Toyota 8FG35N User manual

TABLE OF CONTENTS
TABLEOFCONTENTS
1 FOREWORD ..................................................................................................................en4
2 SAFEUSE......................................................................................................................en5
3 MAINCOMPONENTS....................................................................................................en6
4 OPERATINGCONTROLS .............................................................................................en7
5 HOWTOREADTHENAMEPLATE ..............................................................................en8
6 WARNINGLABELS.......................................................................................................en9
6.1 Recycling/discarding...........................................................................................en11
7 SASFUNCTION...........................................................................................................en12
7.1 PrecautionsonSAS ...........................................................................................en12
7.2 DescriptionofSASfeatures ...............................................................................en12
8 OPSFUNCTION ..........................................................................................................en15
8.1 TravelOPSfunction ...........................................................................................en15
8.2 LoadhandlingOPSfunction...............................................................................en15
8.3 OPSoperationinformationfunction....................................................................en15
8.4 Returntoneutral ................................................................................................en15
8.5 Parkingbrakeonwarning...................................................................................en16
8.6 Parkingbrakeoffwarning...................................................................................en16
9 MAINFUNCTIONS ......................................................................................................en17
9.1 Travelcontrolfunction .......................................................................................en17
9.2 Engineautostopfunction ...................................................................................en17
9.3 Ecomode ...........................................................................................................en17
10 SWITCHESANDLEVERS ..........................................................................................en18
10.1 Ignitionkeyswitch ..............................................................................................en18
10.2 Directioncontrollever.........................................................................................en19
10.3 Parkingbrakelever.............................................................................................en19
10.4 Liftlever ..............................................................................................................en20
10.5 Manualloweringvalve ........................................................................................en20
10.6 Tiltlever ..............................................................................................................en20
10.7 Tiltleverknobswitch ..........................................................................................en21
10.8 Clampreleasebutton(Option) ...........................................................................en21
10.9 Integratedlightandturnsignalswitch ................................................................en22
10.10 Keyoffheadlightoffsystem(Option) ................................................................en23
10.11 Torqueconverterinterlockfunction(Option) ......................................................en23
10.12 Tiltsteeringadjustlever......................................................................................en23
10.13 Pedals.................................................................................................................en24
10.14 EZpedal(Option) ...............................................................................................en24
10.15 Hornbutton.........................................................................................................en24
10.16 Rearassistgripwithhornbutton(Option) ..........................................................en24
10.17 Rearworkinglight(Option).................................................................................en25
10.18 Minilever(Option) ..............................................................................................en25
10.19 Joystick(Option)................................................................................................en27
10.20 Armrest(MinileverorJoystickmodels)............................................................en28
11 BODYCOMPONENTS ................................................................................................en30
11.1 Operator'sseat ...................................................................................................en30
11.2 Swivelseat(Option) ...........................................................................................en31
11.3 Seatbelt .............................................................................................................en32
11.4 Enginehood(ExceptMinileverorJoystickmodels) .........................................en32
11.5 Enginehood(MinileverandJoystickmodels) ..................................................en33
11.6 Drawbar .............................................................................................................en34
11.7 Liftingpoints .......................................................................................................en34
11.8 Overheadguard..................................................................................................en34
11.9 Loadbackrestextension.....................................................................................en34
11.10 Mast....................................................................................................................en34
11.11 Forks...................................................................................................................en35
11.12 Rearviewmirror(Option) ...................................................................................en35
12 INSTRUMENT ..............................................................................................................en36
12.1 Combinationmeter .............................................................................................en36
12.2 Multifunctiondisplay(Option) ............................................................................en41
13 LPGDEVICE(OPTION)...............................................................................................en48
13.1 Switches .............................................................................................................en48
13.2 LPGrelatedparts ...............................................................................................en49
13.3 Enginehood .......................................................................................................en50
13.4 OperatingLPGpoweredforklift ..........................................................................en50
13.5 Refuelingyourtruck............................................................................................en51
13.6 ImportantinformationaboutLPG .......................................................................en55
13.7 SafetyprecautionsonLPGpoweredforklifts .....................................................en55

en
TABLE OF CONTENTS
14 CABIN(OPTION) .........................................................................................................en56
14.1 Doors ..................................................................................................................en56
14.2 Rearwindow.......................................................................................................en57
14.3 Wiper ..................................................................................................................en57
14.4 Interiorlamp........................................................................................................en57
14.5 Heater(Option)...................................................................................................en58
14.6 Defroster(Option)...............................................................................................en58
15 PREOPERATIONCHECK..........................................................................................en59
15.1 Walkaroundinspection .......................................................................................en59
15.2 Enginecompartmentinspection .........................................................................en60
15.3 Onboardtruckinspection...................................................................................en63
15.4 Whilemovingslowly ...........................................................................................en66
16 SELFSERVICING........................................................................................................en67
16.1 REFUELINGYOURTRUCK ..............................................................................en67
16.2 CHANGINGTIRES.............................................................................................en68
16.3 FUSEREPLACEMENT ......................................................................................en69
16.4 AIRPURGINGOFTHEFUELSYSTEM............................................................en70
16.5 DRAININGTHESEDIMENTER .........................................................................en70
16.6 ADJUSTMENTOFTHEPARKINGBRAKEOPERATINGFORCE ...................en71
16.7 MAINTAININGTHEBATTERYTERMINALS.....................................................en71
16.8 CLEANINGPRECLEANER(OPTION) .............................................................en71
16.9 FUELTANKCHECK ..........................................................................................en71
17 EMERGENCYPROCEDURE ......................................................................................en72
17.1 USINGJUMPERCABLES .................................................................................en72
17.2 LIFTINGTHETRUCK ........................................................................................en73
18 PLANNEDMAINTENANCE.........................................................................................en74
18.1 STORAGE ..........................................................................................................en74
18.2 WEEKLYMAINTENANCE .................................................................................en74
18.3 PROTECTYOURINVESTMENTWITHTOYOTAGENUINEPARTS ..............en79
18.4 PERIODICMAINTENANCEANDREPLACEMENT ..........................................en79
18.5 SERVICEDATA .................................................................................................en85
18.6 RECOMMENDEDLUBRICANTQUANTITY&TYPES......................................en87
18.7 LUBRICATIONCHART ......................................................................................en88
18.8 FRAMESERIALNUMBER.................................................................................en89
19 TRUCKDIMENSIONS .................................................................................................en90
19.1 Truckweight .......................................................................................................en92

1 FOREWORD
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1FOREWORD
ModelsCoveredbythisManual
InternalCombustionCounterbalancedForkliftTrucks
Capacity(LoadCenter500mm)
kg
Engine Model
4000 1FS 8FG35N
1KD 408FD35N
4500 1FS 8FG40N
1KD 408FD40N
4990 1FS 8FG45N
1KD 408FD45N
5000*1 1FS 8FG50N
1KD 408FD50N
6000*1 1KD 408FD60N
7000*1 1KD 408FD70N
8000*1 1KD 408FD80N
*1LoadCenter600mm
Thismanualcontainsinformationessentialforproperoperationandmaintenance,aswellas
dailylubricationandperiodicinspectionprocedureforyourToyotaforklifttruck.
Pleasereadthismanualthoroughly,eventhoughyoumayalreadybefamiliarwithourforklift
trucks,becauseitcontainsinformationwhichisexclusivetothisseriesoftrucks.Thismanual
isbasedonastandardtruckmodel.Ifyouhavequestionsaboutothermodel(s),please
contacttheToyotaforkliftdealer(Toyotadealer).
Inadditiontothismanual,pleasebesuretoreadtheseparatepublicationentitled
"ManualforSafeOperation."Itcontainsimportantinformationaboutthesafeoperationof
forklifttrucks.
Toyotaisconstantlydevelopingourproducts.Wethereforereservetherighttomake
modificationsatanytimewithoutpriornotice.
Illustrationsmaydifferfromactualdesign.
TOYOTAINDUSTRIESCORPORATION
21,Toyodacho,Kariyashi,Aichi4488671Japan

2 SAFE USE
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2SAFEUSE
BeforeStartingOperation
▪Please read this manual thoroughly. This will give you a complete understanding of
Toyotaforklifttrucksandenable youtooperatethemcorrectly andsafely.Properhand
lingofanewtruckpromotesperformanceandextendsservicelife.Operatewithspecial
caution while becoming familiar with a new truck. In addition to the standard operating
procedures,payattentiontothefollowingsafetyitems.
▪PleaseacquireathoroughknowledgeoftheToyotaforklifttruck.Readtheoperator
’smanualthoroughlypriortooperatingthetruck.Gettoknowitsoperationandcompon
ents.Learn aboutthe safetydevicesand accessoryequipment andtheirlimits andpre
cautions.Besuretoreadthewarninglabelsattachedtothetruck.
▪Pleasefamiliarizeyourselfwithsafeoperatingpointsandsafemaintenanceopera
tion.Understandandmaintainworkareatrafficrules.Asktheworkareasupervisorabout
anyspecialworkingprecautions.
▪Wearappropriateclothingforoperation.Improperclothingfortruckoperationmayin
terfere with smooth operation and cause an accident. Always wear appropriate clothing
foreasieroperation.
▪Pleasekeepawayfromliveelectricpowerlines.Knowthelocationsofinsideandout
sidepowerlinesandmaintainsufficientdistance.
▪Besuretoperformpreoperationchecksandplannedmaintenance.Thiswillprevent
suddenmalfunctions,improveworkefficiency,savemoneyandinsureasafeworkingop
eration.
▪Alwayswarmuptheenginebeforestartingoperation.
▪Be sure to avoid forward tilt when the forks are elevated with a load. In the worst
case,thismaycauseoverturningduetolossofstabilityresultingfromforwardmovement
ofthecenterofgravity.
▪Neverattempttravelingandturningwithaloadontheforkswhentheyareelevated.
If travelling and turning when the forks are elevated, this may impact stability and may
causetheforklifttotipover.Whentravelling,maintainaforkheightabovethegroundof
1020cm(68inches).
▪Please avoid overloading or uneven loading. Overloading or an uneven load is dan
gerous. If the centre of gravity is not evenly distributed, the heaviest side of the load
should be against the fork carriage/load backrest even if the load is less than that spe
cified on the nameplate. Also, the load should have the heaviest weight closest to the
forkswithlighteritemsonthetop.
▪Ifyouhearanyunusualnoiseorsenseanythingunusual,stop,inspectandrepair
immediately.
▪Iftheenginestopsduringtraveling,thiswillaffecttheoperation.Stopthetruckina
safeplaceandapplytheparkingbrake.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.RefertoRefuelingyourtrucksectionofthismanualfor
therecommendedtypesoffuel.
▪Flammable and/or combustible materials can be damaged and in some cases ig
nited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forkliftsoverornearflammableand/orcombustiblematerials,in
cludingdriedgrassandpaperscraps,etc.
– Parktheforkliftwithrearendatleast30cm(12in)awayfromlumber(timber),veneer
board,paperproductsandothersimilarmaterialstoavoiddiscoloration,deformation
orcombustionofthosematerials.
SafetyRequirements
▪ Trucksequippedwithaloadbearingclamp(e.g.paperclamp)shallfeaturecontrol(s)with
asecondaryactiontopreventunintentionalreleaseoftheload.Whenany"loadbearing
clamp"isusedonalifttruck,thecontrol(hydraulichandleverforexample)mustbecon
figuredtoconformtotheISO36911.
Clampreleaseinterlockissetasanoption.Fordetails,refertoClampreleasebutton(Op
tion)sectionofthismanual.
2

3 MAIN COMPONENTS
en‐6
3MAINCOMPONENTS
(4)
(9)
(12)(7)(13)
(8)
(10)
(1) Mast (8) Counterweight
(2) Chain (9) Enginehood
(3) Forks (10) Steeringwheel
(4) Liftcylinder (11) Operator'sseat
(5) Tiltcylinder (12) Driveaxle
(6) Overheadguard (13) Steeraxle
(7) Frame

4 OPERATING CONTROLS
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4OPERATINGCONTROLS
(1) Parkingbrakelever (7) Tiltlever (13) Brakepedal
(2) Directioncontrollever (8) Tiltleverknobswitch (14) Ignitionkeyswitch
(3) Steeringwheel (9) Attachmentlever(Option) (15) Inchingpedal
(4) Hornbutton (10) Multifunctiondisplay(Option) (16) Tiltsteeringadjustinglever
(5) Lightcontrolandturnsignalswitch (11) Combinationmeter
(6) Liftlever (12) Acceleratorpedal
4

5 HOW TO READ THE NAMEPLATE
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5HOWTOREADTHENAMEPLATE
Theloadcapacityisengravedonthenameplate.
Makesureoftheloadcenterandcapacitybeforestartingtheoperation.
(ThesampleshowsthatofanEnglishversion.)
B
BA
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(7)
(13)
(9)
(8)
(7)
(10)
(11)
(12) (12) (12)
(11) (11)
(1) Truckmodel
(2) CodeNo.ofspecialmodel,modelofattachment
(3) FrameNo.specialnumberforthetruck
(4) Truckweight
(5) Maximumliftingheight
(6) Fronttread
(7) Tiresize
(8) Tirepressure
(9) Yearofproduction
(10) Ratedcapacity
(11) Loadcapacity
(12) Loadcenter
(13) Nominalpower

6 WARNING LABELS
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6WARNINGLABELS
Warninglabelsareattachedonatruck.Pleasebesuretoreadthemthoroughly.(Thesample
showsthoseofanEnglishversion.)
a
b
e, f, g, o
h
i
i, j, k, l
j
d, k, l, m, n, p, q
r
c
a Neverlift people with your truckor allow
anyoneundertheforksorload.Safetyof
peoplearoundyouisyourresponsibility.
b When lifting the truck don't risk dropping
the truck, never use the overhead guard
topickitup.Usethecounterweighttolift
thetruck.
c Refer to the warning label for the sound
powerlevelofthetruck.
(Thislabelisasample.Thevalueonthe
labelvariesdependingonthemodel.)
d Dieselenginemodels
Donottouchtheexhaustpipewhenitis
hot.
eWARNING!Please read this Operator’s
Manual carefully before use.
f This truck is equipped with OPS (Oper
atorPresence Sensing).Be sureto read
and follow the instruction of the warning
label.
6

6 WARNING LABELS
en‐10
g3.54.5tonmodels/Modelswithoptional
Cabin
ModelswithMinilever/Joystick(Option)
ModelswithCabin(Option)+Minilever/Joy
stick(Option)
Modelswith+75mmoverheadguard(Op
tion)+Minilever/Joystick(Option)
Don’t damage your truck, follow the in
structions on the warning label when
openingtheenginehood.
h Tip over can cause serious injury or
death.Lookoutforandavoidthehazards
thatcausethemandusetheseatbelt.If
your truck tips, stay in the seat, lean
awayfromthetippingdirection,hangon,
andbraceyourfeet.
i ThistruckisequippedwithSAS.Besure
to read and follow the instruction in the
SASFUNCTIONsectionofthismanual.
j Applytheparkingbrake accordingtothe
Parking brake lever section of this
manual.
k The fan is coloured white to make it
easierto see when itisturning. You still
needtowatchoutforthisdecalandstay
clear.
l Do not open the radiator cap when the
coolantishot.
m Besuretouseonlyspecifiedfuses.Refer
to the FUSE REPLACEMENT section of
thismanualforspecifiedfuses.
n Thislabelindicatesthe hydraulicoiltank
inlet.

6 WARNING LABELS
en‐11
oGasolineenginemodels
Dieselenginemodels
D
Ifyoufillthefueltank,makesureyouuse
the proper fuel. A mistake could cause
verycostlyrepairs.
p Dieselenginemodels
Be sure to read the instructions in this
Operator'sManual before performingthe
maintenanceofthesedimenter.
q
9#40+0)#&8'46'0%+#Replace the timing belt every 4000 hours of use.
Failure to do so could result in serious engine damage.
Reemplace la correa de distribución cada 4.000 horas de operación.
Si no lo hace así, podrían producirse daños serios en el motor.
Dieselenginemodels
Replacethetimingbeltevery4000hours
ofuse.
Failure to do so could result in serious
enginedamage.
The timing belt caution function will in
form the operator when the timing belt
needs to be replaced. Refer to the
INSTRUMENTchapterofthismanualfor
details.
r This decal may be placed in several
placesonthetruck,butlookforit,espe
cially on the mast and on attachments.
Whenyouseeit,stayclear.
ModelswithoptionalCabin
RearwindowoftheCabincanbeopened
byreleasing the lock lever atthe bottom
of the window. Refer to the CABIN
(OPTION)chapter of this manual forde
tails.
ModelswithoptionalCabin
DonottravelthetruckwithCabinwiththe
rear window opened at maintenance
mode.
6.1Recycling/discarding
InaccordancewithEUDirective2006/66/EC,
thissymbolindicates‘separatecollection’for
allbatteriesandaccumulators.
Your truck uses a lead accumulator and, in
case of some batterypowered truck, a lith
iumbattery.
Materials contained in batteries (include ac
cumulators) are hazardous to the environ
mentandhumans,sobatteriesshouldbere
turnedtothemanufacturersforrecycling.
Discardingthebattery
When the working life of the battery in the
truck is at an end (exchange to a new bat
tery) or if the entire truck is to be scrapped,
specialregardtoenvironmentalrisksshallbe
taken when disposing/ recycling batteries.
Consult the Toyota dealers about exchange
ordiscardingthebatteries.
6

7 SAS FUNCTION
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7SASFUNCTION
7.1PrecautionsonSAS
(SAS:SystemofActiveStability)
WheneveryouuseaToyotaforkliftequippedwithSAS,checkthewarninglabelstodetermine
whichSASfeature(s)yourtruckhasbeenequippedwith.DonotoperatethetruckifanySAS
featureisnotoperatingproperly.
ThefollowingareexamplesofthewarninglabelswhichwillbeaffixedonSASequipped
truckstoidentifytheSASfeaturesinstalledonthatspecifictruck.
[Figure1] Figure1
This label will be affixed on SINGLE TIRE
trucksequippedwithSAS.Aspictographson
thelabelindicates,thistruckisequippedwith
thefollowingSASfeatures:
▪ Activecontrolrearstabilizer
▪ Activemastfunctioncontrol
▪ Activesteeringcontrol
[Figure2] Figure2
This label will be affixed on DUAL TIRE
trucksequippedwithSAS.Aspictographson
thelabelindicates,thistruckisequippedwith
thefollowingSASfeature:
▪ Activemastfunctioncontrol
▪ Activesteeringcontrol
DANGER
Toyota forklifts equipped with SAS will operate and handle differently than
similar forklifts without SAS. Operators must use caution when changing
between trucks with and without SAS features. Operation of forklifts without
SASinthesamemannerasforkliftswithSAScanresultinlossofcontroland
potentialtipover.
CAUTION
BeforeoperatingatruckequippedwithSAS,familiarizeyourselfwiththeSASfeatureor
featuresandbesurethatthediagnosisindicatorlampisnotilluminated.Thediagnosisin
dicatorlamp willilluminateintheeventofaSASmalfunctionandthetruckshouldnot
beoperateduntilithasbeenrepaired.
• WhileoperatingatruckequippedwithSAS,shouldthediagnosisindicatorlampilluminate
oranerrorcodebeindicatedonthedisplay, parkthetruckin asafelocation,applythe
parkingbrakeandhavethetruckinspectedbytheToyotadealer.
• TheSASiselectronicallycontrolled.Thesystemmayneedtobeinitializedaftercomple
tionofmaintenance.
• Donotremoveormodifythe SASfeatures.IfinspectionoftheSASisrequired,contact
theToyotadealer.
• Whenwashingthetruck,cautionisrequiredtopreventwaterfrombeingdirectlyapplied
totheelectricalpartsusedintheSAS.Theseelectricalpartsincludeacontroller,sensors
andswitches.
• Onceyouhavefittedorreplacedanyattachmentonaforklift,asktheToyotadealerforan
inspectionandloadratingifrequired.
• If you use two or more removable attachments alternately, the heaviest one should be
usedtocarryoutmatching(SASsetting).ContacttheToyotadealertorequestcompatib
ilitymatching.
• When mounting forks or attachments to a truck without forks, the attachments must be
compatiblewiththemodel.ContacttheToyotadealertorequestcompatibilitymatching.
7.2DescriptionofSASfeatures
ACTIVECONTROLREARSTABILIZER
Thisfeatureisdesignedtotemporarilylockandpreventtherearaxleswingmotiononthe
truck.Thisfeatureincreasesthestabilityofthetruckduringrightandleftturns.
Thelockingoftherearaxleswingmotionisreferredas"SwingLock".
CAUTION
• Thisfeatureisintendedtoenhancethestabilityoftheforkliftundercertainconditions,but
cannotpreventtheforkliftfromtippingoverunderallcircumstances.Youmustcontinueto
usecautionwhenoperatingtheforklift.

7 SAS FUNCTION
en‐13
AUTOMATICFORKLEVELINGCONTROL
When operating the tilt lever forward while
pressing the tilt lever knob switch, the forks
willstop automaticallyat thehorizontal posi
tion(themastpositionedvertically).
Afterstoppingtheforksatthehorizontalposi
tion with the tilt lever knob switch pressed,
youmaywanttotilttheforksfurtherforward.
Return the tilt lever to the neutral position
once.Then,afterreleasingthetiltleverknob
switch,operatethetiltleveragain.
Whenoperatingthetiltleverfromthebackwardtoforwardpositionwhilepressingthetiltlever
knobswitch,theforkswill:
Notloaded Loaded
HighLiftHeight
(Over6feetor2
m)
Stopatthehorizontalposition(with
mastpositionedvertically) Nottiltforward
LowLiftHeight Stopatthehorizontalposition(with
mastpositionedvertically)
Stopatthehorizontalposition(with
mastpositionedvertically)orupto
1°backwarddependingontheload
CAUTION
• Whenyoumovethetiltleverforwardwhilepressingthetiltleverknobswitch,withaload
ata highlift height, themast willstop movingsuddenly.Avoid suchoperation, because
thetruckmaytipover.
• Ifthetruckisequippedwithanattachment,donotuseautomaticforklevelingwithanel
evatedload,andtheenginerunningathighRPM.
• Aheavyattachmentmayaffect alift truckequipped withautomatic forkleveling control.
ConsultwiththeToyotadealerbeforeinstallingthistypeofattachment.
NOTICE
• When moving the tilt lever backwards, the forks will not stop at the horizontal position
evenifthetiltleverknobswitchispressed(excepttrucksequippedwithMinileverorJoy
stick).
OnlifttrucksequippedwithMinileverorJoystick(Option):Whenoperatingthetiltleverfrom
forwardtobackwardpositionwhilepressingthetiltleverknobswitch,theforkswill:
NotLoaded Loaded
HighLiftHeight
(Over6feetor2
m)
Stopatthehorizontalposition(with
mastverticallypositioned)
Stopatthehorizontalposition(with
mastpositionedvertically)orupto
1°backwarddependingontheload
LowLiftHeight
ACTIVEMASTFORWARDTILTANGLECONTROL
Thisfunctionautomaticallylimitstheforwardtiltangleofthemastdependingontheload
weightandliftheight.
Theangleatwhichthemastcanbetiltedforwardisautomaticallycontrolledaccordingtothe
loadweightandliftheightasfollows:
LightLoad(noload) MediumLoad HeavyLoad
HighLiftHeight
(Over6feetor2m)
Nolimitationforfor
wardtiltangle
Forwardtiltanglelim
itedfrom1°to5°de
grees
Forwardtiltanglelim
itedto1°degree
LowLiftHeight Nolimitationforforwardtiltangle
CAUTION
• Thisfeatureisintendedtoenhancethestabilityoftheforkliftundercertainconditions,but
cannotpreventtheforkliftfromtippingforwardortheloadfromfallingoffunderallcircum
stances.Youmustcontinuetousecautionwhenoperatingtheforklift.
• Nevertiltthemastbeyonditsverticalpositionwithaloadatahighliftheight,orthetruck
maytipforward,losingitsstabilityforwardorbackward.
• Whenyouliftaloadfromalowliftheightwiththemasttiltedforward,theactivemastfor
wardtiltanglecontroldoesnotwork.Avoidsuchoperation,becausethetruckmaytipfor
ward.
• A heavy attachment may affect a lift truck equipped with active mast forward tilt angle
control.ConsultwiththeToyotadealerbeforeinstallingthistypeofattachment.
NOTICE
• Whenforksareatthemaximumliftheight,highpressure(reliefpressure)mayremainin
theliftcylinder.Thiswillcausethetrucktodetectthatithasaheavyloadevenifthereis
noload.Asaresult,thetiltforwardangleislimited.Insuchcase,lowerthemastslightly
totiltthemastforward.
7

7 SAS FUNCTION
en‐14
ACTIVEMASTBACKWARDTILTSPEEDCONTROL
Thisfunctionautomaticallyreducesthebackwardtiltspeedofthemastataliftheighthigher
thanapproximately6feet(2m)inordertopreventtheloadfromshifting.
▪ Ata highlift height, thebackward tiltingspeed is automaticallylimited regardlessof the
load weight. When lowering from a high lift height to a lower lift height while tilting the
mastbackward,thetiltingspeedwillnotchange.
▪ Atalowliftheight,thebackwardtiltingspeedisnotlimitedevenifthereisaload.When
liftingfromalowliftheighttoahigherliftheightwhiletiltingthemastbackward,thetilting
speedwillnotchange.
▪ Whenoperatingthetiltleverbackwardwhilepressingthetiltknobswitchatanyliftheight,
thebackwardtilting speedislimitedaslongasthe tiltleverknob switchispressed (ex
cepttrucksequippedwithMinileverorJoystick).
KEYLIFTINTERLOCK
Whenthekeyswitchisturnedoff,theforkswillnotlowereveniftheliftleverisoperated.The
forkscanbeloweredwhentheoperatorisseatedintheoperator'sseatandkeyswitchis
turnedon.
ACTIVESTEERINGCONTROL
Ifthesteeringwheelknobisnotatthesameangleasthesteertires,suchoutofpositionwill
beautomaticallycorrectedwhileturningthesteeringwheel.Thus,theknobiskeptata
constantpositionrelativetothesteertires.
SHOULDAPROBLEMWITHSASOCCUR:
ThetruckwithSASisequippedwithacontroller,sensorsandvariousswitches.Shouldoneor
moreofthesecomponentsexperienceaproblem,thefollowingmayoccur:
▪ The automatic fork leveling control, active mast forward tilt angle control and/or active
mastbackwardtiltspeedcontrolmaynotoperateproperly.
▪ Theswinglockcylindermaybelocked.
▪ Steeringwheelknobpositionmaynotbecorrectedautomaticallyevenifitisoutofposi
tion.
Shouldanyoftheaboveoccur,youcanexpectthefollowing:
▪ Anerrorcodewillbedisplayedinthehourmeter.
▪ Thediagnosisindicatorlamp willilluminateorblink.
Shouldoneormoreoftheseconditionsoccur,movethetrucktoasafelocation,applythe
parkingbrakeandasktheToyotadealerforaninspectionandrepair.

8 OPS FUNCTION
en‐15
8OPSFUNCTION
(OPS:OperatorPresenceSensing)
TheOPSpreventspoweredtravelingandloadhandlingoperationswhentheoperatorisnot
seatedinthenormaloperatingposition(operator’sseat).Iftheoperatorleavestheseatwhile
thetruckisinoperation,theOPSindicatorlampwillilluminatetoinformtheoperatorthatthe
systemisgoingtobeactivated.
Iftheoperatorremainsoutoftheseatfor2secondsormore,thesystemwillbeactivatedand
stoppoweredtravelandloadhandlingoperations.Iftheoperatorreturnstotheseatwithin2
seconds,operationcanbecontinuednormally.
ThistruckisequippedwiththeOPS.ConfirmtheOPSisfunctioningproperlybeforeoperating
truck.
IfanerroroccurswithintheOPS,thediagnosisindicatorlampwillilluminateonthedisplayto
informtheoperatoroftheerror.Thisindicatesthatthereisamalfunction.Havethetruck
inspectedbytheToyotadealer.
8.1TravelOPSfunction
Iftheoperatorleavestheseatwhilethetruckistraveling,theOPSindicatorlampwill
illuminateandpoweredtravelwillbestoppedafter2seconds.
Iftheoperatorreturnstothenormalseatingpositionwithin2seconds,travelingcanbe
continued.
TheOPSwillnotapplythebrakestostopcoastingorpreventrollingbackoninclines.
Torestartpoweredtravel,releasetheacceleratorpedal,returnthedirectioncontrolleverto
theneutralpositionandsitintheseat.
TruckswithEZpedal(Option)
TocancelthetravelOPS,sitintheseatandapplytheparkingbrakeorreleasethe
acceleratorpedalandpressitagain.
CAUTION
TravelOPSisnotabrake.
• OPSstops poweredtravel, but doesnot applythe brake. Applythe parkingbrakeat all
timeswhenleavingtheoperator'sseat.
8.2LoadhandlingOPSfunction
Iftheoperatorleavestheseatfor2secondsormoreduringloadhandlingoperations,the
OPSindicatorlampwillilluminateandloadhandlingoperationswillbestopped.
Iftheoperatorreturnstonormalseatingpositionwithin2seconds,loweringoperationcanbe
continued.
Iftheoperatorleavestheseatwhileoperatingthecontrollever,loweringoperationcanbe
continuedfor2to4seconds.
IftheloadhandlingOPSisactivatedwhentheliftleverisintheloweringposition,returnthe
levertoaneutralpositionandreturntothenormalseatedpositiontorestartloadhandling
operation.
IftheloadhandlingOPSisactivatedwhentheliftleverisinapositionotherthanthelowering
position,theloadhandlingOPSisdeactivated1secondaftertheoperatorreturnstothe
normalseatedposition.
CAUTION
IfyouoperatetheattachmentleverwhentheOPSisactivated,theattachment
mightmoveorlowerbyitsownweight.
TruckswithMinileverorJoystick(Option)
Torestartloadhandlingoperation,returnallleverstotheneutralpositionandreturntothe
seat.
8.3OPSoperationinformationfunction
Iftheoperatorleavestheseat,thebuzzerwillsoundforapprox.onesecondandtheOPS
indicatorlampwillilluminatetoinformtheoperatorthattheOPSisgoingtobeactivated.
Iftheoperatorreturnstonormalseatingpositionwithin2seconds,theOPSwillnotbe
activated.
TheOPSindicatorremainsonuntiltheoperatorreturnstotheseattoconfirmtheactivationof
theOPS.
8.4Returntoneutral
Traveling
WhenthetravelOPSisactivated,iftheoperatorreturnstotheseatwithoutreturningthe
directioncontrollevertotheneutralposition,thebuzzerwillsoundandthetravelOPScannot
bedeactivated.
TodeactivatethetravelOPS,alwaysreturnthedirectioncontrollevertotheneutralposition,
beforereturningtotheseat.
TruckswithEZpedal(Option)
TodeactivatethetravelOPS,releasetheacceleratorpedal.
LoadHandling
WhentheloadhandlingOPSisactivated,iftheoperatorreturnstotheseatwithoutreturning
theliftlevertotheneutralpositionfromtheloweringposition,thebuzzerwillsoundandthe
loadhandlingOPScannotbedeactivated.
8

8 OPS FUNCTION
en‐16
TodeactivatetheloadhandlingOPS,alwaysreturntheliftlevertotheneutralposition,before
returningtotheseat.
TruckswithMinileverorJoystick(Option)
Iftheoperatorreturnstotheseatwhennotallleversareintheneutralposition,thebuzzerwill
soundandtheloadhandlingOPScannotbedeactivated.
TodeactivatetheloadhandlingOPS,alwaysreturnallleverstotheneutralpositionandreturn
totheseat.
8.5Parkingbrakeonwarning
Iftheparkingbrakeisnotreleasedpriortotravel,theparkingbrakeonwarningindicatorwill
blinkontheMultifunctiondisplayandthewarningsoundwillwarntheoperator.
8.6Parkingbrakeoffwarning
Iftheoperatorleavesthetruckorturnsoffthekeyswitchwithoutapplyingtheparkingbrake,a
warningsoundwillwarntheoperator.
Iftheoperatorreleasestheparkingbrakewithin1minuteafterturningoffthekeyswitch,a
warningsoundwillalsowarntheoperator.
Thewarningsoundwillstopafter30seconds.
CAUTION
• Whenleavingtheseat,alwaysreturnthecontrolleverstotheneutralposition,applythe
parkingbrakeandlowertheforkstothefloororground.Then,turnoffthekeyswitchand
removethekey.

9 MAIN FUNCTIONS
en‐17
9MAINFUNCTIONS
9.1Travelcontrolfunction
Function EquippedModels
Maximumspeedlimitation Allmodels
Lowspeedsetting Models with Multifunction Display (Option)/
MultifunctionDisplayDX(Option)
NOTICE
Dependingonthetruckweight,thesetspeedmaynotbeattainedwhiletravelingupagradi
entorincline.Similarly,thesetspeedmaybeexceededduringtraveldownagradientorin
cline,butwillresumeatthesetspeedwhenitisreachedaftergoingdownthegradientorin
cline.
9.1.1MaximumSpeedLimitation
Thisfunctionlimitsthemaximumtravelspeedtoapresetvalue.
Tochangethesettingofthemaximumspeedlimitation,askasupervisorortheToyotadealer.
9.1.2LowspeedSetting
Thisfunctionlimitsthemaximumtravelspeedtoapresetvaluewhenthelowspeedsetting
switchispressedontheMultifunctiondisplay.
ThesettingvalueofthelowspeedsettingcanbechangedontheMultifunctiondisplaybythe
operatorandasupervisor.
Fordetails,refertoINSTRUMENTsectionofthismanual.
9.2Engineautostopfunction
(Option:MultifunctionDisplayDX)
Iftheoperatorleavesthetruckwiththeparkingbrakeappliedandwithoutturningoffthekey
switchforacertainamountoftime,theengineandthepowerwillbestoppedautomatically,
thuspreventingthewasteoffuel.
Torestartthetruck,turnoffthekeyswitch,andthenturnitbackon.
Tochangethesettingtimeoftheengineautostopfunction,askasupervisorortheToyota
dealer.
NOTICE
• Alwaysturnoffthekeyswitch,applytheparkingbrakeandstoptheenginewhenleaving
thetruck.
• Thisfunctionmaynotbeactivatedduringenginewarmup.
9.3Ecomode
(Option:MultifunctionDisplay/MultifunctionDisplayDX)
Whentheecomodeisactive,travelingandloadhandlingaccelerationislimited,inorderto
assistwiththeimprovementinfuelconsumption.
Thisfunctioncanbeturnedon/offontheMultifunctiondisplay.Fordetails,referto
INSTRUMENTsectionofthismanual.
Tochangethesettingvalueoftheaccelerationlimit,asktheToyotadealer. 9

10 SWITCHES AND LEVERS
en‐18
10SWITCHESANDLEVERS
10.1Ignitionkeyswitch
(1)OFF
(2)ON
(3)START
OFFPositiontostoptheengine.Insert/with
drawthekeyinthisposition.
ON Engine operating position. Located one
positionclockwisefromtheOFFposition.
START  Position to start the engine.
Locatedone positionclockwise fromthe ON
position.
To start the engine, turn the key switch to
START position, release the key and it will
return to the ON position automatically. To
restarttheengine,turnbackthekeyswitchto
OFFposition,andturnittoSTARTposition.
NOTICE! For diesel engine models, start
the engine after the glow indicator lamp
goes off.
The engine does not start unless the direc
tioncontrolleverisintheNEUTRALposition.
FortruckswithEZpedal(Option),theengine
doesnotstartunlesstheparkingbrakeisap
pliedortheacceleratorpedalisreleased.
WARNING
• Whenyouturnonthekeyswitch,besurethatyouareinthenormalseatedpositionwith
the seat belt fastened and the parking brake is applied. Otherwise, the truck may start
suddenly,leadingtoanunexpectedaccident.
• Alwaysstarttheenginewiththedirectioncontrolleverintheneutralposition.
• IftheOPSindicatorlampisilluminated,returnthedirectioncontrolandloadhandlingcon
trolleverstotheneutralpositionsandsitintheseat.ConfirmthattheOPSindicatorlamp
isnotilluminated.
• Whenstarting1FSenginemodels(gasoline/LPG),donotpresstheacceleratorpedal.
• DonotleavethekeyswitchintheONpositionwhentheengineisstopped.Itwillcause
thebatterytooverdischarge.
• DonotturntheswitchtotheSTARTpositionwhiletheengineisrunning(excepttrucksfit
tedwithoptionalantirestartignitionkeyswitch).Thismaydamagethestartermotor.
• Ifyourtruckhasanantirestartignitionkeyswitchtoprotecttheengine,youmustturnthe
switch from the ON position to the OFF position before attempting to start the engine
again.
• Do not operate the starter motor for more than 30 seconds continuously. Return the
switchtotheOFFpositionandwaitatleast30secondspriortoattemptingrestart.
• Whenthekeyswitchisturnedoff(enginestopped),theforkswillnotlowerevenifthelift
leverisoperated.Theforkscanbeloweredwhentheoperatorisseatedintheoperator's
seatandkeyswitchisturnedon(Keyliftinterlock).
• Ifthediagnosisindicatorlampisilluminatedanddoesnotgooffwhenyousitintheseat,
thebatteryvoltagemaybelow(overdischarged).Insuchcase,donotoperatethetruck
untiltheindicatorlampturnsoff,becausethetruckmaynotoperatecorrectly.Ifthedia
gnosisindicatorlampdoesnotgooffapproximately1to2minutesafterenginestartsor
whentheenginespeedisincreased,stopoperationandhavethetruckinspectedbythe
Toyotadealer.(Fordieselenginemodels,thediagnosisindicatorlampmaystayillumin
atedduring enginewarmup afteracoldenginestart.Thisdoes notindicate amalfunc
tion.)

10 SWITCHES AND LEVERS
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10.2Directioncontrollever
(1)Forward
(2)Reverse
Shift lever to change the travel direction
betweenforwardandreverse.
ForwardtravelPushtheleverforward
ReversetravelPulltheleverbackward
The neutral position is halfway between the
forwardandreverseposition.
Forwardandreversetravelspeedcanbead
justedbytheamounttheacceleratorpedalis
depressed.
CAUTION
• Alwaysoperatethecontrolleverfromanormalseatedposition.
• Theenginecannotbestartedunlessthedirectioncontrolleverisintheneutralposition.
• Stopthetruckbeforeshiftingbetweenforwardandreversedirection.
NOTICE
• Torestart poweredtravel aftertheactivation ofthe OPS,release the acceleratorpedal,
returnthe direction controlleverto the neutralposition and sitinthe seat. Sittingin the
seat without returning the direction control lever to the neutral position will not allow
poweredtravel.
10.3Parkingbrakelever
(1)Released
(2)Locked
(3)Releaseknobbutton
(4)Grip
Whenparkingthetruck,graspthegripofthe
parking brake lever and fully pull it toward
you.
When releasing the brake, push back the
leverwhilepressingthereleaseknobbutton.
Whileoperatingtheparkingbrakelever,keep
thebrakepedalfullydepressed.
WARNING
• Beforeapplyingtheparkingbrake,depressthebrakepedalandalwaysconfirmthatthe
truckhascometoastop.
• Neverhold theleverat otherthan thegripbecause afinger may bepinched. Whenre
leasingtheparkingbrakebyholdingtheleverforstartingonaslopeforexample,holdthe
gripatabovetheprotrusion.
• Donotparkthetruckonaslope.Alwaysparkonlevelgroundwithforksflatonthefloor
sothatnoonewillrun intothemortripoverthem. Ifparkingonaslopeisunavoidable,
placeblocksbehindthewheeltopreventthetruckfromrolling.
• Travelingwithoutreleasingthebrakewilldamagethetruckandbrakes.
• Iftheparkingbrakeisengagedwhenthedirectioncontrolleverisintravelingposition,a
warningwillsoundtowarntheoperator.Ifthetruckisoperatedwithoutdisengagingthe
parkingbrake,thebrakeswillloseeffectivenesstoholdthetruckwhentheparkingbrake
isapplied.AsktheToyotadealerforaninspection.
• Ifthe operator leavesthetruck or turnsoff the keyswitch without engaging theparking
brake,awarningwillsoundtowarntheoperator.Whenleavingtheseat,alwaysapplythe
parkingbrake,turnthekeyswitchoffandremovethekey.
10

10 SWITCHES AND LEVERS
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10.4Liftlever
(1)Lower
(2)Lift
Levertoliftandlowertheforks.
LowerPushtheleverforward
LiftPulltheleverbackward
The lifting speed can be adjusted by the
amount the accelerator pedal is depressed
and the amount the lift lever is pulled back
ward.
Theloweringspeedcanbeadjustedonlyby
theamounttheliftleverispushedforward.
WARNING
• Alwaysoperatetheliftleverfromanormalseatedposition.
• IftheOPSisactivated,fullyreleasetheacceleratorpedal,returntheliftlevertotheneut
ralpositionandreturntothenormalseatedpositiontodeactivatetheOPS.Ifyoureturnto
theseat while theliftlever is inthe lifting position,theOPS will bedeactivated and the
forkswillstartmoving1secondlater.
• AftertheOPSisactivated,ifyoureturntothenormalseatedpositionwhiletheliftleveris
intheloweringposition,theOPSwillnotbedeactivatedandtheforkswillnotmovedueto
thereturntoneutralfunction.Alwaysreturntheliftlevertotheneutralpositionbeforere
turningtotheseatwhendeactivatingtheOPS.
• Aslongastheengineisoff,theforkswillnotlowereveniftheleverismovedtothelower
ingposition.WhenyousitinthenormalseatedpositionandturnthekeyswitchtoONpo
sition,youcanlowertheforkseveniftheengineisstopped(excepttruckswithoptional
MinileverorJoystick).
10.5Manualloweringvalve
(1)
(1)Manualloweringvalve
If the key switch cannot be turned on for
whatever reason and the forks cannot be
lowered, loosen the manual lowering valve
located on the oil control valve beneath the
floor board, and move the lift lever to the
loweringposition.
NOTICE! Once the forks have been
lowered with the manual lowering valve,
be sure to close and lock the valve.
10.6Tiltlever
(1)Forwardtilt
(2)Backwardtilt
Levertotiltthemastforwardandbackward.
ForwardtiltPushtheleverforward
BackwardtiltPulltheleverbackward
Theforwardorbackwardtiltingspeedcanbe
adjustedbytheamounttheacceleratorpedal
isdepressed andthe amountthetilt leveris
moved.
WARNING
• Alwaysoperatethetiltleverfromanormalseatedposition.
• IftheOPSisactivated,fullyreleasetheacceleratorpedal,returnthetiltlevertotheneut
ralpositionandreturntothenormalseatedpositiontodeactivatetheOPS.Ifyoureturnto
theseatwhilethetiltleverisoperated,theOPSwillbedeactivatedandtheforkswillstart
moving1secondlater.

10 SWITCHES AND LEVERS
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10.7Tiltleverknobswitch
(Automaticforklevelingcontrol)
(1)
(1)Tiltleverknobswitch
Forkswillautomaticallystopatthehorizontal
position when operating the tilt lever from
backward to forward position with pressing
thetiltleverknobswitch.
Itisalsopossibletoslowdownthebackward
tilting speed at a low lift height by pressing
the knob switch (At a high lift height, the
backward tilting speed is automatically re
ducedbytheactivemastbackwardtiltspeed
controlfunctionofSAS).
Fordetailsofthisfunction,pleaserefertothe
SASFUNCTIONsectionofthismanual.
10.8Clampreleasebutton(Option)
(onlywithClampreleaseinterlockoption)
Standardlever
(1)
(2)
To open the clamp attachment, operate the
attachment lever forward with the clamp re
leaseswitchpressed.
Minilever(Option)
(1)
(1)Clampreleasebutton
(2)Clampreleasedecal
10