Toyota Empilhadeira

FOREWORD
We appreciate your purchase of TOYOTA forklift.

This manual describes proper handling of each part of the product based on the operator's action
so that you can use your TOYOTA forklift safely and comfortably.
This manual also includes maintenance procedure and emergency measures for your vehicle.
Be sure to read this manual before using your vehicle.
• IIt is required for you to read and observe the particularly important notes, such as "You must read and know this"
and those marked with, DANGER , Warning and Caution . Failure to observe such notes may lead
to an accident, injury or serious disaster.
• Symbols and wording used in this manual have following meanings.
DANGER An extreme hazard that could kill you or cause very serious injury every time.
Not as serious as Danger, but a hazard that could cause injury or death if you
Warning don't follow the rules.
When you see this word, there will be a message to help you avoid damage
Caution to your vehicle.
Ways to do your job right and easier and to keep your vehicle running well,
Note: follow this word.
• Keep this manual attached to the vehicle for the next-coming operator.
• For anything unclear, ask the sales staff of your vehicle.
• Please note that the contents of this manual may vary from the actual vehicle due to changes of the vehicle spec-
ifications and for some other reason.
• This vehicle passed the type approval tests pursuant to “Ordinance for Special Equipment Safety Inspection” and
“Regulation for Special Equipment Quality Supervision & Safety Inspection.”
TOYOTA INDUSTRIAL VEHICLE
This manual is applicable to following vehicles.
Series Vehicle model Specifications Valtage (V) Controller

Divided type controller system
8FBN15 Standard 48
(Microprocessor + Inverter control)
50-8FBN15 For China 48
1.0 ton series 8FBN16 For China 48
8FBN18 Standard 48
50-8FBN18 For China 48
8FBN20 Standard 48
2.0 ton series 50-8FBN20 For China 48
8FBN25 Standard 48
3.0 ton series 8FBN30 Standard 80
SECTION CONTENTS
ILLUSTRATED CONTENTS.................................................... 2
1. BEFORE INITIAL OPERATION .......................................... 5
2. PROPER OPERATION........................................................ 43
3. OPERATION DEVICES ....................................................... 55
4. OPERATION ........................................................................ 97
5. IN CASE OF EMERGENCY ................................................ 103
6. MAINTENANCE .................................................................. 115
7. SUPPLEMENT .................................................................... 163
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ILLUSTRATED CONTENTS
Shown below are component names and corresponding pages to refer to.
When only a name is given, there is no page to refer to.
MAIN COMPONENTS
6
8
10
1. Mast 7. Steering wheel.......................................................122

2. Chain 8. Counter weight
3. Fork......................................................................... 62 9. Rear wheel
4. Battery hood ......................................................... 108 10. Front wheel
5. Operator’s seat ....................................................... 51
6. Head guard
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DRIVING CONTROLS AND INSTRUMENT PANEL
1 2 3 4 5 6 7 8 9 10 11 En
12 13 14 15 16
1. Parking brake lever..................................................59 12. Tilt steering adjust lever .......................................... 56

2. Direction lever..........................................................58 13. Tilt steering lock release lever................................. 56
3. Steering wheel .......................................................122 14. Key switch ............................................................... 57
4. Horn button..............................................................62 15. Brake pedal ............................................................. 58
5. Turn signal switch 16. Accelerator pedal .................................................... 57
Light control switch ..................................................61
6. Display.....................................................................71
7. Lift lever knob button (option) ..................................60
8. Lift lever ...................................................................59
9. Tilt lever knob button (option) ..................................61
10. Tilt lever ...................................................................60
11. Attachment Lever (option) .......................................67
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1. BEFORE INITIAL OPERATION

TO BUSINESS PROPRIETOR ........................................................... 6
TO OPERATOR .................................................................................. 9
PREPARATIONS FOR SAFETY ...................................................... 20
INDICATORS .................................................................................... 37
FOR PROTECTION OF ENVIRONMENT ........................................ 41
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1. BEFORE INITIAL OPERATION
TO BUSINESS PROPRIETOR
Caution
When the administrator decides to change the
Caution operation plan, be sure to have its details known by
persons concerned.
The administrator in charge of operation must
always know the health condition of the operator.
The administrator must not allow the forklift opera-
tor who has insufficient sleep, poor health condi- Caution
tion of influence or liquor to operate the forklift.
When operators from different companies work
together in one work place, make operation proce-
dures clear among them and appoint the foreman to
Caution ensure safety of the work.
The administrator should provide instructions for
the work by preparing the operation plan.
The operation plan must be made with the space size Caution
and geographical features of the work place as well as Be sure to take safety measures where any danger
the type of the forklift, its capacity and type of the load is anticipated.
taken into account. The operation must be stopped
when the visibility is hindered by mist, snow or rain or
when the wind is strong.
Caution
Operation of the forklift must be performed by a
full-time operator who has had appropriate educa-
tion and training according to the laws of each
country.
Caution When working on the road shoulder, the end of cliff or

Establish your own rules for operation, inspection, the place with a risk of landslide, take necessary pre-
maintenance and safety of the forklift. Give educa- ventive measures to secure safety. Keep away from the
tion to the operator periodically and check if the road shoulder and end of cliff as the ground itself is
rules are observed properly and take corrective fragile.
measures as necessary.
Caution
Caution Chock the vehicle to prevent a downfall.
To ensure safety of pedestrians and vehicles pass-
ing by, make the sidewalk and driveway separate.
For this purpose, use the fence or guiding person
to keep off pedestrians. The operator must perform
as instructed by the guiding person.
Caution
Provide safety education to the forklift operator and
workers so that they can cope with changes of the
work from time to time.
There is a possibility of danger at the quay wall and end

of the platform. Be sure to use a chock to prevent the
forklift from moving further.
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BEFORE INITIAL OPERATION
Caution Caution
Be sure to perform pre-operation checks, periodic Perform checks and maintenance at a specified
maintenance and other inspections according to place equipped with appropriate instruments and
the laws. safety facility. The place must meet the following
conditions. En
• Level and paved ground
• Good ventilation
• No fire
• Fire extinguisher prepared
• Off limit except persons concerned
Caution
This forklift is controlled by an electronic device, its
initialization is necessary after performing the
maintenance work. Do not remove any SAS- and
For the procedures of the periodical self inspection, OPS functional part, disassemble or modify the
consult the Toyota dealer. electric part such as a controller and charger. If any
Forbid operation of the vehicle until the pre-operation of them needs inspection, have it done at Toyota
checks are completed. dealer. Also, when checking the functions of SAS-
Do not allow to use the forklift when the battery fluid and OPS, secure enough space and make sure in
level is low. advance that there is no person obstacle in that
area.
Caution
Keep the vehicle and work site neat, tidy and clean
to ensure safe operation.
If tools, parts, inflammables, lighters, cups that have

nothing to do with the work are scattered or dirt and
grease are attached around the operator’s seat or on
the vehicle, operation may be hindered, leading to an
unexpected accident.
Be sure to secure enough lighting for the work place for
safe operation.
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Caution Caution
Do not remove the head guard. Never tow the vehicle with a draw bar.
Modification of the vehicle is strictly inhibited. Particu- When the vehicle has failed to move, the drive system
larly, operating the vehicle without the head guard and may have a trouble. Do not tow it but contact the Toyota
backrest may result in a dangerous situation caused by dealer.
a dropped load, vehicle tip-over and other dropped
object. Also note that the head guard is not intended to
be proof against all impacts. The operator must be
always watchful overhead. Caution
Be sure to perform tap changer adjustment (input
voltage adjustment) of the charger.
Caution
In a certain special work environment, it is not pos-
sible to use the forklift with standard specifications
as they are. When using the forklift in any of the fol-
lowing environments, consult the Toyota dealer.
• Work place where excessively high or low tempera-
ture is anticipated
• Port or seaside where salt corrosion is anticipated
• Work place where loads including salt water or salt
are handled
• Chemical plant where influence on the forklift from
acid or other chemicals is anticipated
• Environment where a danger of explosion by floating
particles or explosive gas is anticipated Professional technical knowledge is required for this
• Cold, hot or high altitude area adjustment. Be sure to have it done at the Toyota
• Environment where a specified exhaust gas standard dealer.
is applicable
• Work place where excessively high or low tempera-
ture is anticipated
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TO OPERATOR
Caution
For charging the battery, select a place not exposed Before Operation
to rain or water, with good ventilation (airy), free
from fire and with very few persons.
Caution En
The operator of the forklift and workers should per-
form their work according to instructions of the
administrator and guiding person.
Caution
Wear proper clothing for operation.
Charging the battery generates the hydrogen gas which

may explode. For this reason, select a place not
exposed to rain or water, with good ventilation (airy),
free from fire and with very few persons. Also, keep the
battery hood open while charging.
Consult the Toyota dealer when any of the following
condition has occurred.
• Abnormal or bad smell detected
• Electrode darkened
• High electrolyte temperature
Tidy appearance is important when operating the fork-
• Electrolyte level lowering quickly
lift. The loose sleeve cuff or hem may be caught by the
lever, resulting in an unforeseen accident. Also, acces-
sories such as a ring with a projection may cause an
Caution accident.
Be sure to wear a safety cap and safety shoes and
Never loosen any bolts and nuts used for the check your appearance before operation.
divided rim. When replacing the tire of the divided
rim, first let out the tire air pressure completely.
Caution
To dispose of harmful materials such as waste oil,
filter and battery, be sure to follow the applicable
laws and rules.
Caution
For vehicles that are equipped with non-marking
lug tires, please install a static strap.
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Caution Caution
Please read the operator’s manual and the caution Keep the operator’s manual in the seat back pocket
plate attached to the vehicle thoroughly. so that they can be referred to as necessary.
Make sure to familiarize yourself with proper handling of

the TOYOTA forklift by reading this instruction manual. Caution
Sections “Operation system” and “Operation proce-
dure” describe how to use each part properly and cau- If the operator is not seated or seated but improp-
tions for safety operation. erly, the OPS system prevents the forklift from oper-
Use extra care for caution plates attached to the vehicle ating.
as they contain information requiring special attention.
However, if it is the attachment type, even if the OPS
Words “Forward”, “Backward”, “Right side” and “Left system is activated, the attachment lever, if operated,
side” used in this manual indicate directions as shown may cause the forklift to move by its self-weight. For
below. this reason, do not operate the attachment lever.
(3)
Caution
Observe the allowable load.
A name plate indicating the load allowed for safe han-
(1) (2) dling is attached to the forklift. Make sure to observe it
during operation. (Refer to “How to Read the Name
Plate” in page 44.)
(4) Caution
In handling any attachment, follow the attachment
(1) Forward manufacturer's instructions.
(2) Backward
(3) Right side
(4) Left side
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Caution Caution
Prior to operation, adjust the seat to the proper When multiple number of workers work together,
position and wear the seat belt properly when oper- follow instructions of the guiding person.
ating the vehicle.
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Be sure to appoint a guiding person when the work is

Fasten the seat belt properly. The seat belt, worn
done in a small or crowded area or when the same
improperly, may cause serious injury if the vehicle
work is done simultaneously by a multiple number of
should tip over.
forklifts. Only one guiding person should be appointed
to avoid confusion and all operators should follow
instructions of the guiding person. The guiding person
Caution must no allow unnecessary person or un-permitted
vehicle to enter the work area.
When you get on the vehicle, be sure to check each
function of SAS- (System of Active Stability: refer
to page 45) and OPS (Operator Presence Sensing:
refer to page 49) System for proper operation Caution
before starting operation.
To avoid any contact accident, study signs and traf-
fic rules applicable to the work site in advance and
follow instructions of the guiding person. As the
forklift with the load cannot stop right away, always
yield the way to the loaded forklift.
Caution
Check the surrounding area for safety before get-
ting on the vehicle.
Before getting on the vehicle check that no one is work-
ing in the hard-to-see area from the operator’s seat
such as the front, rear or underside of the vehicle. If a
If this check is neglected, the malfunction of SAS- and worker is in the nearby area, tell a worker that the vehi-
OPS may result in unexpected accident. cle will be operated and not to come close to it.
Caution
Make a fire extinguisher always available in the
work area and familiarize yourself with how to use
it.
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Traveling and Load Handling

Caution
When working in a dark location or at night, ensure
the necessary illumination and turn ON the work
Caution
lights. Even if the vehicle is equipped with SAS-, always
operate it carefully and properly.
Caution
Do not operate the vehicle when you are tired, had
alcohol or medicine with sleeping ingredient.
SAS- equipped vehicle does not always mean that it

does not tip over.
Poor health condition hinders your judgment in case of

Caution
emergency. Avoid operation when you are fatigued and Practice well before operating the forklift.
absolutely never attempt operation after drinking liquor.
Caution
Warm up the drive unit before operating the forklift
and avoid rough handling during operation.
• Practice fully to be familiar with each device in

advance. Even after you are accustomed to handling
it, operate it carefully avoiding forcible operation. Oth-
erwise, human injury or material damage may possi-
bly occur.
• When using multiple number of vehicles, note that
each one has unique features of braking, accelerator
As a warming up step before operating the forklift, be and loading device in spite of the same specifica-
sure to check the drive unit, up and down movement of tions. When you move from one vehicle to another
the fork, tilt operation and attachment function and temporarily, grasp its unique features before opera-
avoid rough handling of the forklift while operating it. tion. In particular, pay attention to braking feeling.
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Warning Caution
When backing up, check the rear of the vehicle When going up the slope, operation with yourself
visually before starting operation. lifted or seated improperly will cause OPS to func-
tion and the vehicle to stop and then to move down.
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Even for a short distance, backing up without looking at

the rear or only by using the rear view mirror is very Be sure to fasten the seat belt and do not lift yourself off
dangerous as the forklift may hit other worker or some the seat during operation.
obstacle.
Warning
Caution
In the event of a tip-over, do not jump out of the
Stay sit on the operator’s seat properly while travel- vehicle.
ing and load handling operations.
If the vehicle should tip over, tilt your body in the oppo-
Do not put any object on the seat. It may disturb correct site direction from the tip-over, hold the yourself
operation of OPS. securely to avoid being involved in a danger which may
occur then.
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Caution Caution
Keep the traffic rules in the work area. When leaving the operator’s seat, lower the fork to
the ground, apply the parking brake and remove the
key switch.
Understand and maintain work area traffic rules.
The vehicle stopped or parked with the fork raised is

dangerous when a person comes close to it suddenly. If
Caution it is not possible to lower the fork to contact the ground,
Confirm safety in the surrounding area while travel- keep it surrounded with fence or the like to prevent a
ing. person from tipping over.
Also, when leaving the operator’s seat even for a short
time, lower the load to the ground.
Caution
When carrying the load with the forklift from the
load bed of the truck, start the work with the load
which is placed closer to the end of the load bed.
Caution
When the load is far from the end of the load bed of
• While working on a narrow road or platform, maintain the truck and the fork cannot be inserted far
the safe distance from the edge so that the vehicle enough for the load to reach the root of the fork,
does not come off. keep other workers away as the load may come off.
• If the vehicle becomes immovable in a dangerous
place such as a railroad crossing, let nearby others
know that the vehicle failed.
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Caution Warning
If the bar type fork is used, be sure to set the fork Never put your hand, foot or any other part of your
stopper securely before handling the load. body between masts.
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• When the body touches the operation lever, the mast

Caution may start moving suddenly and catch your hand, foot
or any other part. Leave the inspection and repair of
When drawing the fork off from the pallet, make the mast to the full-time service staff.
sure that the fork is not in contact with the pallet. • Do not put your body outside of the operator’s seat.
Contacting with some obstacle may result in an injury.
Caution
Warning
Be sure to travel to know the locations of inside and
outside power lines, etc. Never make a sudden turn.
Unless you have good understanding of the work area If the forklift is turned suddenly, even if the fork is set at
conditions, the power lines or vehicle itself may be dam- 15 to 20 cm above the ground position, it may roll over.
aged. As a roll over or tip-over will lead to a serious accident,
be sure to reduce the speed when making a turn.
Caution
Never operate the forklift with too much confidence
in the forward tilt control function of the mast.
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Warning Warning
Never tilt the mast forward beyond its vertical posi- Never attempt traveling with a load on the fork lifted
tion when a load is lifted. Also, never raise the load beyond the specified height.
with the mast tilted forward.
Traveling with a load on the fork lifted beyond the spec-

The vehicle may tip over, losing its stability forward and ified height may cause tip-over due to upward shifting of
backward even within the allowable load weight. the center of gravity. Keep the fork at 15 to 20 cm above
the ground when traveling.
Caution
Caution
Never turn off the key switch or disconnect the bat-
tery plug while traveling. Note that the stopping distance increases on the
downhill or wet road surface. Apply the brake ear-
lier to be in time.
On the downhill road, the vehicle speed may exceed its
maximum speed and the stopping distance is longer.
Maintain the speed level lower than the maximum
speed throughout the period of operation.
With the key switch turned off or the battery pug discon-
nected, the power system of the power steering does
not function and the steering becomes heavy suddenly,
leading to a very dangerous situation.
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Caution Caution
Never park or stop the vehicle on a slope. Pay attention to each warning indicator during
operation.
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• To avoid a possible dangerous situation, make sure

to park or stop the vehicle on a level ground. The When the warning lamp lights up and an error code
vehicle parked or stopped on a slope may start mov- appears on the display, move the vehicle to a safe
ing by itself or start moving when the operator gets on place, stop it and have it inspected at the Toyota dealer.
it again.
• If you have to start the vehicle on a slope, keep
enough distance from the vehicles in front and rear as
the vehicle may move down depending on how Caution
strongly the pedals are depressed. If the vehicle has a trouble with the hydraulic sys-
tem and motor system, do not move it by towing.
Towing may cause further damage to the brake and
Caution motor system.
Avoid overloading or uneven loading. Operate the
vehicle according to the load table.
Caution
Do not over discharge.
When the battery capacity indicator indicates over dis-
charge and outputs the warning sound, stop operation
and charge the battery.
Repeated over discharge will shorten the service life of
the battery.
Caution
Do not remove or modify the functions of SAS- and
Overloading and uneven loading is very dangerous. Put OPS during the maintenance work.
loads according to the load table (name plate). Over- As SAS- (refer to page 45) is controlled electronically,
loading will cause the rear wheels to lift up and vehicle initialization is required after the maintenance work.
control will be lost, possibly resulting in a big accident. When inspection is necessary, have it done at the
Uneven loading will make the vehicle unstable and Toyota dealer.
increase the danger of tip-over.
The load table (name plate) indicating the maximum
load that can be loaded safely and the allowable load is
attached to the forklift. Always follow the specified
allowable load. (Refer to “How to read the name plate”
on page 44.)
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After Completion of Work

Caution
When washing the forklift, be careful not to splash
Caution electrical parts directly with water.
Park the vehicle at the specified place and keep the Water splashed over electrical parts directly will cause
key switch. their malfunction or failure. When washing is unavoid-
able, protect electrical parts (particularly controller sec-
tion, tilt angle sensor, accelerator sensor, brake sensor,
load handling lever sensor, oil control valve switch,
height switch, horn button, blinker switch, meters,
motor, instrument panel switches and electrical parts in
the battery hood or the like) by covering them with vinyl
cover or the like and use care while washing the vehi-
cle.
When cleaning the top face of the battery, wipe it with
wet cloth before charging.
Do not wipe or dust with dry cloth or cover it with vinyl
sheet.
When parking the vehicle, avoid the nearby place of the

safety facilities such as emergency exit, emergency Caution
stairway and fire extinguisher and select the location
Never park the vehicle on a slope.
where the vehicle will not be in the way of pedestrians
or other traffic. Remove the key switch from the vehicle,
keep it at a specified place out of reach of other people.
Also, put up a sign or signal lights around the vehicle as
necessary.
Caution
At the end of the work everyday, clean the vehicle
before inspection and maintenance.
The vehicle parked on a slope may start moving by

itself or when the operator gets on it again. To avoid
such dangerous situation, make sure to park the vehicle
on a level ground.
Cleaning the vehicle helps find malfunctioning part in

the early stage. Remove dirt and dust from the vehicle
thoroughly and check the vehicle for abnormality to be
prepared for the next day.
If the vehicle was exposed to salt water, snow melting
agent such as chloride calcium or oxidation solution
and left as it was, electric parts including the motor may
fail and corrosion may progress. Be sure to remove
such things after the work is over.
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Battery Charging
Caution
If you hear any abnormal noises or sense anything
unusual, inspect and repair immediately.
Caution
While charging the battery, put up “NO FIRE” sign
at an easily noticeable place. En
If any abnormal noise or any other abnormal condition

is found, park the vehicle at a safe place and inform
about it to the administrator or Toyota dealer and keep As explosive hydrogen gas is generated during battery
other people away from the vehicle. charging, strict inhibition of fire is essential. Also, keep
the battery hood open during battery charging.
Caution
Do not operate or park the vehicle around any flam-
Caution
mable material. To stop battery charging which is still going on, do
not disconnect the charge plug or battery plug.
Caution Such disconnection may cause sparks to occur, leading

to an unexpected accident. Be sure to use the switch
When keeping the vehicle unused, be sure to dis- panel operation to stop charging properly. Do not turn
connect the battery plug. off the power switch or breaker to stop battery charging,
either. The battery charger may take it as the power fail-
Even when the key switch is turned off, faint electric
ure, causing a malfunction.
current flows to the controller. If the vehicle is not used
for 2 weeks or longer, perform equal charge to the full
level and disconnect the battery plug. If the unused
period is longer, perform equal charge regularly every 2
months.
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PREPARATIONS FOR SAFETY

Caution
To prevent labor accidents in the transportation work, the
Do not alter electrical parts. forklift operator and administrator ought to understand and
• As the battery type forklift is equipped with precise observe various related regulations. In addition, it is neces-
electronic devices, alteration of wiring may cause a sary for them to keep “Safety first” in mind and make
trouble or unexpected accident. If some alteration is efforts for accident prevention.
necessary, be sure to consult the Toyota dealer. Described in this section are “Information for safety” rec-
• Installing any electric accessory to the vehicle other ommended for the forklift operator and administrator to
than those specified by Toyota may affect the existing know by all means. Please read this section thoroughly
electric devices, causing a trouble or unexpected and observe cautions for the work safety while working
accident. Never add electrical alteration. If some with the forklift.
alteration is necessary, be sure to consult the Toyota
dealer. Precautions before Starting Operation
The forklift operators and workers should work safely
based on instructions of the administration and guiding
person.
Caution Perform inspections such as pre-operation check without
fail.
Follow the precaution statements below while
Wear a safety cap, working wear and safety shoes when
charging if thunder can be heard.
operating the forklift.
• If thunder can be heard in the distance, stop charging
the battery and disconnect the charging plug.
• If thunder can be heard close by, do not touch the
power supply plug or cord because you may receive
an electric shock if lightning strikes close by.
• Setup of a lightning rod or a lightning arrester in the
electric circuit is strongly recommended in areas
where thunder is frequently heard.
Caution
Providing for emergency, secure the safe parking
space and confirm where fire extinguisher, emer-
gency contact addresses and first-aid kit are kept. Do not operate the forklift with wet hands or oily hands.
Be sure to renew the fire extinguisher whenever its Do not overload beyond the allowable load weight.
usable period expires and refill the first-aid kit as
necessary.
Never operate the forklift if its hydraulic system has some

trouble.
Caution
If the vehicle should become on fire, turn off the key
switch and if the time allows, fight the fire with a fire
extinguisher. Be sure to perform the periodical
maintenance for the fire extinguisher.
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Do not use a damaged or deformed pallets. Symmetrically set the forks relative to the center of the
vehicle and then apply the stoppers securely.
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Make sure to use pallets suitable for the load in strength

and size.
Adjust the distance between forks in compliance with the

load size or the pallet size. Since the adjustment of the
forks involves a hazard of getting fingers pinched by the
forks, move the fork from the opposite side by pushing it
with your foot.
To adjust the distance between the fork, lean your body to
the backrest and move the fork with your foot. Never try to
move the fork with your hands.
Check to make sure that the load is loaded on the pallet

safely and securely.
Always keep the work area neat and tidy in order to ensure
safe work.
When loading any load on the pallet, be careful for the fol-
lowing points.
• To stack two loads, fasten them with a rope so as to pre-
vent the load from collapsing.
• To transport any load in bulk or unpackaged, place it on
the center of the pallet and then fasten it with a rope, etc.
Do not place any load on a single fork alone.
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Clean soles of your shoes before operation. Keep the battery and around it clean.
Dirt and grease attached to the shoe sole will cause feet to Do not use the cup holder (option) as an ashtray.
slip and operation to be erroneous.
Check to make sure that the fork stoppers are fixed
securely. If they are not fixed, the forks may move causing
the load to drop and be damaged.
Adjust the distance between forks in compliance with the

load size.
Prior to operation, adjust the seat to the proper position

and properly wear the seat belt with the adjusting mecha-
nism.
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Precautions while Traveling On the operator's seat, do not place anything that may
To get on or get off the vehicle, use the assist grip and the actuate the pedal or the lever depending on the motion of
step, and do not hold the steering wheel. the vehicle.
En
Before starting, check to ensure that no person is around Do not place anything which will obstruct the operator’s
the vehicle. Give some signal or beep the horn depending visibility around the operator’s seat or on the counter
on the situation to avoid any danger during operation. weight.
When moving the vehicle, keep the mast in the backward

tilting position to hold the load securely.
Never allow anyone other than the operator to get on any

part of the vehicle (except when the vehicle is equipped
with a safe auxiliary seat).
If a metallic pallet is used, maintain the forks in a low posi-
tion and the mast in the backward tilting position when
moving the vehicle with any load, since the pallet is slip-
pery.
Sudden start, sudden stop and sudden turn are strictly

inhibited.
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Observe the specified traveling speed. Do not look off while operating the forklift.
Never attempt traveling with a load on the fork lifted Do not run over wood piece or the like scattered on the
beyond the specified height. road. If the ground is rough, reduce the traveling speed.
Raise forks about 15 to 20 cm above the ground to ensure Traveling on the poor conditioned road makes big noises
enough visibility. and may deform the tire.
Be sure to make a full stop ensure safety on the right and
left when crossing the road and at a place with poor visibil-
ity like a corner.
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Reduce the traveling speed when carrying a long or wide When moving backward, do not depend on the rear view
load. Pay attention to the fact that the turning radius mirror only. Be sure to check visually.
becomes larger when the vehicle carries a long load.
En
When turning the vehicle during backward move, take care

If the load is as large as to obstruct operator’s visibility, not to let the fork ends hit anything.
move backward or appoint a guiding person.
When moving down on a slope, never turn off the key

When making a turn, use full care for the rear part of the switch. Drive the vehicle slowly while adjusting the speed
vehicle which may sway. using accelerator pedal and applying the brake as neces-
sary.
En-25
When traveling on a slope with a load on the forks, use the Check that there is enough height and road width for the
forward travel on the uphill and backward travel on the vehicle to pass. Particularly, indoors, make sure that the
downhill. When starting the vehicle on a slope, make abso- top of mast does not contact the ceiling or the top of the
lutely sure that there is no person or object in the nearby entranceway.
area as the vehicle may move down.
Check strength of the floor as both the vehicle weight and

Do not cross a steep slope or move diagonally on it. Do not
the load weight are applied.
make a turn on the slope.
When going up the slope with a load hindering the front Reduce the traveling speed as much as possible in the
view, be sure to have a guiding person cooperate with you. area which is wet, slippery or unpaved, or covered with
grass or fallen leaves, on the slope and on the wet iron
plate. Do not travel on a flooded or water covered road.
En-26
Do not enter the soft and week ground area. On a slope or in crowded place, give priority to the vehicle
loaded with a load.
En
Do not keep your foot on the brake pedal while traveling or

do not apply brake frequently. Such acts may cause the When working in a small area, be careful for safety around
brake to be heated excessively, resulting in brake failure. the vehicle and reduce the speed.
Keep a safe distance with other vehicles to avoid any con- Do not put your head or any part of your body out of the
tact accident. When passing another vehicle, reduce the operator’s seat (head guard).
traveling speed and maintain a proper distance.
Do not get on/off or jump into/off the moving vehicle.
En-27
Precautions while Load Handling To take out one load from the stacked loads, move forward
In handling loads, basically use pallets and avoid uneven the vehicle at right angles to that load and then carefully
loading. insert the forks into its pallet.
If the unloaded load is unstable, do not leave it as it is.

Load loads with the right and left well-balanced, avoiding Immediately reset it in the stable state.
uneven loading.
If the forks cannot be fully inserted, temporarily move the

Never let any person get on the forks or pallet. forks to a possible position and then fully insert them.
Keep the forks horizontally while picking up and putting
down loads and keep them down for forward/backward tilt
operation.
Particularly with the load in bulk, be careful so that it will
not collapse.
Stop the vehicle before moving up/down loads. Make sure

that the vehicle is at complete stop and then move forks up
or down. It is very dangerous to move the forks up/down
while the vehicle is moving. Never drive the vehicle and
handle loads at the same time.
En-28
When storing any load on a shelf, etc., take care not to let Do not carry any unstable load. The load to be carried
the forks protruding from the pallet. They may damage the must be fixed securely.
shelf.
En
Do not raise the load or travel with the mast tilted forward.
Do not allow any person to enter the area under the load or
forks.
Do not raise the loaded load when the vehicle leans to one
side.
Never put your hand, foot or any part of your body in the
opening of the mast.
En-29
Do not lower the loaded load quickly. Do not suspend any load using a rope on the fork (the rope
tends to slip).
Before loading and unloading loads to and from the truck,

always make sure that the parking brake of the truck is Do not perform any work for other than originally intended
applied securely and chocks are used in place. purpose including pushing any load with the forks or pull-
ing it with a rope hooked on the fork.
When a load is forked at a high position, move back once,

lower the forks and tilt the mast backward. Do not tilt the Do not handle a load from the raised forks.
mast backward when the load is held at a high position.
If the chains are loosened when a load is unloaded, use
the lift lever to slightly raise the forks, check that the chains
are not loosened, and then draw out the forks.
Do not push the load on the forks.
En-30
Do not push or roughly move any load with the forks. Precautions after Completion of Work
If the vehicle or any other device has a trouble, repair it
without delay and do not operate the vehicle until such
trouble is completely repaired.
En
Do not carry loads higher than the backrest height.
Turn off the key switch while charging the battery.

Make absolutely sure to observe all precautions including
those for battery charging.
When leaving the operator’s seat, lower the forks to the
ground, apply the parking brake and remove the key
switch. (If it is unavoidable to park on the slope, always
chock the wheels.)
Do not touch the operation lever carelessly when the key

switch is turned on.
If the forks cannot be lowered to the ground because of a

failure, set up a fence, etc., so that any other vehicle or
worker does not collide against the forks.
To temporarily leave the vehicle, lower the load to the

ground.
En-31
After the work, clear away things in the work place and Precautions for Inspection and
clean the vehicle.
Maintenance
Wear working clothes and safety outfit (safety cap, safety
shoes, safety goggles and gloves).
Keep the key switch stored in the specified place.
When a number of workers work together, appoint the

director and perform each role following the director’s
instructions.
Lock up the storage place to keep off any outside person.
If all inspection items have not been checked at one time,

keep the record so that what to be done is clearly known
when restarting the inspection.
En-32
While working together, speak to one another to let others All operational levers must be in the neutral position when
know what you are doing. inspecting or maintaining the vehicle.
En
To prevent any trouble and malfunction beforehand, per- Lower the forks and other operation equipment to the
form periodical replacement of the parts specified to ground.
replace periodically even if they are free from abnormality
then.
Inspection and maintenance should be performed by the
specified licensed personnel.
For any work that requires a license, e.g., in handling com-
pressed air, use licensed personnel. In that case, adjust
the pneumatic pressure of the compressor in advance.
Maintenance of the vehicle must be done on the level
ground with secure foothold, using appropriate tools.
If the forks cannot be lowered because of a failure, put

some cloth or the like over them to prevent any other vehi-
cle or worker from colliding against them.
When inspecting the vehicle, keep the key switch removed

and the battery plug disconnected.
En-33
To clean electric parts, do not wash them with water but Do not check for oil leakage with a bare hand.
use compressed air. When using compressed air, be sure
to wear safety goggles and dust mask.
Never use the mast in place of stairs.

While working on the vehicle, be careful not to fall off.
When checking the tire inflation pressure, apply the gauge

When using inflammables such as greased cloth, watch
from the side and not directly from the front.
out for fire.
Confirm the location of the fire extinguisher and other fire When replacing the tire, if the matching rim bolts are loose,
extinguishing equipment and how to use them, the location jack up the frame and release the tire inflation pressure
of the first-aid kit and contact addresses in case of emer- completely in advance.
gency.
En-34
When checking raised forks, do not put your foot under Precautions for Transportation
them or straddle over them.
To check the raised forks, previously take measures for
preventing the forks and mast from falling down.
En
Taking the forklift on the trailer may involve risks. Be sure

to use a hoist crane or winch with wire rope.
Wipe off spilled oil and grease immediately. Use special care for the following instructions when taking
the forklift on the trailer.
• To fasten the vehicle on the trailer, use well trained per-
sonnel. To fasten the vehicle on the trailer, use a rope
that has sufficient strength.
• For loading, unloading and carrying the forklift, observe
laws and standards defining the length, width and height
of the truck used for such work.
• Lock the dock board at the center of the trailer. In order
to prevent slip or any other similar hazard, ensure that
the surface of the dock board is free from grease.
• When loading and unloading the forklift, set the right and
left path boards to the same height for safe traveling.
• For loading, move the forklift backward gradually so that
After operating the vehicle, the electric system, hydraulic the right and left tires get on the path boards at the same
system and other parts are hot. For after work inspection, time.
wait until the vehicle cools off. • Do not change the direction or move sideway on the
path boards to avoid any possible danger.
• Use hooks in specified locations.
• When towing, hook the rope at the specified position
only.
• Low speed vehicles including the forklift are, in principle
carried on the truck or the like. If moving by itself is
unavoidable, avoid the heavy traffic time, be careful for
the running speed and do not make a sudden turn or use
sudden braking.
When opening or closing the tow board, the battery hood,

the battery cover, etc., take care not to get your fingers
caught.
Do not access any high-voltage part. If you get an electric
shock, receive medical attention.
En-35
Precautions for Storage
• Keep the key securely by such measures as locking the

storage place so that no one other than people con-
cerned can take it out.
• When leaving the forklift idle for a long time, disconnect
the battery plug to prevent the battery from discharging.
• To store the vehicle for a long period of time except for
its pneumatic tires, float it with wood blocks of 300 mm
each in height in order to reduce load on the tires.
• When keeping the battery unused for a long time, store it
in the place with good ventilation and very little risk of
fire.
• Do not expose the battery to rain or sea water. Also, do
not wash the vehicle when the battery is mounted on it.
Water will cause a damage or fire to it.
• If the forks cannot be lowered because of a failure of the
vehicle, put cloth or the like over the forks to call atten-
tion and park the forklift at a place away from the traffic
area.
En-36
INDICATORS
Toyota industrial vehicles have indicators and caution plates each of which is attached at the position as shown below. Follow
instructions given by each indicator and caution plate to ensure safe operation and work without any accident.
En
Caution
Replace the indicator and caution plate which are illegible or stained with new ones. You can obtain them from
the Toyota dealer.
About this mark.

Warning! Please read this Operator’s Manual carefully before use.
En-37
Contents of Warning and Caution Plate

Erroneous operation, lubrication, inspection and maintenance are very dangerous. Any of such act may cause a personal
injury or material damage. Therefore, please have full understanding of the contents of caution plates marked with
Warning or Caution attached to the vehicle before performing operation, lubrication, inspection and maintenance.
En-38
En
En-39
What to Do in the Event of Tip-over

Do not jump out of the vehicle in the event of a tip-over.
A sudden turn causes the vehicle to lose its balance and may result in tip-over of the vehicle. If tip-over of the vehicle occurs,
the operator should not jump out of the vehicle in a hurry. Observe following instructions, stay within the vehicle and avoid
any danger from tip-over. After it has tipped over, turn off the key switch and get away from the vehicle quickly.
(1) (2) (3) (4) (5)
(1) Always fasten your seat belt when operating the vehicle.
(2) Read the operator’s manual thoroughly and understand Toyota industrial vehicles well.
(3) In the event of a tip-over, do not jump out of the vehicle.
(4) Grip the steering wheel, brace your feet and hold your body.
(5) Lean away from the direction of tip-over, and stay with the vehicle.
En-40
FOR PROTECTION OF ENVIRONMENT

Dispose of waste parts and waste oil/grease properly according the laws and regulations applicable to each country.
Care before operating the vehicle
Check around the vehicle to ensure that there is no oil or liquid leakage. Such oil or liquid flowing into underground river, will
cause soil contamination and water pollution. Be sure to collect spilled waste liquid and wipe off.
En
Care during operation
• If an excessive load is applied to the vehicle, its motor system may be damaged.
• When performing the work, be considerate for the people living in the nearby area. Particularly when operating the vehicle
at night or early in the morning, use full care for noise, direction of lighting etc.
Care for inspection and replacement
• Keep the cloth with grease and oil used for cleaning, inspection, etc. at a specified place. If it is left as it is, grease or oil
may spread underground with rain water, or may even cause a fire.
• Ask a professional waste disposal agent to dispose of changed oil, filter, light parts, etc. properly.
• The battery contains lead and dilute sulfuric acid. As its careless disposal will affect the environment adversely, have the
battery replaced at the Toyota dealer.
• As burning a tire produces poisonous gas and affects the environment adversely, have the tire replaced at the Toyota
dealer. Otherwise, ask a professional waste disposal agent.
Proper disposal of waste
• When you decide to disuse the vehicle you have used for many years, consult the Toyota dealer. Illegal disposal of the
vehicle is strictly prohibited as it will lead to destruction of the environment.
• Be sure to dispose of the waste from replacement of the tire, battery, hydraulic fluid properly,
En-41
En-42
En
2. PROPER OPERATION
DESCRIPTION OF FORKLIFT ......................................................... 44
HANDLING SAS- FUNCTION (Option) ........................................... 45
OPS SYSTEM................................................................................... 49
LOW SPEED SETTING .................................................................... 50
ADJUSTING THE SEAT ................................................................... 51
En-43
2. PROPER OPERATION
DESCRIPTION OF FORKLIFT How to Read the Name Plate

The forklift is a convenient industrial vehicle capable of
loading/unloading and carrying large and heavy loads eas-
ily.
In order to fully utilize functions and features of the forklift,
however, it is essential to have good understanding of
“Relationship of stability between the load and vehicle” of
the forklift to ensure its proper operation. If loads are
loaded improperly, the forklift becomes unbalanced and
subject to some danger.
Please read “Load to Vehicle Stability” and “How to Read
the Name Plate” carefully so that you can operate the fork-
lift properly.
Load to Vehicle Stability

For certain areas, instead of on the load capacity chart, the
load capacity is engraved on the name plate.
Make sure of the load center and capacity before starting
the operation.
(1) Vehicle model
(1) (2) Specialty model or attachment model
(3) Frame No.
(2) (3) (4) Vehicle weight (except battery)
(5) Maximum lifting height
(4) (5) (6) Front tread
(6)
(7) Tire size
(1) Load (8) Tire press
(2) Front wheels (9) The year of manufacture
(3) Rear wheels (10) Battery voltage
(4) Load capacity (11) Battery unit weight (min. and max.)
(5) Load on rear wheels (12) Rated capacity
(6) Supporting point (13) Actual capacity
As shown above, the forklift is structured like a balance (14) Load center
with front wheels as the supporting point and with the load
capacity on one side balanced with the load on the rear
wheels. Caution
Therefore, the farther the load center of the load is from
• Loading a load exceeding the allowable load is
front wheels (supporting center), the smaller the loadable
very dangerous. The rear wheels may float up
load is.
while traveling and steering may be disabled.
If a load exceeding the balanced load is loaded by mis-
As possibility of tip-over will be also increased,
take, the rear wheels will float off the ground, possibly
always make sure to observe the allowable load
resulting in a dangerous tip-over or steering failure.
limit strictly.
• Adding a new attachment or modifying the exist-
Caution ing attachment will affect the allowable load
value. Consult the Toyota dealer for more infor-
Even when the load is less than the maximum load, mation.
if it is placed to much forward on the forks, danger
in vehicle tip-over will be increased. In such case,
an unexpected load will be also applied to the mast
and forks, causing damage to the vehicle.
En-44
PROPER OPERATION
HANDLING SAS- FUNCTION Lift height and Load Sensing Turn Speed
(Option) Control
This function automatically restricts the traveling speed
(SAS-: System of Active Stability)
depending on the lift height, load conditions and turning
Whenever you operate an SAS- model, please check the
radius when making a turn so as to secure the lateral sta-
caution plate to discover which functional features the
vehicle has. Do not operate the vehicle before making sure
bility of the vehicle. En
that each of the features is operating properly.
Caution
• As having SAS- function does not always mean
that the vehicle is free from tip-over, always oper-
ate the vehicle properly.
• As a loaded load is raised, the gravity center of
the vehicle shifts forward and upward, causing
possibility of tip-over. Do not travel or turn with
the load raised up.
Lift Height, Load Sensing Traveling

Speed, Acceleration/Deceleration
Control
Caution
• When getting on the vehicle, always check to Caution
make sure that each of the SAS- functions oper-
ates properly. • Do not put too much confidence in the lift height,
load sensing traveling speed, acceleration/decel-
• While traveling, be alert for the diagnostic mode eration control function. It restricts the maximum
indicator. Should an error code be indicated as speed and quick acceleration/quick deceleration
the diagnostic mode indicator blinks, park the based on the lift height and load conditions but
vehicle in a safe location and have it inspected at does not assure that no tip-over will occur.
a Toyota dealer.
• There are cases where the speed limit and accel-
• The SAS-, which is electronically controlled, eration feeling change temporarily depending on
must be initialized after maintenance is per- conditions of the road surface and load handling
formed. Do not unnecessarily remove or modify operations.
any SAS- features.Whenever an inspection is
necessary, contact a Toyota dealer.
• When washing the vehicle, carefully prevent
Lift height, load sensing traveling speed
water from splashing directly over the electronic limit
components (controller, sensors and switches) If the vehicle travels with a load held at a high position, the
employed in the SAS-. maximum speed is restricted depending on the applied
load to secure stability of the vehicle subject to high lift
height and high load.
Note:
• When the load is lowered, the maximum speed
limit function is cancelled but quick acceleration
is restricted until the accelerator pedal is
depressed again.
• If the load is raised while the vehicle is traveling
at a higher than the limited speed, the traveling
speed is reduced gradually to the limited speed.
• If the vehicle has the maximum speed limit func-
tion and low speed setting function, the traveling
If a trouble should occur with SAS- functions, the spanner
speed is restricted to the lowest level, including
indicator blinks and an error code appears on the display.
the traveling speed control function.
En-45
PROPER OPERATION
Lift height, load sensing acceleration/decel- When the tilt lever knob button is turned on and the tilt
eration limit lever is operated from the backward to forward position,
This function restricts acceleration and deceleration the mast will perform as follows:
depending on the applied load when the load is kept at a
high position, so as to make load collapse hard to occur. Not loaded Loaded
Forks stopped at their
High height
horizontal position
Caution (approx. 2 m
(with mast vertically
No forward tilt
or higher)
Never depress the accelerator pedal suddenly with positioned)
the load raised high or operate the direction lever Forks stopped at their horizontal position
forward or backward with the accelerator pedal Low height
(with mast vertically positioned)
depressed. Either of such acts will cause a danger-
Highest posi-
ous situation. No forward tilt
tion
Backward
Note: When the forks are tilted backward from the forward posi-
Brake operation always has a priority over deceler- tion with the automatic fork leveling stop switch pressed,
ation restriction by the travel control function. the mast will stop automatically at the fork horizontal posi-
tion (with the mast vertically positioned).
Travel control (lift height, load sensing trav-

eling speed, acceleration/deceleration con- Note:
trol) indicator The mast will not tilt forward if the tilt lever knob
When the travel control function is activated, the travel button is turned on while there is a heavy load at
control indicator lights up to inform the operator. high lift (2 m or more).
Caution
• When the tilt lever knob switch or automatic fork
leveling switch (mini-lever, joy-stick model) is
pressed while the mast is being tilted forward
with a heavy load at a high position, the mast will
stop. Never use this function while load handling
operations. It may cause a dangerous tip-over.
• In case of the vehicle with some attachment, it is
dangerous to use the automatic fork leveling
function while the tilt lever is pulled down fully
Automatic Fork Leveling Control with a load at a high position.
• If a heavy attachment, etc. is installed to a special
Forward
model, the automatic fork leveling function may
With the vehicle not loaded, press the tilt lever knob button
be restricted (stopped). Check with the Toyota
to turn it on and tilt the mast forward. This will cause the
dealer about this in advance.
fork to stop automatically in a horizontal position (with the
mast in the vertical position).
En-46
PROPER OPERATION
Active Mast Forward Tilt Angle Control

According to lifting height and load, the angle at which the Note:
mast can be tilted forward is automatically controlled within
With the fork raised to the maximum height, high
a range of angles as shown below.
pressure (relief pressure) may remain in the lift cyl-
inder. This high pressure causes the vehicle to
Light load Intermediate
Heavy load
judge that it has a heavy load even if unloaded. As a En
(no load) load result, the mast will be hindered from tilting forward
Angle restricted and stopping automatically in a horizontal position.
between 1 Forward tilt In this case, lower the fork slightly from the top (to
High height No restriction release the pressure), and the mast can be tilted
degree forward angle
(approx. 2 m for forward forward.
angle and the restricted to
or higher) tilt angle
most forward 1 degree
angle Active Mast Forward and Backward Tilt
Low height No restriction for forward tilt angle Speed Control
• At a high lift, the mast’s forward or backward tilt speed is
controlled (slowed down) regardless of load weight.
Caution Even if the lifting height changes from high to low while
the mast tilts backward, the control speed will remain in
• If a load is lifted while the forks are tilted forward effect.
at low lift, the vehicle may tip over when the forks • At a low lift, the mast can be tilted without any speed
stop at position having tilt angle beyond the restrictions regardless of load weight. Even if the lifting
specified angle range. Never lift the load, there- height changes from low to high while the mast tilts for-
fore, while the mast is tilted forward. ward or backward, the speed will not be restricted.
• With a heavy load at a high lift, never adjust the
load position by controlling the mast forward tilt
angle, as the vehicle may tip over.
• Even with a load positioned within the allowable
load range, never tilt the mast beyond its vertical
position, or the vehicle may tip over, losing its
stability forward and backward. Never tilt the
mast forward when a load is lifted.
• Mounting heavy attachments onto some specialty
models may disable active mast forward tilt con-
trol. Confirm with a Toyota dealer in advance.
• After mounting or replacing any attachment on a
forklift model, have it inspected at a Toyota
dealer. Key-lift Interlock
With the key switch at OFF, the forks will not lower even if
• If you use two or more removable attachments the lift lever is so operated.
alternately, the heaviest one should be used to
carry out matching (SAS- setting). Ask a Toyota
Active Steering Synchronizer
dealer for help in advance.
If the steering wheel knob is not aligned with the tires, the
• When attaching forks or attachments to a forkless offset will be corrected automatically while the steering
model, the vehicle needs initialization. Contact wheel is turned. Thus, the knob is kept at a constant posi-
your Toyota dealer to request compatibility tion relative to the tires.
matching.
En-47
PROPER OPERATION
If the SAS- Feature should Fail: Precautions for Battery Forklift

The SAS- model is controlled with a controller, sensors
and various actuators. If any of them is found not to be
operating normally, the following may occur: Caution
• Steering wheel knob offset may not be corrected.
• Such features as automatic fork leveling control, active Be sure to follow instructions listed below.
mast forward tilt angle control and/or active mast back- Neglecting them will cause a trouble or injury.
ward tilt speed control may be disabled. • If the battery capacity indicator is dimmer than
the set level and it starts blinking, stop using the
If any of the phenomena referred to above should take vehicle as soon as possible and perform charg-
place, ing.
• Diagnostic mode indicator will blink.
• An error code will be displayed. • If any abnormal noise or smell is noted, stop
operation immediately.
Thus, the operator will be informed. In such an event,
• For charging, select a place with good ventilation
move the vehicle to a safe location and have it repaired at
and without fire.
a Toyota dealer.
• Do not connect and use a battery to a dedicated
charger other than the originally installed one. It
may cause a trouble.
• Do not drive the vehicle or operate the hydraulic
system while charging.
• Do not put any metal on the battery. (Warning)
• Do not charge the battery in the refrigerator.
• Have a high voltage fuse replaced at the Toyota
dealer.
• When checking the electric parts, be sure to dis-
connect the battery plug. Also, use the air for
cleaning.
When any trouble occurs with the SAS- function, the
• Avoid operating the vehicle on the unpaved
spanner indicator blinks.
ground or rough road as much as possible.
• In handling freezer / refrigerator specification
model (Option), follow “Handling of refrigerator
specification model” to use the vehicle.
• Do not move a vehicle other than freezer/refriger-
ator specification model into the freezer/refrigera-
tor.
Note:
When not using the vehicle for 2 weeks or longer,
perform equal charging to the fully charged level,
disconnect the battery plug and store it.
If the battery is stored as it is for a longer time, per-
form equal charging every 2 months.
En-48
PROPER OPERATION
Precautions for Towing OPS SYSTEM

The OPS (Operator Presence Sensing) system prevents
traveling and load handling operations when the operator
Caution is not seated in the operator’s seat.
If, during operation of the forklift, the operator leaves the
When using a battery powered vehicle, avoid forc-
ible towing, pushing and climbing uphill beyond its
seat, the OPS indicator will light up and the buzzer will En
sound (a constant “pii” sound) for 1 second, alerting the
ability. These acts may cause damage to the con-
operator to the situation. If the operator remains out of the
troller and motor.
seat for 2 seconds, the OPS system will operate, bringing
the powered travel and load handling to a stop. However, if
Precautions for Being Towed the operator returns to the seat within 2 seconds, the sys-
tem will not be activated, powered travel and load handling
operations can be continued.
Caution Should an abnormality occur in the OPS system, the diag-
nostic mode indicator blinks and an error code appears on
• When towing the battery powered vehicle to the the display, notifying the operator of the situation. At this
work site or to the repair workshop, use full care time, a problem with the OPS system should be assumed
so that its maximum speed is not exceeded. For to exist. Therefore, please request an inspection from a
example, when the maximum speed of a battery Toyota dealer.
powered vehicle is 10km/h, the speed while tow-
ing must never exceed 10km/h.
• When towing a vehicle whose parking brake can-
not be released due to a failure, it is necessary to
release the parking brake manually. Ask the
Toyota dealer to tow the vehicle.
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 properly.
Travel OPS Functions

When the operator leaves the seat while traveling, this
function causes the OPS lamp to light up and the electric
brake to operate 2 seconds later, stopping the vehicle. But
it does not stop traveling forcibly. (If the operator comes
back and sits in the seat properly within 2 seconds, the
vehicle can travel as it is.)
If the OPS function is activated while traveling uphill, the
vehicle may come down. Be sure to sit in the seat properly
again and operate the vehicle. To cancel the travel stop
function, return the direction lever to the neutral position
take your foot off the accelerator pedal and sit in the seat
properly.
Load Handling OPS Functions

If the operator leaves the seat during load handling opera-
tions, the OPS indicator will light up, and 2 seconds later,
load handling operations will be stopped. (If the operator
returns to the seat within 2 seconds, load handling opera-
tions can be continued.) If the operator leaves the seat
with operating the load handling lever, load handling
actions will be stopped in 2 to 4 seconds.
To deactivate this function, sit on the seat again and return
all of the levers to the neutral position.
En-49
PROPER OPERATION
OPS Operation Informing Functions LOW SPEED SETTING

If the operator leaves the seat, the buzzer will sound (“pii”) Press the low speed setting switch to activate this function
for about 1 second and the OPS indicator will light up and which prevents the vehicle from traveling at a speed
inform the operator that the OPS system is active. If the exceeding the preset speed. The low speed setting indica-
operator returns to normal seating position, the OPS indi- tor lights up to inform the operator.
cator will turn off.
Return-to-neutral Warning
If, while the travel OPS functions are operating, the opera-
tor sits on the seat but does not return the direction lever to
the neutral position or keep the accelerator pedal
depressed, the buzzer will sound (“pipipipi...”), indicating
that the travel OPS functions have not been deactivated.
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 (“pipipipi...”) indicating that the OPS system has not
been deactivated.
OPS Controller Abnormality Warning The low speed can be set every 1 km within the range of 2
If the OPS system registers an abnormality, the diagnostic to 20 km/h.
mode indicator blinks and an error code appears on the
display to inform the operator.
If the diagnostic mode indicator starts blinking, the OPS Note:
system may have malfunctioned. Stop the vehicle at a safe
location and have it inspected at the Toyota dealer. • Because of the self-weight of the vehicle, the
If either of the following conditions is applicable, stop oper- speed may not reach the set speed level on an
ating the vehicle and have it inspected at the Toyota uphill road and may exceed the set speed level on
dealer. a downhill road.
• The OPS indicator does not light up even if the operator • When the maximum speed limit is set at the same
leaves the seat. time, the lower set speed has a priority.
• The OPS indicator does not turn off even if the operator
is re-seated. • For setting the maximum speed, consult the
administrator or the Toyota dealer.
Caution
If the operator remains seated with the key switch
turned off for a long time, the spanner indicator
may blink when the key switch is turned on next
time. In such case, leave the seat once and check
the spanner indicator. If it turns off, it means that
there is nothing abnormal.
En-50
PROPER OPERATION
ADJUSTING THE SEAT Longitudinal position adjustment

1. Pull the slide lever to the left to move the seat back
and forth.
ORS Seat
(ORS: Operator Restraint System) 2. The seat will be fixed when the lever is released.
En
Caution
• Seat adjustment before operating the vehicle is
absolutely necessary to avoid accidents.
• Do not adjust the seat while traveling to avoid
accidents.
• Adjust the seat position so that you can depress
all pedals fully with your back leaning against the
backrest of the operator’s seat.
• Unless the operator sits in the seat properly, the
seat switch disables vehicle traveling and load
handling. Be sure to sit in the seat properly to Reclining adjustment
perform each operation. Also, do not perform any 1. Pull up the adjust lever to adjust the angle of the back-
operation with some object placed in the seat. rest.
• Do not perform any operation with the seat switch 2. The position of the backrest is fixed when the adjust
turned on by a method other than sitting in the lever is released.
seat. 3. After adjustment, try moving the seat lightly back and
forth to ensure that it is fixed securely.
It is possible to adjust the longitudinal position and the
backrest angle of the operator’s seat. The operator taking
place of the previous one must adjust the seat position
before starting operation.
(3)
(4) (2)
(1)
(1) Slide lever

(2) Adjust lever
(3) Seat belt
(4) Adjust knob
En-51
PROPER OPERATION
Fastening seat belt (self retractable) Pocket for storage

1. Pull the seat belt by the tab found on your right and fit There is a pocket to store Operator’s Manual, etc. on the
it into the buckle until it is locked. back of the backrest.
Use both hands to open and close it.
Note:
If your seat belt can not be pulled out as a locked
status, loosen your seat belt after pulling it out
strongly, and then pull it out slowly again.
2. To release the lock, press the red button at the mouth

of the buckle. The belt will be automatically retracted
into its housing on your right.
Note:
Be sure to close the flap of the pocket and lock it
securely.
Magazine box
(1)
There is a magazine box to store small items such as a
sketch board, gloves, etc. attached to the pocket. Fix it
securely with its belt so that what is in it will not come out
(1) Lock release button (red) of it when opening and closing the battery hood and while
traveling on a rough road.
Caution
• Always fasten your seat belt when operating the
vehicle. Always fasten your seat belt when oper-
ating the vehicle. It is very dangerous not to fas-
ten it as the operator may be thrown out, should a
tip-over or the like occur.
• Before fastening the seat belt, check its bracket
and belt itself for any abnormal condition.
• Do not fasten the seat belt in the twisted state.
• Wear the hip belt at the lowest possible part of the
hip bone tightly.
• Do not adjust the seat belt loose from the body by
adding slack purposely with a clip or the like.
• If the seat belt is exposed to a strong impact in an
accident, the belt may be scratched or torn. As
such seat belt can not perform its intended func-
tion, replace it.
• If the seat belt is damaged, do not use the forklift
until it is repaired.
En-52
PROPER OPERATION
Adjustment of suspension mechanism

(Whether the seat is adjustable or not depends on mod-
els.)
Turning the adjusting knob clockwise moves in the heavier
direction on the weight adjusting scale and counterclock-
wise in the lighter direction respectively.
Make a fine adjustment based on the road surface condi-
En
tion while traveling for the optimum ride comfort.
(2)
(1)
(1) Lighter
(2) Heavier
Note:
• Weight adjustable range is from 40kg to 120kg.
• If adjusted to the weight of the operator, the opti-
mum ride comfort is available by the suspension
mechanism.
En-53
PROPER OPERATION
En-54
En
3. OPERATION DEVICES
TILT STEERING ADJUSTMENT ...................................................... 56
KEY SWITCH.................................................................................... 57
PEDAL .............................................................................................. 57
SWITCHES AND LEVERS ............................................................... 58
MINI LEVER (Option)........................................................................ 64
JOY STICK (Option).......................................................................... 67
ARMREST......................................................................................... 70
STANDARD DISPLAY ...................................................................... 71
MULTIFUNCTION DISPLAY (Option)............................................... 75
SCREEN FUNCTIONS ..................................................................... 84
OPTIONAL FEATURES.................................................................... 88
En-55
3. OPERATION DEVICES
TILT STEERING ADJUSTMENT Tilt Steering Lock Release Lever

It is possible to adjust the steering wheel position back and Using this lever, the steering wheel can be tilted.
forth.
(1)
(1)
(1) Tilt steering lock release lever

(1) Tilt steering adjust lever
Adjustment procedure Note:
1. The steering wheel position may be adjusted back
and forth while the tilt steering adjust lever is raised. If the steering wheel is returned after being tilted
once, the steering tilt angle remains in the memory.
2. Lower the lever to fix the steering wheel at the Thus, resetting is not necessary.
adjusted position.
3. After the adjustment, try to move the steering wheel
back and forth to make sure that it is locked into posi-
tion.
Caution
• Always adjust the steering wheel position before
traveling.
• While traveling and load handling operations, do
not adjust the steering wheel position or mirror
position. It may affect operation and handling,
leading to an unexpected accident.
• After adjusting the steering wheel position, check
that the steering wheel is fixed securely. If it is not
fixed completely, its position may change sud-
denly, leading to an unexpected accident.
En-56
OPERATION DEVICES
KEY SWITCH PEDAL

Function at Each Position Accelerator Pedal
This pedal controls the travel speed. Depending on how
far the pedal is depressed, the speed can be changed from
nearly zero to maximum. En
(1)
(2)
(1) OFF.............The key can be inserted and pulled

(1)
out in this position.
(2) ON ..............Turn the key clockwise from the OFF
(1) Accelerator pedal
position. The vehicle is ready to start
when the key is in this position.
Insert the key with the teeth facing backward. Caution
• Depressing the accelerator pedal quickly is dan-
Caution gerous as the vehicle may start moving suddenly
and loads, if loaded, may fall off or collapse.
• To operate the key switch, be sure to get on the Depress the accelerator pedal gradually.
vehicle and fasten the seat belt first. Otherwise,
• If the OPS indicator on the display is lit, sit in the
the vehicle may start suddenly, leading to an
seat properly again, take your foot off the acceler-
ator pedal, return the direction lever to the neutral
• When you turn on the key switch, be sure that position and confirm that the OPS indicator has
you are sitting on the seat. If the OPS indicator turned off.
lights up, return each lever to the neutral posi-
• Do not turn the key switch to the ON position
tion, take your foot off the accelerator pedal and
while depressing the accelerator pedal.
sit on the seat again to confirm that the OPS indi-
cator has turned off.
• Do not turn the key switch to ON while depress-
ing the accelerator pedal.
• Before turning the key switch to the ON position,
confirm that the parking brake is applied.
• Remove the key switch when the vehicle is not in
use.
• When the key switch is turned off, the fork will not
lower even if the lift lever is shifted forward. (Key-
lift interlock)
• Do not depress the accelerator pedal at the same
time as you turn on the key switch.
En-57
OPERATION DEVICES
Brake Pedal SWITCHES AND LEVERS

The brake pedal is used for decelerating the vehicle speed
and stopping the vehicle. Direction Lever
This lever selects forward or reverse travel.
Forward................Push the lever forward
Reverse ................Pull the lever backward
The neutral position is between the forward and backward
positions.
(1)
(1)
(1) (2)
(2)
(1) Brake pedal (3)
(3)
Caution
• Be sure to take your foot off the accelerator pedal
when depressing the brake pedal. (1) Forward
• Never use sudden braking which may cause the (2) Neutral
vehicle to be unbalanced, possibly leading to a (3) Reverse
tip-over.
The forward and backward travel speed can be adjusted
• The brake feeling with loads loaded differs from by the depressing degree of the accelerator pedal.
that without loads. Adjust brake pedal depression Push the lever in the direction opposite to the traveling
by yourself according to the load condition. direction, and depress the accelerator pedal to activate the
• Do not keep your foot on the brake pedal while electric brake for smooth braking.
traveling. The brake may become overheated and
disabled.
Caution
• If disconnect the battery plug due to a failure of
the controller, drive motor or in case of emer- • Stop the vehicle when shifting to forward or
gency, the regenerative brake will not be acti- reverse.
vated. In this case, depress the brake pedal
• Operate the electric brake carefully when the
stronger than usual to stop the vehicle.
forks are loaded.
• Always operate the lift lever while correctly
seated.
• Do not operate the direction lever by snapping it.
• If the direction lever is at the forward position or
reverse position, even when the operator sits in
the seat, the vehicle remains at stop. Set the
direction lever to the neutral position once and
then move it to the forward position or reverse
position.
• After the OPS system operates, return the accel-
erator pedal to its fully released position and set
the direction lever to the neutral position, and sit
on the seat to restart the operation.
(Even though the operator sits on the seat, travel-
ing is impossible unless the direction lever is in
the neutral position.)
• Do not operate the direction lever while depress-
En-58
OPERATION DEVICES
Parking Brake Lever Lift Lever

When parking the vehicle, pull the parking brake fully while Raises and lowers the forks.
depressing the brake pedal. Raise .................... Pull backward
Lower ................... Push forward
A
(3) En
C
B (2) (1)
Applying parking brake

To activate the brake, pull the lever to position B. When (1) Lift lever
released, it returns to the parking position C. (2) Raise
Releasing parking brake (3) Lower
To release the brake, pull the lever once and keep the
Raising and lowering speed is controlled by the angle of
knob at the top of the lever grip pushed, and the lever
this lever.
returns to the original position A.
Caution Caution
• After the OPS system operates, return the direc-
• Be sure to depress the brake pedal when operat-
tion lever and the load handling lever to the neu-
ing the parking brake.
tral position, re-seat yourself, and then resume
• When operating the lever, hold only the grip of operating the fork.
the lever.
• If the operator returns to the seat while pushing
• Always chock the wheels when parking on a the lift lever forward, the fork will not descend
slope. If it is unavoidable to park the vehicle on a due to the return to neutral function.
slope, position it in parallel with the slope and
apply chocks securely.
seated.
• If you fail to release the parking brake and travel,
• While traveling, keep forks raised about 15 to 20
it may deteriorate the braking effect. Have the
cm above the ground.
vehicle inspected at a Toyota dealer.
• As long as the key switch is off, the fork does not
move down even if so operated. However, if you
sit in the seat and turn on the key switch, you can
lower the fork. (Key-lift interlock)
En-59
OPERATION DEVICES
Lift Lever Knob Button (Option) Tilt Lever

Press the Lift lever knob button to set ON/OFF the forks Tilts the mast forward and backward.
height selector. When the height selector is ON, forks can Forward................Push forward
not be raised over the pre-set height limit, and a buzzer will Backward .............Pull backward
warn the operator if the limit is reached.
(2)
(1)
(3)
(1)
(1) Tilt lever

(1) Lift lever knob button
(2) Forward
Key-lift Interlock (3) Backward
When the key switch is OFF, the fork cannot be lowered Forward and backward tilting speed is controlled by the
even if the lift lever is so operated. angle of this lever.
If the forks will not lower due to system malfunction or
other reasons, loosen the lift lock release bolt of the oil
control valve beneath the toe board, and push the lift lever Caution
forward with the key switch is ON.
• Always operate the tilt lever from a properly
seated position.
• While traveling, always keep the mast at the back-
ward tilt position.
(1) tral position, re-seat yourself, and then resume
operating the fork.
• If you operate the tilt lever backward to adjust the
mast position when the OPS is at work, the mast
may move back by its own weight. So, do not
operate the tilt lever when the OPS is at work.
(1) Lift lock release bolt
Caution
• Before operating the lift lever, sit in the seat and
turn the key switch ON.
• When the fork has been lowered by using the lift
lock release bolt, be sure to retighten the bolt to
its original position.
En-60
OPERATION DEVICES
Tilt Lever Knob Button (Option) Light Control Switch

When the switch is ON, operate from a backward tilt to a With this switch, the lights can be turned on and off,
forward tilt to stop the fork automatically in a horizontal whether the key switch is at ON or OFF position.
position.
It is also possible to slow down the backward tilt speed at a
low lift. (2)
En
(1)
(1)
(1) Position 1
(2) Position 2
(1) Tilt lever knob button This is two-stage turning switch.
The lights indicated by “” in the table below light up at
Automatic fork leveling control each turning position.
• Forward
Turn the tilt lever knob button ON and operate the mast
from a backward tilt to a forward tilt using the tilt lever. The Light name Position 1 Position 2
mast will automatically stop with the fork in a horizontal Work lights – 
position. This feature is convenient when loading and
Side clearance lights and
detaching the fork.  
tail lights (Option)
Motion upon operation from backward to forward tilt while
the tilt lever knob button is ON:
Turn Signal Switch (Option)
This switch causes the turn signal switch to blink.
Not loaded Loaded Left turn ............... Push the lever forward
Forks stopped at their Right turn............. Pull the lever backward
High height
horizontal position
(approx. 2 m No forward tilt
or higher)
positioned)
Forks stopped at their horizontal position (1)
Low height
Highest
No forward tilt
position
(2)
• Backward
When the forks are in forward-tilted positions, operating
the lever backward while pressing the automatic fork level-
ing switch will automatically stop the forks at their horizon-
tal position.
(1) Left turn
Active mast tilt speed control
When the mast is raised to a high position, tilt speed will (2) Right turn
automatically slow down. The turn signals will operate even when the key switch is
OFF. The turn signal switch returns automatically to the
original position after a direction change.
En-61
OPERATION DEVICES
Note: Caution
• Traveling on public roads with work lights lit may • When adjusting the forks, always set the loaded
be prohibited. (Observe laws and regulations of load so that its center of gravity is positioned at
each country.) the center of the vehicle. If the center of gravity is
• Do not leave the work lights lit for a long time deviated, the load may drop or the vehicle may
after the key switch is turned off. even tip over.
• To move the fork, do not grasp it as your finger
may be caught. Slide it by pushing it with your
Fork foot from the other side, using care to maintain
It is necessary to adjust the fork position depending on the balance of yourself.
pallet in use.
• Make sure the forks are locked before carrying a
load.
(1) Horn Button

Press the button in the center of the steering wheel to
sound the horn.
The horn will sound even when the key switch is OFF.
(2)
(1)
(1) Fork stopper

Fork position adjustment
1. Lift each fork stopper and turn so that the forks can be
shifted left and right.
2. Adjust the forks in the position most appropriate for
the load.
3. When adjusting the forks, make sure that the center of (1) Horn button
gravity of the load corresponds to the center of the
(2) Press
vehicle.
4. After adjustment, turn the stoppers to lock the forks in Rear Pillar Assist Grip Model (Option)
place. The horn will sound when the button at the top of the rear
pillar assist grip is pressed. Use this horn when backing
up.
Note: The horn will sound even when the key switch is OFF.
When moving the forks, set the mast forward a little
by operating the tilt lever so as to reduce the sliding
friction.
(2)
(1)
(1) Horn button

(2) Press
En-62
OPERATION DEVICES
Rear Work Light Switch (Option)

This switch turns the rear work light on. Caution
ON.........................Raise the switch
It is necessary to restrict backward tilt of the mast
OFF .......................Lower the switch
to avoid the mast interferes with the windshield
wipers. Consult the Toyota dealer.
En
(1) (2)
(3)
(1) Rear work light switch

(2) ON
(3) OFF
When this switch is set to the ON position, the LED lamp
lights up to inform the operator that the rear work light is lit.
Note:
Do not leave the rear work light turned on for a long
time after the key switch is turned off.
Wiper Switch/Washer Switch (Option)
(1) (2)
(1) Wiper switch

(2) Washer switch
Turn on the wiper switch located at the right of the instru-
ment panel, and the wiper will be activated. Press the
washer switch, and the washer fluid will be injected.
Note:
Check and replenish the washer fluid in the reser-
voir tank located at the right of the operator’s seat.
En-63
OPERATION DEVICES
MINI LEVER (Option)

Caution
Direction Lever • Stop the vehicle when shifting to forward or
This lever selects forward or reverse travel. reverse.
Forward ............... Push the lever forward
Reverse ............... Pull the lever backward
forks are loaded.
positions. • Always operate the lift lever while correctly
seated.
(1) • Do not operate the direction lever by snapping it.
• If the direction lever is at the forward position or
(2)
then move it to the forward position or reverse
position.
erator pedal to its fully released position and set
the direction lever to the neutral position, and sit
on the seat to restart the operation.
(Even though the operator sits on the seat, travel-
(1) Forward ing is impossible unless the direction lever is in
(2) Reverse the neutral position.)
The forward and backward travel speed can be adjusted • Do not operate the direction lever while depress-
by the depressing degree of the accelerator pedal. ing the accelerator pedal.
Push the lever in the direction opposite to the traveling
direction, and depress the accelerator pedal to activate the
electric brake for smooth braking.
Lift Lever
Raise and lower the forks.
Raise ....................Pull backward
Lower ...................Push forward
Note:
Depending on the vehicle specifications, the posi-
tion of the direction lever may vary.
(1)
(2)
(1) Lower
(2) Raise
Raising and lowering speed is controlled by the angle of
this lever.
En-64
OPERATION DEVICES
Key-lift Interlock
Caution When the key switch is OFF, the fork cannot be lowered
even if the lift lever is so operated.
If the forks will not lower due to system malfunction or
other reasons, loosen the lift lock release bolt of the oil
control valve beneath the toe board, and push the lift lever
operating the fork.
forward with the key switch is ON.
En
• If the operator returns to the seat while pushing
the lift lever forward, the fork will not descend
due to the return to neutral function.
seated.
cm above the ground. (1)
• As long as the key switch is off, the fork does not
move down even if so operated. However, if you
sit in the seat and turn on the key switch, you can
lower the fork. (Key-lift interlock)
Height Selector Button (Option) (1) Lift lock release bolt

Press the height selector button to set ON/OFF the forks
height selector. When the height selector is ON, forks can
not be raised over the pre-set height limit, and a buzzer will Caution
warn the operator if the limit is reached.
(1) its original position.
(1) Height selector button
En-65
OPERATION DEVICES
Tilt Lever Automatic Fork Leveling Button (Option)

Tilt the mast forward and backward. (Works same as the tilt lever knob button.)
Forward ............... Push forward
While pressing the button and the forks are tilted forward
Backward ............ Pull backward
from backward-tilted positions, or backward from forward-
tilted positions, the forks will automatically stop at their hor-
izontal position. Releasing the switch will allow for normal
tilt lever operation.
(1)
(2)
(1)
(1) Forward
(2) Backward
Forward and backward tilting speed is controlled by the
angle of this lever. (1) Automatic fork leveling button
Automatic fork leveling control
• Forward
Caution When the forks are in backward-tilted positions, operating
the lever forward while pressing the automatic fork leveling
• Always operate the tilt lever from a properly
switch will automatically stop the forks at their horizontal
seated position.
position. This function is convenient when handling loads
• While traveling, always keep the mast at the back- or attaching/detaching forks.
ward tilt position.
While pressing the automatic fork leveling switch, operat-
• After the OPS system operates, return the direc- ing the forks forward from backward-tilted positions:
operating the fork. Not loaded Loaded
• If you operate the tilt lever backward to adjust the High height
horizontal position
mast position when the OPS is at work, the mast (approx. 2 m No forward tilt
may move back by its own weight. So, do not or higher)
positioned)
operate the tilt lever when the OPS is at work.
Forks stopped at their horizontal position
Low height
Highest
No forward tilt
position
• Backward
tal position.
When the mast is raised to a high position, tilt speed will
automatically slow down.
En-66
OPERATION DEVICES
Attachment Levers JOY STICK (Option)

These levers operate an attachment.
Attachment speed are controlled by the angle of this lever. Direction Lever
This lever selects forward or reverse travel.
(1) Forward................ Push the lever forward
Reverse................ Pull the lever backward En
positions.
(1)
(2)
(1) Attachment lever
Caution
• When the OPS indicator is lighted, return all of
the levers to the neutral position and sit on the (1) Forward
seat again. Then confirm that the OPS indicator (2) Reverse
has gone off.
The forward and backward travel speed can be adjusted
• Always operate the attachment lever from a prop- by the depressing degree of the accelerator pedal.
erly seated position. Push the lever in the direction opposite to the traveling
direction, and depress the accelerator pedal to activate the
electric brake for smooth braking.
Note:
Depending on the vehicle specifications, the posi-
tion of the direction lever may vary.
En-67
OPERATION DEVICES
Caution Caution
• Stop the vehicle when shifting to forward or • After the OPS system (Option) has been acti-
reverse. vated, return the accelerator pedal and all other
levers to their neutral positions and re-seat your-
self in proper position before recommencing
forks are loaded.
operations.
• Always operate the lift tilt lever from a properly
seated.
seated position.
• Do not operate the direction lever by snapping it.
• If the direction lever is at the forward position or cm above the ground.
• While traveling, always keep the mast at the back-
ward tilt position.
then move it to the forward position or reverse • When the key switch is OFF, the fork cannot be
position. lowered even if you operate the lift tilt lever down.
erator pedal to its fully released position and set Key-lift Interlock
the direction lever to the neutral position, and sit When the key switch is OFF, the fork cannot be lowered
on the seat to restart the operation. even if the lift lever is so operated.
(Even though the operator sits on the seat, travel- If the forks will not lower due to system malfunction or
ing is impossible unless the direction lever is in other reasons, loosen the lift lock release bolt of the oil
the neutral position.) control valve beneath the toe board, and push the lift lever
• Do not operate the direction lever while depress- forward with the key switch is ON.
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 (1)
Forward-tilt ......... Operate the lever forward
Backward-tilt....... Operate the lever backward
(3) (1)
(1) Lift lock release bolt

(2) (4)
Caution
its original position.
(1) Raising
(2) Lowering
(3) Forward-tilt
(4) Backward-tilt
The raising and lowering speed or forward and backward
tilt speed can be adjusted by the operating degree of the
lever.
It is possible to operate in diagonal direction. Therefore,
simultaneous operation of lifting and tilting is possible.
En-68
OPERATION DEVICES
Automatic Fork Leveling Button (Option) Attachment Lever

(Works same as the tilt lever knob button.) This lever operates an attachment.
Attachment speed are controlled by the angle of this lever.
While pressing the button and the forks are tilted forward
from backward-tilted positions, or backward from forward-
tilted positions, the forks will automatically stop at their hor-
izontal position. Releasing the switch will allow for normal En
tilt lever operation.
(1)
(1)
(1) Attachment lever
Caution
(1) Automatic fork leveling button • When the OPS indicator is lighted, return all of
the levers to the neutral position and sit on the
seat again. Then confirm that the OPS indicator
Note: has gone off.
Automatic fork leveling switch does not work • Always operate the attachment lever from a prop-
unless SAS- or automatic fork leveling control set- erly seated position.
ting is completed.
Automatic Fork Leveling Button (Option)

Automatic fork leveling control Press the automatic fork leveling button (joy stick models)
• Forward to set ON/OFF the forks height selector. When the height
When the forks are in backward-tilted positions, operating selector is ON, forks can't be raised over the pre-set height
the lever forward while pressing the automatic fork leveling limit, and a buzzer will warn the operator if the limit is
switch will automatically stop the forks at their horizontal reached.
position. This function is convenient when handling loads
or attaching/detaching forks.
While pressing the automatic fork leveling switch, operat-
ing the forks forward from backward-tilted positions: (1)
Not loaded Loaded

High height
horizontal position
(approx. 2 m No forward tilt
or higher)
positioned)
Forks stopped at their horizontal position
Low height
Highest (1) Automatic fork leveling button
No forward tilt
position
• Backward Note:
On joy stick models, the height selector button and
the automatic fork leveling button functions are
combined.
tal position.
When the mast is raised to a high position, tilt speed will
automatically slow down.
En-69
OPERATION DEVICES
ARMREST Adjusting the forward-backward position

(Mini levers and joy stick models) Pull up and thereby the forward-backward position adjust-
ing knob is released. Adjust the armrest forward-backward
The armrest position is adjustable to be suitable for the position. Then press the knob, securing it in place.
operator.
(1)
Mini levers models

(1) Forward-backward position adjusting knob
Caution
After adjusting the forward-backward position,
always return the knob to the original position to fix
the armrest. Loosened knob during operation will
cause a malfunction.
Adjusting the height position

Turn the knob counterclockwise to release the lock. Then,
Joy stick models move the armrest up-and-down to place it to an appropri-
ate height.
Caution
(1)
• Before operating the vehicle, adjust the armrest
to set the optimum driving position.
• After you have finished adjusting the armrest for-
ward-backward position, height and tilt, confirm
that the knob and the lever have been secured in
place. Loose knob and lever will cause operation
mistake or an accident.
• Do not adjust the position of the armrest while
operating the vehicle.
• To operate the vehicle safely, fix down the arm-
rest securely. Before operating the vehicle, (1) Height adjuster knob
always confirm that the lever for turning and
securing the armrest is locked.
Caution
• Do not apply an excessive load to the armrest.
After adjusting the height position, always tighten
the knob to fix the armrest. Loosened knob during
operation will cause an error in operation.
En-70
OPERATION DEVICES
Tilt adjustment STANDARD DISPLAY

1. Pull up the tilt adjustment lever to release its lock. The
tilt angle is adjustable in the range from 15° downward
to 5° upward.
En
(1) (2)
(1) (1) Power selection switch

(2) Display area
(1) Lever for turning and securing the armrest
Description of Display Area
2. Then push the lever down, securing it in place.
This lever is used in order to turn the armrest when you (1) (2) (3)
open and close the battery hood.
Caution (4)
(6)
After adjusting the angle, be sure to lock the lever (5)
so that the armrest is fixed securely. Loosened
lever during operation will cause an error in opera-
tion.
(7) (8) (9) (10)
(1) OPS indicator

(2) Overheat warning indicator
(3) Diagnostic mode indicator
(4) Battery capacity indicator
(5) Power select indicator
(6) Hour meter
(7) Hour meter active indicator
(8) Parking brake indicator
(9) Battery overheat warning indicator
(10) Battery electrolyte level warning indicator
Caution
Use your finger to operate the control panel. Do not
use anything with a sharp tip as it may cause a
damage to the switch.
En-71
OPERATION DEVICES
Display Screen Detailed Description

Key ON initial screen OPS indicator
When the key switch is turned on, the key ON initial screen When the operator leaves the operator’s seat, this indica-
is displayed for 2 seconds. tor lights up and the buzzer sound is output for 1 second.
Parking brake indicator

This indicator is lit while the parking brake is at work.
The battery electrolyte level warning indicator functions

only when the vehicle is equipped with a JIS battery
(option).
The battery overheat warning indicator functions only
when the vehicle is equipped with a JIS battery (option)
and battery protection function (option).
Normal screen
The normal screen appears after the initial screen.
Caution
If the indicator does not go out when the parking
brake is released, stop operating the vehicle and
have it inspected at a Toyota dealer.
Diagnostic mode indicator

When some trouble has occurred on the vehicle, this indi-
cator blinks and at the same time a warning sound is out-
put. At this time, an error code is displayed in the key on
hour meter area.
Diagnosis screen
When the diagnosis function is activated, the spanner indi-
cator blinks and a warning sound is output, informing the
operator that some trouble has occurred.
At this time, an error code and key on hour meter appear
alternately in the hour meter area, thereby the trouble can
be located. Caution
Up to 6 error codes are displayed at 2 seconds’ intervals. If the diagnostic mode indicator is displayed, move
the vehicle to a safe place, stop it and have the
(1)
(2)
(1) “E” standing for error

(2) Error code
En-72
OPERATION DEVICES
Overheat warning indicator

This indicator lights up, a warning sound is output and the
vehicle functions are restricted if the temperature of the
controller, motor driver or travel and load handling motor
has risen excessively.
The buzzer sounds for a few seconds to warn overheat.
When an overheat trouble has occurred, the buzzer keeps
En
sounding until the trouble is corrected.
Also, when the motor driver is cold, this indicator lights up, Note:
a warning sound is output at the same time for a few sec- When the battery electrolyte warning indicator
onds and the output is restricted to protect the element in lights up, check electrolyte level. If the level is too
the motor driver. low, replenish it.
Battery capacity indicator

This indicator indicates the charged level of the battery in
10 stages.
Warning
If the warning indicator does not go out after 20 to
30 minutes, have it inspected immediately at a
Toyota dealer.
Battery overheat warning indicator (Option)

When the temperature of the battery electrolyte exceeds
the specified level, this indicator lights up, a warning sound
is output at the same time and the vehicle functions are
restricted. Battery residual capacity warning
This is to prevent the battery service life from being short- When the battery residual capacity has become lower than
ened due to an excessively high temperature of the elec- the specified level, the battery capacity indicator blinks.
trolyte. Also, when the key switch is turned on, a warning sound is
However, if this function disturbs the operation, have it output for a few seconds to warn the operator.
cancelled at the Toyota dealer.
Battery electrolyte level warning indicator

(Option)
When the vehicle is equipped with a JIS battery, a short-
age of the battery electrolyte is detected, this indicator
lights up to inform it. If such shortage is left as it is, the
buzzer sounds for some seconds for warning when the key
is on. Also, when the key is turned off, this indicator blinks
to urge replenishment of the battery electrolyte.
Note:
If the vehicle is used further in that state when you add bat- If the battery capacity indicator blinks, charge the
tery protection function (Option) to the vehicle with a JIS battery.
battery, in addition to the above, functions of the vehicle
are restricted depending on the duration of time passed.
En-73
OPERATION DEVICES
Battery over-discharge warning Key switch on hour meter

If the vehicle is operated for traveling and load handling The key switch on time is accumulated and indicated using
when the battery residual capacity is lower than the speci- 0.1 hour (6 minutes) unit.
fied level, all segments of the battery capacity indicator While the hour meter is at work, the operation indicator
blink and a warning sound is output to warn the operator of blinks.
over discharge. At this time, functions for traveling and
load handling are restricted.
(1)
(1) Hour meter active indicator
Warning Sound
Note: Parking brake lever release reminder
If the battery capacity indicator blinks, charge the If traveling is attempted without releasing the parking
battery. brake, this indicator lights up and a warning sound is out-
put to warn the operator.
Power select indicator Parking brake lever reminder
This indicator indicates the power select mode (S, P or H) If the operator turns off the key switch or leaves the seat
currently selected. for 2 seconds or longer with the parking brake released, a
If the H mode lock is set to “Enabled”, it is not possible to warning sound is output to warn the operator.
select H.
Return to neutral warning for travel OPS
If you sit in the seat while travel OPS is working, without
the direction lever returned to the neutral position or with
the foot kept on the accelerator pedal, a warning sound is
output to warn the operator that the travel stop mode has
not been cancelled. (Nothing is indicated on the display.)
Return to neutral warning for load handling
OPS
If you sit in the seat while load handling OPS is working
without the load handling lever returned to the neutral posi-
tion, a warning sound is output to warn the operator that
the load handling stop mode has not been cancelled.
(Nothing is indicated on the display.)
Key switch ON return to neutral warning
Note: If the accelerator pedal or direction lever is not at the neu-
tral position when the key switch is turned on, a warning
For switching between “Enabled” and “Disabled” of sound is output to warn the operator. Turn the key switch
the H mode lock, have it done at the Toyota dealer. to the OFF position once, take your foot off the accelerator
pedal, return the direction lever to the neutral position.
Travel and load handling warning while
charging
(Onboard charger equipped model: Option)
If the accelerator pedal or load handling lever is operated
with the AC plug connected while charging, a warning
sound is output to warn the operator and the travel and
load handling functions are stopped.
En-74
OPERATION DEVICES
Setting Function MULTIFUNCTION DISPLAY

Power select function (Option)
To select the mode (S, P or H) of the power select function,
press the power select switch on the normal screen. Every Status Screen
time the switch is pressed, the mode changes in the order
of S  P  H  S  and on. En
When the H mode lock is set to “Enabled”, “H” mode is not (7) (6) (5) (10)
(11)
selectable. For setting of “Enabled” and “Disabled” of the H
mode lock, consult the Toyota dealer.
(8)
(12)
(1)
(9) (13)
(1) (2) (3) (4)
(1) Switch [1] .... Low speed control set switch / Switch
for down
(2) (2) Switch [2] .... Power selection switch / Switch for
left
(1) Power mode (3) Switch [3] .... Time or date selection switch /
(2) Power selection switch Switch for right
(4) Switch [4] .... Meter mode selection switch / Enter
switch
Note: (5) Multi-screen display area
For setting of “Enabled” and “Disabled” of the H
(6) OPS indicator
mode lock, consult the Toyota dealer.
(7) Parking brake indicator
(8) Height limiter indicator
(9) Low speed setting indicator
(11) Overheat warning indicator
(12) Battery overheat warning indicator
(13) Battery electrolyte level warning indicator
Note:
The administrative function are available in multi-
function display. Administrators can use this fea-
ture to limit various vehicle performances for safety
management, or to fit the vehicle settings to each
operator's favorites. Consult the Toyota dealer to
ask how to use the administrative function.
En-75
OPERATION DEVICES
Low speed control set switch Meter mode selection switch

Press switch [1] to switch the activation of the low speed Press switch [4] to switch the hour meter display.
setting function. The low speed setting indicator informs of
its activation.
(9)
(4)
(1)
(4) Meter mode selection switch
(1) Low speed control set switch

OPS indicator
This indicator lights up when the operator leaves the seat,
(9) Low speed setting indicator and the buzzer sounds for 1 second.
Power selection switch
Press switch [2] on the status screen to change the travel-
ing/load handling power select mode.
(14)
Parking brake indicator

This indicator is lit while the parking brake is at work.
(2)
(2) Power selection switch

Time or date selection switch
Press switch [3] on the status screen to switch the date Caution
and time indicator. If the indicator does not go out when the parking
brake is released, stop operating the vehicle and
(15) have it inspected at a Toyota dealer.
Height limiter indicator

While the height limiter is at work, its indicator on the dis-
play is lit.
(3)
(3) Time or date selection switch

(15) Time/date indicator
En-76
OPERATION DEVICES
Low speed setting indicator Overheat warning indicator

This indicator comes on or goes off whenever the operator Overheat warning indicator lights up and buzzer sounds
presses switch [1]. This indicator is lit when the low speed for 5 seconds, to warn the operator in the case of tempera-
setting function is in effect, limiting the vehicle speed at a ture rise of traveling motor, pump motor, main controller or
preset value. The speed control value can be set using the motor driver.
low speed setting screen.
En
In error stage, the alarm sounds until the error is recov-

ered. Although error code is not displayed on the multi-
Note: screen display area, it is recorded by the system.
Overheating part is displayed on the screen:
If the administrator sets the menu lock ON, the C/R........................ Main controller
speed control value cannot be set. DCR ...................... Traveling motor driver
PCR ...................... Pump motor driver
Diagnostic mode indicator DM ........................ Traveling motor
PM ........................ Pump motor
If any abnormality occurs while the vehicle is in use, this
indicator blinks and the warning buzzer sounds. At this
time, a diagnosis error code is displayed in the multi-
screen display area. The error code varies with each error
location and error level.
When overheated, the performance of vehicle is limited.

Caution
After the warning indicator is displayed, leave the vehicle
If the diagnostic mode indicator is displayed, move with the key switch ON for 20 to 30 minutes.
Warning
If the warning indicator does not go out after 20 to
30 minutes, have it inspected immediately at a
Toyota dealer.
En-77
OPERATION DEVICES
Battery overheat warning indicator (Option) Other Alarms and Indicators

When the temperature of the battery electrolyte exceeds
the specified level, this indicator lights up, a warning sound Parking brake lever release reminder
is output at the same time and the vehicle functions are If traveling is attempted without releasing the parking
restricted. brake, this indicator lights up and a warning sound is out-
This is to prevent the battery service life from being short- put to warn the operator.
ened due to an excessively high temperature of the elec- Parking brake lever reminder
trolyte. If the operator turns off the key switch or leaves the seat
However, if this function disturbs the operation, have it for 2 seconds or longer with the parking brake released, a
cancelled at the Toyota dealer. warning sound is output to warn the operator.
Return to neutral warning for travel OPS
If you sit in the seat while travel OPS is working, without
the direction lever returned to the neutral position or with
the foot kept on the accelerator pedal, a warning sound is
output to warn the operator that the travel stop mode has
not been cancelled. (Nothing is indicated on the display.)
Return to neutral warning for load handling
Battery electrolyte level warning indicator OPS
If you sit in the seat while load handling OPS is working
(Option)
without all load handling levers returned to the neutral
When a shortage of the battery electrolyte is detected, this
position, a warning sound is output to warn the operator
indicator lights up to inform it. If such shortage is left as it
that the load handling stop mode has not been cancelled.
is, the buzzer sounds for some seconds for warning when
(Nothing is indicated on the display.)
the key is on. Also, when the key is turned off, this indica-
tor blinks to urge replenishment of the battery electrolyte. Key switch ON return to neutral warning
If you keep operating the vehicle with the battery electro- If the accelerator pedal or direction lever is not at the neu-
lyte being insufficient as it is, the accumulated time is indi- tral position when the key switch is turned on, a warning
cated on the display and the vehicle function is restricted sound is output to warn the operator. Turn the key switch
depending on the duration of time passed. to the OFF position once, take your foot off the accelerator
pedal, return the direction lever to the neutral position.
Travel and load handling warning while
charging
(Onboard charger equipped model: Option)
If the accelerator pedal or load handling lever is operated
with the AC plug connected while charging, a warning
sound is output to warn the operator and the travel and
load handling functions are stopped.
Note:
When the battery electrolyte warning indicator
lights up, check electrolyte level. If the level is too
low, replenish it.
En-78
OPERATION DEVICES
Maintenance indicator Over speed alarm

When the maintenance hour meter exceeds a preset time, When the set speed is exceeded, the speedometer blinks
the maintenance indicator is displayed. and the buzzer sounds to inform the operator of the over
The buzzer also sounds for 5 seconds each time the key speed.
switch is turned on under the above condition. Unlike low speed setting, even if the set speed is
exceeded, any speed limitation is not applied.
En
Note:
The buzzer does not sound when the elapsed time
Note:
has just exceeded the preset hour while the vehicle If the administrator sets the menu lock ON, the over
is in operation. speed alarm setting value cannot be set using the
over speed alarm setting screen.
Auto traveling speed control indicator

(Option) Shock indicator (Option)
This indicator is displayed when the auto traveling speed When the shock goes over the preset value, the shock
control is active. See “Auto speed control”. indicator blinks and the buzzer sounds. The indicator will
be displayed continuously until the administrator resets it.
See “Shock sensor”.
En-79
OPERATION DEVICES
Battery residual capacity warning Multi-screen Display Area

When the battery residual capacity has become lower than The multi-function display helps operators to identify vari-
the specified level, the battery capacity indicator blinks. ous information easily by changing screens depending on
Also, when the key switch is turned on, a warning sound is the vehicle conditions.
output for a few seconds to warn the operator.
Initial screen
Initial screen is displayed for 2 seconds after key switch is
turned on.
(2) (3) (4) (5)
(1)
(6) (7) (8)

Note:
If the battery capacity indicator blinks, charge the (1) Date display
battery.
(2) Maximum speed limiter active
(3) Over speed alarm active
Battery over-discharge warning
If the vehicle is operated for traveling and load handling (4) Auto speed control (Option) active
when the battery residual capacity is lower than the speci- (5) Maximum height limiter (Option) active
fied level, all segments of the battery capacity indicator
(6) Shock sensor (Option) present
blink and a warning sound is output to warn the operator of
over discharge. At this time, functions for traveling and (7) Active mast front tilt control (Option) disabled
load handling are restricted.
(8) Turn speed control (Option) disabled
Some features are explained further in this chapter.
(2) - (6)
Not indicate except the features in the vehicle specification
(7) - (8)
Not indicate except the features with the setting being
completed
Note:
Confirm the specification of each feature and the
setting status on this screen.
Note:
If the battery capacity indicator blinks, charge the
battery.
En-80
OPERATION DEVICES
Status screen Battery capacity indicator

Different features are displayed on screen, depending if Battery capacity indicator indicates amount of charge in
the vehicle is traveling or stopped. the battery in 10 stages.
When the battery capacity reaches the set warning level of
Travel screen
remaining charge (default: two level):
(1) (6) (1) The battery capacity blinks.
En
(2) After the key switch is turned to ON, a warning
buzzer sounds for 5 seconds.
(5)
(2) (3) (4)
Vehicle stop screen

• Except SAS- equipped model with the steering knob
position correct control function.
(6)
Caution
• If the battery capacity indicator blinks, stop oper-
ation early and charge the battery.
• To change the set level, consult with a Toyota
dealer.
Battery over discharge warning

When the battery residual capacity goes down below the
• SAS- equipped model with steering knob position cor- set level, the whole battery capacity indicator will be
caused to blink and a warning sound (“peep! peep!”) will
rect control function.
be output by continuing traveling/load handling to give the
(7) operator a warning of over discharged status. At this time,
stop the work at once and charge the battery.
In this status, the operations of load handling is disabled
but the operation of only travel is enabled. Load handling is
enabled only once (for about 30 seconds) when the key
switch is turned from OFF to ON.
If the battery is further discharged, all segments in the bat-
tery capacity indicator blink and a buzzer sound to warn
the operator. At this time, the travel or load handling func-
(8)
tion is restricted.
(1) Battery capacity indicator

(2) Menu lock indicator
(4) Time/date indicator
(5) Function operation indicator display area
(6) Speedometer
(7) Wheel indicator (Option)
(8) Direction indicator (Option)
Some features are explained further in this chapter.
En-81
OPERATION DEVICES
Speedometer
I
Caution Speedometer indicates the vehicle speed digitally in 1 km/

h.
• Stop the work at once and charge the battery.
• For changing the set level, consult with the
Toyota dealer.
Menu lock indicator

When menu lock setting is ON, the menu lock indicator is
displayed.
When the menu lock indicator is displayed, if the operator
presses switch [1] for more than 2 seconds on the status
screen, the indicator blinks to inform its invalid operation.
Direction indicator (Option)

The direction selected by the direction lever is displayed.
When the vehicle speed is detected, the speedometer
value is displayed.
Power select indicator

The selected power mode (E, S, P, H or original) is dis-
played. (1) (2) (3)
(1) Forward
(2) Neutral
(3) Reverse
Time/date indicator
It shows time: hour and minute (in 12/24 hours) or date:
day and month.
En-82
OPERATION DEVICES
Wheel indicator (Option)

The traveling direction of the vehicle is indicated with the Note:
“” mark. When the vehicle speed is detected, the speed-
• As this value is a result of a simple measurement
ometer value is displayed.
based on the detected cylinder pressure of the
lift, do not use it when checking for overload in
(1) (2) (3) the range close to the allowable load. En
• The load weight is indicated “0.01t” when it is
less than 100 kg.
• The load weight is indicated for a few seconds
per one time operation, but it is not indicated
when the vehicle speed is detected.
(1) Turning clockwise • Be sure to measure the load weight, adjusting the
fork height, approximately 500 mm from the
(2) Going straight
ground and setting the mast in vertical position.
(3) Turning counterclockwise
Diagnostic code display
When diagnosis is activated, the diagnostic mode indicator Caution
comes on and blinks and a buzzer sounds to warn the
operator that some abnormality has occurred on the vehi- This value is indicated for operational rough stan-
cle. Also, up to six diagnosis error codes are displayed on dard. It is not available for any commercial transac-
the screen. tion or certification.
The accuracy is deteriorated when measurement is taken

at a raised high position.
Recommendation for the operator to measure at a lower
position is displayed.
Caution
If the diagnostic mode indicator is displayed, move
Live load meter (Option)

When the lift lever is stopped from the operating status, the
loaded weight is indicated using 0.01 t unit on the display.
En-83
OPERATION DEVICES
SCREEN FUNCTIONS
Note:
Power Select • If the administrator sets the menu lock ON, the
The selected power mode (E, S, P, H or original) is dis- power control setting menu screen cannot be dis-
played. played.
• This screen is not displayed in the PIN code entry
(1) (2) (3) (4) (5) system model (Option).
Travel power control

Select the “DRIVE POWER” on the power control menu
screen to display the travel power control screen.
Switch [2] ..............Select the lower level.
(1) E mode
Switch [3] ..............Select the higher level.
(2) S mode Switch [4] ..............Returning to Power control setting
menu screen.
(3) P mode
(4) H mode
(5) Original mode
Note:
• For switching between “Enabled” and “Disabled”
of the H mode lock, have it done at the Toyota
dealer.
• If the administrator sets the menu lock ON, the
power select mode cannot be changed.
Power Control Setting Function

Press switch [2] on the status screen for 2 seconds or Note:
more, the power control menu screen will be displayed.
Select an item with switch [1], and press switch [4] to dis- For switching between “Enabled” and “Disabled” of
play each setting screen. the H mode lock, have it done at the Toyota dealer.
Load handling power control

Select the “LIFT POWER” on the power control menu
screen to display the load handling power control screen.
Switch [2] ..............Select the lower level.
Switch [3] ..............Select the higher level.
Switch [4] ..............Returning to Power control setting
menu screen.
(1) (2) (3) (4)
(1) Switch [1]

(2) Switch [2]
(3) Switch [3]
(4) Switch [4]
Note:
For switching between “Enabled” and “Disabled” of
the H mode lock, have it done at the Toyota dealer.
En-84
OPERATION DEVICES
Clock Set Multi Meter Display Screen

Press switch [3] in the status screen, the date and time are Press switch [4] on the status screen, the display changes
displayed alternately. over in sequence of Key switch ON hour meter, Lap time
meter  Traveling motor service hour meter, Pump motor
service hour meter, Traveling/pump motors service hour
meter, Seat ON hour meter  Odometer, Trip meter 
Planned maintenance hour meter  status screen.
En
(1)
(2)
(1) (2) (3) (4)
(1) Switch [1]

(2) Switch [2]
(3) Switch [3]
(4) Switch [4] (1) Key switch ON hour meter (KEY ON)
It counts the time when the key switch is turned on.
Operation procedure
(When logged on for models with PIN code entry system
The year, month, day, time and 12/24-hour display can be
(Option).)
set. Press switch [3] on the status screen for more than 2
seconds, and clock set screen is displayed. (2) Lap time meter (LAP)
Functions of switches on the clock set screen:
It counts the time when the key switch is turned on.
Switch [1] ..............Exit (not set)
(When logged on for models with PIN code entry system
Switch [2] ..............Decrease the selected (highlighted in
(Option).)
reverse) value.
Pressing switch [1] for more than 2 seconds can reset
Switch [3] ..............Increase the selected (highlighted in
the meter.
reverse) value.
Switch [4] ..............Enter the selected (highlighted in
reverse) value and proceed to the
next item. (3)
Pressing switch [4] while “MINUTES” is selected can com-
plete setting and the screen returns to the status screen.
(4)
(5)
(6)
(3) Traveling motor service hour meter

It counts the time when the traveling motors are active in
the power running mode or regenerative brake mode.
(Not when the traveling motors are freewheeling).
(4) Pump motor service hour meter

It counts the time when the pump motor is active in the
power running mode for the load handling operations.
(Not when the motor is active only for the power steer-
ing).
(5) Traveling/pump motors service hour meter

It counts the time when the traveling or pump motor are
active in the power running mode or regenerative brake
En-85
OPERATION DEVICES
mode. (Not either when the traveling motors are free- Setting Screen
wheeling, or when the pump motor is active only for the Pressing switch [1] on the status screen for more than 2
power steering). seconds will display the setting menu screen.
(6) Seat ON hour meter Select an item with switch [1], and press switch [4] to have
each setting screen displayed.
It counts the time when the operator is seated, and the
key switch is turned on.
(7)
(8) (1) (2) (3) (4)
(1) Switch [1]
(7) Odometer (ODO) (2) Switch [2]
It counts the traveling distance of the vehicle. (3) Switch [3]

(4) Switch [4]
(8) Trip meter (TRIP)
It counts the travel distance, and it can be reset. Press-
ing switch [1] for more than 2 seconds can reset the Note:
meter.
If the administrator sets the menu lock ON, the set-
ting menu screen cannot be displayed. (Also, in
case of PIN code entry, the setting menu screen
cannot be displayed except simple automatic lift
stop (option).)
(9)
Low speed setting screen

The limit speed of the low speed setting function can be
changed.
Switch [2] ..............Setting traveling speed down.
Switch [3] ..............Setting traveling speed up.
Switch [4] ..............Returning to setting menu screen.
(9) Planned maintenance hour meter

The present service interval time and the current
elapsed time are displayed.
The hour meter integrates the elapsed time while the key
switch is turned on (logged on time for PIN code entry
system (Option)).
It also continues to integrate the elapsed time even if the
preset service interval time has been exceeded.
Note:
The administrator controls maintenance time. For It is adjustable from 2 to 20 km/h with a step of 1 km/h.
setting procedures, consult the administrator. If the operator sets the speed to more than 20 km/h, the
low speed setting function is disabled. In that case, “OFF”
is displayed.
En-86
OPERATION DEVICES
Automatic height control clear screen

Note: (Option: For simple automatic lift stop only)
For details, see “Automatic height control”.
This screen is not displayed in the PIN code entry
system model (Option).
En
Over speed alarm setting screen
The traveling speed to activate the over speed alarm func-
tion can be changed.
Switch [2] ..............Setting traveling speed down.
Switch [3] ..............Setting traveling speed up.
Switch [4] ..............Returning to setting menu screen.
Height limit setting screen

(Option: For simple automatic lift stop only)
For details, Refer to “Height limit setting”.
It is adjustable from 5 to 20 km/h with a step of 1 km/h.

If the operator sets the speed to more than 20 km/h, the
over speed alarm function is disabled. In that case, “OFF”
is displayed.
Note:
This screen is not displayed in the PIN code entry
system model (Option).
Automatic height control setting screen

(Option: For simple automatic lift stop only)
For details, see “Automatic height control”.
En-87
OPERATION DEVICES
OPTIONAL FEATURES Login operation

The operator has to enter the PIN, and then press the login
switch to activate the vehicle.
PIN Code Entry System (Option)
When each numerical key is pressed, the green LED lights
Only operators who have registered PINs (Personal Identi-
up and the buzzer sounds briefly.
fication Number) can activate the vehicle with this feature.
The system checks the entered PIN to the registered PINs
This can contribute to avoidance of irregular uses by
after the login switch is pressed.
uncertified persons.
If the key switch has been already turned on at that time,
the buzzer outputs a short peep sound, the green LED
lights up and the vehicle is activated.
When it is turned off, the system waits for the key switch to
be turned on for 10 seconds with the green LED blinked.
After 10 seconds passed without the key switch turned on,
the approval is canceled and the LED lights off.
When the vehicle is activated, the profile assigned by the
PIN is loaded and the vehicle operates under the settings.
When the entered PIN is not approved, the buzzer sounds
longer and the system returns to the logoff state.
(1)
Note:
(1) PIN key pad
• Pushing the logoff switch before completing
entering a PIN resets the entered numbers and
returns the system to the logoff state.
(1) (2) • The entered numbers are reset and returns the
system to the logoff state if no key is entered for
over 10 seconds before completing entering a
(3) PIN.
• If 9 or more numbers are set and then the login
switch is pressed, the system will recognize none
(4) (5) of the PIN numbers at all.
Logoff operation
The operator can turn off the vehicle by pushing the logoff
(1) Red LED switch when the vehicle activates.
At that time, the system turns off the green LED, lights the
(2) Green LED
red LED for 1 second, and the buzzer sounds briefly.
(3) Numerical switches Leaving the vehicle without performing operations for a
(4) LOGOFF switch period of time (Auto power off setting) also turns it off auto-
matically.
(5) LOGIN switch Turning off the key switch (without pushing the logoff
PINs range from 4 to 8 figures. switch) can shift to the waiting mode for the key switch.
The system has one non-erasable “INITIAL PIN” for emer- In this mode, the green LED blinks and the operator can
gency, set by administrators. activate the vehicle again without entering the PIN but only
This system also can register ten different vehicle settings by turning on the key switch before the waiting time
called “PROFILE”, and each PIN can be assigned one set- passes.
ting out of the ten settings.
Administrators can use this feature to limit various vehicle
performances for safety management, or to fit the vehicle Note:
settings to each operator’s favorites. To change the waiting time, contact the administra-
tor.
Caution
• PIN code entry is not an anti-theft security sys-
tem.
• Do not tell PIN code to others.
En-88
OPERATION DEVICES
Protection from password attacks

The system has a protection function from the password Note:
attacks.
• This option is available only for V or FSV mast.
This function processes the following operations depend-
ing on counts to enter wrong PINs continuously. • Actual fork height stopped by this height selector
1-4 .........................This function sounds the buzzer and function may vary depending on the weight of
lights the red LED for 1 second, and loads and/or the tilt angle conditions.
En
also prohibits entering new PIN dur-
• Please contact the administrator or your Toyota
ing this period.
dealer for setting the lift height.
5-10.......................This function sounds the buzzer and
lights the red LED for 5 seconds, and • The height that can be set for the V mast is 150
also prohibits entering new PIN dur- mm or more from the lowest possible position of
ing this period. forks and that for the FSV mast of each model is
11-20 .....................This function sounds the buzzer and the value as given in the table below or more
lights the red LED for 1 minute, and respectively.
also prohibits entering new PIN dur-
ing this period. (mm)
After the counts have reached 20, the system transfers
itself to the lock-mode. Maxi- Vehicle model
The green and red LED’s blink simultaneously and the mum
buzzer sounds for 5 seconds if an operator enters any PIN height 8FBN15 8FBN16 8FBN18 8FBN20 8FBN25
on this mode. 4300 1765 1765 1765 1770 1770
Only administrators can reset the lock mode.
4500 1835 1835 1835 1840 1840
Before the system has transferred itself to the lock-mode, it
resets the counts to enter wrong PINs when a correct PIN 4700 1915 1915 1915 1920 1920
for operators is entered. 5000 2015 2015 2015 2020 2020
5500 2175 2175 2175 2180 2180
Note: 6000 2365 2365 2365 2370 2370
The counts to enter wrong PINs do not increase by

pushing the logoff switch before completing enter-
ing a PIN. Maximum height limiter
When the lift lever is operated backward and the forks
reach the maximum height limiter position, the forks auto-
Height Selector (Option) matically stop there and buzzer sounds for 1 second.
This option consists of three functions that automatically If the lift lever is operated backward at the height where
stop the forks at the appropriate height as follows. forks have already exceeded the maximum height limiter
Maximum height limiter position, the forks never rise and the buzzer also sounds
for 1 second.
The administrator can set a maximum height limit position.
Only the administrator can use the setting menu for “Maxi-
Subsequently, forks can never be raised over the height
mum height limiter”.
set by administrator.
Height limiter (1)
The operator can set a height limiter position. Therefore,
forks can not be raised over the height set.
The operator can enable/disable this feature by the height
limiter switch (see “Switches and Levers“).
Automatic height control
The operator can set up to three height favorite positions.
By pressing the height selector switch (see “Switches and
levers”) the operator can enable one of the favorite height
positions, therefore, forks can not be raised over those lim-
its.
(1) “Maximum height limiter active” icon on initial

screen
En-89
OPERATION DEVICES
Height limiter
This feature is activated only when the height limiter posi-
tion is memorized and the height limiter switch (1) is
pushed down.
(1)
Setting function
Operators can use the setting menu for “Height Limiter” on
the setting menu screen. See “Multi function display”.
(1) Height limiter switch

When the lift lever is operated backward and the forks
reach the memorized height limiter position, the forks auto-
matically stop there and buzzer sounds for 1 second.
If the lift lever is operated backward at the height where
forks have already exceeded the memorized height limiter
position, the forks never rise and the buzzer also sounds
for 1 second.
Here, the operator can lift the forks up over memorized
height limiter position by releasing the height limiter switch. (1) (2) (3) (4)
When the height limiter position is memorized and the
height limiter switch is pushed down, the height limit indi-
cator lights up, to inform the operator that this feature is (1) Switch [1]
active. (2) Switch [2]
(3) Switch [3]
(4) Switch [4]
The setting screen for “Height Limiter” is displayed by
selecting the menu “HEIGHT LIM” by using the switch [1]
and switch [4] on the operator’s menu screen.
Note:
• It is possible to set the values for the height lim-
iter and maximum height limiter at different loca-
tions.
• If you attempt to raise forks while they are caught Operators can overwrite the memory of the height limiter at
by a rack or something, the lift stop screen may the current height by continuing to press switch [1] “SET”
appear and the buzzer may output a peep sound. for two seconds under the condition that “SET” is selected
The same may occur at the top end of the lift. by using switch [2] and switch [3].
En-90
OPERATION DEVICES
Counts of clicks and the selected target memory are

related as follows.
0............................ This feature will not be activated.
En
Status screen
Operators can also clear it by continuing to press switch [1]
“CLR” for two seconds under the condition that “CLR” is 1............................ The lowest target is selected.
selected by using switch [2] and switch [3].
Lowest target screen
2............................ The middle target is selected.
Automatic height control

Target selection before lift-up operation
The operator can memorize up to three favorite height
positions (A, B and C) within the possible setting height.
Target height memory can be selected by click operation of
the height selector switch while the lift lever is at neutral.
Middle target screen
The click operation is defined as the brief push operation
of the height selector switch (1) within 1 second.
3............................ The highest target is selected.
The long push operation over 1 second will be ignored.
(1)
Highest target screen
When the highest target has been selected, one extra click
returns to the original situation of the count zero.
(1) Height selector switch

When the operator is selecting the target, the assistant
screen is displayed.
En-91
OPERATION DEVICES
The order of the height memories is always displayed on Operation to stop the selected target
the screen in low order. Operating the lift lever backward within 10 seconds with
the target height selected and keeping the lever backward
will stop forks automatically at the selected target.
At that time, the number of the short buzzer sounds
informs the operator of the selected target height as fol-
lows while the lift lever is operated backward.
The lowest target: the single brief buzzer sound repeats
with frequency of 1 second (pi..pi..pi..).
The middle target: two brief buzzer sounds repeat with fre-
quency of 1 second (pipi..pipi..pipi..).
Example: Height of memories B < A < C The highest target: three brief buzzer sounds repeat with
frequency of 1 second (pipipi..pipipi..pipipi..).
Note:
• The lowest height target is always shown with Note:
first click wherever the fork height is. This is to • The operator can make the forks stop at any time
keep the relationship between the number of by returning the lift lever to the neutral position
clicks and the height selection. even while this feature is active.
• This assistant screen will not be displayed when • When other limiting functions of the load han-
no position has been memorized. dling or hydraulic OPS function activates, they
will make the mast movement stop prior to all of
the height selector functions and its assistant
Restriction on joy stick models screen is canceled.
On joy stick models, favorite height can not be selected
during tilting operations. Doing so activates the automatic • When selecting a favorite height position lower
fork leveling function. than the current height, this feature prevents
forks from moving backward. In this case, the
buzzer sounds for 1 second, and the screen
informs the operator of the invalid operation.
Target change while lifting up

(1) Only before the forks have stopped at the target, extra
clicks can change the target to the next level up to the
highest target memory.
But after they have once stopped at a target, one extra
click cannot change the target to the next and the forks
cannot be lifted until the lift lever has returned to the neu-
tral position.
(1) Automatic fork leveling switch

Note:
Cancel of the target and activation
• While the lift lever has been already operated, the
Displaying the status screen by clicks can cancel the target
target can be changed only up to height memory
before lift-up operation.
in all the memories.
The target and the assistant screen are canceled if neither
click nor lift-up operation is done over 10 seconds. • Neither cancel of the target nor change of the tar-
Operating the lift lever forward, or returning it to the neutral get to the lower level can be done by any clicks
position while this feature is activating also cancels them. on the highest screen.
• While lift-up operation with the status screen on
the display, any clicks cannot activate this fea-
ture.
En-92
OPERATION DEVICES
Setting function The screen to clear all the memories is displayed by

Operators can use the setting menu for “Automatic height selecting the menu “HEIGHT SET CLR” by using switch [1]
control” on the operator’s menu screen (“HEIGHT SET” and switch [4] on the operator’s menu screen.
menu). Continuing to press switch [1] “CLR” for 2 seconds can
Operator must lift the forks up to the height that they want clear all the memories on the screen.
to memorize. At this time, the setting screen displays the
height relation between three memories and the current
En
height.
So operators can select the memory to overwrite out of A,
B or C by using switch [2] and switch [3].
Continuing to press switch [1] “SET” for 2 seconds can
overwrite the current height on the selected memory. If the
memory has been overwritten, “OK” screen is displayed
and the setting screen refreshed about the height relation
is displayed by pressing switch [4].
(1) (2) (3) (4)
(1) Switch [1]

(2) Switch [2]
(3) Switch [3]
(4) Switch [4]
(1) (2) (3) (4)
(1) Switch [1]

(2) Switch [2]
(3) Switch [3]
(4) Switch [4]
Note:
• The height position memories of the height lim-
iter and the maximum height limiter cannot be
cleared by this procedure.
• If the administrator sets the menu lock ON, this
clear screen cannot be displayed.
Note:
• If the administrator sets the menu lock ON, this
setting screen cannot be displayed.
• The height position close to other two memorized
heights cannot be memorized. (Minimum distance
on design will be 150 mm. They may increase
depending on various conditions.)
In addition, in the operator’s menu, all three memories can

be cleared simultaneously.
En-93
OPERATION DEVICES
Interference avoidance with the height lim-

iter function Caution
There is a case that the maximum height limiter or the
• This function will reduce maximum speed, accel-
height limiter has been set at lower height than the memo-
eration and deceleration according to the load
rized position(s) of the automatic height control.
weight and height. But it does not necessarily
In such case, the memorized position(s) is ineffective and
mean that the vehicle will no longer tip over. So
cannot be selected. In addition, it will not be displayed on
safe driving is always necessary.
the screen.
• Just as previous model, on the condition of the
loads with high height, do not step on the accel-
erator pedal abruptly and do not shift the direc-
tion lever to drive position from neutral while the
accelerator pedal is depressed.
• The vehicle speed and acceleration may vary
depending on the road surface conditions.
Specifications of control
Lift-height and load-sensing vehicle speed control
This feature controls the vehicle maximum speed accord-
ing to the load weight at the high height. This control
Example:
improves the vehicle stability while driving with heavy
Height of memories A < B < Height limiter function < C
loads at high height.
The height switch and the load sensor installed for SAS-
control detect the height and the load weight, and the con-
Note: trol limits the maximum speed in the range from approxi-
The ineffective height memories have been retained mately 8 km/h to unlimited speed when the load is at the
and become available again when the maximum high height.
height limiter has been cleared.
Note:
Auto Speed Control (Option)
This function automatically limits the maximum speed, the • The speed limit will be released when the height
acceleration and the deceleration by detecting the forks switch detects the load height in low height stage.
height (low/high) and the loaded weight. It helps to reduce However the acceleration will be limited in order
the chance of spilling a load. to prevent rapid acceleration until the accelerator
pedal is stepped off or the speed reaches the
released target speed.
High • In case that the vehicle speed has already
exceeded the maximum speed, it is gradually
decreased and limited to the maximum speed
when the height switch is turned into the high
Slightly Slow Slow side.
• If the maximum speed limiter and/or low speed
setting has been set, the lowest limit speed is
Low adopted including the limit speed of this feature.
Fast Fast
Light Heavy
Lift-height and load-sensing acceleration and deceler-
ation control
This feature also improves the vehicle stability while driv-
ing with the heavy load at the high lift position by limiting
the acceleration and deceleration depending on the load
weight at the high lift position.
It helps to reduce the chance of spilling a load by opera-
tional errors such as the case that the accelerator pedal
has been suddenly stepped on (off) or that the direction
lever has been shifted while the accelerator pedal is fully
stepped on.
The height switch and the load sensor detect the height
and the load weight, and the control limits the maximum
En-94
OPERATION DEVICES
acceleration and deceleration in steps according to the Shock Sensor (Option)

load weight when the load is at high height. When this feature detects the intense shock on the vehicle,
it warns the operator with the buzzer sound, and it records
its date and time into the memories in the multi-function
Note: display.
Because only the administrator can cancel the buzzer
Brake pedal operation always has priority over this
sounds, the operator necessarily must report it to the
En
deceleration limitation due to auto speed control.
administrator. This is effective to suppress the rough oper-
ation.
Auto speed control indicator Here, this feature can record the PIN into the memories in
The auto speed control indicator (1) is displayed on the addition to the date and time when the option “PIN code
multi-function display while it is active. entry” is taken simultaneously. It becomes easier to identify
The indicator is also displayed for a while after the key the operator who has made the intense shock.
switch is turned on to inform that this feature is available.
If only acceleration/deceleration control is available (with
speed control disabled by dealer), the indicator is shown Warning
with inverted colors.
• The strength of the shock generated on the vehi-
cle depends on the objects where the vehicle col-
(1) (1) lided. Not all of the collisions can be detected.
• The shock generated in the usual operation
depends on the road conditions, the loads, and
the load handling operations. To prevent detect-
ing collisions in the usual operation, ask the
administrator for setting the detection level.
Initial screen after key-on

Shock sensor indicator (1) is displayed on the initial screen
of the multi-function display after the key switch is turned
on, and it informs of installation and activation of this fea-
(1) Auto speed control indicator with speed control ture.
disabled
(2) (2)
(1)
(1) “Shock sensor present” indicator on initial screen

(2) Lift height, load sensing acceleration/deceleration
limit active only
En-95
OPERATION DEVICES
Shock detection and alarm operation

If the detected shock exceeds the present alarm value on
either front-back or lateral direction while the vehicle is
operating, the “Shock indicator” (5) and buzzer-sound
alarm the operator.
The alarm continues as long as the key switch is turned on
with the battery connected until an administrator resets it,
even if the operator turned the key switch off or discon-
nected the battery.
The detected shock values, date and time are recorded on
the multi-function display at the moment of the detection.
In the case of the model with “PIN code entry system”
(Option), PIN is also recorded.
(5)
(1) (2) (3) (4)
(1) Switch [1]

(2) Switch [2]
(3) Switch [3]
(4) Switch [4]
(5) Shock indicator
Note:
In case of warning alarm sounds, an operator
should ask administrator to reset the alarm.
Auto Power Off Function

If the operator turns on the key switch and leaves the vehi-
cle, the vehicle becomes the state of key switch OFF after
the preset time passes, thus preventing waste of energy.
To restart the vehicle, turn off the key switch, and then, turn
it on.
En-96
OPERATION DEVICES
En
En-97
En
4. OPERATION
HANDLING NEW VEHICLE.............................................................. 98
OPERATION OF VEHICLE............................................................... 98
En-97
4. OPERATION
HANDLING NEW VEHICLE OPERATION OF VEHICLE

How a new forklift is handled affects its performance and
service life to a great extent. Operation Procedure
For initial 100 hours, operate the new forklift, using full
care for the following instructions.
• Avoid rough handling and try not to operate the vehicle
forcibly.
• Never use sudden start or sudden acceleration.
• Have the periodic maintenance done without fail.
• Supply grease and change oil in the earlier stage.
• Be sure to have the free periodical maintenance of a (1)
new vehicle done without fail. (2)
(1) OFF
(2) ON
Preparation for starting

1. Check to make sure that the direction lever is at the
neutral position and the parking brake is pulled.
2. With your foot taken off the accelerator pedal, depress
the brake pedal with your right foot and turn on the
key switch.
Caution
• Turn on the key switch only after getting on the
vehicle and fastening the seat belt. Otherwise, the
vehicle may start moving suddenly, causing an
• Sit in the seat first and then turn on the key
switch. If the OPS indicator is lit, return each
lever to the neutral position, sit in the seat prop-
erly again and confirm that the OPS indicator has
turned off.
• Concentrate on the operation while traveling and
load handling the vehicle without using a radio or
cellular phone.
• Be sure to perform check and adjustment of the
tilt steering, rear-view mirror and lamps before
moving the vehicle.
En-98
OPERATION
3. Using the lift lever and tilt lever, raise the forks 15 to
20 cm off the ground and tilt the mast backward. Note:
• Using the return-to-neutral function, set the direc-
tion lever to the neutral position, take your foot
(2) off the accelerator pedal and turn on the key
switch. En
• Minimize operation of the accelerator pedal while
depressing the brake pedal.
Steering
1. Operate steering, holding its knob with the left hand.
(1)
(1) 15 - 20 cm
(2) Backward
4. Release the parking lever.
* This completes the preparation for starting.
Traveling
1. Move the direction lever forward or backward.
2. Take your foot off the brake pedal.
3. Depress the accelerator pedal.
2. When turning a corner, direct the front wheels inward.
The vehicle will move forward or backward.
(1) (2)
(1) Forklift
Caution (2) Usual automobiles
• Confirm that no person is around the vehicle

before starting. Caution
• Never operate the lever while the accelerator The forklift, different from usual automobiles, has a
pedal is depressed. The vehicle may start sud- rear-wheel steering mechanism. When turning a
denly, leading to an unexpected accident. corner, make a turn closer to the corner. Be careful
• Do not shift the direction lever to the neutral posi- for sway at the rear of the vehicle while turning.
tion while traveling.
En-99
OPERATION
Stopping and parking 5. Check the rear of the vehicle on the right and left for
1. When stopping the vehicle, select a location which is safety and move backward.
not in the way of other vehicles. 6. Lift the load 15 to 20 cm above ground, check for
2. Be sure to apply the parking brake. safety around and then start traveling.
3. Lower the forks until they reach the ground and
remove the key switch without fail.
(2)
Caution
• Do not park the vehicle on a slope.
• If it is unavoidable to park the vehicle on a slope,
position it in parallel with the slope and apply
chocks securely.
• Set up a caution sign, signal light, fence etc. as (1)
necessary where the vehicle is parked.
• Carefully select a firm road surface so that
(1) 15 - 20 cm
wheels will not slip, be caught in the ground or
become immovable. (2) Backward
• Be sure to lower forks until they contact the
ground. If they cannot be lowered for some trou-
ble, cover their ends with cloth or the like, park Note:
the vehicle so that the forks are directed away If it is not possible to insert forks to their root, per-
from people or vehicles passing by and apply the form following steps.
parking brake securely. 1. Insert the forks about 3/4 of the fork length and
• Do not drive or park the vehicle on dead grass or lift them a little (5 to 10 cm).
trash which are inflammable. 2. Draw the pallet about 10 to 20 cm forward and
lower it once.
Basic load handling 3. Once again, insert forks to their root.
1. Stop the vehicle in front of loads once, and set the
mast in vertical position or tilted a little forward.
2. After confirming positions where forks are inserted, Warning
move forward gradually and insert forks fully to their
root. • Never allow any person to get on forks or pallet
as it may cause an injury or fatal accident. Also,
never allow any person to enter the area under
(1) the lifted load or forks.
• Do not put your hand, foot or any part of the body
between the vehicle and mast and between vehi-
cle and backrest.
• Traveling with the load lifted high is unstable and
may result in a dangerous tip-over. Never attempt
such an act.
• Never tilt the mast forward from the vertical posi-
(2)
tion while the load is raised high. Also, never
(3)
raise the load with the mast tilted forward.
(1) Mast in vertical position

(2) Move forward gradually
(3) Insert forks to their root
3. Lift the load on forks 5 to 10 cm and check if it is safe
and free from unbalanced load.
4. After making sure that there is nothing abnormal, tilt
the mast backward fully.
En-100
OPERATION
Caution Note:
• Be sure to stop the vehicle when raising and low- If the front and rear of the pallet or load are not
ering the load. properly aligned, perform the following steps.
1. Lower the forks a little so that the load does not
• Do not thrust the forks into the load suddenly.
come over the forks. En
• Keep the end of forks away from people and
2. Move the vehicle backward by about 1/4 of the
obstacles. The end of the forks is pointed and
fork length.
may cause an injury when contacted.
3. Again raise the forks (5 to 10 cm) and move for-
• When traveling with a load placed on the forks,
ward to the position where the load can be
keep them at 15 to 20 cm above ground and tilt
loaded safely and properly.
the mast fully backward.
4. Lower the load slowly.
• If it is hard to see ahead because of the loaded
load, always move the vehicle backward or with
the help of a guiding person. Getting On and Off the Vehicle
• When putting loads on shelves, use care so that Always use the assist grip and step when getting on and
they do not hit against shelves. off the vehicle.
• Do not draw out forks with the chain loosened.

• On the downhill, reduce the speed as much as (1)
possible and drive the vehicle at a speed lower
than the specified speed.
• On the downhill, always travel backward when a
load is loaded and forward when no load is
loaded.
• When climbing up a steep slope, adjust before
the slope so that the end of forks or the bottom of (2)
the pallet does not come in contact with the road
surface and drive the vehicle carefully.
• On the downhill and wet road, the stopping dis-
tance is longer. When using the brake, apply it (1) Assist grip
well beforehand. Maintain the speed lower than (2) Step
the maximum speed on a downhill as the travel-
ing speed may possibly increase higher than the
maximum speed and the stopping distance is lon- Caution
ger.
• When getting on and off the vehicle, be sure to
check for safety around the vehicle in advance
Unloading and use the assist grip and step. At this time, do
1. Lower the forks at the destination and unload the load not get on or off with some tool in your hand or
with the mast positioned vertically or tilted a little for- hold on to the lever or steering wheel. Even if the
ward. vehicle should start to move in the unmanned
2. Confirm safety at the rear of the vehicle on the right state, do not jump on it to stop it.
and left and move backward to draw the forks out. • Get off the vehicle only after the vehicle comes to
3. Move the vehicle with the forks raised 15 to 20 cm and a complete stop.
the mast tilted backward. • As jumping off the car is dangerous, causing an
accident, never attempt it. When getting off the
vehicle, be sure to face the vehicle, hold on to the
assist grip and use the step.
En-101
OPERATION
En-102
En
5. IN CASE OF EMERGENCY
FUSE REPLACEMENT................................................................... 104
BURNT-OUT BULB......................................................................... 105
TIRE REPLACEMENT .................................................................... 105
BATTERY REPLACEMENT............................................................ 108
BATTERY REPLACEMENT............................................................ 108
VEHICLE HOISTING METHOD...................................................... 112
TRANSPORT THE VEHICLE ......................................................... 112
PRECAUTIONS DURING TRANSPORTATION ............................. 113
DRAW BAR..................................................................................... 113
En-103
5. IN CASE OF EMERGENCY
FUSE REPLACEMENT
When lights do not light up or electrical system devices do
Caution
not function, the respective fuse may be blown. See if the • Always replace with a fuse with the same capac-
fuse for each device is blown. Fuses are installed in the ity.
side frame right hand.
• If the new fuse is blown immediately after
8FBN15 - 25 series models, 50-8FBN series models replacement, ask Toyota dealer for inspection.
• When the fuse is being replaced, never short
(4) (5)
between terminals.
(2)
(3)
(1)
8FBN30 model
(1)
(4)
(5)
(2)
(3)
(1) F1
(2) F4
(3) F5
(4) F6
(5) F7
Note:
Each fuse corresponds to the following devices:
• F1 (for main circuit)
• F4 (for lights)
• F5 (for control circuit)
• F6 (for controller)
• F7 (for oil control valve solenoid)
En-104
IN CASE OF EMERGENCY
BURNT-OUT BULB TIRE REPLACEMENT

When lights do not light, possibility is a blown fuse or When replacing the tires, unload loads, move the vehicle
burnt-out light bulb. to a place with level and firm ground and apply the parking
brake.
Bulb Replacement Before replacement, prepare tools, jack, chocks and tire
Replacement procedure
and apply chocks to the tire located at a diagonal position En
of the tire to be replaced.
1. Turn off the key switch. After replacement, be sure to put tools, etc. back to original
2. Disconnect the battery plug. positions.
3. Remove the lens fixing screw to remove the lens. Jack-up

4. Turn the bulb while pushing it lightly to remove it.
Warning
Caution
After jacking up, never enter the area under the
• Do not replace the bulb with your naked fingers. forks and frame. If the jack should fail to support
the vehicle, you may be caught and subject to a big
• Select a correct bulb of the same capacity refer-
danger.
ring to the table below.
• Check to make sure that the bulb is installed
securely in place. Front
1. With the mast positioned vertically, raise the forks 2 m
or more.
Light name Capacity 2. From the side with the tire to be replaced, apply the
Work lights 40W 48V jack accurately to the jack-up point under the frame.
Work lights 40W 48V
Bulb
Clearance lights 10W 48V
type
Combination Turn signal lights 25W 48V
lights (Option) Work lights 16.8W 48V
LED
Clearance lights 1.92W 48V
type
Turn signal lights 2.88W 48V
Turn signal lights 25W 48V
25W/10W
Rear combination Stop and tail lights
48V/48V
lights (Option)
Backup light
25W 48V
(Right hand only)
Rear work light (Option) 40W 48V
Caution
Bulb type 35W 48V
Rotary lamp (Option) • Do not enter the area under the forks. You may
LED type 9.6W 48V
bump into them and be injured on the head, etc.
• Before jacking up, check to make sure that there
is no person or load on the vehicle and apply
Note: chocks to the tire.
LED can’t be exchanged. Please exchange assy • When jacking up the vehicle, do not put any
when it doesn’t work. object on or under the jack.
• Do not jack up higher than the level high enough
for tire replacement.
• Use wood blocks or the like to support the jacked
up vehicle. Without them, the vehicle may tip
over, causing an injury.
• Apply the jack at the jack-up point using care so
that the vehicle does not slip off from it.
En-105
Rear 1·2 ton (Side ring rim)

Apply the jack accurately to the jack-up point under the
counter weight and jack up the vehicle. (1) (1)
(1)
(3) (3)
3 ton (Side ring rim)
(1) (1)
(1) Counterweight
Caution
• Apply the jack at the jack-up point using care so
that the vehicle does not slip off from it.
• Before jacking up, check the counter weight set-
ting bolt for looseness. If it is loosened, the coun- (3) (4)
ter weight may come off, causing an injury.
• Use a wood block or the like to support the jacked
(1) Hub nuts
up vehicle. Without it, the vehicle may tip over,
causing an injury. (2) Rim nuts
(3) Front tire
Tire Replacement (4) Rear tire
Replacement procedure 2. Release the air pressure completely.
1. Jack up the vehicle until the tires are about to leave 3. Jack up the vehicle until the tires leave the ground.
the ground and loosen the hub nuts. Remove the hub nuts, and then remove the wheel.
Caution Warning
Never loosen bolts and nuts of the divided rim. The When disassembly or assembly are necessary,
wheel may be exposed to an extreme danger of rup- leave it to an expert.
ture.
1·2 ton (Divided rim)
(1) (1)
(2) (2)
(3) (4)
En-106
4. After replacing the tire, tighten hub nuts temporarily 6. Make the vehicle travel at a low speed a few times in
and then tighten nuts according to the procedure the forward and backward directions to inspect hub
described below until the tire is free from looseness. nuts for any loosing, and retighten them as required.
Caution Note:
En
Never loosen bolts and nuts of the divided rim. The See the service data for the hub nuts tightening
wheel may be exposed to an extreme danger of rup- torque.
ture.
Tire air pressure adjustment
1·2 ton (Divided rim) After replacing the wheel, check and adjust the tire air
pressure.
(1) (1)
(2) (2)
1 1
3 6 3 6
5 4 5 4
2 2
(3) (4)
1·2 ton (Side ring rim)
(1) (1)
Note:
1 10 1 See the service data for the tire air pressure.
5 8 3 6
3 4
7 6 5 4
9 2 11 2
(3) (3)
3 ton (Side ring rim)
(1) (1)
1 1
5 8
3 6
3 4
5 4
7 6
2 2
(3) (4)
(1) Hub nuts

(2) Rim nuts
(3) Front tire
(4) Rear tire
5. Lower the jack and tighten hub nuts to the specified
torque.
En-107
BATTERY REPLACEMENT
Caution To replace the battery for continuous operation of the vehi-
• For disassembly and assembly of the tire, tube, cle, or wash it with water, open the battery hood and dis-
rim, etc. and filling air into the tire, be sure to mount the battery from the vehicle according to the
leave them to an expert. (Observe laws and regu- procedure described below.
lations of each country.) Note that handling fork-
lift tires is very dangerous, as their air pressure is Opening/Closing Battery Hood
high (about 4 times of those used for passenger
Opening
cars).
1. Press the steering lock lever to raise the steering
• When filling the air into the tire which has been wheel forward.
removed from the vehicle, check each condition
2. Move the seat fully forward position.
of the tire, rim, bolts and nuts carefully, place the
tire in the special safety frame as shown below 3. Release a battery hood catch.
and fill the air, strictly observing the specified air
pressure value.
(1)
(1) Battery hood catch

4. Lift the battery hood with holding the assist hole in the
• For installation of the tire, be sure to use nuts
left end of the hood.
specified exclusively for the wheel in use.
5. Open the battery hood fully, move it a little to check if
• Do not apply oil or grease to the threaded parts of
the battery hood damper is locked securely and take
the tire.
your hand off from it.
• Use tires of the same manufacturer, same model
and same tread pattern and without wear differ-
Closing
ence. 1. Lift the battery hood and release the lock of the bat-
tery hood damper by pressing it.
2. Holding the assist hole in the left end of the hood,

close the battery hood quietly to fix the battery hood
catch.
3. Check the battery hood is locked securely.
4. Replace the seat to the original positions.
En-108
Closing
Caution 1. Lift the battery hood and release the lock of the bat-
tery hood damper by pressing it.
• When pressing the release button of the battery
hood damper, use care so that your finger is not 2. Close the battery hood quietly to fix the battery hood
caught. catch.
• Operating the vehicle without firmly locking the 3. Check the battery hood is locked securely. En
battery hood is very dangerous. Be sure to check 4. Replace the armrest and seat to the original positions.
that it is firmly locked before operating the vehi-
cle.
• When opening/closing the battery hood, use care Caution
so that your hand is not caught.
• When pressing the release button of the battery
hood damper, use care so that your finger is not
Battery Hood caught.
(Mini levers/joy stick models: Option) • Operating the vehicle without firmly locking the
battery hood is very dangerous. Be sure to check
that it is firmly locked before operating the vehi-
cle.
• When opening/closing the battery hood, use care
so that your hand is not caught.
Battery Replacement
Caution
• Have the battery hoisted by a person who has
had sufficient education and training. As the bat-
Opening tery is heavy, mishandling it will cause an acci-
dent.
1. Move the mini levers’ box fully backward position and
fully lowest position as well. • Be sure to perform battery replacement on a level
ground.
2. Raise the mini levers’ box to the uppermost position.
3. Remove the battery hood catch, raise the battery
hood with holding the assist hole in the left end of the Replacement procedure
hood. 1. Turn off the key switch.
4. Open the battery hood fully, move it a little to check if 2. Open the battery hood.
the battery hood damper is locked securely and take 3. Disconnect the battery plug.
your hand off from it.
En-109
4. Remove the battery case stopper and side covers Replacement procedure
(option).
(Battery side-out: Option)
1. Turn off the key switch.
2. Open the battery hood.
(1)
3. Disconnect the battery plug.
(1) Battery case stopper

5. Attach the hanger to the battery case, and remove the
battery by hoisting.
4. Remove the battery case stopper.
(1)
Caution
• After replacing the battery, make sure to fix the
battery case stopper securely. Insert the battery
plug securely.
Note:
• After replacing the battery, fix the battery case
Prepare another fork lift acceptable to weight and
stopper and battery hood catch.
width of the battery to be replaced.
• When closing the battery hood, use care so that The fork length required minimally for the vehicle
your hand is not caught. on which the battery will be replaced is 975mm.
En-110
5. Make sure that the widths of forks meet the fork pock- Replacement procedure
ets.
(Battery roll-out: Option)
1. Turn off the key switch.
2. Open the battery hood.
3. Disconnect the battery plug. En
(1)
(1) fork pocket

6. Insert forks into fork pockets by fork lift, and then lift up
the battery case.
4. Remove the battery case stopper.

Caution
• Be sure to check the horizontal position of the
forks before insertion.
• Make sure that the forks will not interfere with the
head guard.
• Be sure to insert forks into fork pockets without (1)
scratching the battery case.
• Since the forks may tilt forward due to deflection
when lifting the battery case up, lift up slowly
while operating the tilt lever.
7. Pull the battery case out while reversing the vehicle

and replace it.
5. Loosen the battery case stopper knob, and then
release the battery case stopper while turning it for-
ward.
(1)
(2)
(1) Battery case stopper knob

6. Replace the battery case by using the battery puller
system.
En-111
VEHICLE HOISTING METHOD TRANSPORT THE VEHICLE

To hoist the vehicle, sling a fiber belt or a wire rope at the To load the vehicle on the trailer, always observe following
side of the beam on top of the outer mast for the front side instructions.
and at the draw bar for the rear side.
Caution
Caution
As loading the forklift on the trailer can be a dan-
• Use wire rope of sufficient strength. gerous work, use a winch and wire rope.
If they are not available, observe the following
instruction.
Series Vehicle weight (Reference)
• Park the trailer on a level and firm ground.
1 ton series approx. 3500 kg
2 ton series approx. 4800 kg • Apply the parking brake of the trailer securely
and apply chocks to tires to prevent them from
3 ton series approx. 5400 kg moving.
• Apply a jack to the trailer so that it will not sink.
• Never use the wire rope if kinked, deformed, with • Use the ramp board which can stand the vehicle
broken strand (10%) or worn. weight fully and which will not come off the trailer
• Never use the holes on the upper side of the platform.
counterweight to hoist the vehicle. • Fix the ramp board with a less gradient and with
• Before hoisting the vehicle, check that the draw centers of the trailer and vehicle aligned.
bar does not move upward. • When moving up and down to and from the
• If the draw bar moves upward, the vehicle should trailer, reduce the speed and be careful for stabil-
put down and the draw bar should be pushed to ity and strength of the ramp boards.
the correct position. • When moving up on the ramp board, never
• Have hoisting performed by an expert who has change the course on it and observe instructions
had sufficient education and training. of the guiding person.
• Never enter the area under the hoisted vehicle. • To prevent the vehicle from moving during trans-
portation, apply chocks to the tires and fix them
• When using the counter weight section to hoist with wire rope.
the vehicle, check fixing bolts of the counter
weight for looseness in advance. Also, check the • Tell the driver of the trailer not to move the trailer
section to be hoisted for any abnormality. until the loading work is completed.
• Be sure to cover rear combination lights or the • To prevent the vehicle from slipping on the ramp
head guard with cloth or the like when hoisting boards, remove dirt from under-body area of the
the vehicle. vehicle and dirt, oil and other things attacked to
the ramp boards.
En-112
PRECAUTIONS DURING DRAW BAR

TRANSPORTATION The draw bar is located at the back of the weight, and is
used to pull the vehicle out if its tires drop into a gutter or
Low speed vehicles including the forklift are, in principle
become stuck in mud. The draw bar can also be used for
carried on the truck or the like. If moving by itself is
loading the forklift onto a vehicle or another truck.
unavoidable, avoid the heavy traffic time, be careful for the
traveling speed and do not make a quick turn or use sud- En
den braking.
Caution
• The draw bar should not be used for towing the
forklift or for towing another vehicle using the
forklift.
• When towing the vehicle, do no apply a load to
the wire rope suddenly.
(1)
(1) Draw bar
En-113
En-114
En
6. MAINTENANCE
BEFORE MAINTENANCE .............................................................. 116
GENERAL NOTICE ........................................................................ 116
PRE-OPERATION CHECK............................................................. 117
WALKAROUND INSPECTION ....................................................... 118
ON BOARD VEHICLE INSPECTION.............................................. 119
INSPECTION OF CHARGER ......................................................... 124
INSPECTION WHILE TRAVELING SLOWLY ................................ 126
INSPECTION AFTER OPERATION ............................................... 126
PERIODIC INSPECTION................................................................ 127
DAILY MAINTENANCE................................................................... 127
PRECAUTION FOR BATTERY CHARGING .................................. 129
HOW TO CHARGE THE BATTERY ............................................... 132
BASIC METHOD FOR CHARGING ................................................ 133
SERVICE DATA.............................................................................. 143
LUBRICATION CHART................................................................... 146
PERIODIC MAINTENANCE............................................................ 147
PERIODIC REPLACEMENT TABLE .............................................. 147
PERIODIC MAINTENANCE TABLE ............................................... 148
BATTERY CASE & MINIMUM WEIGHT REQUIRED ..................... 153
WHEELS & TIRES .......................................................................... 154
MAST SPECIFICATIONS & RATED CAPACITIES ........................ 156
VEHICLE DIMENSIONS ................................................................. 160
En-115
6. MAINTENANCE
BEFORE MAINTENANCE GENERAL NOTICE

In order for you to use the Toyota industrial vehicle in fine • For replacement, be sure to use “Toyota genuine” parts
conditions, daily inspection before starting to work and and have it done at the TOYOTA dealer.
periodic maintenance (inspection and maintenance items • Be sure to use “TOYOTA genuine” grease of the viscos-
recommended by Toyota) are essential. ity which is suitable for the temperature. Do not mix oil of
This section describes mainly how to perform daily pre- different types.
operation inspection and weekly (every 40 hours) mainte- • Before filling oil and grease, clean the oil filler port and
nance. grease fitting, using a brush, waste cloth and the like.
For the periodic maintenance, consult the Toyota dealer • For filling oil and checking the oil level, park the vehicle
and have it done together with periodic inspection and on the level ground.
other inspections according to the laws. • Drain oil carefully while the oil temperature is still high
after operation.
• Do not leave behind any inflammables such as paper
and cloth in the control room.
• Perform inspections with the power turned off by turning
off the key switch and disconnecting the battery plug
except when checking the inside with the door and cover
opened and when checking for lighting and proper oper-
ation in the course of electric system inspection.
• Do not use any organic solvent such as benzine and
gasoline for maintenance of the painted surface.
• Do not use any organic solvent or stiff brush for mainte-
nance of lights, etc.
• While replenishing oil, do not leave that place.
• For the oil to wash parts with, use noninflammable one.
• As the deposit around the motor and battery may cause
a fire, remove any deposit or anything attached to them
after operating the vehicle.
• When closing the battery hood after inspection, be care-
ful not to have your hand caught.
• Before using the air compressor, adjust its air pressure
correctly.
En-116
MAINTENANCE
PRE-OPERATION CHECK
The daily pre-operation inspection is essential for the fork-
Caution
lift. Even a minor fault can cause a serious accident. If
You must perform this check before starting to work every you noted even a small fault, report it to the admin-
day so that you can work safely all day. istrator and never operate the forklift until it is cor-
rected completely. En
Check wiring for looseness and damage everyday and if you find anything faulty, have the Toyota dealer check it.
After the repair, perform a trial operation to confirm that there is nothing faulty.
The table blow shows check items of pre-operation inspection and daily inspection.
Item Inspection
Fault location Has the fault noted during operation on the previous day been checked and corrected?
Exterior Vehicle posture; oil leakage; water leakage; loose sections; exterior damage.
Wheels Tire; wear or damage; rims; hub nuts.
Lights Light condition; cracked.
Rear-view Mirror Stain; damage; good rear visibility.
Hydraulic oil Oil level; contamination; viscosity.
Brake pedal Pedal play; braking action.
Brake fluid Fluid level.
Parking brake Braking action.
Steering wheel Looseness; play; vibration; pulling.
Horn Sound.
Instruments Functioning.
Load handling system Function of each section; oil leakage; cracking; looseness; SAS-.
Motor Abnormal noise; rotation.
Battery Charging. (Check with battery capacity indicator being lit)
Charger Performing properly.
Operator restraint Cut; frays and deck latch OK; seat belt & buckle.
En-117
MAINTENANCE
WALKAROUND INSPECTION
Before getting on the vehicle, walk around it first to check
Caution
the body, lens, tires, etc. • When checking the tire air pressure, apply the
gauge from its side and not directly from the
front.
• Adjust the air pressure of the compressor in
advance.
• Do not inflate beyond the specified air pressure.
Excessive inflation will cause a tire rupture.
2. After adjustment, check for air leakage from the valve.
Damage, Crack and Wear of Tire and Rim

Inspect the tires for any damage or wear and the rim for
any bending.
Vehicle Posture
Does the vehicle excessively lean to one side or the other?
If the vehicle leans to one side excessively, check very
Caution
carefully. A tire can be flat or some part in the under body If there is any difference in tire wear between the
area can be faulty. front and rear or left and right tires, or if damage or
a bent rim is found, have the vehicle inspected at a
Beneath the Vehicle Toyota dealer.
Check for any oil or water leakage on the ground or floor
where the vehicle was parked. Check for loose or distor-
tion of each section. If anything unusual is found, have the Hub Nut Inspection
vehicle inspected at a Toyota dealer. Check the tightness of the hub nuts.
Caution
Be careful not to put your foot under the forks or
stumble over them.
Tire Inflation Pressure

Tire inflation pressure adjustment
1. Using a tire pressure gauge, adjust the tire air pres-
sure to the specified value.
Note:
Refer to the “SERVICE DATA” (page 143) section for
hub nuts proper torque.
Caution
When checking the tightening torque of hub nuts,
apply the gauge from the side of the tire and not
directly from the front.
Note:
The specified tire air pressure varies depending on
the vehicle type. For the specific data, refer to the
indicator attached to the vehicle or the “SERVICE
DATA” (page 143) section of the manual.
En-118
MAINTENANCE
OPS Indicator Inspection ON BOARD VEHICLE INSPECTION

Sit on the seat, turn the key switch to ON and check that
the OPS indicator is not lighted. Hydraulic Oil Level Inspection
When the oil temperature in the hydraulic system is high,
dangerous hot gas may blow up. Be sure to release the
inner pressure before inspection. En
Inner pressure relieving method
1. Lower the forks to the ground.
2. Turn off the key switch and remove the key, and then
turn the hydraulic oil cap slowly.
Warning
Before checking the hydraulic oil, release the inner
pressure of the tank by turning the oil cap gradu-
ally. Neglecting this may cause hot gas to blow up.
Note:
When the operator sits on the seat and turn the key
switch to ON, the OPS indicator lights up for a few Note:
seconds.
Park the vehicle on a level surface and lower the
fork to the ground before checking the level of the
hydraulic oil.
Warning
If the OPS indicator is activated and an error code Inspection method
appears on the display, it is possible that the OPS 1. Open the oil filler port cover and pull out the oil cap.
has some trouble. Have it inspected at the Toyota
dealer.
Light Inspection
Check each lamp for burn-out and the lens for breakage
and dirt.
Rear-view Mirror Inspection (Option)

Check the rear-view mirror for breakage and the lens for
dirt, and then adjust the angle.
2. Wipe the level gauge attached to the oil cap with clean
cloth, and insert it again into the tank.
Note:
Check the oil level in the position to hook into O-
ring of the oil cap.
Caution
Adjust the position of the rear-view mirror to ensure
clear visibility of the rear view and clean the mirror
frequently.
En-119
MAINTENANCE
3. Draw out the level gauge gently and check that the oil 2. Check the level of the brake fluid in the reservoir tank
attached position is up to the lifting height line. if it is at the maximum level shown in the figure.
(3)
(5)
10 mm
(2) (1)
(1) (4)
Oil level range: 0 - 10 mm
(1) Maximum level

Model Mast type Lifting height Remarks
3. If the level is below the lower limit, add genuine Toyota
1·2 ton
(1) V, FSV, FV 3,000 - 6,000 brake fluid up to the maximum level.
series
3 ton
(2) V, FSV, FV 3,000 - 4,700
series
3 ton
(3) V, FSV 5,000 - 6,000
series
3 ton Rust proof Spec.
(4) V, FSV 3,000 - 4,700
series Cold storage Spec.
3 ton Rust proof Spec.
(5) V, FSV 5,000 - 6,000
series Cold storage Spec. (1)
4. If the oil level is insufficient, add oil. Spilled or

splashed oil must be wiped off thoroughly.
Brake Fluid Inspection (1) Maximum level
Inspection method
1. Remove the rear toe board. Caution
• If the decrease in brake fluid is excessive, the
(1) brake system may be leaky. Have the vehicle
inspected at a Toyota dealer as soon as possible.
• Never use any oil other than the specified brake
fluid.
• Do not allow dirt to get into the reservoir tank.
Also, add brake fluid through the filter in the res-
ervoir tank.
(2)
• Check the small vent hole in the reservoir tank
cap frequently to make sure that it is not clogged
with dirt.
• When adding brake fluid, be careful not to spill it.
(1) Rear toe board
• As brake fluid is harmful, use special care in han-
(2) Reservoir tank
dling it.
En-120
MAINTENANCE
Brake Pedal Inspection Parking Brake Inspection

Pull the lever and check if the parking brake is active.
Inspection method Return the lever to the original position and check if the
1. Depress the brake pedal fully and check the floor parking brake is released.
clearance value (clearance between the pedal and
floor).
En
Warning
Note: If an abnormality is found, have the vehicle
inspected at a Toyota dealer.
For the floor clearance value, refer to the “SEREV-
ICE DATA” (page 143) section.
2. When the pedal is kept depressed, make sure that it

does not sink any further.
3. Also check that no abnormality of pedal depression
and return movement is observed.
4. To check the play, depress the brake pedal with your
hand until resistance can be felt.
Note:
• See the service data section for the value of brake
pedal play.
• Ask a Toyota dealer for inspection if the play is
excessive, pedal movement is abnormal or brake
performance is improper.
En-121
MAINTENANCE
Inspection of Measuring Instruments Steering Wheel Inspection

Measuring instruments are indispensable for understand-
ing the vehicle status during operation.
Turn the key switch to ON to check the normal functioning Note:
of each instrument.
Perform the inspection after turning the key switch
to ON.
Load handling System Inspection
Inspection method
Inspection method
1. Check the fork for the installation position, cracks and
1. Check the steering wheel play after setting the rear
bending.
wheels in the straight travel position.
2. Check for mast distortion, chain tension and oil leak-
age from cylinders and piping.
3. Operate the lift and tilt levers to check their function-
ing.
Note:
See the service data for the standard steering wheel
play.
Note:
2. Turn the steering wheel and move it up and down to
Be sure to perform full-stroke operation for each check that there is no looseness.
cylinder piston a few times before starting daily
operation.
Caution
If any abnormality is found, have the vehicle
Caution inspected at a Toyota dealer.
Be sure to check the chain for expansion, damage,
crack and lubrication. Its continuous use with any
of such symptom left as it is will lead to a trouble or
an accident. If any abnormality is found, have the
En-122
MAINTENANCE
Lubrication of the Chains, Steering Retightening Bolts and Nuts

Linkage, etc. Retighten each bolts and nuts of the chassis and load han-
Supply grease to the chains, steering linkage, etc. periodi- dling related parts.
cally according to the lubrication table.
Caution En
Caution If the rear frame fixing bolts is found loose, do not
• For inspection of the lift chain, lower the forks to retighten it but contact the Toyota dealer and
the ground, set the forward/backward lever at the replace it with a new one.
neutral position, pull the parking lever and
remove the key and then check it from the front of
the vehicle.
• When supplying grease, make sure to remove the
key switch to avoid any danger.
• Use chocks and wood blocks as safety measures
where necessary.
• Remove existing grease and dust from the fitting
section with a brush or cloth and then supply
grease.
Lubrication of Chain
• Use a stable step for lubrication work.
• Never climb up the vehicle or grab the mast or Inspection of Load Handling Hose for
chain as you may be caught. Attachment
• If the chain has become rusty, it looses strength Push or pull the hose lightly with fingers at its center to
to a great extent. Be sure to add grease periodi- check that it is tense enough not to come off the pulley. At
cally to avoid grease shortage. Also, replace the the same time, check that the hose is not twisted.
rusty chain immediately.
Lubrication of the Steering Link Related Parts
• Before supplying grease, clean the tip of the
grease fitting thoroughly.
• After greasing, wipe off excess grease.
En-123
MAINTENANCE
Horn Inspection INSPECTION OF CHARGER

Press the horn button to see that the horn sounds nor-
mally. On-truck Type Charger
(1)
(1) Horn button

(1) : Lighting
Rear pillar assist grip
(2) : Light out
Inspection method
1. Press the charge start switch and check that charging
is started.
2. Check that either NORMAL LED or EQUAL LED lights
up at the same time as charging is started.
(1) 3. When charging is completed, check that all segments
of the battery capacity indicator on the display as well
as the UP LED on the charger panel light up.
4. Confirm that the UP LED on the charger panel is not
blinking and that no abnormality message (diagnosis)
appears on the display.
(1) Horn button (Option)
SAS- System Inspection Caution

Check the SAS- system to make sure that it is functioning
properly. Check the mast to make sure that it can be prop- Use your finger to operate the control panel. Do not
erly tilted forward and backward and raised up. Also, make use anything with a sharp tip as it may cause a
sure that the mast can automatically stop at its horizontal damage to the switch.
position.
Traveling and making a turn with loading loads, confirm
that travel control and turn control functions are performed,
travel control indicator appears on the display and steering
knob position correct control function is performed as well.
Caution
If any abnormality is found, or when the diagnostic
mode indicator blinks or lights up, or an error code
appears on the display, stop operation immediately
and have the vehicle inspected at a Toyota dealer. If
using it continuously, it may cause break down.
En-124
MAINTENANCE
Off-truck Type Charger

Caution
• Use your finger to operate the control panel. Do
not use anything with a sharp tip as it may cause
a damage to the switch.
• Connect the grounding cable when using the
En
charger.
• Do not pull the cable of the charger.
• When removing the fuse of the charger, be sure
to disconnect the AC plug on the power supply
side or turn off the electromagnetic switch.
GS YUASA type • As the charger is under high voltage, do not
touch the conductive part when installing, storing
and checking it.
• Do not put the plug of the charger directly on the
ground or where exposed to water and possibility
of a damage.
• Do not insert or connect other metallic object to
the charger itself or connection part of the power
cable or output cord.
• Never connect or disconnect the plug with the
wet hand before and after charging.
• Do not disconnect the charging plug or battery
Beijing DeLong type plug while charging.
• Be sure to connect or disconnect the charging /
Inspection method
battery plug straight with holding the plug itself
1. Press the NORMAL switch or EQUAL switch and
while charging or after charging.
check that charging is started.
2. Check that the “ending” lamp has turned off and the
“completed” lamp has turned on after charging.
3. Check to make sure that the TEST lamp is not lit.
Note:
For charging procedure by off-truck type charger,
refer to page 140 in the manual.
En-125
MAINTENANCE
INSPECTION WHILE TRAVELING INSPECTION AFTER OPERATION

SLOWLY After operation, clean each part and perform following
inspections after cleaning.
• Inspect for oil leakage.
Brake Performance • Inspect each component for warping, scratches, dents or
Depress the brake pedal, and see if there is any abnormal- cracks.
ity in braking performance or if the brake is applied only on • Supply grease to each part as necessary.
one side. • Fully raise and lower the fork to lubricate the inside of
Effect the parking brake and insure that the vehicle can be the lift cylinder.
stopped and that a parked condition can be maintained. • If you sense anything unusual during operation, notify
your supervisor.
Caution
If anything feels even slightly unusual, stop vehicle Caution
operation immediately and have the vehicle • Even a small erroneous operation can cause a
inspected at a Toyota dealer. serious accident.
• If you find even a small abnormality with the vehi-
Steering Wheel Inspection cle, report it to the administrator and never oper-
While moving the vehicle slowly in a safe location, turn the ate the vehicle until it is corrected completely.
steering wheel to the left and right and check for any
unusual movement.
Motor Inspection
Run the vehicle to check the motor for smooth running
without any abnormal noise.
Also operate the load handling levers to check the pump
motor.
En-126
MAINTENANCE
PERIODIC INSPECTION DAILY MAINTENANCE

Weekly (every 40-hour) Inspection Battery Inspection
Add the following items to the pre-operation inspection How the battery is handled and maintained daily the ser-
items. Have necessary adjustments and replacements vice life and functions of the battery to a great extent. Be
performed at a Toyota dealer. sure to perform inspections and maintenance properly to En
always keep the battery in the best condition.
For the daily inspection, select some cells as standard bat-
Weekly (every 40-hour)
teries and check the battery condition.
inspection items
Change the standard batteries once a month and keep
Battery electrolyte level records of the inspection results.
Battery electrolyte specific gravity
Hydraulic oil level
Note:
Braking action
Be sure to keep record of the check results of the
Retightening of bolts and nuts battery and use it as reference to know the battery
Chain lubrication Engine oil condition.
Greasing MP grease
Maintenance required for the above items are mainly Caution

checking and addition. As oil or grease needs periodic
replacement depending on the degree of contamination, • When you find the battery in the following condi-
take proper action as required. tions, consult the Toyota dealer.
Never fail to perform pre-operation inspection and weekly There is bad smell, darkened electrodes, high
maintenance to maintain safe, comfortable operation. electrolyte temperature, quick drop of electrolyte
level.
Battery Electrolyte Level • Be sure to wear safety goggles, rubber gloves
See the “Battery Inspection” section for the inspection pro- and rubber sole shoes.
cedures. • As the battery is under high voltage, do not touch
the conductive section when installing, maintain-
Hydraulic Oil ing and inspecting it. You should be fully familiar
See the “ON BOARD VEHICLE INSPECTION” section for with its handling, as erroneous handling will
the inspection procedures. cause a fire, explosion, damage and injury.
• Do not disassemble or repair the battery. If a
Brake Performance
repair is necessary have it done at the Toyota
See the “INSPECTION WHILE TRAVELING SLOWLY”
dealer.
section for the inspection procedures.
Greasing Specific gravity inspection

Sufficiently grease the chains, steering linkage, etc. in 1. Measure the specific gravity periodically to check if
accordance with the lubrication table. the battery is properly charged and if there are differ-
ences in performance among cells.
Note:
• Clean the grease fitting tips thoroughly before
greasing.
• After greasing, wipe off excess grease.
En-127
MAINTENANCE
Inspection procedure of electrolyte
Caution
(1)
• When checking the battery electrolyte, discon-
nect the battery plug.
(2) • If the battery is used continuously even after the
battery electrolyte level dropped, not only parts in
(3) the battery case become deteriorated to reduce
its service life but also an explosion may occur.
• If you use the vehicle with the battery electrolyte
at a lower level, the battery may be overheated
(1) Hydrometer
and service life may be shortened.
(2) Outer tube
• Use distilled water or purified water when adding
(3) Nozzle water. Do not overfill. Overflow of the electrolyte
2. When the specific gravity is below 1,150 (at 20°C), be may induce a short circuit.
sure to charge until the specific gravity is up to 1,280 • When the battery electrolyte level is low, add puri-
(at 20°C). fied water before charging. (Never use mineral
water when adding water.)
1. Open the cap.
Relationship between fluid specific gravity

and temperature
Specific gravity after charging1,280 (20°C)

Specific gravity after discharging1,150 (20°C)
2. If the white line on the red float is lower, add water
until the white line on the float can be seen.
Caution
Check the fluid temperature with a thermometer
and convert the measured specific gravity to the
specific gravity at 20°C. (1)
(2)
Note:
Specific gravity conversion equation
S20 = St + 0.0007 (t-20)
• S20: Specific gravity at 20°C conversion (3)
• St: Measured specific gravity at t°C
• t: Electrolyte temperature (°C) at the time of (1) Stopper
measurement
(2) White line
(3) Float
En-128
MAINTENANCE
PRECAUTION FOR BATTERY

Caution
CHARGING
• As soon as you see the white line, stop adding While charging the battery, explosive hydrogen gas is pro-
water. If the end of the float contacts the stopper, duced.
it means water is close to overflow. If hydrogen gas stays indoors or remains inside of the
• To check the specific gravity of the battery, have vehicle, it is very dangerous. Be sure to observe instruc- En
the float of the gravimeter float vertically and free tions given below.
from contact with the outer tube.
Caution during Charging
• After the battery inspection, tighten the battery
Absolutely never bring a fire near the battery (as explosive
cap securely.
gas will be produced).
• Battery electrolyte contains sulfuric acid which
may cause burn when it gets on the skin. In case
of an emergency, provide the first aid and call for
the doctor.
When it gets on the skin or in the eye, wash with
water for 15 to 20 minutes.
When it gets on clothes, take them off right away.
Should you swallow it, drink a large amount of
water or milk.
When it gets on the floor, neutralize it with dry
soda (sodium carbonate) or wash it away with
water.
Warning
Battery Storage During battery charge, do not touch the battery ter-
When the vehicle is to be unused for 2 weeks or longer, minals with any parts of a hanger.
perform equal battery charging to the full level and discon-
nect the battery plug before storing the battery.
To keep it unused for a longer time, perform equal battery
charging at 2 months intervals.
Caution
When the battery is to be unused for a long time,
store it in a place with good ventilation and free
from fire.
En-129
MAINTENANCE
Precautions after Charging

Caution (before starting operation)
• When parking the forklift and charging it, remove
the key.
• Hydrogen gas produced while charging is explo-
sive and dangerous. Absolutely keep away any
fire.
• Keep the battery hood open while charging to let
hydrogen gas out.
• While charging, do not perform lifting and tilting
operation.
• While charging, do not start the vehicle.
• While charging, do not disconnect the power or
charging plug. To stop charging, press the STOP
switch, check that the light turns off and then dis-
connect the plug. Caution
• Do not run over the power cable, charging plug or • As hydrogen gas produced while charging is
battery plug with the vehicle, damage or forcibly explosive and dangerous, diffuse it by blowing
bend or pull it. The cable or plug will break, possi- compressed air between the top of the battery
bly causing a fire and electrical shock. and the body after charging (before starting oper-
ation). Also change the air in the work place by
• Check the power cable for cracks, cut and corro-
opening the door and window.
sion in its core wire, the plug terminals for rough-
ness or distortion, or the plug is damaged. Have • Also, do the same as the above after recharging
the damaged power cable or plug replaced at the the battery.
Toyota dealer. Its continuous use as it is will
cause a fire and electrical shock.
Proper Use of Battery
• Before using the charger, check the plug, cable If the battery is used until the vehicle cannot move, it
and terminals for damage and looseness. means over-discharge of the battery which will shorten its
• Poor connection during battery charging will service life.
cause an electrical shock, fire and heat genera- The battery capacity indicator on the display blinks to
tion. inform the timing for charging when the charge drops
below the set warning level. Charge the battery as soon as
• Be sure to connect or disconnect the battery plug
possible.
with holding the plug itself.
En-130
MAINTENANCE
Only the water content of the fluid (diluted sulfuric acid)

decreases when the battery is charged. Before charging, Caution
add distilled water (purified water) up to the specified level
and reinspect the fluid level one hour after charging is If you notice any of the following conditions, con-
complete. Do not let the electrolyte run out. tact the Toyota dealer and have the battery checked
by them.
• Loose battery lug and charging plug En
• High battery electrolyte temperature
• Quick drop of electrolyte level
• Unusual smell, bad odor
• Cloudy electrolyte
• Loose or rattling terminals of battery
• Electrolyte leakage, corrosion at the top of bat-
tery
• Corrosion around battery
• Damaged battery cap
Keep the battery clean. Especially, keep the battery top
clean and dry. Keep the vent caps tightly closed. • Long charging time
• Short battery performance time per day
Caution
When cleaning the battery, observe following
instructions.
• Be sure to clean the battery before charging.
• To prevent a possible electrical shock, wear rub-
ber gloves and boots.
• Never splash water over the battery plug.
• Do not short between terminals with a spanner or
the like.
• When closing the battery hood, check to make
sure that the cable is fit in the guide.
• When cleaning the top face of the battery, use a
wet cloth.
En-131
MAINTENANCE
HOW TO CHARGE THE BATTERY Handling of Charger

There are two types of charger: one is on-truck type and Make sure to install an electromagnetic switch for each
the other is off-truck type. power unit of the charger. Use an electromagnetic switch
equipped with an earth leakage breaker.
Caution
Caution
• As the power voltage varies slightly depending
on the area and place of use, it is necessary to Build the power facility according to instructions of
adjust the tap changer (input voltage) when using an expert or consult the Toyota dealer.
a charger.
• Failure to adjust the tap changer properly may Preparation for Charging
cause some trouble such as burned transformer Before charging, confirm that following instructions are
and under-charge to occur. observed.
• As adjustment of the tap changer requires exper- • For charging, select a spacious place with good ventila-
tise, have it done at the Toyota dealer. tion (airy), free from fire and with very few people.
• Do not use the charger in place of the battery or

any battery other than the one installed in the
vehicle. Such misuse may cause a trouble.
• With the on-truck type charger, if the power volt-
age is higher than the set voltage of the trans-
former input tap and when the protection circuit
is activated because overheat of the transformer
is detected, “F6-2” error appears on the display
while charging. As the input tap of the trans-
former needs to be switched, have it done at the
Toyota dealer.
• Do not use the charger continuously by changing
batteries one after another.
• Make sure to open the battery hood.
• Check that the battery electrolyte level is within the
specified range before charging. If the level is too low, be
sure to add water.
• If the power outlet and plug connection is loose, the con-
tact terminal is broken, roughness or distortion or the
power cable is damaged, heat will be generated, possi-
bly causing a fire. Always check for above conditions
before charging and if anything abnormal is found, repair
it or contact the Toyota dealer.
• As a large current flows while charging, connect the plug
directly to the specified outlet. Never use multi-tap outlet
or added wiring.
• Set up a “NO FIRE” signboard while charging.
Note:
Charge the battery with the battery cap tightened so
as to keep the top of the battery clean.
En-132
MAINTENANCE
BASIC METHOD FOR CHARGING Description of display

STD display
On-truck Type Charger
Connect the power plug to the charge and press the
charge switch. Then charging is started.
Control panel
En
(2)
(1)
(1)
(4) (2)
(5) (3)
(1) Switch [1]
Description of This switch is used for operation on
the charging completed screen.
(2) Screen display area
The progress of charging and error codes are dis-
(1) EQUAL LED (Yellow) played here.
Lights up when equalized charging is performed.
Multifunction display (Option)
(2) NORMAL LED (Yellow)
Lights up when normal charging is performed.
(3) START switch (6)
With this switch pressed, either normal charging (5)
or equalized charging is started: short time press-
ing for normal charging and long time pressing for
equalized charging. (Even when normal charging
is performed, the microprocessor changes it to
equalized charging at the appropriate timing.)
(4) UP LED (Green)
Lights up when charging is completed. When (1) (2) (3) (4)
charging is discontinued due to an error this LED
blinks to indicate the trouble.
(1) Switch [1]
(5) STOP switch This switch is used to move the cursor downward
With this switch pressed, normal charging or on the menu screen.
equalized charging is stopped before it is com-
pleted. (2) Switch [2]
This switch is used to have the charging counter
displayed while charging.
Note: (3) Switch [3]
As the microprocessor control function adjusts This switch is not used for the charger.
charging for the optimum level, usually charge the (4) Switch [4]
battery by normal charging. This switch is used for the final operation on the
menu screen and for the stop operation on the
charging screen.
Caution (5) Multi screen display area
The menu screen, charging counter, progress of
Use your finger to operate the control panel. Do not charging and error codes are displayed in this
use anything with a sharp tip as it may cause a area.
This indicator blinks when some trouble has
occurred on the vehicle. At this time, if the trouble
is with the charger, an error code is displayed in
the multi screen display area.
En-133
MAINTENANCE
Charging procedure Starting normal charging

Press the START switch on the control panel.
STD display Then, normal charging is started, the NORMAL LED on the
1. Connect the power plug to the AC outlet. control panel lights up and the screen indicating charging
appears on the display.
2. Connect the charging plug to the charger. (If the microprocessor judges that it is the time recom-
mended for equalized charging, the EQUAL LED lights up
and equalized charging is started.)
Caution
Confirm that the charging plug is connected
securely. If not, not only charging failure but also a (4)
short circuit or heat generation may occur. If you
find the part between pins of the plug dark, pins are
rough or distorted, contact the Toyota dealer.
(5)
(3)
(1) : Lighting
(2) : Light out
(3) START switch
(5) On charging Screen
In this stage, the AC power is turned on, the start-up
screen appears on the display and all LED’s on the control Starting equalized charging
panel light up. Press the START switch for 2 seconds continuously.
2 seconds after the start-up screen, the initial screen Then, equalized charging is started, the EQUAL LED on
appears on the display and all LED’s on the control panel the control panel lights up and the screen indicating charg-
turn off. ing appears on the display.
Caution (4)
If the initial screen does not appear on the display,
possibility is a power failure, breakage of the power
cable or the like. Check for the causal factor.
(5)
(3)
(1) : Lighting
(2) : Light out
(3) START switch
(4) EQUAL LED (Yellow)
(1) (2)
(1) Start-up screen (All LED lighting)
(2) Initial screen (All LED light out)
(3) : Lighting
(4) : Light out
En-134
MAINTENANCE
Completion of charging Stopping charging

When each charging is over, the UP LED on the control To stop charging before it comes to completion, press the
panel lights up and the screen indicating completion of STOP switch on the control panel.
charging appears on the display. When charging is stopped, the LED goes out and the initial
screen appears on the display.
En
(4)
(6)
(5) (3) (7) (4)

(3)
(1) : Lighting
(1) : Lighting
(2) : Light out
(2) : Light out
(3) START switch
(3) STOP switch
(4) UP LED (Green)
(5) STOP switch
Disconnecting the charging plug without pressing the
STOP switch is judged as a power failure and a power fail-
(7) Switch [1] ure state appears on the display.
Caution
When charging is completed, press the STOP
switch on the control panel or switch [1] on the dis-
play to turn off the UP LED and then disconnect the
AC plug.
Disconnecting the AC plug without turning off the UP LED

(1)
is judged as a power failure. Neither LED nor display
changes and the charging completed state remains as it is.
(This arrangement is used so that completion of charging
is known even if a power failure occurs after completion of
charging.) (1) Power failure state screen
• From the above state, if the STOP switch on the control
panel or the switch [1] on the display is pressed, the UP
LED as well as the display goes out.
• From the above state, if traveling or load handling is per-
formed or the key switch is turned ON/OFF, the UP LED
as well as the display goes out.
En-135
MAINTENANCE
Multifunction display (Option) Starting normal charging

Connect the AC plug for preparation. Press the START switch on the control panel.
Then the AC power is turned on, the start-up screen Then, normal charging is started, the NORMAL LED on the
appears on the display and all LED’s on the control panel control panel lights up and the screen indicating charging
light up. appears on the display.
2 seconds after the start-up screen (charging counter) (If the microprocessor judges that it is the time recom-
appears, the initial screen takes its place and all LED’s on mended for equalized charging, the EQUAL LED lights up
the control panel go out. and equalized charging is started.)
Caution (4)
If the initial screen does not appear on the display,
possibility is a power failure, disconnection of the
power cable, etc. Check for the causal factor.
(5)
(3)
(1) : Lighting
(2) : Light out
(3) START switch
(1) (2)
(5) Normal charging screen
(1) Start-up screen (All LED lighting) It is also possible to start charging by selecting the menu
item [NORMAL CHARGE] on the display and pressing the
switch [4] for 2 seconds.
(3) : Lighting
(4) : Light out
(1)
(1) Switch [4]
En-136
MAINTENANCE
Starting equalized charging Completion of charging

Press the START switch for 2 seconds continuously. When each charging is over, the UP LED on the control
Then, equalized charging is started, the EQUAL LED on panel lights up and the screen indicating completion of
the control panel lights up and the screen indicating charg- charging appears on the display.
ing appears on the display.
En
(3) (7)
(4)
(5) (4) (5) (6)

(3)
(1) : Lighting
(1) : Lighting
(2) : Light out
(2) : Light out
(3) UP LED (Green)
(3) START switch
(4) STOP switch
(4) EQUAL LED (Yellow)
(5) START switch
(5) Equalized charging screen
(6) Switch [4]
It is also possible to start charging by selecting the menu
(7) Completion of charging screen
item [EQUALIZE CHARGE] on the display and pressing
the switch [4] for 2 seconds.
Caution
When charging is completed, press the STOP
switch on the control panel or switch [4] on the dis-
play to turn off the UP LED and then disconnect the
AC plug.
Disconnecting the AC plug without turning off the UP LED

is judged as a power failure. Neither LED nor display
changes and the charging completed state remains as it is.
(1) • From the above state, if the STOP switch on the control
panel or the switch [4] on the display is pressed, the UP
LED as well as the display goes out.
• From the above state, if traveling or load handling is per-
(1) Switch [4]
formed or the key switch is turned ON/OFF, the UP LED
as well as the display goes out.
Stopping charging
To stop charging before it comes to completion, press the
STOP switch (4) on the control panel, it is also possible to
stop charging by pressing the switch [4] for 2 seconds.
When charging is stopped, the LED goes out and the initial
screen appears on the display.
En-137
MAINTENANCE
Off-truck Type Charger

(Full automatic microprocessor charger)
Beijing DeLong
Control panel
(2)
(4)
(3)
(4) (7)
(3) (5)
(1) : Lighting
(6)
(2) : Light out
(3) STOP switch
(1)
(4) Initial screen
Disconnecting the charging plug without pressing the (1) Equalized charging switch
STOP switch is judged as a power failure and a power fail- Equalized charging is started with this switch.
ure state is displayed. When this switch is pressed during normal charg-
ing, charging is switched to equalized charging.
(2) Pulse charging LED
This LED lights up when pulse charging is per-
formed.
(3) Charging progress indicating LED’s
As charging progresses, they light up one after
another from the left. When 2 LED’s in the center
light up, it means that charging (normal charging,
equalized charging) is in the end stage.
(1)
(4) Charging complete LED
This LED lights up when charging is completed
and it remains on.
(1) Power failure state screen (5) Check LED
This LED lights up when anything abnormal
Charging counter screen occurs while charging. The error code is displayed
The charging counter is displayed by pressing the switch on the LCD display.
[2] while charging, it is also possible by selecting [CHG
(6) Stop switch
COUNT] from the initial screen and pressing the switch [4].
This switch is used to stop charging before its
completion. Charging stops when it is pressed.
When this switch is pressed 2 times other than
while charging, the test mode is activated.
(7) LCD display
The charging current, charged state, error code,
etc. are displayed on this display.
Caution
(3)
(1) (2) Use your finger to operate the control panel. Do not
(1) Switch [2]
(2) Switch [4]
(3) Charging counter screen
En-138
MAINTENANCE
Normal charging 4. After confirming that 3 charging progress indicating

LED’s are lit, turn off the AC power switch and discon-
Charging procedure nect the battery plug.
2. Turn on the AC power switch.
3. Connect the charging plug to the battery plug. En
Start charging automatically.
(1) : Lighting
(2) : Light out
Caution
Caution
• To stop charging before it is completed, be sure
Confirm that the battery plug is connected securely. to press the stop switch first and then disconnect
If not, not only charging cannot be performed but the battery plug and turn off the AC power switch.
also, a short circuit or heat generation may occur. • Never turn off the AC power switch, disconnect
the power plug or battery plug before charging is
completed as such act will cause a trouble.
Caution
Use your finger to operate the control panel. Do not Equalized charging
use anything with a sharp tip as it may cause a If only normal charging is repeated, some difference in per-
damage to the switch. formance will occur among battery cells. Equalized charg-
ing is intended to make performance of cells equal by
charging slightly excessively. Perform equalized charging
As charging progresses, charging progress indicating periodically (once or twice a month as a guide) depending
LED’s light up one after another. When 2 of them light on operation conditions. Also, when charging the vehicle
up, it means that charging is in the end stage. When which has not been used for a long time, perform equal-
charging is completed, the charging circuit is turned ized charging.
off automatically and at the same time 3 charging
progress indicating LED’s remain on, it means that
charging is completed. Note:
Note that performing equalized charging more than
necessary will shorten the service life of the bat-
tery.
En-139
MAINTENANCE
Charging procedure Off-truck Type Charger

(Full automatic microprocessor charger)
2. Turn on the AC power switch.
3. When connecting the charging plug to the battery GS YUASA
plug, start charging automatically by normal charging. Control panel
Press the equalized charging switch when it is started
and then the equal lamp lights up and equalized
charging is performed. (7)
(2)
Use the same procedure as normal charging to com-
(1) (6)
plete charging.
(4)
Supplementary charging (3)
If one time charging is not enough to do whole day work,
charge the battery using the recess time during the day as (5)
(8)
supplementary charging. Use the same procedure as nor-
mal charging to charge.
(9)
Caution
(1) NORMAL switch
• To stop charging before it is completed, be sure Switch for starting normal charging.
to press the stop switch first and then disconnect Press this switch to start normal charging.
the battery plug and turn off the AC power switch.
(2) NORMAL LED (red)
• Never turn off the AC power switch, disconnect This LED lights up while normal charging is per-
the power plug or battery plug before charging is formed and goes out when it is completed.
(3) EQUAL switch
Switch for starting equalized charging.
Press this switch to start equalized charging.
(4) EQUAL LED (red)
This LED lights up while equalized charging is
performed and goes out when it is completed.
(5) CHARGING PROGRESS INDICATING LED’s
(red)
As charging progresses, they light up one after
another from the bottom. When the third one from
the bottom lights up, it means that charging (nor-
mal charging and equalized charging) is in the
end stage. (End stage of charging: when each cell
is charged to about 2.4V and after)
(6) OK LED (red)
When charging (normal charging or equalized
charging) is completed, 3 charging progress indi-
cating LED’s and OK LED light up and remain on.
(7) CHECK LED (red)
This LED lights up when charging is stopped by
the total timer.
(8) STOP switch
This switch is used to stop charging before it is
completed. Charging stops when it is pressed.
(9) TEST LED (red)
This LED lights up when the timer is checked for
any trouble. Pressing the NORMAL or EQUAL
switch for 5 seconds or longer will set to the timer
test mode, the TEST LED lights up and the timer
test mode is activated.
En-140
MAINTENANCE
3. Press the NORMAL switch.

Caution When it is pressed, the EQUAL LED goes out, the
NORMAL LED remains on and charging is started.
Use your finger to operate the control panel. Do not The microprocessor control function adjusts charging
use anything with a sharp tip as it may cause a for the optimum level.
En
Caution
Caution Do not press the NORMAL switch for 5 seconds or
longer continuously. When it is pressed so long,
If a timer test is necessary and to a failure of the
the mode changes to the timer test mode and
timer, contact the Toyota dealer.
charging cannot be performed.
Normal charging
Charging procedure
2. Connect the charging plug to the battery plug and turn
on the AC power switch.
Both the NORMAL LED and EQUAL LED light up to
indicate that charging is available.
Caution
Use your finger to operate the control panel. Do not
As charging progresses, CHARGING PROGRESS

INDICATING LED’s light up one after another. When
Caution the third LED from the bottom of CHARGING PROG-
RESS INDICATING LED’s lights up, it means that
Confirm that the battery plug is connected securely. charging is in the end stage. When charging is com-
If not, not only charging cannot be performed but pleted, the charging circuit is turned off automatically
also, a short circuit or heat generation may occur. and at the same time, the NORMAL LED goes out.
When 3 CHARGING PROGRESS INDICATING LED’s
and OK LED remain on, it means that charging is
completed.
4. After confirming that 3 CHARGING PROGRESS INDI-
CATING LED’s and OK LED are lit, turn off the power
switch and disconnect the charging plug.
En-141
MAINTENANCE
Caution
to press the stop switch first and then turn off the
power switch and disconnect the charging lug.
• Never turn off the power switch, disconnect the
power plug or charging plug before charging is
Equalized charging
If only normal charging is repeated, some difference in per-
formance will occur among battery cells. Equalized charg-
ing is intended to make performance of cells equal by
charging slightly excessively. Perform equalized charging
periodically (once or twice a month as a guide) depending
on operation conditions. Also, when charging the vehicle
which has not been used for a long time, perform equal-
ized charging.
Note:
Note that performing equalized charging more than
necessary will shorten the service life of the bat-
tery.
Charging procedure
2. Connect the charging plug to the battery plug and turn
on the AC power switch. Both the NORMAL LED and
EQUAL LED light up to indicate that charging is avail-
able.
3. Press the EQUAL switch.
The EQUAL LED lights up and equalized charging is
performed. Use the same procedure as normal charg-
ing to complete charging.
Supplementary charging
If one time charging is not enough to do whole day work,
charge the battery using the recess time during the day as
supplementary charging. Just like the normal charging pro-
cedure, press the NORMAL switch for starting.
Caution
to press the STOP switch.
• Never turn off the power switch, or disconnect
the power plug or charging plug before charging
is completed. Such act will cause a trouble.
En-142
MAINTENANCE
SERVICE DATA
Adjustment Value Table
8FBN15 8FBN18 8FBN20

Item
50-8FBN15
8FBN16
50-8FBN18 50-8FBN20
8FBN25 8FBN30 En
Front
700 (7) 775 (8)  900 (9)  800 (8)
wheels
Tire air pressure
Rear
kPa (kg/cm2) wheels 800 (8) 800 (8)  750 (8)  900 (9)
Steering wheel play mm 25 - 50     

11 - 15 11 - 15 11 - 15
Brake pedal play 11 - 15 11 - 15 
50-8FBN15 50-8FBN18 50-8FBN20
mm
3-7 3-7 3-7
Brake pedal floor clearance
mm 92 or more     
(Measure from top surface of toe board)
8FBN15
15.5
(158)
[2247] 15.5 14.8 17.2 18.1
Lift (158)  (151) (175) (185)
50-8FBN15 [2247] [2146] [2494] [2625]
14.0
(143)
[2030]
Oil control valve set 8FBN15
pressure 15.5
(158)
[2247] 15.5 14.8 17.2 18.1
2-way (158)  (151) (175) (185)
50-8FBN15 [2247] [2146] [2494] [2625]
Tilt 14.0
(143)
[2030]
11.8 14.8 15.7
Mpa (kgf/cm2) [psi] 3, 4-way (120)   (151) (160) 
[1711] [2146] [2277]
Battery electrolyte specific gravity (at 20°C) 1.280     
180 - 220
Parking brake operation force (18 - 22)     
N (kgf) [lbf] [40 - 49]
118 - 196 177 - 392

Divided
(12 - 20)   (18 - 40)  –
rim
Front [87 - 145] [131 - 289]
wheels 177 - 392 118 - 196 294 - 588
Side ring
(18 - 40)   (12 - 20)  (30 - 60)
rim
Hub nuts tightening torque [131 - 289] [87 - 145] [217 - 434]
89 - 157 118 - 196
Divided
(9 - 16)   (12 - 20)  –
rim
Rear [66 - 116] [87 - 145]
wheels 118 - 196
Side ring
N•m (kgf-m) [ft-lbf] – – – – – (12 - 20)
rim
[87 - 145]
En-143
MAINTENANCE
Item 8FBN15 8FBN18 8FBN20 8FBN25 8FBN30

Sound pressure level (LPA) in accordance with EN 12053*
dB (A) 68 68 67 67 69
Uncertainty K=4 dB (A)
* Note:
• The vibration values shown above are obtained from the measurements in accordance with EN 13059.
• The magnitude of hand arm vibration of lift trucks is 2.5 m/s2 or below as defined in EN 13059.
• The whole body vibration values shown above cannot be used for calculating 8 hour vibration exposure in 2002/
44/EC (Vibration Directive).
(If calculated according to the general forklift operation pattern, the result will be lower than 0.5 m/s2.)
• The sound pressure values shown above can be used as the sound level at operators' ears.
(Valuse are in accordance with EN 12053 measurement methods.)
Fuse Capacity Table
Item 1 ton 2 ton 3 ton

F1 (for main circuit) 500A 600A 500A
F4 (for lights) 10A  
F5 (for control circuits) 10A  
F6 (for controller) 10A  
F7 (for oil control valve solenoid) 10A  
Fuse Capacity Table for On-truck Type Charger (Option)
Power supply capacity

Transformer model Fch
50Hz 60Hz
K47-240C048-425 80A 20A 20A
K47-260C048-414 100A 30A 30A
K47-280C048-404 150A 40A 30A
K47-270C080-603 80A 30A 30A
En-144
MAINTENANCE
Fuse Capacity Table for Off-truck Type Charger (Option)
Battery Power supply Transformer Power supply capacity

Vendor Fch
voltage voltage model 50Hz 60Hz
SG3-69-80JBY 80A 30A 20A En
200V SG3-69-100JBY 100A 30A 30A
SG3-69-130JBY 150A 40A 40A
48V
SG3-69-80JBY 80A 15A 10A
GS YUASA
400V SG3-69-100JBY 100A 15A 15A
SG3-69-130JBY 150A 20A 20A
200V SG3-115-80JBY 80A 40A 30A
80V
400V SG3-115-80JBY 80A 20A 15A
D48/50P 63A 10A –
D48/60P 100A 10A –
D48/70P 100A 10A –
48V 400V
Beijing D48/80P 100A 10A –
DeLong D48/90P 125A 15A –
D48/100P 160A 15A –
D80/50P 63A 10A –
80V 400V
D80/60P 100A 15A –
Lubricant Capacity and Type Table
Applicable place Capacity Type

1 ton series 4.5 L
Hypoid gear oil SAE 75W - 80W
Differential and drive unit oil 2 ton series 4.7 L
API GL-4
3 ton series 5.6 L
Brake fluid SH-H
Brake line Proper amount
(Cold storage spec. : Brake fluid Arctic S)
Chassis and mast grease fitting Proper amount MP Grease
Applicable place Model Mast type Lifting Height Capacity Type

V, FSV H3000 - H5500
17.5 L
FV H3000 - H3500
1·2 ton series
FSV H6000 21.4 L
FV H4000 18.9 L Daphni super hydro 32AT
Hydraulic oil
V, FSV H3000 - H4700 (Cold storage spec. : Daphne hydro GT-T)
19.1 L
FV H3000
3 ton series
V, FSV H5000 - H6000
22.0 L
FV H3500
En-145
MAINTENANCE
LUBRICATION CHART
1. Chain I Inspect every 8 hours (daily)

2. Drive unit II Inspect every 40 hours (weekly)
3. Tilt cylinder front pin III Inspect every 250 hours (6 weeks)
4. Mast support bushing IV Inspect every 1000 hours (6 monthly)
5. Front wheel bearing V Inspect every 2000 hours (annually)
6. Tilt steering lock mechanism
7. Steering knuckle king pin  Inspection
8. Rear wheel bearing  Replacement
9. Tie rod end pin (1) MP Grease
10. Rear axle cylinder end pin (2) Engine oil
11. Brake master cylinder (3) Hypoid gear oil
12. Oil tank (4) Hydraulic oil
(5) Brake fluid
* Located both right and left (6) Molybdenum disulfide grease
Note:
In case of the hard operating condition, the service interval of 170 hours or 1 month may be recommendable.
En-146
MAINTENANCE
PERIODIC MAINTENANCE
Periodic inspection and maintenance are necessary to If operation time exceeds 250 hours within 6 weeks use
keep your Toyota industrial vehicle running smoothly. The the number of hours as the guide for performing periodic
designated number of hours in the inspection cycle are as inspection. Pre-operation checks and weekly inspections
follows. should be performed by the user. 6 weeks, 3 months, 6
Daily (pre-operation check) ..... Every 8 hours months and annual inspections should be performed by a En
Weekly ....................................... Every 40 hours Toyota dealer since high-level technology and special tools
6 weeks ...................................... Every 250 hours are required.
3 months .................................... Every 500 hours Refer to the periodic maintenance table to determine
6 months .................................... Every 1,000 hours inspection and maintenance items and inspection cycles.
Annually ..................................... Every 2,000 hours Use only genuine Toyota parts for replacement parts, and
use the recommended types of lubricants.
PERIODIC REPLACEMENT TABLE

Periodic Replacement Table
REPLACEMENT PERIOD EVERY 6 WEEKS 3 6 12 MONTHS

(Accumulated hours of operation or monthly
periods of operation, whichever comes sooner.) EVERY 250 500 1000 2000 HOURS
Hydraulic oil  
Hydraulic oil filter *  
Brake fluid  
Drive unit oil 
Wheel bearing grease 
Brake master cylinder rubber parts 
Wheel cylinder cup seals 
Brake fluid reservoir hose (Every 2 years)
Power steering hose (Every 2 years)
Power steering rubber parts (Every 2 years)
Hydraulic hose (Every 2 years)
Chain (Every 3 years)
* For new vehicles
Note:
In case of the hard operating condition, the service interval of 170 hours or 1 month may be recommendable.
En-147
MAINTENANCE
PERIODIC MAINTENANCE TABLE

Periodic Maintenance
INSPECTION METHOD
I ......................... Inspect, correct and replace as required.
T ......................... Tighten.
C ......................... Clean.
L ......................... Lubricate.
M ......................... Measure and correct, and adjust as required.
INSPECTION PERIOD EVERY 6 WEEKS 3 6 12 MONTHS

ELECTRICAL SYSTEM
Motor
Rotation sound I I  
Looseness in the connecting parts T   
Insulation resistance M  
Battery
Charging level I   
Electrolyte level I   
Electrolyte specific gravity M   
Terminal looseness I   
Abnormality in the upper portion of the battery case I   
Insulation resistance M  
Voltage measurement of each battery cell after charging M
Magnet contactor
Contact looseness, damage, abrasion I   
Operating condition of the auxiliary contact, contamina-
I   
tion, abrasion
Mounting condition of the arc shooter I
Operating condition and timings I
Looseness of the coil mounting parts I
Mounting condition of the main circuit lead wire, loose-
I
ness
Microswitch
Operating condition and timings I   
Damage and looseness of installing parts I   
Direction switch
Operating condition, damage I   
Controller
Operating condition I   
Interior contamination, damage C   
Motor input voltage M
Fuse
Looseness I   
En-148
MAINTENANCE

Wiring (including charging cord)

Harness deterioration, clamp damage and looseness I   
En
Looseness in connecting parts, taping condition I   
Connecting condition and damage of the battery connec-
I   
tor and charger connector
POWER TRANSFER SYSTEM
Drive unit
Oil leakage I   
Oil level I   
Bolt or nut looseness T
DRIVE SYSTEM
Wheels
Tire cuts, damage and uneven wearing I   
Loose rim and hub nuts T   
Tire groove depth M   
Metal chips, pebbles and other foreign matter trapped in
I   
tire grooves
Rim, side bearing and disc wheel damage I   
Abnormal sound and looseness of front wheel bearing I   
Abnormal sound and looseness of rear wheel bearing I   
Front axle
Cracks, damage and deformation of housing I
Rear axle
Cracks, damage and deformation of beam I
Looseness of axle beam in vehicle longitudinal direction M* M
STEERING SYSTEM
Steering wheel
Play and looseness I   
Function I   
Steering valve
Looseness of mounting T   
Power steering
Mounting and linkage looseness I   
Damage of power steering hose I
Knuckle
King pin looseness I   
Cracks and deformation I
BRAKING SYSTEM
Brake pedal
Play and reserve M   
Braking effect I   
En-149
MAINTENANCE

Parking brake
Operating force I   
Braking effect I   
Rod and cable looseness and damage I   
Brake pipe
Leak, damage and mounting condition I   
Reservoir tank
Leak and fluid level I   
Master cylinder and wheel cylinder
Function, wear, damage, leak and mounting looseness I
Brake drum and brake shoe
Clearance between drum and lining M   
Wear of shoe sliding portion and lining I
Drum wear and damage I
Shoe operating condition I
Anchor pin rusting I
Return spring fatigue M
Automatic adjuster function I
Backing plate
Deformation, cracks and damage I
Loose mounting T
LOAD HANDLING SYSTEM
Forks
Abnormality of fork and stopper pin I   
Misalignment between left and right fork fingers I   
Cracks at fork root and welded part I*1
Mast and lift bracket
Deformation and damage of each part and crack at
I   
welded part
Mast and lift bracket looseness I   
Wear and damage of mast support bushing I
Wear, damage and rotating condition of rollers I   
Wear and damage of roller pins I
Wear and damage of mast strip I   
Chain and chain wheel
Tension, deformation or damage of chain I   
Chain lubrication I   
Elongation of chain I
Abnormality of chain anchor bolt I   
Wear, damage and rotating condition of chain wheel I   
Various attachments
Abnormality and mounting condition of each part I   
En-150
MAINTENANCE

HYDRAULIC SYSTEM
Cylinder
En
Loosening and damage of cylinder mounting T   
Deformation or damage of rod and rod end I   
Cylinder operation I   
Natural drop and natural forward tilt
M   
(hydraulic drift)
Oil leakage and damage I   
Wear and damage of pin and pin support I   
Lifting speed M   
Uneven movement I   
Oil pump
Oil leakage and abnormal sound I   
Hydraulic oil tank
Oil level and contamination I   
Tank and oil strainer C 
Control lever
Loose linkage I   
Operation I   
Oil control valve
Relief pressure measurement M
Relief valve and tilt lock valve functions I   
Hydraulic piping
Deformation and damage I   
Loose joint T   
SAFETY DEVICES, ETC.
Head guard
Cracks at welded portion I   
Deformation and damage I   
Back-rest
Loosening of mounting T   
Deformation, crack and damage I   
Lighting system
Function and mounting condition I   
Horn
Direction indicator
Instruments
Functions I   
En-151
MAINTENANCE

Backup buzzer
Rear-view mirror
Dirt, damage I   
Rear reflection status I   
Seat
Loosening and damage of mounting I   
Seatbelt damage and function I   
Seat switch function I   
OPS
Functions I   
Body
Damage and cracks of frame, cross members, etc. I
Bolts and nuts looseness T
SAS-
Function I   
Loosening and damage at sensor mounting portion I   
Damage, deformation, oil leakage and loosening of the
I   
mounting of functional parts
Loosening and damage of wire harnesses I   
Rusting and corrosion of load sensor I
Others
Grease up L   
* For new vehicles

*1 Flaw detector
Note:
In case of the hard operating condition, the service interval of 170 hours or 1 month may be recommended.
En-152
MAINTENANCE
BATTERY CASE & MINIMUM WEIGHT REQUIRED

When purchasing the battery locally, adjust its weight to satisfy the minimum required weight by referring to the table below.
Be sure to use a case allowing installation of the battery case stopper.
Battery Compartment
En
8FBN15
8FBN16 8FBN20
Vehicle model 8FBN18 8FBN25 8FBN30
50-8FBN15 50-8FBN20
50-8FBN18
390AH - 480AH - 440AH - 600AH - 370AH -
Battery capacity
470AH 565AH 565AH 725AH 480AH
Front to rear length X mm 459 548 548 655 730
Compartment
Width Y mm 996 996 996 996 1058
dimensions
Height Z mm 627 627 627 627 627
(1)
(3)
(2)
(1) Front to rear length X

(2) Width Y
(3) Height Z
Battery Weight
8FBN15
50-8FBN15
Battery weight 8FBN16 8FBN20 50-8FBN20 8FBN25 8FBN30
50-8FBN18
8FBN18
Necessary minimum with case kg 629 628 696 672 805 964
Referenced maximum with case kg 894 894 1118 1118 1118 1257
En-153
MAINTENANCE
WHEELS & TIRES
Front wheel Rear wheel

Model Type
Tire size Rim size Tire size Rim size
J-Lug 5.00-8-10PR
Standard Ribbed-Lug 9x4.00E DT
6.00-9-10PR
single Ribbed-Lug Divided rim 5.00-8-8PR
(Dunlop)
J-Lug 5.00-8-10PR
Oversize Ribbed-Lug 10x5.00F DT 8x3.00D DT
Pneumatic 6.50-10-10PR
single Ribbed-Lug Divided rim 5.00-8-8PR Divided rim
(Dunlop)
J-Lug 21x8-9-14PR 5.00-8-10PR
Special Ribbed-Lug 9x6.00E TB
8FBN15 single Ribbed-Lug 21x8-9-10PR Side ring rim 5.00-8-8PR
50-8FBN15 (Dunlop)
J-Lug
Standard 9x4.00E DT
U-Lug 6.00-9
single Divided rim
Non-marking
J-Lug
Pneumatic shaped Oversize 10x5.00F DT 8x3.00D DT
U-Lug 6.50-10 5.00-8
cushion single Divided rim Divided rim
Non-marking
J-Lug
Special 9x6.00E TB
U-Lug 21x8-9
single Side ring rim
Non-marking
J-Lug 5.00-8-10PR
Standard Ribbed-Lug 10x5.00F DT
6.50-10-10PR
single Ribbed-Lug Divided rim 5.00-8-8PR
(Dunlop) 8x3.00D DT
Pneumatic
J-Lug 21x8-9-14PR 5.00-8-10PR Divided rim
single Ribbed-Lug 21x8-9-10PR Side ring rim 5.00-8-8PR
(Dunlop)
8FBN16 J-Lug
Standard 9x4.00E DT
U-Lug 6.00-9
single Divided rim
Non-marking
J-Lug
Pneumatic shaped Oversize 10x5.00F DT 8x3.00D DT
U-Lug 6.50-10 5.00-8
cushion single Divided rim Divided rim
Non-marking
J-Lug
Special 9x6.00E TB
U-Lug 21x8-9
Non-marking
En-154
MAINTENANCE
Front wheel Rear wheel

Model Type
Tire size Rim size Tire size Rim size
J-Lug 5.00-8-10PR
Standard Ribbed-Lug 10x5.00F DT
6.50-10-10PR
single Ribbed-Lug Divided rim 5.00-8-8PR En
(Dunlop) 8x3.00D DT
Pneumatic
J-Lug 21x8-9-14PR 5.00-8-10PR Divided rim
single Ribbed-Lug 21x8-9-10PR Side ring rim 5.00-8-8PR
8FBN18
50-8FBN18 (Dunlop)
J-Lug
Standard 10x5.00F DT
U-Lug 6.50-10
single Divided rim
Pneumatic shaped Non-marking 8x3.00D DT
5.00-8
cushion J-Lug Divided rim
Special 9x6.00E TB
U-Lug 21x8-9
Non-marking
J-Lug 18x7-8-16PR
Standard Ribbed-Lug 9x6.00E DT 18x7-8-14PR 8x4.25 DT
Pneumatic 21x8-9-14PR
single Ribbed-Lug Divided rim Divided rim
18x7-8-10PR
(Dunlop)
8FBN20
50-8FBN20 J-Lug
8FBN25 Standard 9x6.00E TB
U-Lug 21x8-9
Pneumatic shaped single Side ring rim 8x4.25 DT
Non-marking 18x7-8
cushion Divided rim
Oversize J-Lug 10x6.50F TB
23x9-10
single U-Lug Side ring rim
J-Lug 18x7-8-16PR
Standard Ribbed-Lug 15x7.00T IR 8x4.33R TB
Pneumatic 28x9-15-14PR
single Ribbed-Lug Side ring rim 18x7-8-14PR Side ring rim
8FBN30 (Dunlop)
J-Lug
Pneumatic shaped Standard 15x7.00T IR 8x4.33R TB
U-Lug 28x9-15 18x7-8
cushion single Side ring rim Side ring rim
Non-marking
En-155
MAINTENANCE
MAST SPECIFICATIONS & RATED CAPACITIES
(D)
(L) (M)
(A)
(C)
(G)
A Maximum fork height H Without load backrest

B Overall height I With standard load backrest
C Lowered J Tilt range
D Extended K Forward
E Without load backrest L Backward
F With standard load backrest M Load capacity at 500 mm LC
G Free lift
8FBN15, 50-8FBN15
B G J M
Mast A D 500 mm
C H I K L
Type E F (24 in.) LC
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs)
3000 118.1 *1970 77.6 3635 143.1 4250 167.3 145 5.7 145 5.7 7 10 1500 3300
3500 137.8 *2220 87.4 4135 162.8 4750 187.0 145 5.7 145 5.7 7 10 1500 3300
V 4000 157.5 *2570 101.2 4635 182.5 5250 206.7 145 5.7 145 5.7 7 10 1500 3300
4500 177.2 *2820 111.0 5135 202.2 5750 226.4 145 5.7 145 5.7 7 5 1450 3200
5000 196.9 *3070 120.9 5635 221.9 6250 246.1 145 5.7 145 5.7 7 5 1350 3000
3000 118.1 *1970 77.6 3600 141.7 4250 167.3 *1405 55.3 *755 29.7 7 10 1500 3300
FV
3500 137.8 *2220 87.4 4100 161.4 4750 187.0 *1655 65.2 *1005 39.6 7 10 1500 3300
4300 169.3 *1970 77.6 4870 191.7 5550 218.5 *1435 56.5 *755 29.7 7 5 1400 3100
4500 177.2 *2040 80.3 5070 199.6 5750 226.4 *1505 59.3 *825 32.5 7 5 1350 3000
4700 185.0 *2120 83.5 5270 207.5 5950 234.3 *1585 62.4 *905 35.6 7 5 1350 3000
FSV
5000 196.9 *2220 87.4 5570 219.3 6250 246.1 *1685 66.3 *1005 39.6 7 5 1200 2650
5500 216.5 *2380 93.7 6070 239.0 6750 265.7 *1845 72.6 *1165 45.9 7 5 1100 2450
6000 236.2 *2570 101.2 6570 258.7 7250 285.4 *2035 80.1 *1355 53.3 7 5 900 2000
Note:
Standard load backrest height is 1220 mm.
* With optional tire size, 6.50-10-10PR (I). Plus 25 mm
En-156
MAINTENANCE
8FBN16
B G J M
Mast A D 500 mm
C H I K L
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) En
3000 118.1 *1995 78.5 3635 143.1 4250 167.3 145 5.7 145 5.7 6 11 1600 3550
3500 137.8 *2245 88.4 4135 162.8 4750 187.0 145 5.7 145 5.7 6 11 1600 3550
V 4000 157.5 *2595 102.2 4635 182.5 5250 206.7 145 5.7 145 5.7 6 11 1500 3300
4500 177.2 *2845 112.0 5135 202.2 5750 226.4 145 5.7 145 5.7 6 6 1450 3200
5000 196.9 *3095 121.9 5635 221.9 6250 246.1 145 5.7 145 5.7 6 6 1400 3100
3000 118.1 *1995 78.5 3600 141.7 4250 167.3 *1430 56.3 *780 30.7 6 11 1600 3550
FV
3500 137.8 *2245 88.4 4100 161.4 4750 187.0 *1680 66.1 *1030 40.6 6 11 1600 3550
4300 169.3 *1995 78.5 4870 191.7 5550 218.5 *1460 57.5 *780 30.7 6 6 1500 3300
4500 177.2 *2065 81.3 5070 199.6 5750 226.4 *1530 60.2 *850 33.5 6 6 1450 3200
4700 185.0 *2145 84.4 5270 207.5 5950 234.3 *1610 63.4 *930 36.6 6 6 1400 3100
FSV
5000 196.9 *2245 112.0 5570 219.3 6250 246.1 *1710 67.3 *1030 40.6 6 6 1300 2850
5500 216.5 *2405 94.7 6070 239.0 6750 265.7 *1870 73.6 *1190 46.9 6 6 1000 2200
6000 236.2 *2595 102.2 6570 258.7 7250 285.4 *2060 81.1 *1380 54.3 6 6 800 1750
Note:
* With optional tire size, 21x8-9-10PR (I). Minus 25 mm
8FBN18, 50-8FBN18
B G J M
Mast A D 500 mm
C H I K L
3000 118.1 *1995 78.5 3635 143.1 4250 167.3 145 5.7 145 5.7 6 11 1750 3850
3500 137.8 *2245 88.4 4135 162.8 4750 187.0 145 5.7 145 5.7 6 11 1750 3850
V 4000 157.5 *2595 102.2 4635 182.5 5250 206.7 145 5.7 145 5.7 6 11 1650 3650
4500 177.2 *2845 112.0 5135 202.2 5750 226.4 145 5.7 145 5.7 6 6 1550 3400
5000 196.9 *3095 121.9 5635 221.9 6250 246.1 145 5.7 145 5.7 6 6 1200 2650
3000 118.1 *1995 78.5 3600 141.7 4250 167.3 *1430 56.3 *780 30.7 6 11 1750 3850
FV
3500 137.8 *2245 88.4 4100 161.4 4750 187.0 *1680 66.1 *1030 40.6 6 11 1750 3850
4300 169.3 *1995 78.5 4870 191.7 5550 218.5 *1460 57.5 *780 30.7 6 6 1550 3100
4500 177.2 *2065 81.3 5070 199.6 5750 226.4 *1530 60.2 *850 33.5 6 6 1500 3400
4700 185.0 *2145 84.4 5270 207.5 5950 234.3 *1610 63.4 *930 36.6 6 6 1500 3400
FSV
5000 196.9 *2245 112.0 5570 219.3 6250 246.1 *1710 67.3 *1030 40.6 6 6 1250 2750
5500 216.5 *2405 94.7 6070 239.0 6750 265.7 *1870 73.6 *1190 46.9 6 6 900 2000
6000 236.2 *2595 102.2 6570 258.7 7250 285.4 *2060 81.1 *1380 54.3 6 6 750 1650
Note:
* With optional tire size, 21x8-9-10PR (I). Minus 25 mm
En-157
MAINTENANCE
8FBN20
B G J M
Mast A D 500 mm
C H I K L
3000 118.1 *1970 77.6 3705 145.9 4250 167.3 125 4.9 125 4.9 7 10 2000 4410
3500 137.8 *2220 87.4 4205 165.6 4750 187.0 125 4.9 125 4.9 7 10 2000 4410
V 4000 157.5 *2570 101.2 4705 185.2 5250 206.7 125 4.9 125 4.9 7 10 2000 4410
4500 177.2 *2820 111.0 5205 204.9 5750 226.4 125 4.9 125 4.9 7 5 1900 4200
5000 196.9 *3070 120.9 5705 224.6 6250 246.1 125 4.9 125 4.9 7 5 1650 3650
3000 118.1 *1970 77.6 3640 143.3 4250 167.3 *1365 53.7 *760 29.9 7 10 2000 4410
FV 3500 137.8 *2220 87.4 4140 163.0 4750 187.0 *1615 63.6 *1010 39.8 7 10 2000 4410
4000 157.5 *2570 101.2 4640 182.7 5250 206.7 *1965 77.4 *1360 53.5 7 10 2000 4410
4300 169.3 *1970 77.6 4980 196.1 5550 218.5 *1325 52.2 *760 29.9 7 5 1850 4100
4500 177.2 *2040 80.3 5180 203.9 5750 226.4 *1395 54.9 *830 32.7 7 5 1800 3950
4700 185.0 *2120 83.5 5380 211.8 5950 234.3 *1475 58.1 *910 35.8 7 5 1800 3950
FSV
5000 196.9 *2220 87.4 5680 223.6 6250 246.1 *1575 62.0 *1010 39.8 7 5 1550 3100
5500 216.5 *2380 93.7 6180 243.3 6750 265.7 *1735 68.3 *1170 46.7 7 5 1200 2650
6000 236.2 *2570 101.2 6680 263.0 7250 285.4 *1925 75.8 *1360 53.5 7 5 900 2000
Note:
* With optional tire size, 23x9-10. Plus 30 mm
50-8FBN20
B G J M
Mast A D 500 mm
C H I K L
3000 118.1 *1970 77.6 3705 145.9 4250 167.3 125 4.9 125 4.9 7 10 2000 4410
3500 137.8 *2220 87.4 4205 165.6 4750 187.0 125 4.9 125 4.9 7 10 2000 4410
V 4000 157.5 *2570 101.2 4705 185.2 5250 206.7 125 4.9 125 4.9 7 10 1950 4300
4500 177.2 *2820 111.0 5205 204.9 5750 226.4 125 4.9 125 4.9 7 5 1900 4200
5000 196.9 *3070 120.9 5705 224.6 6250 246.1 125 4.9 125 4.9 7 5 1650 3650
3000 118.1 *1970 77.6 3640 143.3 4250 167.3 *1365 53.7 *760 29.9 7 10 2000 4410
FV 3500 137.8 *2220 87.4 4140 163.0 4750 187.0 *1615 63.6 *1010 39.8 7 10 2000 4410
4000 157.5 *2570 101.2 4640 182.7 5250 206.7 *1965 77.4 *1360 53.5 7 10 1950 4300
4300 169.3 *1970 77.6 4980 196.1 5550 218.5 *1325 52.2 *760 29.9 7 5 1850 4100
4500 177.2 *2040 80.3 5180 203.9 5750 226.4 *1395 54.9 *830 32.7 7 5 1800 3950
4700 185.0 *2120 83.5 5380 211.8 5950 234.3 *1475 58.1 *910 35.8 7 5 1800 3950
FSV
5000 196.9 *2220 87.4 5680 223.6 6250 246.1 *1575 62.0 *1010 39.8 7 5 1550 3100
5500 216.5 *2380 93.7 6180 243.3 6750 265.7 *1735 68.3 *1170 46.7 7 5 1200 2650
6000 236.2 *2570 101.2 6680 263.0 7250 285.4 *1925 75.8 *1360 53.5 7 5 900 2000
Note:
En-158
MAINTENANCE
8FBN25
B G J M
Mast A D 500 mm
C H I K L
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) En
3000 118.1 *1970 77.6 3705 145.9 4250 167.3 125 4.9 125 4.9 7 10 2500 5500
3500 137.8 *2220 87.4 4205 165.6 4750 187.0 125 4.9 125 4.9 7 10 2500 5500
V 4000 157.5 *2570 101.2 4705 185.2 5250 206.7 125 4.9 125 4.9 7 5 2500 5500
4500 177.2 *2820 111.0 5205 204.9 5750 226.4 125 4.9 125 4.9 7 5 2300 5050
5000 196.9 *3070 120.9 5705 224.6 6250 246.1 125 4.9 125 4.9 7 5 1800 3950
3000 118.1 *1970 77.6 3640 143.3 4250 167.3 *1365 53.7 *760 29.9 7 10 2500 5500
FV 3500 137.8 *2220 87.4 4140 163.0 4750 187.0 *1615 63.6 *1010 39.8 7 10 2500 5500
4000 157.5 *2570 101.2 4640 182.7 5250 206.7 *1965 77.4 *1360 53.5 7 5 2500 5500
4300 169.3 *1970 77.6 4980 196.1 5550 218.5 *1325 52.2 *760 29.9 7 5 2300 5050
4500 177.2 *2040 80.3 5180 203.9 5750 226.4 *1395 54.9 *830 32.7 7 5 2050 4500
4700 185.0 *2120 83.5 5380 211.8 5950 234.3 *1475 58.1 *910 35.8 7 5 2050 4500
FSV
5000 196.9 *2220 87.4 5680 223.6 6250 246.1 *1575 62.0 *1010 39.8 7 5 1650 3650
5500 216.5 *2380 93.7 6180 243.3 6750 265.7 *1735 68.3 *1170 46.7 7 5 1250 2750
6000 236.2 *2570 101.2 6680 263.0 7250 285.4 *1925 75.8 *1360 53.5 7 5 1000 2200
Note:
8FBN30
B G J M
Mast A D 500 mm
C H I K L
3000 118.1 2015 79.3 3765 148.2 4265 167.9 135 5.3 135 5.3 7 10 3000 6600
3500 137.8 2265 89.2 4265 167.9 4765 187.6 135 5.3 135 5.3 7 10 3000 6600
V 4000 157.5 2615 103.0 4765 187.6 5265 207.3 135 5.3 135 5.3 7 10 3000 6600
4500 177.2 2865 112.8 5265 207.3 5765 227.0 135 5.3 135 5.3 7 5 2850 6300
5000 196.9 3115 122.6 5765 227.0 6265 246.7 135 5.3 135 5.3 7 5 2350 5200
3000 118.1 2015 79.3 3660 144.1 4265 167.9 1400 55.1 795 31.3 7 10 3000 6600
FV
3500 137.8 2265 89.2 4160 163.8 4765 187.6 1650 65.0 1045 41.1 7 10 3000 6600
4300 169.3 2165 85.2 4960 195.3 5565 219.1 1550 61.0 945 37.2 7 5 3000 6600
4500 177.2 2215 87.2 5160 203.1 5765 227.0 1600 63.0 995 39.2 7 5 2800 6300
4700 185.0 2265 89.2 5360 211.0 5965 234.8 1650 65.0 1045 41.1 7 5 2800 6300
FSV
5000 196.9 2425 95.5 5660 222.8 6265 246.7 1810 71.3 1205 47.4 7 5 2400 5300
5500 216.5 2615 103.0 6160 242.5 6765 266.3 2000 78.7 1395 54.9 7 5 1900 4200
6000 236.2 2865 112.8 6660 262.2 7265 286.0 2250 88.6 1645 64.8 7 5 1450 3200
Note:
En-159
MAINTENANCE
VEHICLE DIMENSIONS
V mast, lifting height: H3000
(A) (B) (C) (H)
(D) (E) (G)

(F)
(I)
(N) (O (Q)
(J)
(K) (R)
(M) (S)
(L) (T)
(P) (W) (Y)

(U) (V) (X)
(Z)
mm (in.)
50-8FBN15 50-8FBN18 50-8FBN20
A 1060 (41.7) 1065 (41.9)  1180 (46.5)  1235 (48.6)
B 920 (36.2)   1020 (40.2)  1070 (42.1)
C 200 (7.9)    245 (9.6) 
D 100 (3.9)    122 (4.8) 
E 885 (34.8)   975 (38.4)  1010 (40.0)
F 2175 (85.6)  2185 (86.0) 2410 (94.9) 2430 (95.7) 2695 (106.1)
G 1770 (69.9)  1780 (70.1) 1980 (78.0) 2000 (78.7) 2210 (87.0)
H 895 (35.2)   940 (37.0)  980 (38.6)
I 4250 (167.3)     4265 (167.9)
J 3000 (118.1)     
K 1970 (77.6) 1995 (78.5)  1970 (77.6)  2015 (79.3)
L 145 (5.7)   125 (4.9)  135 (5.3)
M 1220 (48)     
N 7 6  7  
O 10 11  10  
P 35 (1.4)   40 (1.6)  45 (1.8)
En-160
MAINTENANCE
mm (in.)
50-8FBN15 50-8FBN18 50-8FBN20
Q 1065 (41.9)     
R 2085 (82.1) 2095 (82.5)  2085 (82.1)  2255 (88.8) En
S 940 (37.0)     1110 (43.7)
T 355 (14.0)    350 (13.8) 415 (16.3)
U 405 (15.9)   430 (16.9)  485 (19.1)
V 1410 (55.5)   1525 (60.0)  1675 (65.9)
W 34 36  30  41
X 265 (10.4)  300 (11.8) 295 (11.6) 370 (14.6) 325 (12.8)
Y 45  40 39 34 35
Z 2080 (81.9)  2115 (83.3) 2250 (88.6) 2325 (91.5) 2485 (97.8)
En-161
MAINTENANCE
En-162
MAINTENANCE
En
En-163
MAINTENANCE
En-164
MAINTENANCE
En
En-165
En
7. SUPPLEMENT
FRAME SERIAL NUMBER ............................................................. 164
En-163
7. SUPPLEMENT
FRAME SERIAL NUMBER

Frame Number Punching Format
Punching Format
Series Vehicle model
Except EEC specification EEC specification
8FBN15 8FBN18 10011
8FBN16 8FBN18-10011 –
1.0 ton series 8FBN18 8FBN18 10011

50-8FBN15
508FBN18-10011 –
50-8FBN18
8FBN20
8FBN25-10011 8FBN25 10011
2.0 ton series 8FBN25
50-8FBN20 508FBN20-10011 –
3.0 ton series 8FBN30 8FBN30-10011 8FBN30 10011
Frame Serial Number Location

The frame serial number is punched on the front cross plate. Please refer to the frame serial number when making inquiries
about your vehicle.
(1)
(1) Frame serial number location
En-164

Toyota Empilhadeira

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FOREWORD

We appreciate your purchase of TOYOTA forklift.

• Symbols and wording used in this manual have following meanings.

This manual is applicable to following vehicles.

Series Vehicle model Specifications Valtage (V) Controller

1. BEFORE INITIAL OPERATION .......................................... 5

3. OPERATION DEVICES ....................................................... 55

5. IN CASE OF EMERGENCY ................................................ 103

6. MAINTENANCE .................................................................. 115

7. SUPPLEMENT .................................................................... 163

1. Mast 7. Steering wheel.......................................................122

DRIVING CONTROLS AND INSTRUMENT PANEL

1. Parking brake lever..................................................59 12. Tilt steering adjust lever .......................................... 56

1. BEFORE INITIAL OPERATION

PREPARATIONS FOR SAFETY ...................................................... 20

FOR PROTECTION OF ENVIRONMENT ........................................ 41

Caution When working on the road shoulder, the end of cliff or

There is a possibility of danger at the quay wall and end

If tools, parts, inflammables, lighters, cups that have

Charging the battery generates the hydrogen gas which

Make sure to familiarize yourself with proper handling of

Be sure to appoint a guiding person when the work is

Traveling and Load Handling

SAS- equipped vehicle does not always mean that it

Poor health condition hinders your judgment in case of

• Practice fully to be familiar with each device in

Even for a short distance, backing up without looking at

Understand and maintain work area traffic rules.

The vehicle stopped or parked with the fork raised is

• When the body touches the operation lever, the mast

Traveling with a load on the fork lifted beyond the spec-

• To avoid a possible dangerous situation, make sure

After Completion of Work

When parking the vehicle, avoid the nearby place of the

The vehicle parked on a slope may start moving by

Cleaning the vehicle helps find malfunctioning part in

If any abnormal noise or any other abnormal condition

Caution Such disconnection may cause sparks to occur, leading

PREPARATIONS FOR SAFETY

Never operate the forklift if its hydraulic system has some

Make sure to use pallets suitable for the load in strength

Adjust the distance between forks in compliance with the

Check to make sure that the load is loaded on the pallet

Adjust the distance between forks in compliance with the

Prior to operation, adjust the seat to the proper position

When moving the vehicle, keep the mast in the backward

Never allow anyone other than the operator to get on any

Sudden start, sudden stop and sudden turn are strictly

When turning the vehicle during backward move, take care

When moving down on a slope, never turn off the key

Check strength of the floor as both the vehicle weight and

Do not keep your foot on the brake pedal while traveling or

Do not get on/off or jump into/off the moving vehicle.

If the unloaded load is unstable, do not leave it as it is.

If the forks cannot be fully inserted, temporarily move the

Stop the vehicle before moving up/down loads. Make sure

Before loading and unloading loads to and from the truck,

When a load is forked at a high position, move back once,

Do not push the load on the forks.

Do not carry loads higher than the backrest height.

Turn off the key switch while charging the battery.

Do not touch the operation lever carelessly when the key

If the forks cannot be lowered to the ground because of a