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!O ®TOYOTA
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rpERATOR'S AND
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o A. WARNING
o • Make sure these important instructions are
o available for the operator.
o Keep this manual in the pocket on the seat
back.
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o • Do not start the truck unless you under-
o stand these instructions.
o
 The following warning is, provided pursuant to
California Health & Safety Code Sections 25249.5 et. seq.

11 WARNING
California Proposition 65
This product contains and emits
chemicals known to the State of
California to cause cancer, birth defects
and other reproductive harm.
CONTENTS
I. OWNER'S SECTION ~ 1 V. OPERATOR MAINTENANCE. 49
•
•
OSHA/ANSI Laws and Standards
Employer Responsibility: Environment, Training, Work Rules,
,Workplace Design
• Fueling (Gas, LP, Diesel)
• Tires/Wheels III
• Proper Lift Truck Selection and Application
• Lift Truck Maintenance and Modifications
• Antifreeze
• Fuses III
• Information Resources
•
•
•
Battery
Parking Brake Adjustment
Tag Out
1m
II. SAFETY INFORMATION ..;
• Training
7
VI. EMERGENCY PROCEDURES 57
III
• OSHA/ANSI Safety Rules
• Operational Hazards and Avoidance
• Dead Battery, Jump Starting
• Lifting II
III. KNOW YOUR TRUCK :
• General Description, ANSI Designation
17
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Transporting
Towing 1m
• Intended Uses, Typical Applications
• Expected Work Environment
• Expected Skill Levels of Operators/Mechanics
•

VII.
Jacking

PLANNED MAINTENANCE 63
1m
• Training
• Maintenance Requirements
• Manuals, Parts
• Warning and Informational Decals
• Planned Maintenance, Dealer Service
• Controls, Switches, Instruments, Restraints
• Weekly Maintenance
• Data Plate/Capacities
• Storage
• Maintenance Schedules
IV. DAILY OPERATION ~.: 37
• Daily Inspection (Pre-Operation Checks) • Replacement Schedules
• Starting Engine (Gas, LP, Diesel) • Service Data
• Lubrication Chart
• Brakes
• Lifting and Lowering Controls
• Direction Controls
• Lifting Loads
• Traveling
• Stacking Loads
• Attachments
• Parking
• Unexpected Emergencies
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I. oj 'lER'S SECTION

.1. OWNER1S SECTION AN IMPORTANT MESSAGE FOR THE

C CONTENTS OWNER/EMPLOYER
o • OSHA/ANSI Laws and Standards ."
Work Rules,
The most expensive part of a material handling oper ion is not t h e .

o • Employer Responsibility: Environment, Training,

Workplace Design
equipment, but the people who operate it.
Toyota has designed this lift truck to work safely and eff ciently with the
o • Proper Lift Truck Selection and Application operator, but you have the primary responsibility for Hewell-being of
your employees.
o •
•
Lift Truck Maintenance and Modifications
Information Resources Training of operators and the responsibility for providing ( safe workplace
o 'are required by the Occupational Safety and Health Act (e ~HA).
Both OSHA and ANSI (American National Standards In titute) provide
o AN IMPORTANT MESSAGE FOR THE OWNER/EMPLOYER
PROPER LIFT TRUCK SELECTION
1
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operational arid maintenance rules. The last page of this ection provides
sources for these and other publications that can help you
o CHOOSING OPTIONS AND ATTACHMENTS 2 This section of the manual will help you identify ways y< u can carry out

o LIFT TRUCK OPERATIONS

WORKPLAC~ ENViRONMENT
3
3
your responsibilities, and the sections relating to safety ir ormation point
out hazards that you can eliminate from the workplace s well as ideas

o LIFT TRUCK MAINTENANCE 4

that can be incorporated into your training programs and ork rules.

o LIFT TRUCK MODIFiCATIONS 5

o INFORMATION RESOURCES 5

c PROPER LIFT TRUCK SELECTION

o
o Industrial trucks may be highly individualized for specific vorkplaces and
special jobs. Changing the job or moving a truck to a new rea can result

o in inefficiencies; but more importantly, can cause hazards 0 operators or

other workers.
o If conditions exist in your workplace that could cause lift tl ~cks to present
o hazards to pedestrians such as high noise, low lighting, intermixing of
pedestrian and mobile equipment, ANSI requires hat you add
o appropriate audible or visual alarms to your equipment. any types are
available and your Toyota dealer can help you make the ight decisions
o when you buy a new truck or a previously owned machine. He can modify

c a truck to fit your application, including safety equip :nent such as

pedestrian warnings that may be effective in your workplar ~.
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I. OWNER'S SECTION

CHOOSING OPTIONS AND ATTACHMENTS

Now that you have selected the right truck for your business, spend time
with your Toyota dealer to discuss how options and attachments can help
make your employees jobs safer and more efficient. Side shifters can
speed pallet movement for little additonal cost, clamps and rotators are
more sophisticated, but if you handle paper rolls or transfer liquids from
barrels to larger containers, the payback in increased efficiency and
reduced product damage will continue as long as you own your truck.

Many other options are available which cannot all be listed here. Your
Toyota dealer is an expert in solving material handling problems so take
them to him or invite him in to help you build the truck that is right for
you.

Clamp Truck with Audible and Visual Alarms: This highly specialized truck
works in close spaces with a high noise level and many pedestrians. The
owner choses audible and visual alarms tailored to his workplace.

Trucker Special: This lift truck has special equipment that lets it work
easily in loading and unloading trailers.

Cushion Truck: The solid tires on this truck provide resistance to damage
or punctures, but their small diameter and the under-clearance of the
truck make it suitable only for use indoors on clear, smooth, dry floors.

Pneumatic Truck: Larger air filled tires allow this truck to operate on less
smooth surfaces or outside, but care must still be taken to provide a
workplace free of obstacles. Outside use must be restricted to improved
roadways, no dirt or gravel.

Cushion Truck Pneumatic Truck

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LIFT TRUCK OPERATIONS
I. . oj ER'S SECTION.

WORKPLACE ENVIRONMENT

ANSI Standard 856.1-1993 requires operator qualification prior to selec- Many injuries related to lift truck operation are directly tra ed to the work
tion based on visual, auditory, physical and mental ability relative to the
environment and injuries are most easily avoided by re oving hazards
specific requirements of the employer. Similarly, the training required by
presented by plant layout, by improved housekeeping, 0 instituting and
OSHA and ANSI must be tailored to the workplace. Unique operations can enforcing work rules for truck operators and nearby worke s.
present hazards even to an experienced operator if the work is different.
Clean, smooth lift truck aisles separated frcim pedestrian alkways, large
Training of new operators, refresher training for experienced operators,
well-placed intersection mirrors, work rules requiring h n use at blind
plus appropriate supervision, will provide the basics for safe lift truck
intersections, and pedestrians trained to be alert to mo i1e equipment,
operation. One of the most important aspects of training is the
will be effective in lowering the incidence of pedestrian inj ries.
experience necessary for the daily truck inspections required by OSHA.
Your Toyota dealer can provide training aids to help you meet all of your
employee obligations. Dock related injuries can be reduced or eliminated by t use of trailer
locks, proper edge guarding and well designed doc levelers. To
eliminate. creeping, never allow your fork lifts to enter trai rs that are not
All training must include stLidy of the appropriate Toyota materials, OSHA
properly parked. Chock the wheels and use a jack to sup, ort the front or
and ANSI operating rules; but most importantly, the workplace rules
rear when necessary.
specific to your operation. This book and the National Safety Council
publications listed at the end of this section will help you develop your
rules.

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I. OWNER'S SECTION

LIFT TRUCK MAINTENANCE

Lift trucks are versatile industrial machines, but don't use them when
other equipment is needed. Man-lifts and mobile work platforms are
designed to lift people; lift trucks are not. Ladders or scaffolding may
require more time to reach high areas than climbing up a lift truck mast,
but the extra safety is worth the wait.

Lift truck tipovers can be the source of serious injuries. You can eliminate
hazards which cause them by training your operators, enforcing work
rules against overloading and high speeds, and promoting the use of
appropriate operator restraints. Provide a hazard free environment for
your people so that they can work more efficiently.

Please read the section on workplace hazards and eliminate them so your
operators will not have to recognize and avoid them while also
concentrating on their job. The section on operator rules is for you also. It
will help you set up work rules suited to your workplace.

Planned maintenance provides not only the least expensive way to

operate your Toyota trucks, but also the safest. OSHA requires inspection
of lift trucks daily or at the start of every shift. This daily check is an
important aspect of equipment safety and availability, and you should
provide the time, training materials, and discipline necessary to make it
work for you.

ANSI and OSHA require that authorized mechanics perform maintenance

and repairs, not operators. Toyota dealers can provide planned
maintenance service, daily operator check lists and genuine Toyota
replacement parts to help you comply with lift truck maintenance
standards.

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o LIFT TRUCK MODIFICATIONS
I. oj ER'S SECTION

INFORMATION RESOURCES
o
o You should become familiar with the operating, mainten nce and safety
instructions contained in these publications:

o General Industry Standards, OSHA 2206: "OSHA Saf ty and Health

o Standard mast
Standards (29 CFR 1910)", "Subpart N-Materials Handlin and Storage",
Section 1910.178 "Powered Industrial Truck". For sale by: Superintendent
o of Documents, U.S. Government Printing Office, Washingt n, DC 20402.

o ANSI/ASME 856.1-1993: "Safety Standard for Low Li and High Lift

o Trucks" (Safety Code or Powered Industrial Trucks). Publi hed by: Society
of Mechanical Engineers, United Engineering Center, 345 E. 47Th Street,
o New York, NY 10017.

o RATED CAPACITY WITH VERTICAL UPRIGHT EQUIPPED AS SHOWN. FSV mast

(Full-Free Lift
NFPA 505-1982: "Fire Safety Standard for Powered Indust al Trucks; Type
Designations, Areas of Use, Maintenance and Operation".
o Three-Stage mast)
NFPA 58: "Storage and Handling Liquified Petroleum Ga es". Available
Ol from: National Fire Protection Association, Inc., Batt rymarch Park,
o Quincy, MA 02269.

o National Safety Council Data Sheets: "1-664_ Writing nd Publishing

Employee Safety Regulations"; "479-Liquified Petrol m Gases for
o The capacity rating of your Toyota lift truck is determined by extensive
testing to provide you with a safe, efficient material handling tool.
Industrial Trucks"; "317-Powered Hand Trucks"; "653-Po ered Industrial

o Changes or additions to the truck, such as installation of a side shifter or

changing an upright, change the load capacity. OSHA and ANSI require
Lift Trucks"; "195.71-The "In-Plant "Pedestrian".
Available from: National Safety Council, 444 North Mi, higan Avenue,
Chicago, IL 60611.
c' that any changes made to a lift truck that potentially affect its safety must
be approved by the manufacturer in writing. Please protect your
0) employees by contacting your Toyota dealer before making any change
Accident Prevention Manual for Industrial Operations: Two volumes:
"Administration and Programs", and "Engineering an, Technology".
o to your truck. Available from: National Safety Council, 444 North Mi, higan Avenue,
Chicago, IL 60611.
o The examples of adding a side shifter or changing a mast or
counterweight are some of the many changes that require approval and Publications Concerning Safe Handling and Storage of Gas: Contact:
o revision of a machine's data plate. Other changes to the steering or
braking system, overhead guards, wheels and tires, can all affect safety.
National LP Gas Association, 1301 West 22nd Street, Oak ook, IL 60521

OJ If you are in doubt, call your Toyota dealer and ask.

If you have any questions about the application of this inf mation to your

o workplace, contact your Worker's Compensation Insuran e Company or

Toyota Industrial Equipment, 19001 South Western Avenu , Torrance, CA
90509.
II
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5
I. OWNER'S SECTION

6
o
o II. SAFET INFORMATION
o II. SAFETY INFORMATION
o ,CONTENTS
SAFETY AND OPERATION INFORMA triON
o • Training
Don't just read over this safety information, it could save flour life. Make
sure you understand it. If you don't understand somethin ,ask your boss
o • OSHA/ANSI Safety Rules before you take a chance of being wrong.

o • Operational Hazards and Avoidance

A Every time you see this safety alert symbol in this ook or on your
truck, there is important safety information for you. It means PAY
I
o SAFETY AND OPERATION INFORMATION 7 ATTENTION! LOOK OUT! YOUR SAFETY IS INVOLVED!

o OPERATOR AND OWNER SAFETY INFORMATION : 8

WORKPLACE RULES.............................................................. 9
The word after the A symbol will tell you about the hazard or

o HAZARDS 12
importance of the rule.

o A DANGER -- An extreme hazard that could kill yo

serious injury every time.
or cause very

o .A WARNING -- Not as serious as DANGER, but a h zard that could

o cause injury or death if you don't follow the rules.

o Two other words will be used to help you find better w ys to run your
o truck:

o Caution -- When you se-e this word, there will be a mess ge to help you
avoid damage to your truck.
o
o Note -- Ways to do your job right and easier and to
running well, follow this word.
eep your truck

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o 7
II. SAFETY INFORMATION
OPERATOR AND OWNER SAFETY INFORMATION
TRAINING
Even simple hand tools can't be used efficiently or safety by people not
trained or experienced with them. Lift trucks are complicated industrial ma-
chines that can be dangerous if used by people who are not trained. Lift
trucks are not all the same. Even if you are trained on one type it does not
means you can operate any machine or do any job.
OSHA and ANSI require that formal training, specific to the place where
you work, must be given to lift truck operators. On-the-job training must
be a part of any training program, but it must really be training with close
supervision, not just driving around or being assigned to a potentially
dangerous job without gradual increases in difficulty.
Increased safety and fewer accidents are major benefits of proper
training, but so are decreased costs due to better efficiency, decreased
maintenance costs, and lower product damage rate.
When people successfully complete the training course, give them
recognition for it. Issue authorization cards or jacket patches that show
they are authorized operators, and if possible assign them to one truck
that they have the responsibility for.
8
Contact your Toyota dealer for help in putting together a training course
suited to your operation and think about the following areas as they
apply to the work you do.
• How and where to perform daily truck inspections (OSHA regulation
for every shift in multiple shift operations).
• Specialized trucks or attachments that you use (roll clamp, ASME LP
tank).
• Particular areas where hazards to pedestrians are created (lunch
room, entrance doors).
• Hazards that can't be eliminated (outside ramp with ice in shadow,
low overhead clearance).
• Loading docks, rail cars or containers (loading container with portable
ramp).
• Plant traffic rules (speed zones, right-of-way, one-way aisles).
• Procedures for reporting truck maintenance or repair problems (forms,
out-of-service tags)
• Special refueling procedures (LP tank storage,"Diesel Only" sign on
truck).
• Fire hazard areas restricted to some lift trucks (acetone barrels, cotton
warehouse).
The examples above are intended to be thought joggers, not necessarily
all of the things that need to be taught to your operators. Before putting
your training course together, walk around the plant, look at your
operations, and ask people who work there if they know of ways to teach
operators how to become safer and more efficient.
 II. SAFET INFORMATION

Gloves

Protective shoes

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o WORKPLACE RULES
o Lift truck operators need to remember these rules for safety while they
OPERATOR
• Training: Must be formally trained on specific equipm nt before being
C) are working. Some may be more important in your workplace and you authorized to operate fork lift truck.
may know of some others that are only necessary where you work. In
o either case, supervisors need to know all the rules to help operators stay
safe. • Drugs/Alcohol Mentality: Mixing emotional problems, rugs or alcohol
with a heavy industrial machine is a dangerous situati I n.

o Remember, this is not a training manual for new operators. Lift trucks are
so much different than cars that even experienced automobile drivers
• Personal Equipment, Clothing: Proper protection may be necessary in
some operating environments. Use hard hats, seat elts, protective
o need formal training, and OSHA requires it! shoes, gloves, etc. Mental ability is affected by co ort and fatigue
level.
o Many of these rules are in the OSHA, ANSI, National Safety Council, and

o other publications at the end of the first section of this book. We can't put
all of that information in this book, so please study them when setting your
• Smoking: Never smoke when refueling, in other hazar, ous areas of the
plant, or when operating the truck. Both hands are needed for safe
o work rules. operation.

o Use this section of this book as a starter to develop workplace rules that
keep your plant safe. Call meetings with your people to explain your rules
• Operator Restraints: Restraints must be used to redu, e the possibility
of injury from overturns or other accidents.
n
''---"
-- post them where they can be read and enforce them.

o 9
II. SAFHY INFORMATION

TRUCK
• Daily Check: OSHA requires daily or each shift checks of major
equipment. Don't operate faulty equipment. Report problems and tag
machine so others will not use it.
• Capacity: Capacity is based on load and length of load. Either condition
in excess can cause loads to fall or tip a truck over.
• Maintenance: Operators are to perform only authorized simple
maintenance such as refueling or checking fluid levels and tire
pressures. Authorized, specially trained mechanics are needed to
repair trucks. Park a truck that needs to be repaired. Don't risk injury
by trying to fix it.
• Truck Application: Know the ways your truck can operate safely. Don't
try to operate on rough ground with a cushion truck, or push a rail car
with the carriage.

• Rampsllnclines: Travel loaded with load uphill at all times. Never turn
or park on an incline.
• Stay Protected: Don't travel with legs, arms .or head outside the
overhead guard. Watch for long objects that could come into the
compartment as you travel. Never put hands or feet through the
upright.
• Rules of the road: Unless directed otherwise by your employer, signs,
etc., keep right; no passing at intersections or other dangerous places.
Use horn only when necessary for signaling. Give pedestrians right-of-
way.

Never turn an incline!

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o II. SAFer INFORMATION
o
o PARKING
o • Hydraulic Drift: Dorh park with
• Forks: Forks must e long enough
to go at least 2/3 the way under

o loads in the air. Even 'Well

maintained hydraulic systems can
a load. Spread I rks as far as
possible and 10' k them to the

o change position over time and

cause a load to drop.
carriage.

C) • Safety Exits/Equipment: Don't

park where emergency exits are
o blocked, heavy traffic must go, or

o where emergency equipment

such as fire extinguishers are
stored.
0: • Forks Down: Lower forks or
o attachments to help keep the
truck from rolling and to avoid trip
o •
hazards.
Direction Control: Shift control to
• Loose Loads: Don t carry loose or
unstable load' restack if

o NEUTRAL even if parked for a necessary. Carryall loads lifted

just high enough clear the floor
c) •
short time.
Parking Brake: Make sure the
and tilted back to radle them.
parking brake works and use it
o every time you stop. Chock
c! wheels if there is any question
about the truck moving.
o • Key Switch: Stop the engine
when you park. For LP engines,
o turn off the tank valve, run engine
out of fuel, then turn off the key.
o LIFTING
o • Operating Position: Operate the
• People: Don't u a lift truck to
raise, people - use a work
o truck only when properly
positioned -- never standing on
platform or ladde. Don't use the
upright or over ead guard to
C) the floor or leaning outside the reach high poi s. Don't let
operator's compartment. anyone stand und r raised forks.
C)
o
OJ Do not lean out of the
o operator's compartment..

o 11
II. SAFETY INFORMATION

HAZARDS
TRAVELING
• Pedestrians: Give right-of-way to
pedestrians; especially watch tail
swing -- pedestrians may not
know about it. Never take riders.
Use the horn to make sure
pedestrians see you. Flashing
lights and beepers dc;>n't always
work.

• Speed: Smoothness is important for safety and to avoid loads falling or

being damaged. Turn, stop and start gently.
• Go Backwards: REVERSE direction is to be used if vision is blocked by
attachments or load. Always make sure your intended path is clear.
Watch for people.
• Mirrors: Never depend on mirrors for traveling in reverse, look where
the truck will be going. Use mirrors for extra side vision and to check
tail swing when going forward.
• Weight: A loaded 6000lb truck can weigh over 8 tons (17600Ib). Eleva- WORKPLACE HAZARDS
tors, upper floors, ramps or highway trucks may not be able to support
We can't know all the hazards in your work area, but here are three very
this weight. Ask about your trucks weight. Ask your Toyota dealer if good rules to follow to help recognize and avoid some hazards:
you are not sure what your truck weighs.
1. If you see one of these conditions that can cause an accident or injury,
eliminate it. Guard drop offs and fill pot holes. Don't allow
maintenance of your truck to fall behind. Train your people about the
unique design of the lift truck.
2. If a hazard occurs, avoid it. For example, stay clear of slippery spots
and make sure they are cleaned up. Change or repair a low tire, don't
keep driving.
3. Look for other hazards that may only be in your workplace; things that
could cause injury that only you know about and that only you can
eliminate or avoid.

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o
o II. INFORMATION
o
o LIFT TRUCK HAZARDS
o • Truck vs Car: Lift trucks are not cars. They have small tir~s;i1o springs,
• Carbon Monoxi
produce carbon
e: All engines
onoxide, even

o and are very heavy. They can pick up a heavy weight fnat raises; the
center of gravity and they steer from the rear very sharply: . ,
LP and diesel.
without good ve
Don't operate
ilation. don't
o • Rear Steer: Rear steer is necessary for doing its job. Combined with
sharper turn, results in tail swing that can surprise and injure
let trucks idle unn
truck and get fres
cessarily. Stop
air if you feel
o pedestrians or damage product. drowsy, sick or h
from exhaust fum
ve a headache
s.
o
o • Mainteriance: Do 't drive a truck
that is not right. rk it and tag it
Cl out so others won be hurt.
o
o • No Suspension: Lift trucks cannot
go over bumps or through pot
• Empty Trucks: large counter-
weight on the re r balances the
o holes because springs can't be
used when the weight and center
load in front an you know that
high speed or q ick turns with
o of gravity change due to picking
up loads. Avoid these hazards.
that load could c use an overturn
or spilling of the ad. When you"
C) drop off the loa , that does not"

o give you the gre light to forget

about safety. Th heavy counter-
o weight is still wi h you so when
empty, the true can be more
o unbalanced tha when loaded.
This large weig t can cause a
o truck to tip ove when the rear
wheels are bei g straightened
o • Overturn: Lift trucks can overturn if improperly operated or if hazards
are not avoided. Empty trucks can overturn at high speed; loaded
when coming t of a curve.

o •
trucks can overturn while stopped.
Attachments: Attachments that hold onto loads or even side shifters
Steering tighter a ain will restore
balance until th truck can be

o can cause dynamic loadings that can upset a truck if smooth operation
of controls or brakes is not used.
slowed, but it is always best to
"turn, stop and s rt smoothly to
o • Slack Chains: When slack chains occur, something is wrong with the
ii' avoid tipovers.
.• Refueling: Gasol ne, diesel and
o mast. Operate the lift control to take up the slack before you move
the truck. Forks or rails may be caught or jammed. ',;' LP all, can cause rious injuries if
not handled p operly. Avoid
c: spills, see the 0 erator Mainte-
nance section for ore important
o information.

C: 13
II. SAFETY INFORMATION
LOAD HAZARDS
• People: Lift trucks are designed ruggedly to carry and stack heavy loads.
If problems occur in a mast, it is often when it is lightly loaded. Stacking
operations rarely require a mast to go to full height as is often done
when trying to reach a high area. Don't use your truck to lift people.
• High, Wide, Unstable: These loads can falloff and be damaged,
interfere with a doorway or overhead beam, and tip a truck over or fall
onto the operator or a bystander. Sometimes wide loads must be
carried high to be lifted over other stacked material. If so, minimum
load, height and speed must be used.
• Suspended Loads: Carrying a load
on a chain or cable can introduce
dynamics due to swinging that
can unbalance a truck or strike a
bystander.
• Overhead Guard, Load Backrest Extensions: These design features are
incorporated to protect the operators from falling loads. Make sure
they are in place and in good repair.
• Inclined Storage: Stacking loads on an incline can result in damaged
goods, falling loads, injury to bystanders, or upsetting of the truck.
• Mast Tilt: Getting it just right takes training and experience. Too far
forward could cause tip up; too far rearward could contribute to lateral
overturn.
14
ENVIRONMENTAL HAZARDS
• Slippery Surfaces: Ice, water, oil, snow, sand, etc. can cause loss of
control. Avoid these hazards--get them removed.
• Rough Terrain: Pot holes, bumps and pavement edges can damage or
upset a truck. Go around them and see that they are fixed.
• Railroad Tracks: If you must cross them, go at an angle so one wheel
crosses at a time. Trucks can be damaged, loads lost, or the truck
upset.
• Poor Lighting/Noise: Loud noises can make it hard to concentrate or
damage your hearing. Noise and hearing protectors make it harder for
pedestrians to notice you. If you need light to be seen or to work
properly, your Toyota dealer can supply a truck mounted light to fit
operating conditions.
• Pedestrians: People are a big part
of a work area. They have their
own jobs and are concentrating
on them, not lift trucks. Your
responsibility is safe operation.
Don't depend on flashing lights or
beepers to avoid injuring people.
Watch for them and make sure
they know you are near. Us~
your horn and make eye contact if
you have to.
• Explosions/Fire: Chemical vapors and even some types of dust can
explode if you drive into areas restricted to lift trucks. Fibers such as
cotton may collect on the truck and have to be removed from the
radiator screen or exhaust area. Make sure your truck is the right one
for the job and that it stays clean.
• .F:loor Hazards: Watch for loose materials, open or loose drainage
channel covers, posts or gratings. Lift trucks need smooth, level floors
for safe operation.
 II. SAFETJ INFOIlMATION

LOADING DOCK HAZARDS • F100'" Mek. s J f100" ;n ,,;1

• Falls: Rail or higQway docks cars, highway truc s, and trailers
present drop offs, maiiYof whi<;h are strong enough or your truck.
are not guarded,';: Use· the Don't fall through weak area.
Operator Restraint System and
stay with the truck if it falls.
r--j
~~~~?f-
L Watch rear steering near edges,

~-~'i:'
back away, don't go forward.
o
() ~.~
Use the Operator Restraint System
()
o • Trailers: Unrestrained trailers··can creep·due to a lift truck going in or
• Dock Boards: Must be properly sized for the job and irmly in place.
() out. Chock wheels if dock restraints are not used; follow signals if they Watch for any shifting or movement.
are. If the trailer moves forward, the dock board or lift truck can fall. • Portable Ramps: If using a portable ramp to load a trail
() Trailers without a tractor must be supported under the king pin and at is secured to the trailer, that the lip remains in pia
r, make sure it
the rear. and that all
o wheels are off supporting surfaces. Keep driving surfac
Operate lift truck slowly and smoothly.
clean and dry.

() • Truck Drivers: Don't become distracted by truck driv rs, make sure
they are not in your operating area, but in a safe zone way from the
() loading/unloading traffic. Don't rely on them to choc wheels, make
sure it is done properly.
o If a trailer is not held up by a tractor, be sure the landi
down and steady.
g gear legs are
()
()
o
()
C)
C
(i
o
()
C) 15
II. SAFETY INFORMATION

16
c
o III. KNOI~ YOUR TRUCK
o III. KNOW YOUR TRUCK
o CONTENTS
o • General Description, ANSI Designation

o •
•
Intended Uses, Typical Applications
Prohibited Uses
o • Expected Work Environment

o • Expected Skill Levels of Operators/Mechanics

C)
o
o
•
•
•
•
Maintenance Requirements
Warning and Informational Decals
Controls, Switches, Instruments, Restraints
Data Plate/Capacities
•
o MAIN COMPONENTS 18
o LIFT TRUCK DESCRiPTION
WARNING AND INFORMATIONAL DECALS
19
20
o OPERATING CONTROLS 23
C) INSTRUMENTS 24

o SWITCHES AND LEVERS

BODY COMPONENTS
29
33
Ci
o
o
o
o
o
o
o
o
o
o
o 17
III. KNOW YOUR TRUCK

MAIN COMPONENTS

10
6

-L.-U-:l---11
8

13

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

18
o
o III. KNO YOUR TRUCK

o LIFT TRUCK DESCRIPTION

o Trucks are built in many shapes and sizes. The Toyota 6FGU15-30: and
o 6FDU 15 - 30 are classified by ANSI and OSHA as pneumatic tired, internal
combustion powered, high lift, sit-down rider industrial ,truck~;Expected
TOYOTA FORKLIFT TRUCK
r.:----dl

o safe operation of these machines would be in well ventilated ,indoor erwi-

ronments with smooth, dry floors such as warehousing and tn.icl<ing termi-
o nals.
Pneumatic tires are usable for operation over improved surfaces. But care
o must still be taken to provide a workplace free of obstacles. Outside use RATED CAPACITY \\'ITH VERTICAL UPRIGHT EQUIPPED AS SHOWH.
CAPACITY LOAD CENTER "8" THIS FORKLIR TRUCK

o must be restricted to improved roadways, no dirt or gravel. ' 4410

4000
3510
LB.
LB.
LB.
24
30
20 IN. MEETS OR EXCEEDS DESIGN
IN. ~~;~I~~~~T[~N~F~C~S~~
IN. THE DATE OF MANUFACTURE.

o The 6FGU may use either gasoline or LP gas as fuel; the 6FDU uses diesel
fuel. ' ,
o The designation of the respective models for purposes of environmental us-
age are: 6FGU type G; 6FGU (LP fuel) type LP; 6FDUtype D.
o They must not be used in locations presenting fire hazards as defined in
OSHA 1910.178. The chart on your truck tells you how much load it can sa Iy pick up. We
o will explain the one shown here but follow the specific on on your truck.

o All internal combustion engines produce carbon monoxide gas which can
be dangerous in high concentrations. OSHA requires proper ventilation to
"The capacity chart shown above is for Toyota standard
rated capacity is 4,000 pounds at 24 inch load center. Thi
ft truck whose
chart specifies
o provide a safe atmosphere for workers. Contact a licensed health
professional to assure your ventilation is adequate. Contact your Toyota
that this lift truck can lift 4,000 pounds at 24 inches load
pounds at 20 inch load center or 3,510 pounds at 30 inch
nter, or 4,410
ad center. Be-
o dealer about special catalytic mufflers to help lower carbon monoxide and
odors from the burned fuel, but remember, nothing can completely
fore attempting to pick up or lift a load, make sure that its
the rated capacity of the truck at the load center involved.
eight is within

o eliminate them.

o Toyota designed these trucks to be operated by personnel trained as

Note
If the load is not uniform, the heaviest portion should be laced closer to
o required by ANSI and OSHA. Section I of this manual will help you set up
programs that will result in years of safe, efficient use.
the load back rest and center on the forks."

o The unique design of Toyota lift trucks requires special training for
1111111111111111111111111111111111111111 111111111111111111111111111
o mechanics. Toyota dealers have the tools and knowledge necessary to A WARNING

o keep your truck running for many years without breakdowns, and we
recommend you contact your local dealer about a Service Contract.
This decal is not mea
for training, but is he
t to substitute
as a reminder

o If you want to perform your own maintenance and repairs, do not attempt
of the more importan
in a training course.
areas covered
se it to refresh
o it without asking your dealer for the proper instructions and manuals.
OSHA requires it.
your memory often.
1111111111111111111111111111111111111111 111111111111111111111111111
o Decals and plates that give you information about safe operation are on
o your truck. Study them and if you have any questions, ask your

o supervisor. Make sure they stay on your truck in clean, readable

condition.
CJ 19
III. KNOW YOUR TRUCK

WARNING AND INFORMATIONAL DECALS AWARNING

1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111
A.WARNING
BREAKING THESE RULES WILL CAUSE DEATH OR SERIOUS INJURY TO
BREAKING THESE RULES WILL CAUSE DEATH DR SERIOUS INJURY TO YOYRSELF AND OTHERS I YOURSELf AND OTHERSI
• Do not operate this truck unless your employer says you are trained and authorized.
• Read the Operator Manual before you start this truck. • Do not operate this truck unless your employer says you are trained
If it is missing or you do not understand it, ask your employer for help.
and authorized.
• Lift trucks must be inspected every shift (See Operator Manual).
Do not try to operate a truck that needs repairs or try to fix it yourself. • Read the Operator's and Owner's Manual before you start this truck. If it
Report all problems to your employer. is missing or you do not understand it, ask your employer for help. .
• Never lift or carry riders on forks or on truck. The mast can lower rapidly if not control- • Lift trucks must be inspected every shift (See Operator's and Owner's
led or maintained properly. Manual). Do not try to operate a truck that needs repairs or try to fix it
• Learn and follow your employer's safety rules for operation. traftic. and speed. yourself. Report all problems to your employer.
Look where your truck is going to avoid people, obstructions, and drop-ofts.
Check clearances in all directions, including overhead. • Never lift or carry riders on the forks or the truck. The mast can lower
Travel in reverse if the load blocks your view. rapidly if not controlled or maintained properly.
'. Never turn, park, or stack loads on slopes. Travel them with loads uphill, and watch for • Learn and follow your employer's safety rules for operation, traffic, and
slippery surfaces.
speed.
• Lift trucks can tip over even when empty, slow down for turns: steer smoothly and
slowly. Always fasten the seatbelt and stay with the truck if it tips.
Look where your truck is going to avoid people, obstructions and drop-
• Keep under the overhead guard. Do not lift over'capacity loads or unbalanced loads.
offs.
Keep forks low and tilted back. Carry long, high or wide loads slowly. Check clearances in all directions, including overhead. Travel in
• Park only in authorized places. Before getting oft truck, lower the forks or attachments to REVIERSE if the load blocks your view.
the floor, put drive in neutral, turn oft key, and set parking brake.
• Never turn, park or stack loads on slopes. Travel with the loads uphill,
(~ 'l') 57851-23800-71-A
and watch for slippery surfaces.
• Lift trucks can tip over even when empty. Slow down for turns; steer
smoothly and slowly. Always fasten the seat belt and stay with the
111I11I11I11I11I1111I11I11I11I1111111111I111111I111111I11I11I1111I11111111I111111111111I11111111I111I111I1111I1111111111I11I11111111I1111I111111I trucl< if it tips.
• WARNING • Keep under the overhead guard. Do not lift over-capacity loads or
unbalanced loads.
This decal is not meant to substitute for training. It is here as a reminder of Keep forkl; low and tilted back. Carry long, higt! or wide loads slowly.
the more important areas covered in a training course. Use it to refresh • Park only in authorized place. Lower the forks or attachments to the
your memory often. floor.
1II1111111111111111111111111111111111111111111111111mlllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllll11I11I1111I1111 Put drive in NEUTRAL, turn off key, and set parking brake.
111111111111 n111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111

20
o
o III. KN01 YOUR TRUCK
o
o
o This decal may be placed in several
places on the truck, but.look for it,
especially on the m~sr and on
If you fill the fuel t nk, make sure
you use the proper ue!. A mistake
could cause very cos y repairs.
C attachments. Wheh yi:HYsee it, stay
clear. . Cl) GASOLINE
Ci au ONLY
o
C;
Ci
o
o
o Never lift people with your truck or
allow anyone under the. load. Safety
Tipovers can cause serious injury.
Learn to see and a id the hazards
o of people around you is your
responsibility.
that cause them a use the seat
belt. If your truck 'ps, stay in the
o seat, lean away fro the fall, hang
on, and brace your f t.
o
o
C
C
o
o A minor adjustment of the brake is
easily made to keep it working
Don't risk dropping e truck, never
use the counterweigh to pick it up.
c Adjustment of parking brake
properly. Use the brake whenever
you leave the truck and keep it well
o Hard

(/j{OJ
D>soft Operating force'~~~~s
adjusted.

o . Turn the knob to ad)USl

the operatlng force vtthtn
~~~~.
o See Sel"'vtce Manual fol"
.

"
I:lore tnfOt'mat ion or tr

o ad}ustncnt can" not be made.

(ENGLISH) 57863~U2000-71

C)
o 21
III. KNOW YOUR TRUCK

This is a reminder of inspections that Don't damage your truck, adjust the
are required by OSHA for all lift seat forward first.
trucks,

r
qW"",w.atW&"~%"AFWTWiiii_.-<",A\"''f;;WWW~,WfjmW'"
g£(4t~<ti~{~~'>i:":i$~;u::r.~, z;~;-:,?~,~,_~x:-.Y<;;;-';:;:' >1.·?v4'ffif:~il
"051" C,_,Ct lin ,~ .. o;'5 .....·S' H l"~~(C'[O u '>-£ ~"<>I CT E~C" ~"l""
'~H "'t"~'O:: "'<'J,,,~ <(<> !'.S<;:C'IC" "0 .... I ••T(•••·rE I'S"CO'''U'C''

:.. _;.".,..... ~':~:~~:IC" . . l·"~.:. :·~;~ ~:_c.£::~: ~I:::~...~. I

i ~;~;'~::::'~;.;;~:~':'::;:."''''
''f.:.;.:~: ~. ,", ."" •.' ".
.,:.:~ .:,;:.r.j_·~,~;.~ ,::':,-
i\:,:.,\
. ~
TO OPEN' ENGINE HOOD,
ADJUST SEAT FULL FORWARD.
Ii
.. ", ' " .•.. , . 57871-U20&0-71

I ':ff,;~~:t:::'::::·:-::·:~:':':::·~
"~" '

-----=="""-'---

Batteries can be very dangerous if

you do not follow these rules.

A DANGER I
• SMOKING. FLAMES OR SPARKS WILL RESULT
IN BATTERY EXPLOSION
EXPLOSIVE GASES

A. ~
• SEE OWNERS/OPERATORS MANUAL FOR,' ","",p
STARTING OR CHARGING INSTRUCTIONS
.KEEP TOOlS AWAY FROM TERMINALS

£
BATTERY COHTA1NS SULPHURIC ACID WHICH
CAUSES SEVERE BURN IF TOUCI£D.
• .IF' ACID TOUCHES SKIN OR EVES. FLUSH WITH
WATER AND GET MEDICAL HELP IMMEOIATELY.
57868-23800~71

The fan is white to make it easier to

see when it is spinning. You still
need to watch out for this decal and
stay clear.

[II\
22
o
o III. KNOI YOUR TRUCK
o OPERATING CONTROLS
n
'-.J

o
o 2 3 4 5

o
o

1. Parking brake lever 6. Lift lever 11. Light control switch

2. Direction control lever 7. Tilt lever 12. Accelerator pedal
3. Steering wheel 8. Engine hood lock release lever 13. Ignition switch
C /
i 4.
5.
Integrated monitoring center
Horn button
9. Tilt steering adjust lever 14. Turn signal switch (Option)
r
~!
10. Inching and brake pedal

23
III. KNOW YOUR TRUCK
INSTRUMENTS
2 3
1. Hour meter
2. Engine oil pressure warning
lamp
3. Sedimenter warning lamp
(Diesel engine models)
4. Glow indicator lamp
(Diesel engine models)
5. Air cleaner warning lamp
6. Charge warning lamp
Integrated monitoring center
Meter illumination lamps are provided for easy meter reading at night.
They come on when the light control switch is set to ON.
24
To check warning lamps
1. For standard integrated monitor-
4 5 6 7
ing center:
All warning lamps come on when
the ignition switch is turned to
ON. If any lamp does not come
on, the bulb may be burnt out and
should be inspected.
2. For integrated monitoring center
with OK monitor (Option): Pull the
Check button parking brake lever, turn the igni-
tion switch to ON position, and
push the check button on the right
side of the meter box. If any lamp
does not come on, the bulb may
be burnt out and should be in-
spected.
Note
The glow indicator lamp (1 DZ type
diesel engine models) remains on for
2 seconds when the engine coolant
temperature exceeds 50°C (122°F).
7. Water temperature gauge
8. Fuel gauge
9. Fuel warning lamp
(OK monitor: Option)
10. Brake warning lamp
(OK monitor: Optionl
11. Engine coolant level warning
lamp (OK monitor: Option)
12. Battery electrolyte level
warning lamp
(OK monitor: Option)
-0
o YOUR TRUCK

Hour meter Sedimenter war Iing lamp

Only operates when ,':t~e ignition (Diesel engine mod Is)
switch is on. It indicates the total
number of truck operating hours. . The sedimenter is a device for
The unit of the right most digit is 1/10 separating water fro I the fuel.
hour. 1. The warning lam comes on to
Use this meter to schedule periodic indicate water in he sedimenter
maintenance using the charts in Sec- exceeds the pred termined level
tion VII. while the enginei running.
2. If normal, the I p comes on
when the ignition witch is turned
on, and goes off hen the engine
starts.

Engine oil pressure warning
lamp
1. Comes on to indicate low engine
oil pressure while the engine is
running.
2. If normal, the lamp comes on
when the ignition switch is turned
on and goes off when the engine
starts.
3. If the lamp comes on while the
engine is running, either the
engine oil is insufficient or the
lubrication system is faulty. Stop
the operation immediately and
Caution
Continued operation with the
lamp on may cause seizure
of the injection pump and pump
damage.
Note
If an OK monitor i provided, the
lamp does not com on when the
ignition switch is tur ed on. It func-
tions the same w y as the OK
monitor.
3. If the lamp come on while the
engine is runnin , drain water
immediately.
(See the Self-Ser ice Section for
the draining meth I d.)

o ask your Toyota dealer to inspect

and repair.

o Note
o The "engine oil pressure warning
lamp" does not indicate the oil level.
o Check the oil level with the oil level
gauge before starting work.
o
o
o
o 25
III. KNOW YOUR TRUCK
Glow indicator lamp
(Diesel engine models)
Indicates heating of the glow plugs.
When the ignition switch is turned on,
the lamp comes on and glow plug
heating begins. The lamp goes off au-
tomatically when glow plug heating is
complete.
The engine will start easily once the
glow plugs are heated.
Note
The glow indicator lamp is on for 2
seconds when the engine coolant
temperature exceeds 50°C (122°F).
Caution
If the indicator lamp does not go off
the glow plugs may be defective.
Please ask your Toyota dealer to in-
spect and repair.
Air cleaner warning lamp
1. This lamp comes on when the air
cleaner element gets clogged
during engine running.
2. If normal, the lamp comes on
when the ignition switch is turned
on and goes off when the engine
starts.
26
Note
If an OK monitor is provided, this
lamp does not come on when the
ignition switch is turned on. It func-
tions the same way as the OK
monitor.
3. If the lamp comes on while the
engine is running, stop the engine
and clean the element and dust
cup. For the cleaning method,
refer to the Weekly Inspection
Section.
Charge warning lamp
1. This lamp comes on to indicate a
problem in the charging system
while the engine is running.
2. If normal, the lamp comes on
when the ignition switch is turned
on and goes off when the engine
starts.
3. If the lamp comes on while the
engine is running, stop the
operation immediately, inspect
the fan belt for cuts or loosening,
adjust it, and restart the engine.
If the lamp does not go off, the
generator system may be faulty.
Ask your Toyota dealer immediately
to inspect and repair.
o
o III. KN0 1 .:VOUR TRUCK
o
o Water temperature gauge
o Indicates the temperature of the
Caution
• If the truck is ot level, the
o engine cooling water. . ...
1. Operates when the ignition
correct level
indicated.
ay not be

o switch is on.
2. In the normal state the indicator
• Add fuel early wh
approaches O.
n the indicator

o is in the center of the green zone. • With diesel in pari icular, be sure
o 3. If the indicator is in the red zone,
the engine may be overheating.
to refuel befor
because once i
it runs out
causes the
o Stop the truck, idle the engine for
a while, and stop the engine
engine to sto
becomes necessa
running, it
y to bleed air
o when the indicator falls. from the fuel sup y system.

o 4. Temporary overheating may be

caused by water leakage, low
Reference
Remaining fuel at 0
o engine coolant level, loosened fan 1.5-1.75

o belt, or other problem in the

cooling system. Ask a mechanic
tons
Approx. pprox.
o to inspect the cooling system.
8.5 e
2.24 US gal
2.5 e
.30 US gal
o
o OK monitor
(Option)
o Senses the fuel level, engine coolant
o 00000 level, battery fluid Ie
brake status. The la
I, and parking
p comes on to
o indicate a problem. If
on when the ignitio
he lamp comes
switch is on
o
~,~~
Fuel gauge (irrespective of the gine speed ),
(Excluding LPG models) the corresponding part may be
o Indicates the fuel level in the fuel abnormal. Ask
inspect the part.
a mechanic to

o tank from empty to full. 432

o It takes some time for the indicator to

stabilize after the tank is filled and the
1. Fuel warning lamp
Caution
Always perform re-operation
o ignition switch is turned on.
2. Brake warning lamp
3. Engine coolant level warning
checks. Do not re y on the OK
monitor, even if it is t lit.
o lamp

o 4. Battery electrolyte level

warning lamp
o 27
III. KNOW YOUR TRUCK

1. Fuel warning lamp 3. Engine coolant level

Comes on to indicate that. the warning lamp
remaining fuel quantity is less than (1) Comes on when the engine
the value shown below. coolant in the radiator reservoir
tank is too low.
(2) When the lamp comes on, add
Model 1.5-1.75 2.0-3.0 engine coolant to the upper level
tons tons in the reservoir tank.
Remaining (See the Engine Coolant Inspec-
fuel Approx. Approx. tion Section for the method of
quantity adding coolant. )
e (US gal) 10.5 (2.77) 16.0 (4.22)

2. Brake warning lamp 4. Battery electrolyte level

(1) Comes on in any of the following warning lamp
cases: (1) Comes on when the battery
• When the parking brake is electrolyte surface is below the
kept applied. (It goes off low level.
when the brake is released.) (2) If the lamp comes on, add
• When the brake fluid is below distilled water to the upper level.
the specified level.
(2) If the lamp remains on even after
the parking brake is reh~ased,
inspect the brake fluid level.
(See the Brake Fluid Inspection
Section for the method of adding
brake fluid.)
(3) If the lamp comes on while the
brake fluid level is proper, ask
your Toyota dealer to inspect.

Caution
Before starting the truck, always
release the parking brake lever and
check that the lamp goes off.

28
o
o YOUR TRUCK
o SWITCHES AND LEVERS
c Torque converter oil
o temperature gauge
Ignition switch
The ignition key is i erted with the
o (Option)
Indicates the torque converter oil
teeth facing upward.
OFF --- Engine stop position. Key
o temperature. insertion and withd awal are per-

o 1. Operates when the ignition

switch is on.
formed in this positio
ON ;--- Engine ope
.
ation position.

o 2. Indicates the green zone if the oil

temperature is normal during
Located one position
the OFF position.
clockwise from :

o operation.
3. If, during operation, the gauge
The glow plug Jig
before starting the di
must go off
sel model.
o indicates the red zone, stop the
operation.
START --- Engine
Located one position
start position.
clockwise from
o Inspect the oil level and add oil if
insufficient. (See the Torque
the ON position.
After engine starts, elease the key
o
,)
Converter Oil Inspection Section and it will return to e ON position
automatically.
c for the methods of inspection and
addition.) The engine does not
control lever is in
tart unless the
the NEUTRAL
o 4. If the gauge indicates the red
zone while the torque converter position.

o oil level is proper, ask your Toyota

dealer to inspect.
o
C/
o
o
o
C)
o
Ci
o
o
o
29
III. KNOW YOUR TRUCK

Caution Light control switch

• Do not leave the switch in the ON A 2-position pull-out switch.
position when the engine is The lamps indicated by 0 in the
stopped. It will cause of the bat- table below come on at each pulled-
tery to discharge. out position.
• Do not turn the switch to the
START position while the engine
is running. This may damage the Lamp Step 1 Step 2
starter motor.
• Always start the engine with the
Head lamps 0
gear shift lever or the control Side clearance
lever in the NEUTRAL position. lamps, tail lamps 0 0
• Do not operate the starter motor (Option)
for more than 30 seconds con-
tinuously. Return the switch to Meter illumi-
the OFF position and wait at least nation lamps 0 0
20 seconds prior to attempting
restart.
• Your truck has an anti-restart Caution
ignition switch to protect the Do not keep lamps such as head
engine. You must turn the lamps on for a long time when the
switch from the ON position to engine is stopped. It will discharge
the OFF position before the battery and make starting
attempting to start the engine impossible.
again.

30
o
o III. KNO YOUR TRUCK
o
o Direction control lever
o Forward Push forward
Horn button
Make sure your truck is seen. Press
o Reverse Pull b~ckward
The NEUTRAL P6sition IS halfway
the button in the enter of the

~
PUSh

o between the FORWARD· and

REVERSE positions.
....
steering wheel to s
The horn will sound
und the horn .
ven when the

o Caution
~
ignition switch is off.

o The engine cannot be started unless

the control lever is in the NEUTRAL
~(J,
o position.
,_Stop the truck before shifting
o . between FORWARD and REVERSE.

o Direction control lever

o (2 speed torque converter
. '" Turn signal lever
(Option)
o models: Option) Make the turn signal I mps blink.

o Forward Push two steps

forward
Left turn
Right turn
PU h forward
P 1I backward

o Reverse Pull one steps

backward The turn signal ever returns
o The NEUTRAL position is halfway be-
tween the FORWARD 1 and REVERSE
automatically to the iginal position
after making a directi ' n change.
o positions.

o Caution

o The engine cannot be started unless

the control lever is in the NEUTRAL
o position.
Stop the truck before shifting
Lift lever
Raises and lowers the forks.
o between FORWARD and REVERSE. Raise Pu I backward

o Lower
The lifting speed can
Pu h forwarp
e adjusted by

o varying the engine

distance the lever is
peed and the
oved.
o The lowering speed
.only by the distanc
n be adjusted
the lever is
o moved.

Oi
C 31
III. KNOW YOUR TRUCK

Tilt lever Tilt steering adjustment

Tilts the mast forward and backward. 1. The steering wheel position can
Forward Push forward be adjusted back and forth by
Backward Pull backward holding the tilt steering adjust
The forward or backward tilting lever down.
speed can be adjusted by varying the 2. Raising the lever at the desired
engine speed and the distance the position locks the steering wheel
lever is moved. in that position.
3. After adjustment, try to move the
steering wheel back and forth to
make sure it is locked.

11111111111I1111I1111I1111I111111I1111I111111111111111111111111111111
A WARNING
Dual-action parking Do not adjust the wheel position
brake lever while the truck is moving.
1111111111111111111I111I1111111I1111111111111111I111I111I111111111111
Pull the lever fully toward you to ap-
ply the parking brake.
To release the parking brake, push in Pedals
the release knob, and then push the From the right, accelerator pedal and
lever forward with the palm on the inching and brake pedal.
grip. While operating the parking
brake lever, keep the brake pedal fully
Inching and
depressed. brake pedal
Accelerator pedal

111I1111I11I111I1111I11I111I11I111I111I1111I11I11I111I111I1111I111I11 Emergency switch

A WARNING
(Used only on UL·GS, LPS,
Grip
• Never hold the lever other than and OS types)
by the grip to avoid trapping the This switch cuts off electric current
fingers. When releasing the
from the battery. Pull this switch in
parking brake or starting on a
the event of electric circuit problems,
Protrusion slope for example, hold the grip
short circuiting, or other dangerous
above the protrusion.
conditions, to prevent fire.
• When parking on a slope, chock
the wheels.
• Traveling without releasing the
brake will damage the braking Emergency switch
system.
32 111111111111111111111111111111111111111111111111111111111111111111111
o
o YOUR TRUCK
o BODY COMPONENTS
o Operator's seat An Operator's and 0 ner's Manual
o ~-~--~---'\

, The seat position can ,be adjusted is located behind the eat.

,,
I
back and forth by·,p~lling the
o adjusting lever to the riQ~6~
If your truck doe not have a
manual, contact you Toyota dealer

o ~
.
I
··ltUl'I
,r
After adjustment, lightly shake the
.seat back and forth to make sure it is
or distributor to obtai a copy.

o I: locked.

-4---'-
~

o 11I1111I1111I1111I11I11I11I1111I111I1111I11I1111I11I1111I111111I11I11
·AWARNING
o Adjust lever
• Never adjust your seating
position while the truck is
o moving.
• Always move the seat to the
o front position before opening the
o engine hood to prevent inter-
ference with the radiator cover.
Seat belt
To fasten your seat 1], It, pull it out of
o 11I1111I11I11I1111I11I1111I11I11I111I11I111I111I11I111I1111I111I1111I
the retractor and in
the buckle.
rt the tab into

o You will hear a dic when the tab

o locks into the buckle

to make sure the b
Pull on the belt
kle is securely

o latched.
The seat belt length tomatically ad-
o justs to your size.

o
o Operator Restraint System
o A specially designed operator's seat
1111111111111111I111I111111I1111111I111I 111I11111I111111111111111I11
A WARNING
o and seat belt are provided for your
safety. Get in the habit of using the
• Buckle up. Your seat and seat
belt can reduce th risk of serious
o seat belt whenever you sit on the
trucks.
injury or death in ase of a truck
tipover. Your ch ces for avoid-
o ing serious injur or death in a
o tipover are betteri you stay with
the truck in the erator's com- .
o partment.
1111111I11I111I1111111I111I1111111I111I1 11111I11111111111111I111I11I
c)
c) 33
III. KNOW YOUR TRUCK

1111111111111111111111111111111111111111111111111111111111111111111II Engine hood

A WARNING Opening
• Always wear your seat belt when 1. Move the seat to the front
driving the truck. The truck can position.
tip over if operated improperly. 2. When the engine hood lock
To protect operators from the release lever on the lower left
risk of serious injury or death in side of the parking brake lever is
the event of a tipover, it is best pulled backward, the steering
to be held securely in the seat. column is tilted forward and the
The seat and seat belt will help engine hood is unlocked.
to keep you safely within the 3. Hold the engine hood using the
truck and operator's compart- Release lever clearance underneath, and raise
ment. In the event of a tipover, it.
don't jump. 4. Fully open the engine hood and
Grip the steering wheel, brace release it after making sure the
your feet, lean away from the hood is locked in place.
direction of tipover, and stay with
the truck.
11111111111111111111111111111111111111111111111111111111111111I111111
Closing
111111111111111111111111111111111111111111111111111111111111111111111
A WARNING
Operating the truck without locking
the engine hood can result in serious
injury or death if the truck overturns.
111111111111111111111111111111111111111111111111111111111111111111111

1. Close the engine hood gently.

Lower the hood until it locks in po-
Disconnecting method sition with a click.
Push the release button and allow the 2. Pull the steering wheel backward
belt to retract. to return it to the original position.

34
c)
o III. KNO YOUR TRUCK
o
o Opening in an emergency Forks
o If the engine hood lock release lever
becomes inoperable, use the
Fork Lock
Lift each fork lock so that the forks
C) following procedure: can be shifted left an
the forks in the pas
right. Adjust
ion most ap-
o 1. Lower the tilt steerihg adjust
lever and tilt the steering column
forward.
propriate for the load
possible. When adjus
nd as wide as
ing the forks,
o 2. Insert the thin plate into the gap make sure that the we
is centered on the truc
ht of the load
. After adjust-
o between the engine hood and the
toe-board. ment, set the fork 10
forks in place.
s to keep the

c Push the hook and unlock.

3. Raise the engine hood by inserting
o hands in the clearance under the
engine hood.
11'1111I1111I11111111111I1111111I1111I11 1111I111111111111011111111
A WARNING
o 4. Fully open the engine hood and
raise it after making sure the hood
Make sure the for s are locked
before carrying a load.
o is locked in place. 11I1111111111111111111111111111111111111 111111111111111111111111111

Ol
o
o
C)
o
Ci
o
o Draw bar
The draw bar is locate at the back of
o the counterweight, an is used to pull

o the truck should its ti

gutter or become stuc
es drop into a
in mud.

o It can also be used

forklift onto a truck
or loading the
another vehi-
o cle. The draw bar sho
for towing the forklif
Id not be used
or for towing
o another vehicle using he forklift.

o
o 35
III. KNOW YOUR TRUCK

36
o
o IV. Dl LV OPERATION

o IV. DAILY OPERATION PRE-OPERATION CHECK

o c ONTENTS 11I111I11I11I111I11I11I11I11I11I11I111I11I1111I1111I11I11I11I1111I11I111I111I11I11I111I11I111I11I11I111111 111111I111111111111111111I111
A
o • Daily Inspection (Pre-Operation Checks) WARNING

o • Starting Engine (Gas, LP, Diesel) OSHA and ANSI require users to inspect trucks at the sta of every shift.
These and other periodic inspections are your responsi ility and these

o • Brakes
guidelines are to assist you in your job.
• Lifting and Lowering <?ontrols ' 11I11I11I111I1111I111I11I11I11I1111I11I111I111I11I11I11I1111I11I11I11I11I11I11I111I111I1111I111I11I1111I11 111111111I111111111111111111
o • Direction. Controls
Inspection .
"

o • Lifting Loads . Item

o • Traveling Previously detected Correct.

o
•
•
Stacking Loads
Attachments
.,. malfunctions
Exterior Body, oil leakage, water leakagel loose parts
and exterior damage.
I
I
o • Parking
Wheels Tire pressure, wear or damage, ms and hub
• Unexpected Emergencies nuts.
o :i.
PRE-OPERATION CHECK .... ~ .. :.................................................. 37
Lamps Lamp condition and damaged la Inps.

o OPERATING YOUR TRUCK .......................................................44

Hydraulic oii
Radiator
Oil level, contamination and con istency.
Coolant level and antifreeze req irement.
OJ UNEXPECTED EMERGENCiES....................................................47
Engine Oil level, contamination, consist ncy, noise and
OJ exhaust.
Inching and brake pedal Pedal play and braking effect.
Oi Brake fluid Fluid level.
o Parking brake Operating force and braking eff! t.

o Steering wheel Looseness, play, vibration and p lIing.

o Horn
Instruments
Sound.
Functioning.
o Load handling system Parts, oilleakage, cracking and I\boseness.

o Fuel. Amount. I
o Overhead guard
Load back rest
Bends, cracks and looseness.
Bends, cracks and looseness.
o Operator restrai nt Cut, frays and deck latch OK, se t belt & buckle

o
o
o /
... ; }

37
IV. DAilY OPERATION

Walkaround inspection Hub nut inspection

Alignment Check the tightness of the hub nuts.
Avoid uneven torque and tighten all
Does the truck lean to one side or the other? If so, check for flat tire or a
of the nuts uniformly. Refer to
problem with the undercarriage.
service data for proper torque and
tightening method.
Beneath the truck
Check for any oil or coolant leakage on the ground or floor where the truck
was parked. Check for loose parts or damage.
If any unusual condition is found, have the truck inspected. Your Toyota
dealer can provide this inspection.

Tire inspection
Damage, cracking and wear of tires and rims
Lamp inspection
Check the tires for damage and wear, and the rims for bending. If the Are the filaments intact? Is there any
tires are damaged, or there is a marked difference in tire wear between lens damage? Always keep the
front and rear or between left and right, or bent rims are found, you lenses clean to insure proper forward
should request an inspection from an authorized Toyota dealer. Allways vision.
follow OSHA rules when changing tires. (Rearview mirror and turn signal
lamps are optional)

Inflation pressure of tires

Use a tire pressure gauge and
measure the inflation pressure.
Adjust it to the proper pressure Engine compartment
Upper limit
11I11I1111I1111I1111I111I1111I11I111I111I11I1111I111I11I11I11I11I1111 inspection
.A WARNING Engine coolant level check and
Use OSHA approved cage when you supply
put air into a tire. 1111I11I111111I111I1111I11I1111I11I11I11I111I1111I1111I11I111I111I11I
• See the service data section for
the proper inflation pressure.
.A WARNING
• Do not raise the pressure beyond Coolant level checks must always be
the proper level. performed when the radiator is cold.
• After adjustment, check for air Removing the cap when engine is
leakage from the valve. hot can cause serious injury.
Lower limit Reserver tank
1111I1111I1111I1111I111I11I11I1111I11I11I11I11I111I111111I11111111I11 111111I1111I1111I11I111I11I1111I111I1111I11I1111I11I11I11I11I11111111
38
o
o IV. DA Y .OPERATION
o
o 1. With the engine off, open the
o engine hood and check the
engine coolant level in the
Note
To close and tighten ' e radiator cap,
o reservoir tank;
match the pawl on t
of the cap with the n
e reverse side
tch in the filler
o Note
port and turn the ca
while pressing it dow
fully clockwise

o The reservoir tank automatically

supplies the engine coolant when Checking hydrauli oil level
o the level in the radiator is low.
Always stop the en ine and lower

o 2. The coolant level is proper if it is

the forks to the
checking the level of t
ound before
e hydraulic oil
o between the upper and lower
limits. If the level is below the
while the truck is on I
1. Open the engi
el ground.
e hood and
o lower limit, supply coolant to the
upper limit.
remove the oil cap
2. Wipe the level ga ge attached to
o 3. The concentration of the long-life
coolant (LLC) in the engine
the oil cap with a
insert it again into
ean cloth, and
he tank.
o coolant must be 30% (or 50% in a
frigid zone). Note
o Note The oil level must be c ecked with the

o If no engine coolant remains in the

reservoir tank, be sure to check the
oil cap inserted compl tely.
3. Remove the level g uge gently and

o coolant level in the radiator, too, but

only when cool.
check if the oil is p to the level
line.

o Checking the engine coolant

Note \.
The full mark on the I vel gauge and
o Reservoir tank
level in radiator the capacity vary wi h ·the model.
Measure at the full m rk on the side
o 111111I111111111I111I11/1111111111/11111111/11/1111I111I11111111I1111
.A. WARNING ' with the tonnage in, ication 1 ton

o Coolant level checks must always be

performed 'When the radiator is cold.
Oil tank Oil cap
models use "P1" ton ge indication,
2-3 ton models use "P "tonnage, in-

o Removing the cap when engine is

hot can cause serious injury.
dication.
4. If the oil level is in ufficient, add

o 1111111111111111111I1111111/111111111/1111111111111111111111111111111
oil. Spilled and spl shed oil must
be wiped off thoro ghly.
Maximum f~rk height:
CJ 1. Remove the radiator cover.
2. Remove the cap and check the
o coolant level from the filler port.
3. If the engine coolant is not visible
t
1 ton models
5.5m{216.5In}-7.0m(275.5in} 6.5
2-3 ton models
256inl 7.0m(275.5inl

o through the filler port, add an

1 ton 2~3 ton
~ 5.0mf197inl
~ 4.3mI169.5 inl ...... 4.8mf189inl
197in) 6.0mC236inl

169.5inl..... 4.8mf189inl

c Radiator cover approriatel amount of diluted

coolant (LLC). Level gau\:le models models
'1. 3.5mI138in)......4.0mI18gin)
~. below 3.3m11301nl belo
13Bjnl-4.0mI157.5inl
3.3m1130inl

C,
,/
39
IV. DAILY OPERATION
Engine oil inspection
1. Park the truck on flat ground. If
the truck is inclined, the indicated
level may be incorrect.
2. The oil level must be checked
before starting the engine or at
least 3 minutes after the engine is
stopped.
3. Remove the oil level gauge and
wipe it with a clean cloth. Insert
it again and check if the oil level is
between the F and L levels.
4. If the oil level is below the L line,
add oil to the F line.
Adding engine oil
1. To supply oil, remove the filler
cap and pour oil through the filler
port. Never let the oil level
exceed the F line.
2. The oil to be supplied must be
appropriate for the season.
SAE40 Ambient temperature
higher than 30°C (86°F)
SAE30 Ambient temperature DOC
to 3DoC (32°F - 86°F)
SAE2D Ambient temperature DOC
to-10°C (32°F-50°F)
Caution
Always use the same brand of oil.
Leakage inspection
Check the engine compartment for
any oil or fuel leakage.
Clean the radiator if it is clogged and
check if there are any foreign objects,
such as paper, on the radiator grill.
40
Reservoir tank
On board Truck Inspection
Brake fluid inspection
~~
, ....J/
[~:-f With the engine off, check the level
\ ......: / of the brake fluid in the reservoir
tank. The level should be within the
range shown in the figure. If the
level is below the lower limit, add
brake fluid up to the proper level.
111111111111111111111111111111111111111111111111111111111111111111111
A WARNING
If the level of brake fluid is low, the
brake system may be leaky. Conduct
an inspection immediately. Call your
Toyota dealer for professional help.
111111111111111111111111111111111111111111111111111111111111111111111
111111111111111111111111111111111111111111111111111111111111111111111
5mm
(0.20 in) A WARNING
• Never use any oil other than
brake fluid.
• Do not allow dirt to get into the
I I reservoir tank. Even a small
! ! amount of dirt in the brake fluid
can prevent proper braking. This
is extremely dangerous.
• Check the small vent hole in the
reservoir tank cap frequently to
make sure that it is not clogged
with dirt.
111111111111111111111111111111111111111111111111111111111111111111111
c
o IV. DAI I Y OPERATION
o
o Inching and brake pedal Parking brake ins ction
o inspection
1. Depress the inching~hdbrake
Pull this lever towards you.
1. Check the ope ating force
o pedal fully, and chebk the floor
required for pulli
lever fully.
the parking

o clearance (clearance between the

pedal and floor). Note
o See the Service Data . ection for' the
operating force.
o
o Inching and brake pedal
Note
See the Service Data Section for the
2. Ask your Toyota de ler to inspect
if any problems are ound.
o floor clearance.

o 2. Make sure that the pedal does

Instrument inspe ion
o not go any further when it is kept
depressed. . Start the engine and see that they
o 3. Also check that no problem is
observed with pedal depression
operate properly.

o and return.

o 4. Manually depress the brake pedal

to check the play until a

o Floor
resistance is felt.

o '""
"'-----~
clearance Note
See the Service Data Section for the
o amount of brake pedal play.

o 1111I11I11I111I1111I11I11I11I11I111I1111I11I11I1111I111I111I11I11I11I
.A.
o WARNING
Ask your Toyota dealer to inspect if
c' play is excessive, pedal movement
isa problem or brake performance is
o improper.
111I11I111I1111I1111I11I11I11I11I11I111I111I11I11I1111I11I1111I1111I1
o
o
o.
o
c 41
IV. DAILY OPERATION
Fuel level check and supply
(Gasoline and diesel)
AOANGER
Follow these rules when refueling to
avoid serious injury or death:
• Refuel only in authorized areas
• Turn ignition off
. ' No smoking or naked flames
allowed
• Clean up spills before restarting
1. Check the gauge to see if the fuel
is sufficient to finish your shift.
Note
After the end of daily operation, fill
the tank with fuel to prevent the
moisture in the air in the tank from
mixing with the fuel.
2. When supplying fuel, stop the
Fuel tank cap engine, remove the fuel tank cap
by turning it counterclockwise,
and pour fuel through the fuel
filler neck.
3. After fueling, be sure to tighten
the fuel tank cap.
Caution
• Carefully prevent entrance of
water and dirt into the tank
during fueling, use only clean,
properly marked containers.
42
Engine inspection
Start the engine and warm it up
sufficiently.
1. Check each meter and warning
lamp to see if there is any
problem.
2. Check if the engine is making an
abnomal sound or vibration.
3. Check the exhaust gas color to
see if it is normal.
Colorless or light blue exhaust
indicates complete combustion;
black exhaust, incomplete com-
bustion; and white exhaust,
burning oil as a result of oil
getting into the cylinders.
1111I11I11I11I11I11I11I111I111I111I11I11I11I11I11I11I11I11I1111I1111I
A WARNING
• The exhaust gas can cause
serious injury if breathed. If you
must start the engine inside a
building or enclosure, insure
sufficient ventilation.
• The gasoline engine carburetor is
equipped with an automatic
choke that keeps the engine
running at a relatively high speed
when cold. The engine resumes
normal speed when it is fully
warmed.
11I11I11I11I111I1111I111I1111I11I11I111I111I11I11I11I11I111I1111I1111
Checking and adjusting chain
. tension
With the truck parked on a level
surface and the forks raised about
20 - 30 em (10 in.) above the ground,
check the chains for tension differ-
ences by pressing each chain with
thumb or by noting the tilt in fork rail.
If the chains do not have the same
amount of tension, they need to be
adjusted.
o
o IV. DAI V OPERATION
o
o Load handling system While moving slowly.
o 1. Check the forks and load backrest Torque converter clutch disengagement
o for cracks and bendin~. .
2. Check for mast distortion, chain Press the inching pedal and check clutch engagement whil

o tension, and oil leakage from

cylinders and piping. Caution
o 3. Operate the lift and tilt levers to
check their operation.
Insure that the control lever operates properly in each ear and then

o If anything unusual is found, have

the truck inspected at a Toyota
make the above checks while moving slowly.

o dealer. Steering inspection

o 11I11I1111I11I1111I11I111I111I11I11I1 In 111I1111I1111I111I1111I11I11I
A WARNING
While moving the truck slowly in a safe location, turn the teering wheel
to the left and right and check for any unusual movement.
o Never check for oil leaks by hand. Oil Brake effectiveness
o under pressure can penetrate your
skin causing a severe· injury. Wear
Inspect to see if there is anything unusual when the inc ing and brake
pedal is pressed or if the brakes only work on one side.
CJ gloves and use a piece of cardboard
to find leaks.
Pull the parking brake on and insure that the truck can be st pped and held
o 11I111I11I11I111I111I111I111I1111I1111I11I11I11I1111I11I1111I11I1111I
against moderate engine speed.

o Steering wheel inspection 111111111111111111111111111I11111111111111111111111111111111111111111111111111111111111111111111111111111111 111111111111111111111111111

A WARNING
o Note
Perform the inspection after starting If anything feels even slightly unusual, stop truck operati
and have' the truck inspected by your Toyota dealer.
immediately
C the engine.
111111111111111111111111111111111111111111111111111111I11111111111111111111111111111111111111111111111111111 111111111111111111111111111
o 1. Check steering wheel play with

o the rear wheels set for straight

travel.
o Note
o See the Service Data Section for the

o standard steering wheel play.

o 2. Rotate the steering wheel and

also move it up and down to
o check that there is no looseness.
3. Push the horn button to check if
CJ the horn sounds normally.
4. If any problems are found, ask
Cj your Toyota dealer to inspect.

0; 43
IV. DAILY OPERATION

OPERATING YOUR TRUCK

The skills needed to operate a lift truck must be developed through Use the seat belt to help keep
training and experience. Both the truck and jobs to be done change from yourself safely inside the truck in
one work area to another. case of an overturn or tip up.

This review will quickly describe use of the basic operating controls. When
you get into new jobs or unfamiliar areas, ask your supervisor for help.

Make sure your truck is safe. Check Start the engine only when you are
Neutral position
over the truck before every shift, sure the direction control is in
using the information at the NEUTRAL and the parking brake is
beginning of this section. ON.

Parking brake lever

Read the Operator's and Owner's Before you release the parking brake
Manual and the warning decals on and shift to FORWARD or REVERSE,
your truck. Stow the manual behind hold the truck in place with the foot
the seat when you finish. Ask ques- brake.
tions if you don't understand.

44
o
o IV. DAI V OPERATION
o
o Place the direction control lever in
o position for travel, then check in that
direction to make sure the,path you
Stopping can be done with the inch-
ing and brake pedal Always use

o will take is clear of all pedestrians

and obstructions.
them smoothly to avoi losing a load.

o
o
o
o
o
o
o Lift your forks or attachments only
high enough to clear the floor and tilt
Pick up loads with f
wide as possible and
rks spread as
ravel with the
o them back.
load centered and fork tilted slightly

o back. Travel in REVE

blocks your view.
SE' if the load

o
o
o
o
o
o Release brake and push acceierator
to change your speed. When
Stacking loads require
practice. Put. the tru
patience and
k in position
o steering, remember about tail swing
with rear steered wheels.
before raising the m
loads only when st
t, and lower
ped and as
o close to the shelves as
J
ossible.

o
o
o
o
C
.
!
./ 45
IV. DAILY OPERATION

Your employer may use special When parking an LP-powered truck

attachments to replace forks on the
truck. There are many different
kinds and you must get special
training in their operation.
overnight, close the shut-off valve
and wait until the engine stops before
turning off the ignition. Park an LP-
powered trucks only in well ventilated
area.

When you leave your truck, park it in

an approved area, not on a grade or
in a fire lane, or blocking pedestrian
walkways.

Be sure your truck will stay parked.

Shift to NEUTRAL, set the parking
brake, lower the forks, and tilt
forward so the tips will not trip
pedestrians, and turn off the ignition
switch.

46
o
o IV. OAI V OPERATION
o UNEXPECTED EMERGENCIES
o Stay alert for unexpected problems. Overturning or tipp ng forward
o We can't know what might surprise
you in your work area, but here are of the truck:
o some things to remember. Stay with the truck. I an away from

o Engine stops white traveling:

the fall and brace you arms and legs
to keep them inside the overhead

o Stop the truck as soon as possible.

Steering will take much more force to
Brace
your
guard.

o operate than normal. feet

o
o
o Load starts to shift or fall white
o stacking:
Loss of brakes whit traveling:

o Lower load if possible. The overhead

guard and load backrest should help
Try the inching an
Steer around hazards
.brake pedal.
and apply the

o protect you from most falling loads.

Sound horn or shout to warn any oth-
parking brake. Shift d
lever to the opposite
ection control
rection.

c' ers in area.

o
o
o
o Pedestrians or other machines
o come into the path of your
Forks, mast or atta hments
hang up:
o truck:
If you see a slack ch in or the mast
o Steer or brake to avoid them. Sound
horn to alert people who may not be
stages lower unevenly raise the forks

c) looking at you.
immediately and find
will avoid a sudden fal .
ut why. This

o
o
o
o t, 47
IV. DAILY OPERATION

48
 V. OPERATOR r,nAINTENANCE

V. OPERATOR MAINTENANCE OPERATOR MAINTENANCE

CONTENTS 1111I11I11I111I11I1111I11I11I1111I11I11I1111I11I1111I11I111I111I111I11I11I1111I1111I111I1111I11I1111I11I11I 11I111I11I11I11I11I1111I111I
• Fueling (Gas, LP, Diesel) .A. WARNING
• Tires/Wheels OSHA requires training for lift truck mechanics. So Ine employers
• Antifreeze authorize operators to perform basic maintenance wor~ This section
gives help in a few of these areas, but it is not a Iisubstitute for
• Fuses comprehensive training and knowing your employer's wor rules.
• Battery 11I11I11I11I111I1111I11I11I11I1111I1111I111I11I11I11I111I11I11I1111I11I11I11I11I"11I111I11I11I11I111I11I11
!
11I11I11I11I11I111I"11I11"
• Parking Brake Adjustment
o • Tag Out
o
o
•
OPERATOR MAINTENANCE 49
REFUELING YOUR TRUCK 50
o CHANGING TIRES 51

o ADDING ANTIFREEZE
FUSE REPLACEMENT :· .'
53
54
o AIR PURGING OF THE FUEL SYSTEM 54

o DRAINING THE SEDIMENTER

MAINTAINING THE BATTERY TERMINALS
; 54
55
o ADJUSTMENT OF PARKINGBRAKE
BATTERY CHARGING ;
55
55
OJ TAG IT OUT PARK IT : 56
o
o
o
o
o
C)
o
o
o
o
49
V. OPERATOR MAINTENANCE

REFUELING YOUR TRUCK

LPG FUEL
Check the gauge on the tank to make sure there is enough fuel to finish
your work.

CHANGING OR REFILLING TANKS

1111111111111111111111111111111111111111 Btl 1111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111
.A WARNING
To avoid serious injury from fire or explosion, you must follow these
rules:
• Switch ignition and lights off.
• Change tanks only in well ventilated, approved areas.
• No fire or flames allowed.
• Check all connections for damage or missing parts.
• Check for leaks.
• Do not restart until all smell of gas is gone.
• If truck will not restart, get a mechanic to inspect it .
• Filling tanks requires special procedures. Make sure someone
explains them all to you.
11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111

Don't get caught with an empty tank. Make sure your truck has enough
fuel to finish the job you start.

Refuel only in a safe. Well ventilated place authorized by your employer.

Find out his rules for carrying and storing fuel and follow them.

Gasoline engine models: Use only un-leaded gasoline of 87 octane rating

or higher.

LPG fuel is a gas that is heavier than air. It will settle in low spots and on
your clothes. Any flame or spark could cause a fire that could cause
serious injury.

When changing tanks, check all connections for damage or missing parts.
If you have a leak or the truck will not restart, ask a mechanic for help.
Never try to restart a truck if you still smell gas.

50
C;
o V. OPERATOR AINTENANCE
o CHANGING TIRES
o 111111I1111I11I11I111I11I11111111I1111I111I11I1111I11I11I11I11I111111I11I11I1111I111111I11I11I11I11I111I11I111111I11I11111111I1111I11I11I
n
~
A WARNING
q.iOO
o You must use a" jack that has a rated capacity of 3.5 tons
more. Make sure the counterweight mounting bolts are fully tightened be-
Ibs) or

o fore lifting the truck. and follow these instructions to avoid injury:
• Truck must be unloaded and parked on a smooth level floor.
o • Make sure the parking brake is properly adjusted and fully applied and
opposite end wheels securely chocked.
CJ 1111I11111111111111I11111111I1111111111111111111111111111111111111111I11111111111I111111111111111I11111111111111111111I111111I111111I1111

o .A DANGER
o You can be killed or seriously injured if a lift truck falls on you.

o After jacking, use blocking or proper stands to hold the truck.

Never get under a truck supported by any hydraulic jack.

o Front wheels
Rear wheels
C) 111111I111I11111I111111111111I11I11111111I111111111111I1111I1111I11I1
A
-'-,- 111111111111111111111111111I111111111111 11111111I1111111111111I111I
A WARNING

o WARNING
To raise the front. lift the forks about
~
To raise the rear. us either a floor
jack or a bottle jack f the right ca-

o 3 feet with the mast vertical and

place a jack under the outer mast.
pacity and place it as hown.
111111I1111111I111111I111111111111111111 11111111111111111111111I111

o Make sure that the jack is properly

positioned.
1. Jack up until the
to leave the gro nd and then.
eels are about

o 11111111111111111111I1111111111111111I11111111111111111111111111I111I
100sel1 the hub nuts
2. Jack up until the heels come off

o 1. Jack up until the wheels are about

to leave the ground and then.
loosen the hub nuts.
the ground then r move the hub
nut and remove the heel.
CJ 2. Jack up until the wheels come off
3. To reinstall the wheel after
changing a tire, pe form the steps
o the ground. Completely remove
the air pressure from the tire then
for removal in rever e order.
4. The hub nuts sho d be tightened"
Ci remove the hub nuts and remove
the wheel.
evenly and in the s quence shown
in the figure.
"j
0) 3. To reinstall the wheel after chang-
ing a tire. perform the steps for re-
5. After replacing th wheel, check
and adjust the tire ir pressure.
CJ moval in reverse order.
The hub nuts should be tightened Portable
Jack setting position
• Hydraulic garage ja k
C) evenly and in the sequence shown hydraulic
jack Set the jack und r the counter
l
in the figure.
C, 4. After replacing the wheel. check
weight.
• Portable hydraulic j ck
o and adjust the tire air pressure. Set the jack in the j ck point under
the counter weight
51
V. OPERATOR MAINTENANCE

Wheel and tire servicing Divided Rim Section

Federal and State laws require you to
be fully trained and qualified before .-
doing maintenance on wheels and
tires. Injury or death can result from
the exploding rim components if
servicing is not done correctly.
L-._. "--._-
Check tire pressure facing the tread Outer rim Inner rim
of the tire, not the side. Use a long
handled gauge to keep your body is
away from rims and wheels.

Remove air from the tire before re-

moving rim locking rings on multi-
piece rims.

Always use a safety cage to inflate
tires after servicing.
AOANGER
• Tire air pressure is very high, so pay attention to rim deformation,
cracks, etc.
Never exceed proper air pressure.
• Never loosen the nuts that hold the inner and outer wheel halves
together when there is air pressure in the tire.
• Completely remove the air pressure from the tire before it is removed
from the lift trucl<. Air Pressure in the tires can cause the tire and
wheel parts to explode, causing serious injury or death. Tires and
wheels must be changed and repaired only by trained service persons.
• If a tire has less than 85% of the correct air pressure, completely
remove the air pressure from the tire. Remove the tire from the lift
truck. Add air pressure to the tires only in a safety cage.

52
o
o V. OPERATOR AINTENANCE
o ADDING ANTIFREEZE
o If the truck is left in an area where the temperature is less than (32 0 Fj, aoc Engine 11111111111111111111111111111111111111111 11111111111111111111111111
o the cooling water will freeze and may damage the radiator and/or cylinder
block. In such cases, antifreeze coolant must be used. ,
drain
plug (GM)
A WARNING

o When long-life coolant (LLC) is used, it must be changed orice every tw()
years.
To avoid burns, only 0 en cap when
engine is cold.

o The freezing temperature varies depending on the amount of antifreeze

added.
11111111111111111111111111111111111111111 11111111111111111111111111

o Antifreeze mixture (%)

1. Remove the radiat cap. Loosen
the drain cock on tie radiator and
o cylinder block a d drain the
cooling water.
o Freeze protection
temperature °c (OF)
-12 (10.4) -15 (5) -24 (-11.2) -35 (-31)
2. Flush out the radiat r and cylinder

o Mixture ('Yo) 25 30 40
Engine drain plug (lj.Y) block by adding clean water
through the radiato inlet.

o 3. After the water has rained out of

the radiator and linder block,

o 111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111II
A WARNING
tighten the radiat, r and engine
drain cocks.
o The antifreeze fluid is flammable, so no smoking and avoide open flame.
4. Add the proper amount of
antifreeze through the radiator
o 11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111 inlet and fill up t e remaining
space with clean w ter.
o Prior to adding antifreeze, inspect the radiator, water pump, piping and
cylinder block for leaks.
5. When warm weath r arrives and
there is no longer ny danger of
o The procedures for adding antifreeze is as follows: freezing, drain the ooling water

o containing the an freeze(expect

LLC, which must be changed
o Engine drain plug (1 DZ) every two years.)
Flush out the radia r and engine
o block and fill with c an water.

o
o
o
o
o
o
o
o 53
v. OPIERATOR MAINTENANCE

FUSE REPLACEMENT AIR PURGING OF THE FUEL SYSTEM

If a lamp does not come on or an (Diesel engine models)
electrical device does not function,
the corresponding fuse may have When fuel has been completely
blown. depleted or when maintenance has
Check the fuse for each device. The been performed on the fuel system,
fuse box is located in the front left as be sure to perform air purging in the
seen from the opened engine hood. following sequence.
1. Open the engine hood.
Note 2. Operate the priming pump up
See the table below for the device and down to perform air bleeding.
corresponding to each fuse.

Fuse assignment
A 7.5 A Horn
B 7.5 A Engine DRAINING THE SEDIMENTER
C Space
Priming pump (Diesel engine models)
D Space
E 7.5 A Stop lamp The sedimenter separates the water
F 7.5 A Turn signal contained in the fuel. It is integrated
G 20 A Head lamp with the fuel filter. If the sedimenter
H 15 A Meter warning lamp comes on,
immediately drain water according
The fuse check and replacement to the following procedure because
procedure is as follows: the accumulated water in the
1. Set the engine switch to the OFF sedimenter is above the specified
position. level:
2. Remove the fuse box cover and Drain hose 1. Place a container to receive the
take off the fuse clip attached to water under the open end of the
the fuse box. drain hose under the fuel filter.
3. Apply the fuse clip to the fuse to 2. Turn the drain cock once or twice
be remove. to loosen it and operate the
4. The fuse is blown if its state is as priming pump up and down to
shown at left in the illustration. drain the water from the
Replace it with a spare fuse. sedimenter.
Caution 3. When light oil starts to flow out
• Use a fuse having the same after the water has drained,
capacity as the one removed. firmly tighten the drain cock.
• If the replaced fuse blows again,
ask your Toyota dealer to inspect. Caution
Wipe the light oil cleanly from the
adjustment area.
54
o
o V. OPERATOR
I
o MAINTAINING THE BATTERY TERMINALS BATTERY CHARGING
o 11I11I11I11I1111I111I11I11I1111I11I111I11I1111I11I11I11I1111I1111I11I
o Grease
A WARNING

o Always stop the engine before

working on the battery .or terminals.
o Remove the negative terminal (-I first,
but replace it last.
o 11I11I1111I/1111I/1111I1 /111111I1111I/1111I11 /1111I111111I /II/II /1111

o 1. A loose or corroded terminal

causes failure in connection. Re-
o move white powder, if any, from
the terminal by pouring warm wa-
o
on
ter over it to dissolve it and then
grease the terminal.
o 2. If the terminal is extremely cor-
roded, remove it from the battery
Cj
!
and brush off the corrosion using a
wire brush or emery paper. Con-
C nect the terminal tightly to the
o battery and grease the terminal.

CJ
o •
•
Charge batteries only in approved, well ventilated areas
Remove caps and negative (-I battery cable.
o • Connect charger leads positve (red or +1 then negative ( ack or-I

o ADJUSTMENT OF PARKING BRAKE

•
•
Charge at the slowest rate and with charger set to rated
Make sure electrolyte stays above minimum level. Use
voltage.
distilled water

o 1. Determine parking brake force

•
only.
Turn charger off before disconnecting leads.

o from service data section.

• Always replace caps tightly and allow battery to cool be re using.

Hi9~ ~w
o 2. Attach a spring scale to the

~
center of the brake lever grip.
o 3. Pull straight back and measure
force.
o 4. Adjust screw for higher or lower
force and re-check.
o 5. Release brake for normal opera-
tion.
o
o
o 55
V. OPERATOR MAINTENANCE

TAG IT OUT ... PARK IT

If any problem starts while you are working, stop and tell your boss.
When you sideline a truck, tag it so others will not be injured by trying to
use it.

If you find a problem in your daily inspection, get it fixed before starting to
work or tag it out and use another truck.

56
o
o VI. EMERGENC'I PROCEDURES
o VI. EMERGENCY PROCEDURES
o CONTENTS
o I

• Dead Battery, Jump Starting

o • Lifting

o •
•
Transporting
Towing
o • Jacking

o USING JUMPER CABLES 58

o TRANSPORTING 59

o TOWiNG
RAISING THE TRUCK ,
60
61
o UL-SPECIFICATION PARTS 61

o
•
MODIFICATIONS 61

o
o
c
o
o
o
o
o
o
o
o
o
o
o
o 57
VI. EMIERGENCY PROCEDURES

USING JUMPER CABLES

These instructions apply to the use of a fully charged booster battery in
another truck to start the engine of a truck with a discharged battery.
(Use only 12-volt battery for 12-volt models)

11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111
A. WARNING
To avoid damage to your truck, or the possibility of harm to yourself,
follow these instructions and warnings, If you have any questions, ask an
experienced mechanic for help.
11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111III

1. Use only a 12-volt negative ground battery to start your truck. (Use 1 2
V battery x1 for 12 V models) If you are not sure of the voltage, or if the
ground is different, do not try to jump start.
Personal injury or damage to the electrical system can result. Damage
to the electrical system will not be covered by the manufacturer's war-
ranty.
2. Check fluid level of the discharged battery. If low, add distilled water
to the correct level.
Be sure to install the caps before jump starting.
3. Put the booster battery as near to the truck as necessary for the
jumper cables to reach both batteries. Check and make sure that the
trucks do not touch each other.

Use particular care when connecting a booster battery to prevent

sparks.

4. On both trucks:
(a) Apply the parking brake.
(b) Put the gear shift lever or directional control lever in the NEUTRAL
position.
(c) Turn the ignition key switch to the OFF position.
(d) Turn all lights and accessories to the OFF position and leave them
off until after the engine has been started and the jumper cables
removed.

58
o
o VI. EMERGENC PROCEDURES
o TRANSPORTING
o 5. Connect the jumper cable in the
o following sequence: . ,
(a) Connect the red jumper cable from the positive (+) terminal on <;lne
11111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111 1111111111111111111111111111
A WARNING
o battery to the positive (+) terminal on the other battery. Never To avoid injury before loading this truck onto a trailer or ighway truck,

c\ connect (+) to H or H to (+) as this may damage the alternator.

Make sure the clamps do not touch any other metal.
make sure the floor has a capacity strong enough to hold
that it has tie down points that will keep the truck from
to follow these instructions:
e weight, and
ving. Be sure

o (b) Next, connect one end of the black cable to the ground H terminal
of the "helper truck" battery.

o (c) Last, connect the other end of the black jumper cable to a
stationary, solid metal point on the engine of the truck you are
• Stay away from edges and remember that lift trucks
rear.
teer from the.

o starting. .
(NOT TO NEGATIVE H TERMINAL OF THE BATTERY.)
• Use the draw bar to load the truck on a tilt trailer, or
dock levelers or plates of the proper capacity are used
ake sure that
f loading from
o Make this connection at a point at least 18 inches (450 mm) away
a dock.
.. Center the truck left and right, lower the forks or atta hments, apply
o from the battery, if possible. Do not connect it to pulleys, fans, or
other parts that move.
the parking brake, and stop the engine.

o • Install chains and chain tensioners from the draw bar in

left and right sides and rearward to the transporting ve
the rear to the
icle.
o 6. Start the engine on the h~lper starting, and run the engine at a moderate
speed.
• Protect the paint and controls on the floor of
compartment with wood or heavy cardboard.
he operator's
.
o 7. Start the engine of the truck with the dead battery.
Follow the starting instructions in the Starting and Operating
• Install a chain from left to right across the floor a
tensioners to a forward position on the transporting ve
d attach with
icle.
o Procedures section of this manual.
Be sure that the engine is at idle speed before disconnecting the
• Operate the tranportiilg vehicle slowly and smoothly
tie downs periodically.
and check the

o jumper cables. 111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111111 1111111111111111111111111111

o 8. Remove the jumper cables by reversing the above sequence exactly.

Start by removing the black jumper cable from the engine block of the

c truck with the discharged battery. Then remove the other and of the
negative H cable from the "helper truck".

o 9. Remove both ends of the red cable.

c
o
o
c
o
o
o
C) 59
VI. EMIERGENCY PROCEDURES

TOWING
Truck hoisting method
When hoisting the truck, use the lift-
ing holes near the top of the mast and
cradle each rear wheels as shown in
the illustration.

1111I11I11I11I11I111I11I11I1111I11I11I111111I11I111I111I11I111I111I11
A. WARNING
• Use wire cable which is suffi-
ciently strong.
• Never use the holes on the upper
part of the counterweight to hoist
the truck.
1111I11I111I11I1111I11I1111I111111111I11I1111I11I11I11I11I111I11I111I

The draw bar is located at the back of the counterweight, and is used to
pull the truck should its tires drop into a gutter or become stuck in mud.
It can also be used for loading the forklift onto a truck or another vechicle.
The draw bar should not be used for towing the forklift or for towing
another vehicle using the forklift.

60
o
o VI. EMERGENC PROCEDURES
o RAISING THE TRUCK
o 1111I111I11I1111I1111I11I11I111I11I11I11I11I111I111I11I11I1111I111I11
UL-SPECIFICATION PARTS
o A WARNING Fuel Cut-Off Val e
(4Y·GM engine IOdeIS)
o You must use a jack th* has a rat~d
capacity of 3.5 tons (7;700 Ibs) :or
o greater.
Make sure the counterweight
This valve serves to c
the fuel tank. It shou
t off fuel from
d generally be

o mounting bolts are fully tightened

before lifting the truck, and follow
set to the ONpositio
OFF position in an e
l
. Set it to the
ergency such

o these instructions to avoid injury:

as when trouble occ
system.
rs in the fuel

o • Truck must be unloaded and

parked on a smooth level floor.
c • Make sure the parking brake is
properly adjusted and fully
o applied and opposite end wheels
securely chocked.
o Counterweight Counterweight • To raise the front. lift the forks
about 3 feet with the mast
Fuel Tank Cap

o I I
vertical and place a jack under the
outer mast rail as shown.
(Used only on UL-G , OS types)

o • To raise the rear, use either a

floor jack or a bottle jack of the
The cap cover can ,e opened by
pulling the knob on p of the cap
o right capacity and place them as
shown.
and sliding it sideway After adding
. fuel, close the cap co r and tighten
n
-/ 1111111111111111I111I1111111I111I1111I1111I11111111111111111111111111
the knob securely.

o A DANGER
lr----/ The entire cap can al be removed
easily by turning it co nterclockwise.
Cj You can be killed or seriously
o injured if a lift truck falls on you.
After jacking, use blocking or proper MODIFICATIONS
o stands to hold the truck.
Never get under a truck supported
OSHA and ANSI St
users to use repair
dards require
r replacement
o by any hydraulic jack. parts of the same de
as those originally
gn and quality
upplied. Your
o Toyota dealer is a reli
these parts and the
ble source for
rvice to keep
o your truck running s fely and effi-

o ciently.

o
o
C: 61
VI. EMERGENCY PROCEDURES

62
o
o VII. PLANNED MAINTENANCE
o VII. PLANNED MAINTENANCE PLANNED MAINTENANCE
(';i
~~

CONTENTS
o • Training
Daily inspections are important (and OSHA requires the ), but planned
maintenance is the least expensive way to keep your T ,yota truck safe
o • Manuals, Parts and productive.

o •
•
Planned Maintenance, Dealer Service
Storage
Toyota dealers have trained mechanics and special tools,
services for you.
provide these

o • Weekly Maintenance

o •
•
Maintenance Schedules
Replacement Schedules
This section of the manual will remind you of the are that must be
inspected and the replacement intervals for various comp! nents. It is not

o • Service Data
meant to be a substitute for the mechanic training OSHA I quires.

c) • Lubrication Chart If you decide to perform any maintenance and have a question or
problem, contact your Toyota dealer immediately for th proper repair
o PLANNED MAINTENANCE 63
manuals and professional advice.

o STORAGE 64 OSHA and ANSI require all lift truck mechanics to be tr ined and auth-
origed to repair and operate this truck.
o WEEKLY MAINTENANCE ;64

•
PERIODIC MAINTENANCE ; 67
o PERIODIC REPLACEMENT TABLE 67

o PERIODIC MAINTENANCE TABLE

SERVICE DATA
68
72
c LUBRICATION CHART
FRAME SERIAL NUMBER
; 74
75
o
o
o
C:
o
o
C;
o
o
o
c 63
VII. PLANNED MAINTENANCE

STOFlAGE WEEKLY MAIINTENANCE

Remove dirt from all truck components and then perform the following: Inspect the items below in addition to the pre-operation items. Have
necessary adjustments or replacements performed at your Toyota dealer.
1. Inspect for oil and water leakage. Inspect the trucks thoroughly to insure safety and pleasant working
2. Inspect each component for warping, scratches, dents or cracks. conditions.
3. Clean the air filter element and lubricate parts as required.
4. Move the forks all the way up and down to lubricate the inside of the Lack of proper lubrication and servicing will quickly show up in increased
lift cylinder. troubles and shortening of truck life.
5. If you sensed anything unusual during operation, notify the supervisor. Set up a certain day and make it a rule to inspect on that day. Record all
inspection results and file them for future reference.
1111I11I11I11I1 ~ III11I1111I1111I1111I11I111111I111I11I11I11I111I11I11I11I11I1111I111I1111I11I1111I11I11I1111I11I11I1111I111I1111I1111I11I Perform the following inspection together with before-operation inspec-
A WARNING tion.
Even a small malfunction can cause a serious accident. Weekly (40-Hour) Inspection Item
Do not operate the truck until repairs have been completed.
1111I111I111I11I1111I11I1111I11I111I11I111I11I11I111111I1111I11I111I11I111I111I11I11I1111I1111I111I1111I11I111I11I11I11I11I11I111I1111I11 Air cleaner Clean
Fan belt Inspect
Torque converter oil level Check
Battery electrolyte level Check
Bolts and nuts Tighten
Mast and steering linkage Grease
Chain Engine oil

• Weekly [40 hour] inspection

The above items are concerned with inspection and lubrication. Re-
placement of lubricants will depend on the amount of contamination
and foreign matter in them. Changes should be made to conform with
the conditions of your workplace and equipment.

64
o
o VII. PLANNED MAINTENANCE
o
o Air cleaner cleaning
o The element can be taken out after
How to wash the lement
1. Soak the elem nt in water
o removing the three catches fixing the
element.
containing mild
approximately 3
detergent for
minutes and
o Element cleaning
then wash. Us
scratch the filter p
care not to
per.
()
'-.-/ 1. Tap the element filter paper 2. After washing, rin e the element
o lightly without causing any
damage or blow dust off with
with clean water (
less than 2.8 kg/c
ater pressure
(40 psi)).
o compressed air (7 kg/cm 2 (99.4
psi) or less) from inside.
3. Allow to dry nat
dryer (cold air).
ally or use a
Never use
o compressed air or lame.

o Note
o 2. After element cleaning, remove
any dust in the evacuator valve.
1. The element shou
after washing six tl
be replaced
es or after it
n
,~.
has been used for 0
2. It is unnecessary to
e year.
lean the inside
element when dea ng the double
cyclone air cleaner Option). Only
clean the outside el ment.
It is essential to re lace both out-
side and inside ele ents, it time of
replacement.
Evacuator valve

111111111111111111111111111111111111111111111111111111111111111111111
.A. WARNING Fan belt inspecti n
Always use eye protection when Inspect the fan belt for cracks, fraying
cleaning with air. and tension.
111111111111111111111111111111111111111111111111111111111111111111111 If any problems are fund, have the
belt replaced or adjust d by a Toyota
Note dealer.
1. Always replace the element if the Refer to for proper
tension.
filter paper is torn or damaged.
2. Wash the element if heavily
contaminated.

65
VII. PLANNED MAINTENANCE

Battery electrolyte check

1. The battery electrolyte should be
between the upper and lower
levels.
Note
For a battery without level indication
on the casing, make sure that the
electrolyte level is above the
electrodes.
2. If the electrolyte level is below
the lower level, remove the cap
and add distilled water to the
upper level through the water
inlet port.

111111111111111111111111111111111111111111111111111111111111111111111
A. WARNING
See Battery Maintenance Section for
other important rules.
Be sure to use distilled water for
battery electrolyte. Also, wear pro-
tective glasses when working on the
battery.
111111111111111111111111111111111111111111111111111111111111111111111
4. Insert the level gauge back into the hole and remove it again to
check if the oil level is between the F and L lines on the level
gauge. Use only oil specified in the lubrication table.
Torque converter oil inspection
1. Perform oil check while the truck
is on level ground with the Retightening of nuts and bolts
parking brake on, the control
lever in the NEUTRAL position, Retighten each nut and bolt on the chassis and load handling system.
and the engine idling.
2. Open the engine hood and Greasing mast and steering linkage
remove the toe board. Grease in accordance with the lubrication table.
3. Remove the level gauge and wipe
it with a clean cloth. Caution
• Clean the grease nipples throughly prior to greasing.
Toe board
• After greasing, wipe off excess grease.
66
o
o VII. PLANNED ~AINTENANCE
o PERIODIC MAINTENANCE PERIODIC REPLACEMENT TABLE
o Periodic inspection and maintenance are necessary to keep your Toyota
o industrial truck running safely and smoothly. The maintenance experts at
your Toyota dealer are specially trained to use the right tools and
REPLACEMENT PERIOD (Accumulated hours of
operation or monthly periods of operation, EVERY 1 3 6 12 MONTHS

o approved procedures to protect the investment you have made in this

high quality truck. Do not entrust it to amateurs.
whichever comes sooner.)
, EVERY 170 500 1000 2000 HOURS

o Engine oil
•
.*
f- f- f-

o The designated number of hours in the inspection cycle are as follow:

Engine oil filter
• f- f-

Cooling water (except LLC, LLC is every 2 years)

• f- f-

o Daily (pre-operation check) ....................................... Every 8 hours

Air Cleaner element
•
Fuel filler
• f-

o Weekly
Monthly
....................................... Every 40 hours
....................................... Every 170 hours
Torque converter oil
Torque converter oil filter
•
•
f-

f-

o 3 - Month ......................................; Every 500 hours

Differential gear oil
•
o Hyqraulic oil
• f-
6 - Month ....................................... Every 1,000 hours Hydraulic oil return filter .*
• f-

o Annual ....................................... Every 2,000 hours Wheel bearing grease

Spark plugs
•
•
o
f-

If the operation time exceeds 170 hours a month, use the number of hours
Master cylinder, wheel cylinder cap and seals
•
o as a guide for performing periodic inspection. Pre-operation checks and Brake f1uiq
Power steering hose
•
(Every 2 y ars)
f-

weekly inspections should preferably be performed by the user. Monthly,

o 3-month, 6-month and annual inspections should be performed by a
Toyota dealer since high-level technology and special tools are required.
Power steering rubber parts
Hydraulic hose
(Every 2 y ars)
(Every 2 y ars)
o Reserve tank tube (Every 2 y ars)

o Refer to the Periodic Maintenance Table to determine the inspection and

maintenance items and inspection cycles.
Fuel hose
Torque converter rubber hose
(Every 2 y ars)
(Every 2 y ars)

o Chain (Every 3 y ars)

o Use only genuine Toyota parts for replacements, and always use the
recommended types of lubricants.
*For new trucks

o
o
o -

o
o
o
o
o 67
VII. PLANNED MAINTENANCE

PERIODIC MAINTENANCE TABLE

Periodic maintenance INSPECTION PERIOD (Accomplish based on
INSPECllON METHOD operating hours or months. whichever EVERY 3 6 12 MONTHS
I: Inspect and correct and replace as required. T: Tighten C: Clean L: Lubricate M: Measure
is soonest.)
and correct and adjust as required.
EVERY 170 500 1000 2000 HOURS

Cooling system
INSPECTION PERIOD (Accomplish based on 21. Radiator cooling water level and leakage .
operating hours or months, whichever EVERY 3 6 12 MONTHS 22. Rubber hose deterioration .
is soonest.) 23. Radiator cap condition .
EVERY 170 500 1000 2000 HOURS
24. Fan belt tension and damage ..

ENGINE 25. Radiator rubber mount ....•.......•.......................................

Basic components
1. Starting condition and unusual noise . POWER TRANSMISSION SYSTEM
2. Rotating condition during idling . M Differential
3. Rotating condition during acceleration . M 1. Oil leakage.....................•.............•..........•.......................... l- I- I-
4. Exhaust condition •.............•....•.............................•........... I 2. Oil level . <- <- <-
5. Air cleaner element . C 3. Loose bolts . T
6. Valve clearance . M
Torque converter and transmission
7. Compression . M
4. Oilleokoge................................................................•....•... <- <- <-
8. Cylinder head bolt . T
5. OilleveL _ . <- <-
9. Muffler rubber mount . I
6. Operating mechanism function and looseness ........••... <- <- <-
Blow by gas reduction device
7. Control valve and clutch function . <- <- <-
10. Clogging and damage of PCV valve and piping . <- <- 8. Inching valve function . <- <- <-
Governor 9. Stall test and oil pressure measurement . M <-
11. Maximum no-load stabilized rotation speed . M <- <- Propeller shaft and a.le shaft
Lubrication system
10. Loosening of joint. . <- I-
12. 011 leakage . <- <- 11. Looseness at spline connection .
13. 011 level........................•..................................................... <- <- 12. Looseness at universal joint .
14. Clogging and fouling of all filter . <- <- 13. Twisting and cracks of axle shaft .
Fuel system
15. Fuel leakage . <- <- (-

16. Carburetor link mechanism operation . <- <-

17. Fouling and damage of fuel filter element. . <- <-
18. Injection timing . M
19. Injection nozzle injection pressure and condition •........ M
20. Draining of sedimenter .

68
o
C) VII. PLANNED AINTENANCE
o
c
o INSPECTION PERIOD (Accomplish based on
operating hours or months, whichever EVERY 3 6 12 MONTHS
INSPECTION PERIOD (Accomplish based on
op~rating hours or months, whichever EVERY 3 6 12 MONTHS
o is soonest.)
EVERY 170 500 1000 2000 HOURS
is soonest.)
EVERY 170 500 1000 2000 HOURS
o RUNNING EQUIPMENT Knuckle

o Wheels 8. King pin looseness . (- (- (-

o 1.
2.
lire air pressure
nrc cuts, damage and uneven treads .
. M
I
(-

(-
(-

(-
(-

(-
9. Cracking and deformation
BRAKING SYSTEM
.

o 3. Loose rim and hub nuts

4. Tread depth .
. T
M
(- (- (- Brake pedal

o 1. Play and reserve .

(- (- (-
M (- (- (-

5. Melal fragmenls, stones or other foreign . I (- (- (- 2. Braking effecl ...........•.........•.............................................. (- (- (-

o 6.
objects in tires

Rim. side ring and disc wheel damage........•.................. (- (- (-

Parking brake

3. Operaling force ..

o
(- (- (-
7. Front wheel bearing unusual noise and looseness .. (- (- (-
4. Braking effecl : . (- (- (-
B. Rear wheel bearing unusual noise and looseness ..

o
(- (- (-
5. Linkage and cable looseness and damage . (- (- (-
Front axle
Brake pipe and hose

o 9. Housing cracks and damage

Rear axle
.
6. Leakage. damage and mounting condition . (- (- (-

o 10. Beam cracks, damage and deformation .

Brake oil
7. Level ..........•..............•........................................................ (- (- .(-

o STEERING SYSTEM
Master cylinder or wheel cylinder
8. Function, wear, damage and mounting looseness .

o Steering wheel
Brake drum and brak.e shoe

o 1. Play and looseness

2. Operating condition
.
.
(-

(-
(-

(-
(-

(-
9. Clea~ance between drum and lining

10. Shoe sliding portion and lining wear

.
..
M (- (- (-

o Steering valve
3. Oil leakage.•.......................................................................
11. Drum wear and damage .
I
I

o 4. Mounting looseness.......................•.•.....•....•................•... T
(-

(-
(-

(-
(-

(-
12. Shoe operating condition ................•...............................
13. Anchor pin rusting.........................................................•.•
I
I

o Power steering

5. Oil leakage......•.......................•.......................................... (- (- (-
14. Return spring wear. etc
15. Automatic adjusting function operation
.

.
M
I

o 6. Mounting and linkage looseness . (- (- (- Backing plate

o 7. Power steering hose damage . 16.

17.
Deformation, cracking and damage

Mounting looseness
.

.
I
T

o
c
o
c 69
VII. PLANNED MAINTENANCE

INSPECTION PERIOD (Accomplish based on INSPECTION PERIOD (Accomplish based on

operating hours or months, whichever EVERY 3 6 12 MONTHS operating hours or months, whichever EVERY 3 6 12 MONTHS
is soonest.) is soonest.)
EVERY 170 500 1000 2000 HOURS EVERY 170 500 1000 2000 HOURS

LOAD HANDLING SYSTEM Oil pump

Forks 9. Oilleakage and unusual noise ........................................ <- <- <-
1. Fork and stopper pin condition ....................................... <- <- <- Hydraulic oil tank
2. Lett and right fork uniformity .......................................... <- <- <- 10. Oil level and contamination ............................................. <- <- <-
3. Cracks in fork base and welded portion ......................... 1'3 n. Tank and oil strainer ......................................................... C <-
Mast and lift bracket 12. Oil leakage......................................................................... <- <- <-
4. Deformation, damage and cracks in welded portion .... <- <- <- Controllever
5. Mast and lift bracket looseness....................................... <- <- <- 13. Linkage looseness ............................................................ <- <- <-
6. Mast support bushing wear and damage ...................... 14. Operation .......................................................................... <- <- <-
7. Roller wear, damage and rotating condition .................. <- <- <- Oil control valve
8. Roller pin wear and damage ........................................... 15. Oil leakage......................................................................... <- <- <-
9. Mast strip wear and damage ........................................... <- <- <- M
16. Relief pressure measurement •.................•................•.....
Chain and chain wheel 17. Relief valve and tilt lock valve function .......................... <- <- <-
10. Chain tension, deformation and damage ......•................ <- <- Oil pressure piping
n. Chain lubrication .•....••...••..••....•..•...•...•....••................•....•. <- <- <- 18. Oil leakage......................................................................... <- <- <-
12. Chain anchor bolt condition ............................................ <- <- <- 19. Deformation and damage ..•...••....••.......•.......••...•...•.....••.. <- <- <-
13. Chain wheel wear, damage and rotating •.....•...•........•...• <- (- <- 20. Linkage looseness............................................................. T <- <- <-
condition
ELECTRICAL SYSTEM
Various attachments (option)
Ignition system
14. Abnormalities and mounting condition •••...............•...... <- <- <- 1. Distributor cap cracking ................................................... <- <- <-
HYDRAULIC SYSTEM 2. Spark plug burning and gap ............................................ <- <- <-
Cylinder 3. Distributor side terminal burning.................................... <- <- <-
1. Cylinder mounting looseness and damage ................... T <- <- 4. Distributor cap center piece wear and damage ............. <- <- <-
2. Rod and rod screw and rod end deformation ................ I <- <- <- 5. Plug cord internal disconnection ....................................
and damage 6. Ignition timing ..........•...•..•.•.....••.•................•.............•...... M <-
3. Cylinder operation ............................................................ I <- <- <- Starter
4. Natural drop and natural forward tilt.............................. M <- <- <- 7. Pinion gear meshing ........................................................ <- <- <-
5. Oil leakage and damage .................................................. I <- <- <- Charger
6. Pin and cylinder shaft support wear and damage ...•..... I <- <- <- 8. Charging effect ........................•............................•....•..•... <- <- <-
7. lifting speed ..................................................................... M <- <- <-
Battery
8. Uneven movement........................................................... I <- <- <-
9. Battery electrolyte level ................................................... <- <- <-
10. Specific gravity ................................................................. M <-

70
o
o VII. PLANNED AINTENANCE
o
o
o INSPECTION PERIOD (Accomplish based on
operating hours or months, whichever EVERY 3 6 12 MONTHS
INSPECTION PERIOD (Accomplish based on
operating hours or months, whichever EVERY 3 6
o is soonest.)
EVERY 170 500 1000 2000 HOURS
is soonest.)
EVERY 170 500 1000
12

2000
MONTHS

HOURS
o Electrical wiring Seat belt

o 11. Wiring harness damage

12. Fuses
.
.
.....
<-
.....
<-
.....
.....
11. Mounting looseness . ..... .....

o
12. Webbing damage .. <- <-
Pre heater 13: Plate damage . <- ..... .....

o 13. Glow plug heat coil breakage

Engine stopping system
. ..... 14.
Body
Buckle damage . ..... ..... .....

o 14. Dieserengine key stop device function . ..... <-- ..... 15. Frame. cross member, etc. damage and cracking . I

o
SAFETY DEVICES, ETC. 16. Boll looseness . T
Over head guard Others

o 1. Welded portion cracking

2. Deformation and damage
.
..
.....
.....
.....
.....
.....
.....
17. Lubrication
For new truck
.. L ..... ..... .....

o Back rest '1 Soap

o 3. Mounting looseness
4. Deformalion, cracking and damage
.
..
T <-
.....
.....
.....
.....
.....
*2
·3
Leakage detector
Fissure and crack detector

o Lighting.system

o 5.
Horn
Operation and mounting condition .. ..... ..... .....

o 6. Operation and mounling condition . ..... ..... .....

o Direction indicators (option)

7. Operation and mounting condition ........•.•....••.•..•....•..... ..... <-- .....
o Instrument

o 8. Operation
Back-up buzzer (option)
.. <-- ..... .....

Ci 9. Operation and mounling condition .. ..... <-- .....

o Seat
10. Mounting looseness and damage . ..... ..... .....

o
o
o
o
c 71
VII. PLANNED MAINTENANCE

SERVICE DATA
Adjustment value table

--
ENGINE

Item
Fan belt tension
110 kg (22Ib) pressure appliedl

Spark plug gap

Spark plug type

(Outside diameter x pitch)
-
Engine model

mmUn}

mm(in)

mm
4Y

8-13
(0.31-0.511
0.7-0.8
(0.028 - 0.031 1

W9EX-U
GM

8-16
(0.31-0.63)
0.97-1.10
10.0382 - 0.0433)

AC-MP43T
lDZ

-
-
-
WHEEIL.

Item

Tire air
Front tire
Model

6.50·10-10PR

7.00-12-12PR

28x 9-15-12PR
1.5t

8.0
(115)

-
-
1.75t

8.0
(115)

-
2.0t

-
8.5
(120)

-
2.5t

8.5
(120)
-

-
3.0t

-
-
8.5
(120)
Ignition or fuel injection timing pressure 8.5
deg 7/1dling speed 3", 2/ldling speed o IStatic) - - - -

--
7.00L-15-12PR
kg/cm 2

-
(8TDC) (1201
Ignition or fuel injection sequence 1-3-4-2 IIb/in21
8.0 8.0
5. 70/5.00·8-8PLY (115) (1151 - - -
Intake o (Self-adjusting) 0.20
(0.008) 7.0 7.0

-
Valve clearance Rear tire 6.90/6.00·9-10PLY - - -
(Hot engine) mmlin) (1001 (100)
Exhaust o (Self-adjusting) 0.36
(0.014) 7.75
6.50-10-10PLY - - - - (110)
Standard 12.5/250 9.14/250 27/260
Engine compression value (178/250) ( 129.9/250) 1384/260)
kg/cm 2/rpm
Ipsi/rpm) 9.0/250 7.03/250 20/260
Limit
(128/250) (100/250) (284/260) : - - - - -Model 1.51 1.75t 2.0t 2.5t 3.0t
Item
No load maximum speed
1.5-1.75t
2.0-2.5t
2600
2600
-
2600"'50
2600
2800 Front
11-20
- 18-40
- 30 60

-
rpm (80-145) (130-289) (217-4341

-
Hub nut tightening
3.0t
1.5-1.75'
2800
750+ 5&
2600",50
-
2800 torque kg·m (ft-Ib)
Rear
9-16
(65-116) - 12-20
(87-145)

-- --
750"'25
Idling speed
rpm
2.0-2.5t
3.0t
750+ 5&
750+ 5&
Divided rim set bolt
tightening torque
kg·m (ft-Ib)
Rear
3-4.5
(22-321 - 5-7
136-51) - -
BATfERY
8allery electrolyte specific gravity (at 20°C 168°FlJ 1.280

STEERING
Steering wheel play (at engine idle speed1 mmlin) 25 - 50 (1.0 - 2.0)

BRAKE
Model

--
Item 1.5 1.75t 2.0 3.0t

Inching and brake pedal IPlay 5-1010.20-0.39)

mm (inll Floor clearance 7012.76) or more
Parking brake operating force kg lib) 15-20133-44) 20-25 (44-55)

OIL CONTROL VALVE

Model
1.5 1.75t 2.0 3.0t
Item

Set pressure kg/cm 2 (psi)

I
r
Lift
Tilt
185 (2630)
150 (2130)
--
7.2
c)
o VII. PLANNED MAINTENANCE

o Lubricant capacities and types

o
o Item 1.5-1.75ton 2-2.5 ton 3.0 ton
-
pe

o Engine oil e(US. gall

Gasoline 4Y
GM
4.0 (1.061
-
<-

3.8 (1.001 <-

API S[ ,SE, SF

o Diesel 1DZ 7.9 (2.091 <- <- API CII , CD

Ci Torque converter e(US. gall

1 speed 11.5 (3.041 <- <-
ATFG JI Dexron® II
o 2 speed 14..0 (3.701 <- <-

o Differential gear e(US.gall 5.4 (1.431 6.4 (1.691 9.0 (2.381 API G
-4
G -5
Hypoid
gear-oil
o Fuel tank e(US.gall 45 (11.91 65 (17.21 <-

o Wheel bearings, chassis, tilt steering

Appropriate amount MP Gr ase

o and mast and grease fittings

Brake lines e(US.gal) 0.2 (0.051 <- <- SAE J 703, DOT-3
o 4Y 9.6 (2.531 9.3 (2.46) 9.6 (2.531

o Engine cooling system

(excluding reserve tankl
e(US.gall GM - 8.8 (2.321 <-

o lDZ 8.1 (2.141 8.3 (2.191 <- L.L.C.

o Radiator reserve tank

(at FULL mark levell
e(US.gall 1.1 (0.291 <- <-

o Hydraulic oil e(US.gall 27 (7.11 34 (9.01 37 (9.81 ISOV 32

o *L.L.C. = Long Life Coolant

o (Appropriately diluted with fresh water)

o
o
o
o
o
o
o
o 73
VII. PLANNED MAINTENANCE

LUBRICATION CHART
1. Chain
2. Differential gear
3. Front wheel bearing
4. Brake master cylinder
5. Torque converter case
6. Rear wheel bearing
7. Steering knuckle king pin
8. Power steering cylinder pin
9. Oil tank
10. Engine crankshaft
1 11. Tilt steering universal joint
14 12. Tilt steering locking mechanism
3 13. Mast support bushing
13
14. Tilt cylinder front pin
14 2 15. Propeller shaft
16. Oil pump spline shaft
13 15 (GM engine models)
3
4 12
11 10

5 9 I. Inspect every 8 hours (daily)

II. Inspect every 40 hours (weekly)
7 16 III. Inspect every 170 hours (monthly)
IV. Inspect every 1000 hours (6 monthly)
7 V. Inspect every 2000 hours (annually)
6
6 0 Inspect and service
8 Replace
8 <D MP grease
~ Engine oil
@ Hypoid gear oil
® Hydraulic oil
@ Automatic transmission fluid

~
II Brake fluid
Molykote G-n Paste
III
IV
V

74
o
o VII. PLANNED AINTENANCE
o FRAME SERIAL NUMBER
o Stamp on the stiffener Frame serial number location
o below the front protector
The frame serial number is stamped
o on the front protector. Refer to the.
frame serial number when making in-
o quiries about your truck.

o
o
o
o
o Frame serial number location

o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o 75
VII. PLANNEID MAINTENANCE

76
o
o
o VII. PLANNED AINTENANCE

o
CI
o
o
o
o
o
o
o
o
o
o
c)
o
o
o
o
Ci
o
o
o
o
o
o
c 77
VII. PLANNED MAINTENANCE

78
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
o
A WARNING
• Make sure these important instructions are
available for the operator.
Keep this manual in the pocket on the seat
back.
TOYOTA Material Handling Company
.. Do not start the truck unless you under- PRINTED IN THE USA Publication No. AU012
stand these instructions. 095040-C