Toyota 02-8FDF18, 02-8FGF20, 02-8FDF20 User Manual [nl]

Operator’s Manual

English Polish Latvian Estonian Lithuanian

Instrukcja obsługi

Juhi käsiraamat Vartotojo instrukcija

02-8FGF15,18,20,25,30 02-8FDF15,18,20,25,30 52-8FDF20,25,30 02-8FGKF20 02-8FDKF20

007080-O

00_A5028-0EE00_cover.p65 7/13/07, 10:12 AM1

02-8FGJF35

Publication No. A5028-0EE00 PRINTED IN FRANCE

52-8FDJF35

00_A5028-0EE00_frontcover.fm Page 1 Wednesday, July 18, 2007 7:16 PM

Operator’s Manual

Instrukcja obsługi

Ekspluatācijas rokasgrāmata

Juhi käsiraamat

en (English)

pl (Polski)

lv (Latviešu)

et (Eesti)

Vartotojo instrukcija

lt (Lietuviškai)

01_A5028-0E00_En.fm 2 ページ２００７年７月４日　水曜日　午後４時１分

ENGLISH

BEFORE INITIAL OPERATION

CONTENTS

Note to Operators and Supervisors ....................................................................................................... 2

Before Initial Operation ........................................................................................................................ 2

Caution Plates ....................................................................................................................................... 6

Main Components................................................................................................................................. 7

Driving Controls and Instrument Panel ................................................................................................ 7

Instruments............................................................................................................................................ 8

Multifunction Display (Option) .......................................................................................................... 12

Switches and Levers ........................................................................................................................... 18

Body Components............................................................................................................................... 29

Handling the Toyota DPF-II System (Option).................................................................................... 37

Pre-Operation Check........................................................................................................................... 40

Before Garaging the Vehicle............................................................................................................... 45

Weekly Maintenance........................................................................................................................... 45

Self Servicing...................................................................................................................................... 47

Fuel Tank Check ................................................................................................................................. 51

Frame Serial Number.......................................................................................................................... 51

How to Read the Name Plate .............................................................................................................. 51

Lubrication Chart ................................................................................................................................ 52

Periodic Maintenance ......................................................................................................................... 53

Periodic Replacement Table ............................................................................................................... 53

Protect Your Investment with Toyota Genuine Parts.......................................................................... 53

Periodic Maintenance Table................................................................................................................ 54

Service Data........................................................................................................................................ 58

LPG Device (Option).......................................................................................................................... 60

Mast Specifications & Rated Capacities............................................................................................. 68

Wheel & Tire ...................................................................................................................................... 76

Vehicle Dimensions ............................................................................................................................ 77

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.

• 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 familiar with a new vehicle. In addition to the standard operating procedures, pay attention to the following safety items.

• Please acquire thorough knowledge of the Toyota Industrial vehicle. Read the operator’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 precautions.

• Wear neat clothing for operation. Improper clothing for vehicle operation may interfere with smooth operation and cause an unexpected accident. Always wear appropriate clothing for easy operation.

• Please keep away from live electric power lines. Know the locations of inside and outside power lines and maintain sufficient distance.

• Be sure to perform pre-operation checks and periodic maintenance. This will prevent sudden malfunctions, improve work efficiency, save money and insure safe working operation.

• 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 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 specified 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 dangerous. 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 operation 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 50 ppm that is based on European diesel fuel standard EN590/99.

CautionCaution

• Don’t use the bio-diesel fuel because of bad influence on the engine.

• In winter, use winter diesel fuel to prevent clogging of the fuel filter caused by paraffin precipitation.

en-2

01_A5028-0E00_En.fm 3 ページ２００７年７月４日　水曜日　午後４時１分

• 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 30cm (12in) away from lumber, veneer board, paper products and other similar materials to avoid discoloration, deformation or combustion of those materials.

• For the vehicles using color tires, a static strap must be fixed.

• Vehicles equipped with the wet brake

option require a warm up period before starting load handling operations when temperature is below -10°C (14°F). The

warm up method consists of driving the vehicle without load for approximately 200 meters (600 ft).

Precautions to be taken when using SAS models

(SAS: System of Active Stability)

CautionCaution

• 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 correctly.

• 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 controlled, 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 prevent 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.

CautionCaution

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 position (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 further 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 backward to forward position with the knob switch depressed, the mast will perform as follows:

Not load Loaded

High lift

Stops with forks level

height

(mast vertical)

Low lift

Stops with forks level (mast vertical)

height

CautionCaution

• 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 operation because this automatic forks leveling 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 leveling control. Confirm with a Toyota dealer in advance.

No forward tilt

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 vertical 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 vertical) 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 automatically controllable within a range of angles illustrated below.

Light load

High lift height

Low lift height

(no load)

No restriction for front tilt angle

CautionCaution

• 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.

Intermediate

load

Angle restricted between 1° and 5° forward tilt angle

Heavy load

Forward tilt angle restricted to 1°

en-3

01_A5028-0E00_En.fm 4 ページ２００７年７月４日　水曜日　午後４時１分

CautionCaution

• Some specialty models onto which a heavy attachment is mounted may not be equipped with the mast forward tilt control. 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 attachments alternately, the heaviest one should be used to carry out matching (SAS setting). 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 backward tilt speed controller (slow down) irrespective 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 models)

• If the low lift height is then changed to a high lift height while tilting the mast backward, 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 position 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-position will be automatically corrected while turning 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 operations (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 System 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 System, 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 functions 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. However, 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 problem, 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 position within 2 seconds, loading can be continued.) If the operator leaves the seat while operating the control lever, loading can be continued 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 deactivate 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.

en-4

01_A5028-0E00_En.fm 5 ページ２００７年７月４日　水曜日　午後４時１分

Return-to-Neutral Warning

If the OPS System has caused traveling operations 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 abnormality, 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 inspection 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 coldstart, but does not indicate an abnormality.)

CautionCaution

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)

CautionCaution

• The optional Auto Speed Control Functions 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 circumstances.

• 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 accordance 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, sudden 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 vehicle 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 accelerator 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 prevent sudden acceleration in operation and the speed limits after load lifting height and weight sensing is de-active, the function on/off indicator 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 approximately. 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 precedence.

• 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.

en-5

01_A5028-0E00_En.fm 6 ページ２００７年７月４日　水曜日　午後４時１分

Maximum speed limit

This function prevents the vehicle from traveling at a faster speed from that speed preset by your supervisor or company. The maximum speed can be set between approximately. 815km/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.

CAUTION PLATES

Caution plates are attached on a vehicle. Before driving it, please be sure to read them thoroughly. (The sample shows those of an English version.)

en-6

01_A5028-0E00_En.fm 7 ページ２００７年７月４日　水曜日　午後４時１分

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

DRIVING CONTROLS AND INSTRUMENT PANEL

1. Control lever

2. Steering wheel

11623 45678

15 14 13 12 11 10 9

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

10 11

en-7

01_A5028-0E00_En.fm 8 ページ２００７年７月４日　水曜日　午後４時１分

INSTRUMENTS

56 8 9

Gasoline engine models

457 8 9

Diesel engine models

Combination meter

(1)

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)

12 13

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) 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 meterlighting lamp.

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 diagnosis 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 displayed.

Caution

Should an error code be displayed, park the vehicle in a safe location and contact your Toyota dealer to request an inspection.

en-8

01_A5028-0E00_En.fm 9 ページ２００７年７月４日　水曜日　午後４時１分

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 predetermined level 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, drain water immediately. (See the self service section for the draining instructions.)

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 controller, 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.

CautionCaution

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.

CautionCaution

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.

en-9

01_A5028-0E00_En.fm 10 ページ２００７年７月４日　水曜日　午後４時１分

Charge warning lamp

1. This lamp comes on to indicate an abnormality 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 vehicle 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 system 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 position, then sit on the seat again.

CautionCaution

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 coolant.

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 blinking 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 stabilized 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.

en-10

01_A5028-0E00_En.fm 11 ページ２００７年７月４日　水曜日　午後４時１分

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 display 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 ignition 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.

CautionCaution

• 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 operations and park the vehicle in a safe location. Contact your Toyota dealer to request an inspection. (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.)

• 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

(1)

(2)

(3)

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 ignition switch is on (irrespective of the engine speed), the corresponding part may be abnormal. Contact your Toyota dealer to request an inspection.

CautionCaution

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 disengaging 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 operator when the brake oil is low.

CautionCaution

• 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 necessary.

• If the warning lamp remains a lighted

even if the brake fluid level is sufficient, contact your Toyota dealer to request an inspection.

en-11

01_A5028-0E00_En.fm 12 ページ２００７年７月４日　水曜日　午後４時１分

(1)

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 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 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.

Brake warning lamp (Wet brake models)

If the wet brake function is abnormal, the warning lamp will light and warning buzzer will sound to inform operator. When the warning lamp lights and buzzer sounds, cease work operation and stop the vehicle in a safe place. Securely set the parking brake and fully depress the brake pedal until buzzer stops with the engine still running. After confirming that buzzer is turned off and warning lamp goes off, restart the work operation.

MULTIFUNCTION DISPLAY (OPTION)

1. Multifunction display area

(Multifunction display) (Multifunction display DX)

2 3 4 5

(Multifunction display DX: Vehicles with Auto speed control)

6 3 4 5

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)

(1) Brake warning lamp

en-12

CautionCaution

If the warning lamp does not go off or buzzer does not stop even when the brake pedal is depressed, ask a Toyota dealer for an inspection.

01_A5028-0E00_En.fm 13 ページ２００７年７月４日　水曜日　午後４時１分

Digital speed meter display

ODO • TRIP Meter display

Maintenance display

(1) Meter display switch

(1)

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 finger 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.

Note:

BT Specification (Option) will not display anything for 1 second when the ignition switch is turned to ON.

(1)

(1) Torque converter oil temperature gauge

(1)

(1) Low speed setting switch or down switch

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.

ODO • TRIP meter

ODO......... Displays the total distance traveled.

TRIP......... After resetting this function, dis-

Note:

• Pressing the low speed setting switch (DX

• Always operate the switch panel with your

plays the total distance traveled until now.

models with Auto speed control) or the down switch for more than 2 seconds will reset the total travel distance.

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

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 2002000 hours setting can be set in 50 hour intervals.

Note:

To change the time setting, consult your supervisor or Toyota dealer.

hour time setting.

en-13

01_A5028-0E00_En.fm 14 ページ２００７年７月４日　水曜日　午後４時１分

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 vertical.

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 display the load display screen.

• If the load is less than 100kg, the meter will

indicate 0.00t.

CautionCaution

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 indication 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 reset maintenance time occurs, the operator will be notified through the display and a warning sound. Conduct necessary maintenance.

Note:

The maintenance time setting should be determined 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 Multifunction display, the operator is notified through a warning sound together with diagnosis error content display.

Note:

• The error code display will be different depending on the abnormal area and nature of the abnormality. There are also occasions 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.

en-14

01_A5028-0E00_En.fm 15 ページ２００７年７月４日　水曜日　午後４時１分

(1)

(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 finger 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.

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.

CautionCaution

• If the vehicle is operated without disengaging 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 disengaged, 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 operator returns to the normal seated position and turns the ignition switch to ON while the parking 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 ignition 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 vehicle 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.

en-15

01_A5028-0E00_En.fm 16 ページ２００７年７月４日　水曜日　午後４時１分

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 setting switch or the down switch and then pressing 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.

Vehicles having Multifunction display DX

(1) (2)

en-16

<Over-speed alarm setting screen>

(1) Down switch (2) Meter display switch

01_A5028-0E00_En.fm 17 ページ２００７年７月４日　水曜日　午後４時１分

Vehicles with Auto speed control and Multifunction display DX

(1) (2)

(1) (2) (4)(3)

(1) Low speed setting switch (2) Left switch (3) Right switch (4) Meter display switch

(2) (3) (4)

Low speed setting screen

When the low speed settings are activated, a range of 8 maximum speed settings can be established. Selecting the level 8 setting will turn off the function.

Left switch ............. Decreases the setting level

Right switch .............Increases the setting level

Meter display switch...... Switches to the menu

screen

Note:

• If level 8 is selected, the setting cannot be changed by pressing the low speed setting switch or the down switch in the standard screen.

• Always operate the switch panel using your finger tips.

Over-speed alarm setting screen

This function allows you to set the traveling speed which will set off the alarm.

Left switch ...................... Reduces travel speed

Right switch ...................Increases travel speed

Meter display switch...... Switches to the menu

Note:

Always operate the switch panel using your finger tips.

screen

<Over-speed alarm setting screen>

(1) Low speed setting switch (2) Meter display switch

(2) Left switch (3) Right switch (4) Meter display switch

en-17

01_A5028-0E00_En.fm 18 ページ２００７年７月４日　水曜日　午後４時１分

SWITCHES AND LEVERS

Ignition switch

{ [OFF] ....... Engine stop position.

I [ON]......... Engine operation position.

The intake heater is preheated before starting in the diesel models.

START ............ Engine, start position. Located

After the engine starts, release the key and it will return to the I [ON] position automatically. In the torque converter model, the engine does not start unless the control lever is set in the neutral position.

CautionCaution

• Never operate the ignition switch without first sitting on the seat. Otherwise, the forklift could start to move uncontrolled, causing an accident.

• When the OPS lamp is on, return each lever to the neutral position and sit on the seat. Then confirm that the lamp has gone off.

• Do not leave the switch in the [ON] position when the engine is stopped. It may cause over discharge of the battery.

• Do not turn the switch to the START position while the engine is running.

• For the sake of safety it is recommended to always start the engine of a vehicle with the transmission gear shift lever shifted in the neutral position.

• 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.

• In case of the anti-restart ignition switch (optionally available), be sure to shift the switch to the [OFF] position before attempting to start the engine again.

Key insertion and withdrawal are performed in this position.

Located one position clockwise from { [OFF] position.

one position clockwise from the I [ON] position.

(2)

(1) Left turn (2) Right turn

(1)

• With the ignition switch OFF (engine off), the forks will not lower even if the lift lever is operated. However, if you sit in the seat and turn on the ignition switch, you can lower the forks. (Except mini lever models) Do not operate the lift lever before getting on the vehicle and starting up the engine. (key-off, lift locked)

• If the diagnosis lamp does not go off even when the operator sits on the seat, the battery power may be low. In such a case, do not drive the vehicle until the lamp goes off, otherwise the vehicle may not operate correctly. If you are obliged to drive the vehicle, do so with the utmost care. Also, stop driving and ask a Toyota dealer for inspection if the lamp does not go off 1-2 minutes after the engine starts, or when you race the engine for a while. (For diesel vehicles, the diagnosis lamp may be on for a while to warm up the engine after cold starting. This is, however, not an engine malfunction or failure.)

Integrated light and turn signal switch

This two-position switch serves as both a light switch and turn signal switch.

Light control switch

Irrespective of a ignition switch position, this switch allows you to turn on and off the lights. This switch has two positions. With the switch at each position, the light comes on as shown below.

Lamp name Step 1 Step 2 Head lamps

Side clearance lamps, tail lamps (Option)

Meter illumination lamp

Caution

Do not keep lights such as head lights on for a long period when the engine is stopped. It may cause over discharge of the battery and make engine starting impossible.

−

{{

{

en-18

01_A5028-0E00_En.fm 19 ページ２００７年７月４日　水曜日　午後４時１分

(1) Forward (2) Reverse

(1)

(2)

Turn signal switch

Makes the turn signal lamps blink

Left turn ................................... Push forward

Right turn ................................ Pull backward

The signal switch will operate when the ignition switch is ON. The turn signal lever returns automatically to the original position after making a direction change.

Control lever

Lever for shifting between forward and reverse.

Forward.................................... Push forward

Reverse..................................... Pull backward

The neutral position is halfway between the forward and reverse position.

Note:

After the OPS System operates, return the accelerator pedal to its fully released position and set the control lever to the neutral position, and sit on the seat to restart driving. (Even though the operator sits on the seat, driving is impossible unless the control lever is in the neutral position.)

CautionCaution

The engine cannot be started unless the control lever is in the neutral position. Stop the vehicle before shifting between forward and reverse direction.

(1)

Torque converter interlock function

(Option)

If you switch the control lever direction to something other than the current travel direction while moving at high speed, this function electrically disengages the drive and sets the torque converter to neutral. Once the speed drops below the set speed while running in neutral, the travel direction is automatically switched. To change travel direction, operate the control lever after travel speed is reduced sufficiently. Ask your Toyota dealer for changing speed setting.

CautionCaution

• When the interlock has engaged, release the accelerator pedal and use the brake pedal to reduce speed. After the vehicle has stopped moving, slowly press the accelerator pedal down to start moving again. Disengaging the interlock while the accelerator pedal is pressed down could result in wheel spin.

• Do not perform Forward or Backward operation on slopes. If control lever is operated on a down slope, torque converter interlock function may not operate correctly.

Horn button

Press the button in the center of the steering wheel to sound the horn. The horn will sound even when the ignition switch is OFF.

(1) Push

en-19

01_A5028-0E00_En.fm 20 ページ２００７年７月４日　水曜日　午後４時１分

(1) Push

(1) Lower (2) Raise

(2)

(1)

Horn button (Option)

The horn will sound when the button at the top of the rear pillar assist grip is pressed. Use this horn when backing up. The horn will sound even when the ignition switch is OFF.

Lift lever

Raises and lowers the forks.

Raise.......................................... Pull backward

Lower ......................................... Push forward

The lifting speed can be adjusted by how far the accelerator pedal is depressed and how far the lever is pull back.

The lowering speed can be adjusted only by how far the lever is pushed forward.

Note:

The idling lifting speed increase function (Option) automatically increases lifting speed by engaging the lift lever.

CautionCaution

• After the OPS System operates, return the accelerator pedal to its fully released position and set the lift lever to the neutral position, and sit on the seat to restart the operation. (If you sit on the seat while raising the lift lever, the forks will start to move 1 second later.)

• If you sit on the seat while lowering the lift lever, the forks will not lower due to the return to neutral function.

• Always operate the lift lever while correctly seated.

• When the ignition switch is turned to OFF and lowering the lift lever, the forks will not lower. However, if the operator sits in the normal seated position then the ignition switch is turned to ON, the forks will be lower even if the engine is off. (Except mini-lever/joy stick models)

(1) Lift lever knob switch

(1)

(1) Lift lock release bolt

(1)

Lift lever knob switch

(Option)

For vehicles with Multifunction display DX (Option), pressing the lift lever knob switch will display the weight of load.

Note:

• Operate this function when you are not performing loading operations.

• When weighing the load, always remember to position the load at a height of about 500mm above the ground and make the mast perpendicular.

Key-lift interlock

When the ignition switch is OFF, the lift will not descend even if the lift lever is lowered. However, if the operator sits properly in the seat and turns the ignition switch ON, the forks can be lowered even if the engine is off (Except mini lever/joy stick models). If the ignition switch cannot be turned ON for whatever reason, loosen the manual lowering valve located on the oil control valve beneath the toe board, and operate the lift lever in the downward direction.

Note:

Once the forks have been lowered with the lift lock release bolt, close and lock the valve.

en-20

01_A5028-0E00_En.fm 21 ページ２００７年７月４日　水曜日　午後４時１分

(1) Forward tilting (2) Backward tilting (3) Tilt lever knob switch

(2)

(3)

(1)

Tilt lever

Tilts the mast forward and backward.

Forward.................................... Push forward

Backward................................. Pull backward

The forward or backward tilting speed can be adjusted by the degrees of accelerator pedal depression and lever operating stroke.

CautionCaution

• Insure the load-handling control levers are in their neutral positions before returning to the operator's seat, if not load-handling functions will start movement 1 second after operator returns to the seat.

• Always operate the tilt lever from a seated position.

• After the OPS System operates, return the accelerator pedal to its fully released position and the tilt lever to the neutral position, and sit on the seat to restart the operation. (If the operator sits on the seat without returning the load-handling control levers to their neutral positions, load-handling functions will start movement 1 second after.)

Automatic forks leveling control

With the forks positioned at backward tilt, use the lever to tilt the forks forward while depressing the tilt lever knob. Then, the mast will be automatically stopped with the forks horizontally positioned.

Motion upon change of tilt from backward to forward, with tilt lever knob switch pressed:

High lift Forks stopped at its horizontal

Low lift Forks stopped at its horizontal position (with mast

Not loaded Loaded

position (with mast vertically positioned)

vertically positioned)

No forward tilt

Active mast rear tilt speed control

At a high lift height, the mast has a backward tilt speed controller (slow down) irrespective 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.

When the fork enters the upper lift height stage from the lower one, the rear tilt speed will be restrained as long as the automatic fork leveling control switch is depressed. If the switch is not depressed, the fully open speed will be applied.

(1) Tilt lever knob switch

(1)

Tilt lever knob switch

Depressing the tilt lever knob switch while changing from backward to forward tilt will automatically stop forks at their horizontal position. It is also possible to slow down the backward tilt speed at a low lift height by depressing knob switch.

en-21

01_A5028-0E00_En.fm 22 ページ２００７年７月４日　水曜日　午後４時１分

(1)

(1) Forward (2) Backward

(1)

(1) Lower (2) Raise

(2)

Mini lever (Option)

Control lever

Lever for shifting between forward and reverse.

Forward.................................... Push forward

Reverse..................................... Pull backward

The speed of forward and backward traveling can be adjusted by the extent of pressing the accelerator pedal.

Note:

• Stop the vehicle before shifting between forward and backward traveling.

• After the OPS System has been activated, return the accelerator pedal and control lever to their neutral positions and return to the seat before recommencing operations.

• Always operate the control lever from a properly seated position.

• Depending on the vehicle specifications, the position of the control lever may vary.

Lift lever

Raise and lower the forks for loading.

Raise.......................................... Pull backward

Lower ......................................... Push forward

Raising speed can be adjusted by the extent of pressing the accelerator pedal and pulling the lift lever. Lowering speed can be adjusted by the extent of pushing the lift lever.

Note:

• After the OPS System has been activated, return the accelerator pedal and all of the levers to their neutral positions and return to the seat before recommencing operations.

• If you return to the seat while lowering the lift lever, the forks will not descend due to the return to neutral function.

• Always operate the lift lever from a properly seated position.

(1)

(1) Lift lock release bolt

(1)

(1) Forward (2) Backward

(2)

Note:

• If you use the idling lifting speed increase function (Option), pulling the lift lever will automatically increase the engine speed and raise the forks at a constant speed without having to step on the accelerator pedal.

• When the ignition switch is turned to OFF, the forks will not descend even if the lift lever is lowered. (Key-lift interlock)

• When the forks will not lower due to system malfunction or other reasons, they can be lowered by opening the lift lock release bolt.

• If you lower the forks by opening the lift lock release bolt, close and lock the bolt.

Tilt lever

Tilt the mast forward and backward.

Forward ..................................... Push forward

Backward..................................Pull backward

Forward or backward tilting speed can be adjusted by the extent of pressing the accelerator pedal and operating the lever.

Note:

• After the OPS System has been activated, return the accelerator pedal and all of the levers to their neutral positions and return to the seat before recommencing operations.

• Always operate the tilt lever from a properly seated position.

en-22

01_A5028-0E00_En.fm 23 ページ２００７年７月４日　水曜日　午後４時１分

(1)

(1) Automatic forks leveling switch

Automatic fork leveling switch

(Works same as the tilt lever knob switch.)

While pressing the switch when the forks are tilted forward from a backward-tilted position, or backward from a forward-tilted position, the forks will automatically stop at a horizontal position. Releasing the switch will allow for normal tilt lever operation.

Forks forward-tilt automatic leveling control

When the forks are in a backward-tilted position, operating the lever forward while depressing the automatic fork leveling switch will automatically stop the forks at a horizontal position. This function is convenient when handling loads or attaching/detaching forks.

While depressing the automatic fork leveling switch, operating the forks forward from a backward-tilted position:

Not loaded Loaded

High lift Forks stopped at their horizontal

position (with mast vertically positioned)

Low lift Forks stopped at their horizontal position

(with mast vertically positioned)

Forks backward-tilt automatic leveling control

When the forks are in a forward-tilted position, operating the lever backward while depressing the automatic fork leveling switch will automatically stop the forks at a horizontal position. This function is convenient when using clamp-type attachments while the mast is tilted forward from the vertical position.

While pressing the automatic forks leveling switch, operating the forks backward from a forward-tilted position:

Not loaded Loaded

High lift

Forks stopped at their horizontal position (with mast vertically positioned)

Low lift

No forward tilt

(1)

(1) Load meter switch

(1)

Active mast rear tilt speed control

When the mast is raised to a high position, backward-tilt speed will automatically slow down.

Load meter switch (Option)

For vehicles equipped with Multifunction display DX (Option), pressing the load meter switch will display the weight of the load.

Note:

• Operate this function when you are not performing loading operations.

• When weighing the load, always remember to position the load at a height of about 500mm above the ground and make the mast perpendicular.

Attachment lever

Operates the attachment. Attachment speed can be adjusted by the extent of pressing the accelerator pedal and operating the lever.

Note:

• After the OPS System has been activated, return the accelerator pedal and all of the levers to their neutral positions and return to the seat position before recommencing operations.

• Always operate the attachment lever from a properly seated position.

(1) Attachment lever

en-23

01_A5028-0E00_En.fm 24 ページ２００７年７月４日　水曜日　午後４時１分

(1) Attachment lever switch

(1)

(2)

(1) Forward (2) Backward

(1)

Attachment lever switch

(Only for 5 ways series)

This switch allows attachment lever operations to be switched between the 3rd and 4th ways. It is for 3rd operation when the changing-over switch is not switched. And it switches to 5th operation while pushing it.

CautionCaution

Operate the attachment lever switch when attachment operations are stopped.

Joy stick (Option)

Control lever

Lever for shifting between forward and reverse.

Forward.................................... Push forward

Reverse..................................... Pull backward

The speed of forward and backward traveling can be adjusted by the extent of pressing the accelerator pedal.

Note:

• Stop the vehicle before shifting between forward and backward traveling.

• After the OPS System has been activated, return the accelerator pedal and control lever to their neutral positions and return to the seat before recommencing operations.

• Always operate the control lever from a properly seated position.

• Depending on the vehicle specifications, the position of the control lever may vary.

(3)

(2)

(1) Raising (2) Lowering (3) Forward-tilt (4) Backward-tilt

(1)

(1) Lift lock release bolt

(1)

(4)

Lift tilt lever

Operation to the left and right controls lift, and forward and backward operation controls tilt.

Raising ...............Operate the lever to the right

Lowering.............. Operate the lever to the left

Forward-tilt ............Operate the lever forward

Backward-tilt.......Operate the lever backward

Raising speed and forward and backward-tilt speed can be adjusted by the extent of pressing down on the accelerator pedal and operating the lever. Lowering speed can be adjusted by operating the lever.

Note:

• Using the idling lifting speed increase function (Option), when the lift tilt lever is raised, the engine’s speed is automatically increased without having to press the accelerator pedal, allowing the forks to be raised at a constant speed.

• After the OPS System has been activated, return the accelerator pedal and all of the levers to their neutral positions and return to the seat before recommencing operations.

• If you return to seated position while lowering the lift lever, the lift will not descend due to the return to neutral warning function.

• Always operate the load handling lever from a properly seated position.

• When the ignition switch is turned to OFF, the forks will not descend even if the lift lever is lowered. (Key-lift interlock)

• When the forks will not lower due to system malfunction or other reasons, they can be lowered by opening the lift lock release bolt.

• If you lower the forks by opening the lift lock release bolt, close and lock the bolt.

en-24

01_A5028-0E00_En.fm 25 ページ２００７年７月４日　水曜日　午後４時１分

(1)

(1) Automatic forks leveling switch

Forks automatic leveling switch

While pressing the switch and the forks are operated forward from a backward-tilted position, or backward from a forward-tilted position, the forks will automatically stop at a horizontal position. Releasing the switch will allow for normal tilt lever operation.

Forks forward-tilt automatic leveling control

When the forks are in a backward-tilted position, operating the lever forward while pressing the automatic forks leveling switch will automatically stop the forks at a horizontal position. This function is convenient when handling loads or attaching/detaching forks.

While pressing the automatic forks leveling switch, operating the forks forward from a backward-tilted position:

Not loaded Loaded

High lift Forks stopped at their horizontal

position (with mast vertically positioned)

Low lift Forks stopped at their horizontal position

(with mast vertically positioned)

Forks backward-tilt automatic leveling control

No forward tilt

(1)

(1) Automatic forks leveling switch

Load meter display

In the case of vehicles with multifunction display DX (Option), pressing the fork automatic leveling switch will display the weight of the load being handled.

Note:

• The load meter switch and fork automatic leveling control switch functions are combined.

• Operate this function when loading is not being conducted.

• When weighing the load, always remember to position the load at a height of about 500mm above the ground and make the mast perpendicular.

Attachment lever

Operates attachment. Attachment speed can be adjusted by the extent of pressing the accelerator pedal and operating the lever.

Note:

• After the OPS System has been activated, return the accelerator pedal and all of the levers to their neutral positions and return to the seat before recommencing operations.

• Operate the attachment lever after you are seated properly in the vehicle.

While pressing the automatic forks leveling switch, operating the forks backward from a forward-tilted position:

Not loaded Loaded

High lift

Forks stopped at their horizontal position (with mast vertically positioned)

Low lift

Active mast rear tilt speed control

When the mast is raised to a high position, backward-tilt speed will automatically slow down.

en-25

01_A5028-0E00_En.fm 26 ページ２００７年７月４日　水曜日　午後４時１分

Mini lever models

Joy stick models

Arm rest

(Mini lever and Joy stick models)

Before starting up the engine, adjust the arm rest to set the optimum driving position.

CautionCaution

• After you have finished adjusting the arm rest forward-backward position, height and tilt, confirm that the knob and the lever have been secured in place. A loose knob or lever may cause an accident.

• Do not adjust the position of the arm rest while operating the vehicle.

• To operate the vehicle in safely, lock the arm rest securely. Before operating the vehicle, always confirm that the lever for turning and securing the arm rest is locked.

Adjusting the backward-and-forward position

Pull up and loosen the forward-backward position adjusting knob. Adjust the arm rest forward-backward position. Then press the knob, securing it in place.

(1) Height adjustment knob

(1)

(1) Tilt adjustment lever

(1)

Adjusting the height position

Turn the knob counterlockwise to release the lock.Then, move the arm rest up-and-down to place it to an appropriate position. Turn knob clockwise to lock.

Adjusting the tilt position

Lift and loosen the lever for turning and securing the arm rest. Adjust the tilt of the arm rest.Then push the lever down,securing it in place.This lever is used in order to turn the arm rest when you open and close the engine hood.

(1)

(1) Backward-and-forward position adjust-

ment knob

en-26

01_A5028-0E00_En.fm 27 ページ２００７年７月４日　水曜日　午後４時１分

Arm rest

(Mini lever and Joy stick with Premium cabin models)

Before starting up the engine, adjust the arm rest to set the optimum driving position.

CautionCaution

• After you have finished adjusting the arm rest forward-backward position, height and tilt, confirm that the knob and the lever have been secured in place. a loose knob or lever may cause an accident.

• When you adjust the arm rest position, confirm by tightening the knob and lock the arm rest securely. A loose knob may cause an operational error.

• Do not adjust the position of the arm rest while operating the vehicle.

• To operate the vehicle in safely, lock the arm rest securely. Before operating the vehicle, always confirm that the lever for turning and securing the arm rest is locked.

Adjusting the backward-and-forward position

Pull up and loosen the forward-backward position adjusting knob. Adjust the arm rest forward-backward position. Then press the knob, securing it in place.

(1)

(1) Height adjustment lever

(1)

(1) Tilt adjustment knob

(1)

Adjusting the height position

Turn the lever counterclockwise to release the lock. Then, move the arm rest up-and-down to place it to an appropriate position. Turn lever clockwise to lock.

Adjusting the tilt position

Lift and loosen the tilt adjustment knob counter clockwise to adjust the tilt of the arm rest. This lever is also used in order to spring up the arm rest.

Adjusting the turning position

Lift and loosen the turning lever counter clockwise to turn the arm rest from side to side.

This lever is used in order to turn the arm rest when you open and close the engine hood.

(1)

(1) Backward-and-forward position adjust-

ment knob

(1) Turning lever

en-27

01_A5028-0E00_En.fm 28 ページ２００７年７月４日　水曜日　午後４時１分

(1) Press down

(2) Release lever

(2)

(1)

Parking brake pedal

Use the parking brake pedal when parking or stopping.

1. When engaging the parking brake, while

stepping on the brake pedal, fully press down on the parking brake pedal.

2. To disengage the parking brake pedal,

while stepping on the brake pedal, pull the release lever toward you.

Warni ng

• Before operating the parking brake pedal, step on the brake pedal and always confirm that the vehicle has come to a stop.

• When parking on a slope, apply wheel chocks to the wheels.

• Traveling without releasing the brake will decrease the brake performance.

Tilt steering adjustment

1. The steering wheel position may be

adjusted back and forth while the tilt steering adjust lever up.

2. Lowering the lever at the proper position

fixes the steering wheel at that position.

3. After the adjustment, try to move the

steering wheel back and forth to see that it is fixed.

(1) Height adjustment lever

(1)

Telescopic steering (Option)

Use the telescopic steering to adjust the height of the steering wheel.

1. Pull up the height adjustment lever

2. Hold the steering wheel with both hands, and adjust the height.

3. Hold the height adjustment lever down at the proper position, and lock the steering wheel securely. The steering wheel will be locked.

4. After you have finished adjusting the steering wheel, move the wheel up and down to confirm that it has been locked securely.

CautionCaution

The steering wheel position must be adjusted before starting the vehicle. Adjustment during traveling must be avoided.

Pedals

From the right: accelerator pedal, brake pedal and inching pedal.

Note:

Accelerator pedal stays neutral even when control lever is shifted to forward-reverse,due to accelerator switch. The vehicle will move only when accelerator pedal is depressed.

(1) Raised

en-28

(1)

CautionCaution

The steering wheel position must be adjusted before starting the vehicle. Adjustment during traveling must be avoided.

01_A5028-0E00_En.fm 29 ページ２００７年７月４日　水曜日　午後４時１分

(1) Forward (2) Backward

(1) (2)

D2 pedal (Option)

These pedals are used for foot pedal for travel shifting, and acceleration.

Forward................... Step on the left side

Backward................. Step on the right side

Each pedal functions as accelerator pedal. Speed is adjustable by depth of depression.

Note:

• When OPS System has been activated, it can be released by sitting on the operator's seat correctly and stepping D2 pedal or by depressing parking brake pedal once and then releasing it.

• D2 pedal models can only start an engine when the parking brake is on.

of the pedal.

BODY COMPONENTS

(1)

(1) Adjustment lever

Operator’s seat

The operator’s seat and seat belt are provided for your safety. The seat can be moved back and forth for position adjustment while the adjust lever is pulled upward.

CautionCaution

• Due to the seat switch, the forklift cannot be driven and the forks cannot be raised or lowered unless the operator is sitting on the seat. Therefore, please sit on the seat before attempting to operate the forklift. Moreover, do not operate it with an object placed on the seat.

• Do not turn on the seat switch by any method other than sitting on the seat.

Operator Restraint System

A specially designed operator’s seat and seat belt are provided for your safety. Get in the habit of using the seat belt whenever you sit on the vehicles.

CautionCaution

Always adjust your seating position before driving the vehicle.

An operator’s manual and operator’s manual for safety operation are located on the rear side of the seat. If your vehicle dose not have an operator’s manual and operator’s manual for safety operation, please contact (your authorized Toyota dealer) to obtain copies for your vehicle.

en-29

+ 352 hidden pages