakes, return the control lever to the neutral
position and sit on the seat again.
Load Handling OPS Function
Forklifts with a standard lever
If the operator leaves the seat during operations,
the OPS lamp will light up, and two seconds
later, load handling operations will be stopped.
(If the operator returns to normal seating posi-
tion within 2 seconds, loading can be contin-
ued.) If the operator leaves the seat while
operating the control lever, loading can be con-
tinued for 2-4 seconds.
If load-handling OPS is activated when the lift
lever is in the lowering position, move the lever
to a position other than the lowering position
and return to the normal seated position to deac-
tivate load handling OPS. If load-handling OPS
is activated when the lift lever is in a position
other than the lowering position, load handling
OPS is deactivated 1 second after the operator
returns to the normal seated position.
Forklifts with a mini lever/joy stick lever
(Option)
If the operator leaves the seat during load han-
dling operations, the OPS lamp will light up,
and two seconds later, load handling operations
will be stopped. (If the operator returns to the
seat within 2 seconds, load handling operations
can be continued.)
To resume load handling functions, return to the
seat and return all of the levers to the neutral
position.
OPS Operation Functions
If the operator leaves the seat, a buzzer will
sound for approx. one second (“pii”) and the
OPS lamp will light up and inform the operator
that the OPS System is active. If the operator
returns to the normal seating position, the OPS
lamp will turn off.
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Return-to-Neutral Warning
If the OPS System has caused traveling opera-
tions to stop, and the operator is re-seated while
the control lever is not returned to the neutral
position, the buzzer will sound (“pi, pi, pi...”)
indicating that the travel OPS functions has not
been deactivated.
Forklifts with a standard lever
If the OPS System has caused load handling
operations to stop, and the operator is re-seated
while the lift lever is still set in the lowering
position, the buzzer will sound (“pi, pi, pi...”)
indicating that suspension of lowering has not
been deactivated.
Forklifts with a mini lever/joy stick lever
(Option)
If the OPS System has caused load handling
operations to stop, and the operator is re-seated
without returning all load handling levers to
neutral position, the buzzer will sound (“pi, pi,
pi...”) indicating that the OPS System has not
been deactivated.
SAS/OPS Controller Abnormality
Warning
If the SAS/OPS System registers an abnormal-
ity, the diagnosis lamp will blink to inform the
operator.
If the diagnosis lamp starts blinking, the SAS/
OPS System may have malfunctioned. Park the
vehicle at a safe location and request an inspec-
tion by your Toyota dealer.
In the following cases, park the vehicle in a safe
location and have the vehicle inspected by your
Toyota dealer.
• The OPS lamp does not light up even if the
operator leaves the seat.
• The OPS lamp does not turn off even if the
operator is re-seated. (In the case of diesel
engine vehicles, the diagnosis lamp may
light up during engine warm-up after a cold-
start, but does not indicate an abnormality.)
Caution
Caution
When the ignition switch is turned to OFF,
and the operator has been seated for a long
period, there are the cases where the OPS
lamp blinks when the ignition switch is
turned to ON. In that case, the light will go
out by leaving the seat once and return to the
normal seated position.
The Auto Speed Control Functions
(Option)
Caution
Caution
• The optional Auto Speed Control Func-
tions limit maximum travel speed and
high speed acceleration relative to load
height and weight and reduces the
chances of tip-overs. However, this feature
will not prevent all tip-overs in all circum-
stances.
• According to road surface conditions and
loading operations, temporary changes in
speed limits and sense of acceleration may
be experienced.
• During operation using the inching and
brake pedal, temporary changes in speed
limitations and sense of acceleration may
be experienced.
• There are cases where the idle-up of
engine increases the vehicle speed, when
the lift lever is operated upward on the
idle conditions.
Speed limits after load lifting height
and weight sensing
(Maximum speed limiter)
When the load is in an elevated position, this
function limits the maximum speed in accor-
dance with the weight of the load. This function
reduces instability caused by sudden stopping.
Note:
• Although the maximum speed limiter will be
deactivated when the load is lowered, sud-
den accelerations will remain limited until
the accelerator pedal is re-engaged.
• If the load height is raised when the speed
limit is exceeded, the speed will be gradually
reduced until the set speed limit is reached.
(Auto speed control indicator)
Auto speed control indicator will be displayed
to inform the operator the speed limit after load
lifting height and weight sensing is in operation.
Load height and weight sensors to
prevent sudden acceleration
(Acceleration limiter)
When the load is in an elevated position, this
function limits sudden acceleration of the vehi-
cle in accordance with the weight of the load.
(Preventing sudden starts)
When the load is in an elevated position at a
high engine rev, this function will suppress the
sudden acceleration of the vehicle and resultant
loss of the load even if the vehicle is operated
erroneously such as by abruptly releasing the
brake pedal or the inching and braking pedal
while the accelerator pedal is engaged, or by
setting the control lever in forward or reverse
direction.
(Loading priority function)
If you depress the clutch and brake pedal when
the load height and weight sensors to prevent
sudden acceleration in operation or when the
control lever in neutral and re-press the acceler-
ator only if below constant speed, this function
will release the Maximum speed limiter and the
Acceleration limiter to reduce the impact of
loading.
(Function on/off indicator)
When the load height and weight sensors to pre-
vent sudden acceleration in operation and the
speed limits after load lifting height and weight
sensing is de-active, the function on/off indica-
tor will be displayed to inform the operator.
Low speed setting
When the low speed setting switch is pressed,
traveling will not be possible at the preset speed
or greater.
Pressing the low speed setting switch again will
deactivate this function.
Maximum speeds can be set between approxi-
mately. 8-15 km/h.
Note:
• Depending on the vehicle weight, the set
speeds may not be attained while traveling
uphill. Similarly, the set speed may be
exceeded during downhill travelling, but
will resume at the set speed when it is
reached after going down the hill.
• When a maximum speed limit has also been
set, the lower speed setting will take prece-
dence.
• Depending on road surface changes and the
vehicle conditions, the set speed may be
exceeded temporarily.
• When setting the maximum speed, consult
your supervisor or a Toyota dealer.
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Maximum speed limit
This function prevents the vehicle from travel-
ing at a faster speed than a speed preset by your
supervisor or company. The maximum speed
can be set between approximately. 8-15 km/h.
Note:
• Depending on the vehicle weight, the set
speed may not be attained while traveling
uphill. Similarly, the set speed may be
exceeded during downhill travelling, but
will resume at the set speed when it is
reached after going down the hill.
• Depending on road surface changes and the
vehicle conditions, the set speed may be
exceeded temporarily.
• When setting the maximum speed, consult
your supervisor or a Toyota dealer.
Increasing the idling lifting speed
When the lift lever is raised, the forks can be
raised at a steady speed without pressing on the
accelerator pedal to increase the engine rev.
Note:
• There are circumstances where the idle-up of
engine increases the vehicle speed when the
lift lever is operated.
• The lifting speed will differ depending on
the vehicle model, specifications, and load
conditions.
Recycling/discarding
In accordance with EU Directive 2006/66/EC,
This symbol indicates ‘separate collection’ for all batteries and accumula-
tors.
Your truck uses a lead accumulator and, in case of some battery-powered
truck, a lithium battery.
Materials contained in batteries (include accumulators) are hazardous to
the environment and humans, so batteries should be returned to the manu-
facturers for recycling.
Discarding the battery
When the working life of the battery in the truck is at an end (exchange to a new battery) or if the
entire truck is to be scrapped, special regard to environmental risks shall be taken when disposing/
recycling batteries.
Consult our Toyota service dealers about exchange or discarding the batteries.
CAUTION PLATES
Caution plates are attached on a vehicle. Before driving it, please be sure to read them thoroughly.
When caution plates become unreadable, dirty, or damaged, replace with new ones. Regarding cau-
tion plate indicators, ask a Toyota dealer.
(The sample shows those of an English version.)
About these marks
Warnings! Please read this Operator's Manual carefully before
use.
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Warning labels
Warning labels comprise of signal words, pictographs, and text to explain about the level of danger, dangerous incidents that might happen, and how to avoid them. Make sure to read warning labels thor-
oughly before operation and act according to the instructions.
Explanation about pictographs
(1) Signal words
(2) Signal color
(3) Pictographs
(4) Text
(1) Signal word →(2) Signal color
• DANGER →Red
Disregarding instructions incurs the risk of death or severe injury.
• WARNING →Orange
Disregarding instructions incurs the potential risk of severe injury or death.
•CAUTION→Yellow
Disregarding instructions incurs the risk of light injury. Or the mark warns about the unsafe act.
(3) Pictographs
Illustrations show dangerous incidents that might happen, the extent of damage, and how to avoid danger.
(4) Text
Text explains about dangerous incidents that might happen, the extent of damage, and how to avoid danger.
Symbols Explanation about symbols. Symbols Explanation about symbols. Symbols Explanation about symbols.
General Prohibition Read operator's manual Read operator's manual
Read operator's manual Read operator's manual Fuel
(2)
(3)
(4)
(1)
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Unleaded Gasoline Explosion Corrosion
Diesel fuel Diagnosis lamp Parking Brake-On
Parking brake OPS lamp Recycle
Check Hydraulic oil Level Crash the hand or finger Crossed-out wheeled bin
Ventilating and air-circulating fan Safety Glass Fasten the seat belt
No open flame Keep out children Keep off under the fork
Symbols Explanation about symbols. Symbols Explanation about symbols. Symbols Explanation about symbols.
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Keep off on the fork Knob position Control Do not water to the DPF Air Cleaner
Lean away from the direction of tipover Mast Control
Grip the steering and brace your feet in
case of a truck tipover. Swing Lock Control
Do not jump, stay with the truck in case of
a truck tipover. No SAS Mast Control
Do not open the cap when the coolant is
hot No Swing Lock Control
How to hoist the truck
(Vehicle hoisting method)
Do not water to the DPF Muffler
Symbols Explanation about symbols. Symbols Explanation about symbols. Symbols Explanation about symbols.
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MAIN COMPONENTS
1. Mast
2. Chain
3. Forks
4. Tilt cylinder
5. Rear axle
6. Engine hood
7. Operator’s seat
8. Head guard
9. Counter weight
10. Frame
11. Front axle
12. Lift cylinder
13. Steering wheel
1
2
3
45
6
7
8
9
10 11
12
13
DRIVING CONTROLS AND INSTRUMENT PANEL
1. Control lever
2. Steering wheel
3. Horn button
4. Light control and turn signal switch
5. Lift lever
6. Tilt lever
7. Tilt lever knob switch
8. Multi function display (Option)
9. Combination meter
10. Accelerator pedal
11. Brake pedal
12. Ignition switch
13. Parking brake release lever
14. Inching and brake pedal
15. Tilt steering adjust lever
16. Parking brake pedal
1
16
23 45678
15 14 13 12 11 10 9
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INSTRUMENTS
Gasoline engine models
Diesel engine models
Combination meter
Meters and warning lamps are arranged as
shown in the left figures.
1. Water temperature gauge
2. Hour meter
3. Brake warning lamp
(OK monitor: Option)
4. Sedimenter warning lamp
(Diesel engine models)
5. Fuel gauge
6. Engine check lamp
(Gasoline engine models)
7. Glow indicator lamp
(Diesel engine models)
8. Engine oil pressure warning lamp
9. Charge warning lamp
10. OPS lamp
11. Diagnosis lamp
12. Air cleaner warning lamp
(OK monitor: Option)
13. Coolant level warning lamp
(OK monitor: Option)
1
10
23
56 8 9 11 12 13
1
10
23
457 8 9 11 12 13
(1) Start
Warning lamp check method
Please check if all warning lamps come on
when the ignition switch is turned to ON.
Note:
Use the light control switch to check the meter-
lighting lamp.
Caution
Caution
• The glow indicator lamp (Diesel engine
models) is only on for 2 seconds when the
engine coolant temperature exceeds
50°C.
• If a lamp does not light up, contact your
Toyota dealer to request an inspection.
Hour meter also serving as diagno-
sis indicator
The hour meter operates when the ignition
switch is turned to ON. It indicates the total
number of vehicle operating hours.
The unit of the right most digit is 1/10 hour.
Please use this meter for the timing of periodic
maintenance and recording the operation
hours.
When an abnormality occurs to the vehicle
(diagnosis lamp lights up or blinks) the error
code and hour meter will be alternately dis-
played.
Caution
Caution
Should an error code be displayed, park the
vehicle in a safe location and contact your
Toyota dealer to request an inspection.
(1)
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Engine oil pressure warning lamp
Comes on to indicate low engine oil pressure
while the engine is running.
1. If normal, the lamp comes on when the
ignition switch is turned to ON and goes
off when the engine starts.
2. If the lamp comes on while the engine is
running, either the engine oil is low or the
lubrication system is faulty. Stop the
operation immediately and ask a Toyota
dealer for inspection and repair.
Note:
The “engine oil pressure warning lamp” does
not indicate the oil level. Check the oil level
using the oil level gauge before starting work.
Sedimenter warning lamp
(Diesel engine models)
The sedimenter is a device for separating water
from the fuel.
1. The warning lamp comes on to indicate
water in the sedimenter exceeds the pre-
determined level while the engine is run-
ning.
2. If normal, the lamp comes on when the
ignition switch is turned to ON and goes
off when the engine starts.
3. If the lamp comes on while the engine is
running, drain water immediately. (See
the self service section for the draining
instructions.)
Caution
Caution
Continued operation with the lamp on may
cause seizure of the injection pump and
pump damage. If the warning lamp lights
up, always make sure to drain the water.
Glow indicator lamp
(Diesel engine models)
Indicates heating of glow plugs.
When the ignition switch is turned to ON, the
lamp comes on and glow plug heating begins.
The lamp goes off automatically when glow
plug heating is complete. The engine will start
easily once the glow plugs are heated.
Note:
The glow indicator lamp is on for 2 seconds
when the engine coolant temperature exceeds
50°C.
Engine check lamp
(Gasoline engine models)
1. When an error occurs to the engine con-
troller, the display will light up to inform
the operator.
2. When condition is normal, the lamp will
light up when the ignition switch is
turned to the ON position. The lamp will
turn off when the engine is started.
Caution
Caution
If the engine check lamp lights up during
operation, stop operations and park the
vehicle in a safe location, ask your Toyota
dealer to perform an inspection.
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Charge warning lamp
1. This lamp comes on to indicate an abnor-
mality in the charging system while the
engine is running.
2. If normal, the lamp comes on when the
ignition switch is turned to ON and goes
off when the engine starts.
3. If the lamp comes on while the engine is
running, stop immediately, park the vehi-
cle in a safe location, stop the engine and
after the engine has cooled down inspect
the fan belt for cuts or looseness, adjust it,
and restart the engine.
If lamp does not go off, the electrical sys-
tem may be faulty.
Please ask a Toyota dealer immediately
for inspection and repair.
OPS lamp
If the operator leaves the seat, the OPS lamp
will light up, indicating that the OPS System is
operating. (If the operator returns to normal
seating position within 2 seconds, loading can
be continued.) In such a situation, return the
control lever and lift lever to the neutral posi-
tion, then sit on the seat again.
Caution
Caution
In the following cases, a malfunction may
have occurred to the OPS System. Park the
vehicle in a safe location and contact your
Toyota dealer to request an inspection.
• If the operator leaves the seat, the OPS
lamp does not light up.
• Even when the operator re-seats, the OPS
lamp does not turn off.
Water temperature gauge
Indicates the temperature of the engine cool-
ant.
1. This gauge functions with the ignition
switch ON, and displays the coolant
water temperature from left to right in a
10-stage gradation scale.
2. The operator will be notified when the
water temperature is 115ºC or over
(above 8th stage), as the final two stages
at far right begin blinking. Again, when
the engine protection function activates
(for vehicles with Multifunction display:
Option), the entire gauge will start blink-
ing to inform the operator.
3. Temporary overheating may be caused by
coolant leakage, low engine coolant level,
loosened fan belt, or other problem in the
cooling system. Contact your Toyota
dealer to request an inspection.
Fuel gauge
(Excluding LPG models)
Indicates the amount of remaining fuel in the
fuel tank in terms of a 10-stage gradation scale.
The operator will be notified that remaining
fuel level is low when the two stages at far left
start blinking.
It takes some time for the indication to be sta-
bilized after refuelling and the ignition switch
is turned to ON.
Note:
• If the operating area is not level, atten-
tion must be paid because the correct
level may not be indicated.
• When the gauge begins blinking, refuel
as soon as possible.
• In case of diesel engine, be sure to refuel
it before it runs out because when this
occurs it becomes necessary to bleed air
from the fuel supply system.
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Diagnosis lamp
If an abnormality is registered by the SAS,
OPS, mini lever, or Auto speed control, the
respective lamps will light up or blink to
inform the operator and the diagnosis error
code will be displayed in the hour meter dis-
play area.
If the following conditions occur to the lamp,
there may be a system abnormality. Contact
your Toyota dealer to request an inspection.
• The lamp does not light up when the igni-
tion switch is turned ON.
• The lamp lights up when ignition switch is
turned ON and stays ON.
• The lamp blinks during ignition switch is
turned ON.
Caution
Caution
• Continuing to use the vehicle while the
diagnosis lamp is lighted or blinking
may lead to a breakdown. When the
lamp lights up or blinks, halt all opera-
tions and park the vehicle in a safe loca-
tion. Contact your Toyota dealer to
request an inspection. (In the case of die-
sel engine vehicles, the diagnosis lamp
may light up during engine warm-up
after a cold-start, but does not indicate
an abnormality.)
• If the operator remains seated for a long
period with the ignition switch turned to
OFF, the next time the ignition switch is
turned to ON, the diagnosis lamp may
start blinking. If this occurs, leave the
seat. The diagnosis lamp will then turn
off.
(1) Brake warning lamp
(2) Coolant level warning lamp
(3) Air cleaner warning lamp
OK monitor (Option)
Senses the engine coolant level, brake fluid
level, clogged air cleaner element and parking
brake status. The lamp comes on to indicate a
problem. If the lamp comes on when the igni-
tion switch is on (irrespective of the engine
speed), the corresponding part may be abnor-
mal. Contact your Toyota dealer to request an
inspection.
Caution
Caution
Always perform pre-operation checks. Do
not rely on the OK monitor, even if it is not
lit.
Brake warning lamp
When the parking brake is engaged or brake
liquid is low, the warning lamp will light up to
notify the operator.
1. The warning lamp will light up when the
parking brake is engaged. After disengag-
ing the brake to operate the vehicle,
check to make sure the warning lamp has
turned off.
2. The lamp will light up to notify the opera-
tor when the brake oil is low.
Caution
Caution
• If the warning lamp does not turn off
when the parking brake is disengaged,
the brake fluid may be low. Inspect the
brake fluid level and replenish it if neces-
sary.
• If the warning lamp remains a lighted
even if the brake fluid level is sufficient,
contact your Toyota dealer to request an
inspection.
(1)
(2)
(3)
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Coolant level warning lamp
1. When the coolant level of the radiator
reserve tank becomes low, the indicator
lamp will light up to notify the operator.
2. If the lamp lights up while the engine is
running, this may indicate a deficiency in
coolant. Stop the engine and inspect the
coolant level in the radiator reserve tank
and the radiator. Before checking coolant
level in the radiator wait for it to cool as it
maybe under pressure when hot.
Note:
Even if the coolant level warning lamp is not
lighted, always inspect the coolant level before
starting operations.
Air cleaner warning lamp
1. This lamp comes on when the air cleaner
element gets clogged while engine is run-
ning.
2. If normal, the lamp comes on when the
ignition switch is turned to ON and goes
off when the engine starts.
3. If the lamp comes on while the engine is
running, stop operations and park the
vehicle in a safe location, stop the engine
and clean the element and dust cup. For
the cleaning method, refer to the Weekly
Inspection Section in this manual.
MULTIFUNCTION DISPLAY (OPTION)
1. Multifunction display area
2. Down switch
3. Left switch
4. Right switch
5. Meter display switch
6. Low speed setting switch (Only for DX
models with Auto speed control)
(Multifunction display DX:
Vehicles with Auto speed control)
1
2 3 4 5
6 3 4 5
(Multifunction display)
(Multifunction display DX)
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(1) Meter display switch
DISPLAY SCREEN TABLE
From the standard screen display, pressing the
meter display switch will change the display
between ODO, TRIP, and Maintenance Hour
Meter display screens.
Note:
Always operate the switch panel with your fin-
ger tips and when the vehicle is stopped.
Start screen
When the ignition switch is turned to ON, the
start screen will appear for 1 second.
Maintenance display
ODO • TRIP Meter display
Digital speed meter display
(1)
(1) Torque converter oil temperature gauge
Standard screen
Vehicle speed is digitally indicated in km/h at
the top of the screen. At the bottom of the
screen, torque converter oil temperature is
indicated in a 10-stage level.
(1) Low speed setting switch or down switch
ODO • TRIP meter
ODO......... Displays the total distance traveled.
TRIP.........After resetting this function, dis-
plays the total distance traveled
until now.
Note:
• Pressing the low speed setting switch (DX
models with Auto speed control) or the
down switch for more than 2 seconds will
reset the total travel distance.
• Always operate the switch panel with your
finger tips and when the vehicle is stopped.
Maintenance hour meter
Displays the set value and current value of the
maintenance hour meter.
CURRENT...............Displays the current time.
SETTING.................Displays the maintenance
hour time setting.
The maintenance hour meter time setting can
be set between 10-2000 hours. 10-200 hours
setting can be set in 10 hour intervals, and 200-
2000 hours setting can be set in 50 hour inter-
vals.
Note:
To change the time setting, consult your super-
visor or Toyota dealer.
(1)
(1)
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Load meter
(Only with DX models)
Pressing the lift lever knob switch or the load
meter switch (mini lever models) will allow
the operator to confirm the weight of the load
being handled.
Note:
In the case of joy stick models (Option), the
load meter switch and fork automatic leveling
control switch functions are combined.
1. Adjust the load to a height of 500mm
above ground level and set the mast verti-
cal.
2. In the standard screen, press the lift lever
knob switch or the load meter switch
(mini lever models).
Note:
• For each operation, the meter reading will
display for 3 seconds. (the display will
remain indicated while the switch is held
down).
• Pressing the lift lever knob switch or the
load meter switch (mini lever models)
while the vehicle is traveling will not dis-
play the load display screen.
• If the load is less than 100kg, the meter will
indicate 0.00t.
Caution
Caution
This function should be used as reference
when conducting handling operations, and
not used in business dealings or as proof.
Load meter error display
When the load meter is operated while the load
is in an elevated position, an arrow will appear
at screen left and the measured weight indica-
tion will blink to notify the operator that the
reading is inaccurate.
To measure the load, always set the load to a
height of approximately 500mm above ground
and set the mast vertical.
Note:
If 0 is slightly deviated toward the minus side,
the display will indicate -0.00 t.
Load meter sensor error display
When the load meter sensor malfunctions, the
display will blink as indicated in the diagram at
left.
Note:
When the load meter sensor blinks to indicate
an error, contact your Toyota dealer to request
an inspection.
Maintenance indicator
When the preset maintenance time occurs, the
operator will be notified through the display
and a warning sound. Conduct necessary main-
tenance.
Note:
The maintenance time setting should be deter-
mined by the supervisor. For information on
setting the maintenance time, contact your
supervisor or Toyota dealer.
Diagnosis indicator
If an abnormality is registered within the Mul-
tifunction display, the operator is notified
through a warning sound together with diagno-
sis error content display.
Note:
• The error code display will be different
depending on the abnormal area and nature
of the abnormality. There are also occa-
sions when the error is not indicated
depending on the area of abnormality.
• When the diagnosis indicator is displayed,
contact your Toyota dealer to request an
inspection.
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(1) Low speed setting switch
Low speed setting indicator
(Only for DX models with Auto
speed control)
When low speed settings have been set, the
turtle mark is displayed.
Each time the low speed setting switch is
pressed, the turtle indicator will light up. When
the indicator is lighted, the low speed setting
control is active.
Note:
Always operate the switch panel with your fin-
ger tips.
Auto speed control indicator
(Only for DX models with Auto
speed control)
When the load height and weight sensors to
prevent sudden acceleration or the speed limits
after load lifting height and weight sensing are
in operation, the auto speed control indicator is
displayed to inform the operator.
Function on/off indicator
(Only for DX models with Auto
speed control)
Even when the speed limits after load lifting
height and weight sensing is deactivated, the
operator is notified via display indication that
the preventing sudden starts function is active.
(1)
Parking brake on warning
When the parking brake is engaged while the
lift vehicle is traveling, the warning indicator
will blink and a warning will sound to notify
the operator.
Caution
Caution
• If the vehicle is operated without disen-
gaging the parking brake, the brake will
lose effectiveness. Contact your Toyota
dealer to request an inspection.
• If the indicator lamp does not turn off
even when the parking brake is disen-
gaged, stop operations and contact your
Toyota dealer to request inspection.
Parking brake off warning
When the ignition switch is turned to OFF or
the operator leaves the seat while the parking
brake is disengaged, a warning sound will
warn the operator to apply the parking brake.
The warning will also be sounded if the opera-
tor returns to the normal seated position and
turns the ignition switch to ON while the park-
ing brake is disengaged.
Note:
• When the parking brake is applied, the
warning sound will stop.
• When leaving the driver's seat, always shift
to NEUTRAL, set the parking brake, lower
the forks, and tilt forward so the tips will
not trip pedestrians, and turn off the igni-
tion switch.
Torque converter oil temperature
overheating warning
When the torque converter oil temperature
reaches level 9 on the indicator (120ºC or
over), the indicator will blink to notify the
operator. When the indicator reaches level 10
(140ºC or over), the entire indicator will blink
to notify the operator.
Note:
When the warning lamp blinks, park the vehi-
cle in a safe location, engage the parking
brake, open the engine hood with the motor
idling, to assist in the cooling of the torque
converter oil.
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Over-speed alarm
(Only for DX models)
When the set traveling speed is exceeded, the
speed meter will blink and a warning will
sound to notify the operator.
Note:
This function does not limit traveling speed
and is an indication only. Pay attention to your
speed when operating the vehicle.
Setting menu screen
With the Multifunction display, pressing the
low speed setting switch or the down switch in
the standard screen for more than 2 seconds
will display the setting menu screen.
Note:
When the supervisor locks the menu, these
screen settings can not be displayed.
Selecting the options using the low speed set-
ting switch or the down switch and then press-
ing the meter display switch will display each
screen setting.
Select [ ] in the setting menu screen,
and then pressing the meter display switch will
return to the standard screen.
Note:
Always operate the switch panel using your
finger tips.
(1) Down switch
(2) Meter display switch
<Standard screen>
<Setting menu screen>
<Over-speed alarm setting screen>
(1) (2)
Vehicles having Multifunction display DX
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