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CONTENT
Note for operators and mechanics .................................................. ................................................. .... 3

Before operation .................................................................. ................................................. ............... 3

Warning labels .................................................................. ................................................. ................. 5

Main components .................................................................. ................................................. ......................... 5

Driving Controls and Dashboard ....................................................... ............................... 6

Measuring instruments ................................................................ ................................................. ................... 6

Switches and Levers .............................................................. ................................................. ...................... 9

Body components .................................................................. ................................................. .............................. 12

Pre-operational check .................................................................. ................................................. ........ 14

Before parking the vehicle in the garage .................................................. ............................. 18

Weekly maintenance .................................................................. ................................................. .............. 19

Self-maintenance ............................................................... ...................................... 20

Checking the fuel tank .............................................................. ................................................. .................... 24

Frame serial number............................................................... ................................................. ......................... 24

How to read the rating plate .............................................................. ................................................. ......... 24

Smearing scheme................................................... ................................................... ......................................... 25

Periodic maintenance ............................................................... ......................................... 25

Periodic replacement table .................................................................. ................................................. ............. 26

Protecting Your Money with Genuine Toyota Parts .................................................. 26

LPG (Liquefied Petroleum Gas) Device (Optional) .............................................................. ............................... 27

Switches ................................................................ ................................................. ...................... 28

LPG tank and related parts .................................................. ................................................. ..28

Operation of forklifts powered by LPG .............................................................. ................. 29

Regulator maintenance .............................................................. ................................................... 33

Inspection and maintenance of LPG forklift trucks .................................................. 33

Lubrication and coolant ............................................................... ................................................. ......... 35

Engine Specifications................................................................... ................................................... 35

Mast Specifications and Rated Loads .................................................................. ............. 35

Wheels and tires ............................................... ................................................. ............................................... 40

Periodic maintenance table .................................................................. ......................... 41

Operating data .................................................................. ................................................. ................. 46

Vehicle dimensions ............................................................................... ............................................... 48

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NOTE FOR OPERATORS AND MECHANICS

This manual explains the proper operation and maintenance of Toyota industrial vehicles, as well as daily lubrication and
periodic inspection procedures. Please read this manual carefully even though you may already be familiar with other Toyota
industrial vehicles, because it contains information that is exclusively relevant to this series of vehicles. This manual is based
on a standard vehicle. However, if you have questions about other types, please contact your Toyota industrial vehicle dealer
(Toyota dealer). Toyota reserves the right to make any changes or modifications to the specifications in this manual without
prior notice and without incurring any obligation.

BEFORE OPERATION
Please read this manual carefully. It will give you a complete understanding of industrial
Toyota vehicles and enable you to operate them correctly and safely. Proper handling
new vehicles provides good performance and increases service life. Drive with extreme caution until you are familiar with your
new vehicle. In addition to standard operating procedures, pay attention to the following safety items.

Please acquire knowledge of Toyota industrial vehicles. Read the operator's manual carefully before operating the vehicle.
Learn the method of its management and its constituent parts. Learn the safe operating practices of devices and optional
equipment and their limits and precautions for use. Be sure to read the warning label attached to the vehicle.

Learn how to drive safely and drive safely. Understand and follow traffic rules in the work area. Ask an official in the work
area about any special work precautions.

Wear proper work clothes. Inappropriate clothing for the operation of the vehicle may interfere with normal driving and cause
an unforeseen accident. Always wear
proper clothing for easy control.
Please stay away from power lines. Find out the location of internal and external power lines and keep a sufficient distance
from them.
Be sure to perform pre-operational inspection, periodic maintenance. This prevents unexpected malfunctions, improves
operating efficiency, saves money and ensures a safe working environment.

Always warm up the engine before starting work.

Be sure to avoid tilting forward when the loaded forks are raised. In the worst case, this can lead to a rollover as a result
of poor stability due to a forward shift in the center of gravity.
Never attempt to ride with a load on raised forks above the specified height.
Riding with forks raised above the specified height may result in a tip over due to an upward shift in the center of gravity. Keep
the forks 10-20cm above the ground while driving.
Please avoid overloading uneven load. Overloading or uneven loading is dangerous. If the center of gravity is closer to the
front side, even when the load is below the maximum, limit the load weight according to the load table.

If you hear an unusual noise or feel anything unusual, check and repair immediately. Be sure to follow the correct
operating procedures and precautions when driving vehicles equipped with power steering and power brakes. If the
engine stops running while driving, the control will be affected. Stop the transport

facility in a safe place as described below. The steering will become tight as the booster will
ineffective. Operate the steering wheel with more force than usual.
Please use only the recommended types of lubricants. Low grade fuels and lubricants will shorten the service life.

Combustible and/or flammable materials can be damaged and in some cases ignite due to the hot exhaust system or
hot exhaust gases. To minimize the possibility of such damage or fire,

The operator must observe the following recommended practices:

Do not operate the lift truck around or near combustible and/or flammable materials, including dry grass and paper waste.

Stop the lift truck with its rear end at least 0.5 m away from furniture, plywood sheets, paper products and other similar
materials to prevent discoloration, damage or fire of these materials.

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OPS system
The OPS (Operator Presence Sensing) system blocks movement and loading/unloading operations if there is no operator in
the driver's seat.
If the operator leaves the seat while the loader is in operation, the OPS indicator will illuminate and an audible signal (1
sec) will sound to alert the operator that the OPS system has been activated. If the operator does not sit on the seat within
2 seconds, the OPS will stop the truck from moving and the loading/unloading operation in progress. If the operator returns
to the seat within 2 seconds, the OPS will not activate, allowing the truck to move and the loading/unloading operation in
progress to continue. In the event of a malfunction of the OPS system, the indicator will light up
OPS, informing the operator about problems. In this case, the OPS system may be malfunctioning. Please contact your Toyota
dealer for verification.

This loader is equipped with an OPS operator presence detection system. Before starting work, it is necessary to carefully
check the operation of all functions of this system.
If the operator leaves the seat while the truck is moving, the OPS indicator will illuminate and the truck will stop after two
seconds. However, emergency braking is not applied (If the operator returns to the seat within 2 seconds, the truck will continue
to move.)
If the OPS is activated while driving uphill, the engine drive will be disabled and the truck will begin to slide downhill. To avoid
this problem, do not get up from the seat during operation.
To disable this feature, move the control lever to neutral and sit in the seat
If the operator leaves the seat during a loading/unloading operation, the OPS indicator will illuminate and the loading/unloading
operation will stop after two seconds. (If the operator returns to the seat within 2 seconds, the loading/unloading operation will
continue.) If the operator leaves the seat while continuing to use the control lever, the loading operation can be continued within
2-4 seconds.

To unlock the loading/unloading operation, move the tilt lever to the neutral position and sit on the seat. After 1 second, the
OPS system will be turned off and the loading/unloading operation can be continued (Remember that if you sit on the seat
without the tilt lever in the neutral position, the loading/unloading operation will begin in 1 second.)

OPS control warning

In the event of a malfunction of the OPS system, the OPS indicator will flash to inform the operator of the problem. A flashing
OPS indicator indicates a possible problem with the OPS system. Park the forklift in a safe place and
contact your Toyota dealer for inspection.
In the following cases, park the loader in a safe place and have your Toyota dealer check it: when the operator leaves the seat,
the OPS indicator does not turn on; when the operator returns to the workplace, the OPS indicator does not turn off.

Warning
If the operator has been in the seat for a long time and the ignition has been turned off, the OPS indicator may flash
when the ignition is turned on. In this case, if the OPS indicator turns on permanently after the operator leaves the
seat temporarily, this does not indicate a malfunction.

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WARNING PLATES
Before driving, please be sure to read the labels on them carefully. (Here are examples of the English version.)

MAIN COMPONENTS
1. Mast 2.
Chain 3.
Fork 4.
Tilt cylinder 5. Rear
axle 6. Engine
hood 7. Operator
seat 8. Overhead guard
9. Counterweight 10.
Frame 11. Front
axle 12.
Lift cylinder 13.
Steering wheel

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DRIVING CONTROLS AND INSTRUMENT PANEL

1. Control lever 2.
Steering wheel 3. Horn button 4.
Light and turn signal control
switch 5. Lift lever 6. Lift lever switch knob (Optional) 7. Tilt
lever 8. Tilt lever
switch knob (Optional) 9. Multifunction display (Optional)
10. DPF-II display
(Optional) 11. Instrument cluster 12. Accelerator pedal
13. Brake pedal 14. Ignition switch 15. Parking
brake release lever 16. Engine
slow crank pedal and 17. Tilt steering
lever 18. Parking brake
pedal

MEASURING INSTRUMENTS
The meter illumination lamp is provided for easy reading of the meter data at night. It lights up when the light control switch
is set to the ON position.
1. Water temperature gauge 2.
Hour counter
3. Brake Warning Light (Optional) 4. Sediment Warning Light
(Diesel Models) 5. Fuel Gauge 6. Engine Warning Light (For
Gasoline Models) 7. Glow
Indicator Light (For 1DZ-11 Engine Models) Engine preheat indicator light (For models
with 2Z engine) 8. Engine oil pressure warning light 9. Charging warning light 10. OPS indicator 11. Malfunction
indicator 12. Air cleaner warning light (Optional) 13.
Coolant level warning light ( On request)

Petrol models Diesel models

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Test method for each warning light

Please check if all warning lights come on when the ignition switch is turned to the ON position.

Use the light control switch to test the instrument light bulb.

Warning
• Glow indicator light (models with 1DZ-II engine) will turn on for 2 seconds when the engine coolant temperature
exceeds 50°C.
• The preheat indicator lamp (models with 2Z engine) will not light when
engine coolant temperature will exceed 2.5°C.
• If the light does not turn on, have your Toyota dealer check it.
The hour counter also serves as an indicator of the diagnostic system
The meter only works when the ignition switch is turned on. It indicates the total number of hours the vehicle has been running.
The digit at the far right is 1/10 of an hour.
Please use this meter to check the timing of periodic maintenance and record hours of operation. In the event of a truck
malfunction (fault indicator blinking or solid), the hour meter display will alternately show the hour meter reading and the code

malfunctions

Warning
If an error code is displayed, stop the vehicle in a safe place and have it checked by a Toyota dealer.

Engine oil pressure warning light

It turns on to indicate low engine oil pressure while the engine is running.
Under normal conditions, the light comes on when the ignition switch is turned on and goes out when the engine is
started. If the light comes on while the engine is running, either the amount of engine oil is insufficient or the
lubrication system is out of order. Stop work immediately and have your Toyota dealer check and repair.

Note: The "engine oil pressure warning light" does not indicate the oil level. Check the oil level with an oil dipstick
before starting work.
"

Sedimentra warning light (Diesel models)

A sedimenter is a device for separating water from fuel.
1. A warning light comes on to indicate that the water in the sediment has exceeded
predetermined level during engine operation
2. Under normal conditions, the light comes on when the ignition switch is turned on and goes out when the engine
starts.
3. If the light comes on while the engine is running, drain the water immediately. (See section on self
maintenance to know the method of draining the water.)

Warning
Continued operation with the light on may cause the fuel pump to seize and damage the pump. When the warning light
comes on, drain the water immediately.
Glow indicator light (Models with 1DZ-II engine)
Indicates the heating of the glow plugs.
When the ignition switch is turned on, the light comes on and the glow plugs begin to warm up.
The light turns off automatically when the glow plugs are finished. The engine will start easily when the glow
plugs are warm.
Note:
The indicator light comes on for 2 seconds when the engine coolant temperature exceeds 50°C.

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Preheat indicator light (Models with 2Z engine)

Indicates preheating of the built-in heater. The ignition switch is turned on, the light comes on and preheating begins. This light turns off automatically when
warming up is completed. The engine will start easily.

Note:
When the engine coolant temperature exceeds 2.5°C, this light will not come on because there will be no preheating.

The length of the preheat time is automatically controlled according to the engine coolant temperature. It takes a little longer when the engine coolant
temperature is low and during the cold season.

Warning
If the indicator light does not turn off while the engine is running, the built-in heater preheat may not be working. Please have your Toyota dealer
check and
repair.

Gasoline engine malfunction indicator (For models with gasoline engine)

This signaling device is used to inform the operator about a malfunction of the engine control unit.

In the absence of malfunctions, the indicator lights up when the ignition is turned on. After starting the engine, the indicator goes out

Warning
If the engine warning light comes on during operation, stop operation, park the truck in a safe place, and have your Toyota dealer check it.

Air Cleaner Warning Light (Optional)

This light comes on when the air cleaner element becomes clogged while the engine is running.
Under normal conditions, the light comes on when the ignition switch is turned on and goes out when the engine is started. If the light
turns on while the engine is running, stop the engine and clean the element and dust cover. For information about the cleaning method,
see the section on weekly
verification.

Charging warning light

This light illuminates to indicate an abnormality in the charging system during operation.
the engine

Under normal conditions, the light comes on when the ignition switch is turned on and goes out when
engine starts
If the light comes on while the engine is running, stop operation immediately, check the fan belt for cuts or looseness, adjust it and start the engine again.

If the light does not turn off, the generation system may be out of order. Please have your Toyota dealer check and repair immediately.

OPS indicator
If the operator stands up from the seat, the OPS indicator will illuminate to indicate that the OPS system has been activated. If this
situation occurs, return the control and lift levers to the neutral position and sit on the seat. If there is a problem with the OPS system,
this indicator will flash. (Behind
except for SAS models)

Warning
In the following cases, the OPS system may be malfunctioning. Park the loader in a safe place and have your Toyota dealer check it.

When the operator leaves the seat, the OPS indicator does not turn on. When the operator returns to the workplace, the OPS indicator does not turn off. If the
operator has been in the seat for a long time and the ignition has been turned off, the OPS indicator may flash when the ignition is turned on. In this case, if the
OPS indicator turns on permanently after the operator leaves the seat temporarily, this will not indicate a malfunction.

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Water temperature gauge

Serves to display the temperature of the cooling water. The flashing of the two extreme right
bars informs the operator that the water temperature has reached or exceeded 115°C (above the eighth bar). Also, when the engine
protection function is activated (for trucks with a multi-function display: optional), all indicators begin to flash, attracting the attention
of the operator. Temporary overheating can be caused by a water leak, insufficient engine coolant, a loose fan belt, or other

deviation from the norm in the cooling system. Check the cooling system.
Fuel gauge
Uses a ten-bar scale to indicate the amount of fuel left in the fuel tank. The blinking of the
two leftmost divisions informs the operator about the low fuel level. It will take a little time
for the indication to stabilize after refueling and turning on the
ignition switch.

Warning
If the road is uneven, then pay special attention, as the correct level may not be indicated. The blinking indicator indicates
the need to fill the fuel tank as soon as possible. Especially in the case of a diesel, be sure to top up the fuel before it runs
out, because if this causes the engine to stop working, it will be necessary to bleed the air from the fuel supply system.

Malfunction indicator
If a malfunction is registered, the corresponding warning lamps will light up or flash, and the diagnostic trouble
code will be displayed on the hour meter display. The following conditions may indicate a system malfunction.
Please contact your Toyota dealer for verification. The indicator does not light up when the ignition is turned on.
The indicator flashes while the truck is moving (during an operation).

Warning
Continuing to operate the loader while the fault indicator is lit or flashing may result in damage to the loader. If the engine
warning light comes on or flashes, stop work and park the truck in a safe place. Please contact your Toyota dealer

for verification. (In the case of loaders equipped with diesel engines, the OPS indicator
may come on while the engine is warming up after a cold start, but this is not a malfunction.) If the operator has been in
the seat for a long time and the ignition has been
off, the engine warning light may flash when the ignition is turned on. In this case, if the indicator turns on permanently
after the operator leaves the seat temporarily, this will not be an indication of a malfunction.

Brake Warning Light (Optional)

Illumination of this warning light informs the operator that the parking brake has been applied or that the brake
fluid level is low. The warning light comes on when the parking brake is applied. After disengaging the parking
brake, make sure that the indicator goes out. Illumination of this warning light informs the operator that the brake
fluid level is low.

Warning
The inclusion of this warning lamp when the parking brake is off may indicate an insufficient amount of working fluid in
the brake system. Check the brake fluid level and top up if necessary. If the warning light still comes on after topping up
the brake fluid, have your Toyota dealer check it.

SWITCHES AND LEVERS

ignition switch

[OFF] Motor stop position. The insertion and removal of the key is done in this
position

[ON] Engine running position. Selected when rotated one position clockwise from the [OFF]
position.
Before starting in diesel models, the intake air heater
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preheated.
START Engine start position. Selected by turning one position clockwise from position I
[ON]
After starting the engine, release the key and it will automatically return to the [ON] position. Models with a torque converter will not start the engine unless the
control lever is in neutral.

Warning
Before turning on the ignition, you must sit on the seat. Otherwise, the forklift may move uncontrollably, resulting in an accident. If the OPS indicator
is on, return all levers to neutral and sit in the seat. After that, make sure that the indicator is off. Do not leave the switch in the [ON] position when
the engine is stopped. This may lead to excessive discharge of the battery. Do not turn the switch to the START position while the engine is running.
For safety reasons, it is recommended that you always start the vehicle engine with the shift lever in neutral. Do not crank the starter motor
continuously for more than 30 seconds at a time. Return the switch to the [OFF] position and wait at least 30 seconds before trying to start again.

In the case of an ignition switch with a restart lock (purchased separately), be sure to turn the switch to the [OFF] position before attempting to start
the engine again.

When the ignition switch is set to the OFF (engine off) position, the forks will not move down even if the lift lever is properly controlled. However, if
you sit on the seat and turn on the ignition, the forks can be lowered. Do not operate the lift lever until the vehicle engine has started. (Lift lock by
turning off the key)

If the fault indicator does not turn off when the operator is seated, the battery voltage is probably low. In such a case, do not start work until the
warning indicator goes out, otherwise the truck will not work properly. Use a forklift if necessary, but with great care. Also, if the indicator does not
turn off 1-2 minutes after starting the engine or after some time after the engine has been idling, stop the truck and contact your Toyota dealer for
inspection. (For diesel engines, the light may be on for a short time while the engine is warming up during a cold start. However, this does not indicate
a breakdown or malfunction of the engine.)

Combined light and turn signal switch

This switch functions as a two position light and turn signal switch.

Light control switch

Regardless of the switch key position, this switch allows you to
turn lights on and off

This switch has three positions. With the switch set to each position, the bulbs turn on,
as shown below.

Name of bulbs/
0 1 2
handle position

headlights
off off incl.

Bulbs for side markers, rear off incl. incl.

lights (Optional)

Measuring lamp off incl. incl.

Warning
Do not leave lamps, such as headlights, on for a long time with the engine stopped. This can cause the battery to over-discharge, making it impossible
to start the engine. turn signal switch

Turns on the turn signal lamps in a flashing mode. Left turn - press forward. Right turn -
pull back. The turn signal indicator works when the ignition is on. The turn signal lever automatically returns to its original position after changing
direction

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1—Forward. 2--Back
Control lever
Lever to switch between forward and reverse.
Forward - Press Forward
Back - Pull back
The neutral position is halfway between the forward and reverse positions.

Note:
After the system is activated, fully release the accelerator pedal, move the control lever
to the neutral position and sit on the seat to continue driving. (Even after
once the operator has sat down on the seat, further movement is not possible until the control lever is moved to
neutral position.)

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

(1) Click
Horn button
Press the button in the center of the steering wheel to sound the horn. The
horn will sound even if the ignition switch is
switched off

1. Lower
2. Raise
3. Lift lever switch handle
lift lever
Raise................. Pull back
Lowering ........... Push forward
Lifting speed can be adjusted by the amount of accelerator pedal depression and lever
stroke
The lowering speed can only be adjusted by the degree of inclination of the lever stroke.

Warning
After the system is activated, fully release the accelerator pedal, move the lift lever to the neutral position and sit on
the seat to repeat the operation. (If you sit on the seat and do not move the lift lever to the neutral position, the forks
may start moving again.)
If the operator returns to the seat before the lift lever is lowered, the forks will not lower due to the return to neutral.
Always operate the lift lever while properly positioned in your work area. With the ignition off, the forks will not move
even if the controls are operated. However, if you sit on the seat and turn on the ignition, the forks can be lowered.

(1) Push down (2) Parking brake release lever

Parking brake pedal

Use the parking brake pedal when parking or stopping the loader.
To apply the parking brake, fully depress the parking brake pedal
while keeping the brake pedal depressed. To release the parking
brake, pull the parking brake release lever while keeping the
brake pedal depressed.

Warning
Before applying the parking brake, you must depress the brake pedal and make sure that the truck has come to a
complete stop. Chock the wheels when parking on a slope. Driving with the brake not released will degrade brake
performance.
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Steering Wheel Tilt Adjustment

With the steering tilt lever up, you can move the steering wheel closer or farther. Lowering the
lever to the desired level, you fix the steering wheel in this position. After adjustment, try moving
the steering wheel back and forth to confirm that it is locked.

Warning.
The position of the steering wheel must be adjusted before the vehicle starts moving.
Adjustments while driving should be avoided.

BODY COMPONENTS
(1) Seat slide lever
(2) Seat reclining adjustment lever (Optional)
(3) Weight Adjustment Lever (Optional)
(4) Seat belt
Operator's seat
The operator's seat and seat belt keep you safe. The seat can be moved back and forth
to adjust the position when the adjustment lever is pulled up.

Warning
The seat is equipped with a switch that prevents the truck from moving and lifting and lowering the forks when the
operator is not sitting on the seat. Therefore, in order to operate the loader, it is necessary to sit on the seat.
Furthermore, do not attempt to operate the forklift with a heavy object placed on the seat. Do not attempt to turn on
the seat switch in any other way - you must sit on the seat.
The seat suspension mechanism provides a comfortable seating position according to the rider's weight. The optimum driving
position can be set using the handle and levers. Seat sliding lever. Pull the sliding lever to the left to adjust the seat back and
forth. The seat will lock into position when you release the lever. Seat reclining adjustment lever (Optional). Pull the lever on
the left side to adjust the seat reclining angle. Weight Adjustment Knob (Optional) Turn the knob on the right side of the seat
clockwise to adjust for heavier body weight. Turn the knob counterclockwise to adjust for a lighter body weight. The adjustment
can be made for a person weighing between 40 kg and 120 kg.

Warning
After adjustment, gently jerk the seat back and forth to confirm that the seat is securely locked in that position.

Pocket
The operator's manual and operator's safety manual are located on the back of the seat.
Be sure to open the pocket on the back of the seat with both hands. If your truck does
not have an operator's manual and operator's safety manual, please contact (your
authorized Toyota dealer) to obtain copies for your truck.

Note:
Make sure the pocket is securely closed.

magazine box
On the back of the pocket there is a drawer for small items such as tablets and work gloves. To
prevent items from falling out of your pocket when opening and closing the engine hood or while
driving on poor road surfaces, secure with a strap.

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Safety belt

To fasten your seat belt, pull it out of the retractor and insert the plate into the buckle. You
will hear a click as the plate locks into place in the buckle. Pull on the strap to confirm that
the buckle is securely locked. The length of the seat belt is automatically adjusted according
to your size. Unfastening method. Press the release button and let the belt retract.

Note:
If the seat belt is fixed and cannot be pulled out, pull it firmly towards you, then loosen it,
and then slowly pull it again.
Warning
Fasten with a buckle. Your seat and seat belt can reduce the risk of serious injury or death in the event of a rollover.
Your chances of avoiding serious injury or death in the event of a rollover are better if you remain in the operator's
cab with the loader. Always use a seat belt when driving a forklift. Loaders can tip over if not properly controlled. To
protect operators from the risk of serious injury or death in the event of a rollover, it is best to be securely restrained
in the seat. The seat and seat belt will help keep you safely within the forklift and operator's cab. In the event of a
rollover, do not jump out, but hold on to the steering wheel, support your feet, lean in the opposite direction of the
rollover, and remain in the loader. Please always buckle your seat belt when driving a forklift.

(1) Engine hood lock release lever

engine hood
opening
To unlock the engine hood latch, pull the release lever, which will open the hood
slightly. Raise the hood fully and then give it a little tug to make sure the hood damper is
securely locked in place, then release the hood.

1. hood shock absorber to unlock it.

2. Gently close the hood, then press it until it clicks.
Warning
Operating a vehicle with the engine hood not securely closed is very dangerous. Be
sure to check the security of the fixation before operating the vehicle.

Closing
Raise the hood and press the hood shock absorber latch to unlock it. Close the hood carefully,
then press it until it clicks.
Warning
Operating a vehicle with the engine hood not securely closed is very dangerous. Be sure to check the security of the
fixation before operating the vehicle.

hitch rod
The hitch bar is located on the rear side of the counterweight and is used to pull the vehicle
out if its tires are caught in a gutter or stuck in the mud. It can also be used to mount a
forklift onto another vehicle.

Warning
The tow bar must not be used to tow a forklift or to tow another vehicle using a forklift

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Pitchfork

Raise the stopper of each fork and rotate to release so that the forks
could move
left and right. Set the forks to the position most suitable for the load. When installing the forks, make sure that the
load center of gravity matches the center of the vehicle. After installation, rotate the stoppers to secure the forks to

place.

Warning
The forks must be locked before transporting the load.

PRE-OPERATIONAL CHECK
Item Checking Pre-operational check
Pre-discovered To correct
Responsibility for
malfunctions
Appearance Vehicle body oil leakage, water leakage, loose parts external pre-operation checks and weekly inspections are
damage the responsibility of users of Toyota Industrial
Vehicles
wheels Tire pressure Worn or damaged rim Wheel nuts

Be sure to follow before

Lamps Lamp condition, damaged lamps
operational check before starting work to ensure
Hydraulic oil Oil level, contamination consistency
safety
Radiator coolant level antifreeze requirement

Engine Oil level pollution consistency noise exhaust

gas

Clutch Engagement, pedal play

Brake pedal Brake Pedal play, brake effect
fluid Liquid level

Parking brake Steering Working force, braking effect

wheel Looseness backlash vibration change of direction

Sound signal sound

Measuring instruments Functioning

Cargo management system Parts, oil leak, cracked looseness

Fuel Quantity

General inspection
Vehicle verticality
Is the vehicle tilted to one side or the other? If so, check for a flat tire or chassis problem.

under the vehicle

Check for any oil or water leaks on the ground or floor where the vehicle was stopped. Check for loose parts or
damage. If any unusual condition is found, have the vehicle checked by a Toyota dealer.

Tire check
Tire pressure
Use a manometer and measure the air pressure. Adjust it to the correct level.

See operating data section for proper air pressure. Do not raise the pressure above the proper level. After
adjustment, check for air leakage from the valve.

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Damaged, cracked or worn tires and rims.

Check the tires for damage and wear and the rims for bending. If the tires are damaged, or if
there is a noticeable difference in front and rear or left and right tire wear, or bent rims are
found, have your Toyota dealer check.

Checking hub nuts

Check the tightness of the hub nuts. Avoid uneven torque and tighten all nuts equally. Refer to
the operating data section for
determining the correct torque.

Checking lamps
Check if the filaments are intact? Is there any damage to the hull? Always keep the windows
clean for the best forward view.

Engine compartment check.

Checking the level and supply of engine coolant
Checking the level and supply of engine coolant should be carried out with cold coolant.
With the engine off, open the engine hood and check the engine coolant level in the reservoir.

Note.
The reservoir that the radiator is equipped with automatically supplies engine coolant when
the amount of coolant in the radiator becomes insufficient. The coolant level is correct if it

lies between the upper and lower limits.

Note:
If there is no engine coolant left in the reservoir, be sure to also check the coolant level in
the radiator.
Checking the engine coolant level in the radiator
Remove the radiator cap.
Remove the cap and check the coolant level through the filler hole.

If coolant cannot be seen through the filler hole, pour an appropriately diluted coolant
into the filler hole.

Note:
To close and tighten the radiator cap, align the latch on the back of the cap with the
groove on the filler neck and turn the cap all the way clockwise, applying downward
force

Warning
When the engine is hot, removing the cover is very dangerous. Checking the
coolant level should always be done when the engine is cold.

Checking the hydraulic oil level.

Always stop the engine and lower the forks to the ground before checking the hydraulic oil
level when the vehicle is on level ground. Open the engine hood and remove the oil cap.
Wipe the level gauge attached to the oil cap with a clean cloth and put it back in the tank
again.

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Note:
Without pushing in the oiler cap, check the oil level by placing a dipstick in the feed inlet
oils.

Carefully remove the level indicator and check if the adhered oil reaches the level line.
(1) Oil cap
(2) Level indicator
(3) Pointer identifier
(4) Lifting height 6100-7000mm
(5) Lifting height 5500-6000mm
(6) Lifting height 4500-5000mm
(7) Lifting height 3300-4000mm
(8) Lifting height 3000mm or less
Checking the oil level
Stop the vehicle on a flat surface. If the vehicle is tilted, the indicated level may not be
correct. The oil level must be checked before starting the engine or at least 3 minutes after
stopping the engine. Remove the oil level gauge and wipe it with a clean cloth. Insert it
again and check if the oil level is between levels F and L. If the oil level is below line L, add
oil up to line F.

Adding oil.
To add oil, remove the filler cap and pour oil through the filler hole. Never allow the oil
level to exceed the F line. The oil added must be suitable for the season.

SAE 40 Ambient temperature over 30°C

SAE 30 Ambient temperature 0°C to 30°C
SAE 20 Ambient Temperature -10oC to 0oC

Checking the brake fluid.

With the engine off, check the brake fluid level in the reservoir. The level must be within the
range shown in the figure. If the level is below the lower limit, add brake fluid to the correct
level. If the loss of brake fluid is excessive, there may be a leak in the brake system. Ask your
Toyota dealer to check as soon as possible.

Warning
Never use any oil in place of brake fluid. Don't let dirt get into the tank. Even a small
amount of dirt in the brake fluid can interfere with normal braking. This will be extremely
dangerous.
Check the small vent hole in the reservoir lid for
confirmation that it is not clogged with dirt.

Checking the brake pedal

Fully depress the brake pedal and check the floor clearance (the clearance between the
pedal and the floor).
Note:
See service data section for floor clearance.
Make sure the pedal does not fall further when it is held down.
Also check that there is no abnormality when pressing and returning the pedal. Depress the brake pedal by hand to check
for free play until resistance is felt.

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Note:
See operating data section for brake pedal free play.

Warning
Ask your Toyota dealer to check if the free play is too large, the pedal movement is
abnormal or the braking performance
wrong.

1 - brake pedal.
2 - clearance from the brake pedal to the floor.

Parking brake pedal.

Fully depress the parking brake pedal and check that the pedal functions properly. Pull the
parking brake release lever towards you and check that the parking brake is released.

Warning
Have your Toyota dealer check if any abnormality is found.

Checking the OPS indicator.

Sit in the seat, start the engine, and check that the OPS indicator is off.
In the following cases, the OPS indicator may be malfunctioning. Park the forklift in a safe place and have your
Toyota dealer check it. When the operator leaves the seat, the OPS indicator does not turn on. When the
operator returns to the workplace, the OPS indicator does not turn off.

Checking measuring instruments

Start the engine and see if they work properly.

Checking the level and refueling fuel.

Look at the fuel gauge and make sure you have enough fuel.
Note:
After finishing the day's work, fill the tank with fuel to prevent the air in the tank from mixing
with the fuel.
When refueling, stop the engine, remove the fuel tank cap by turning it counterclockwise, and
pour fuel through the fuel filler neck. Be sure to tighten the fuel tank cap after refueling.

Warning
Always stop the engine and keep away from sources of ignition before and during refuelling. Be careful not to let water
or dirt enter the fuel tank when refueling.
Engine check
Start the engine and warm it up sufficiently. Check each pointer and each warning light to
confirm that there are no abnormalities. Check if the motor is making abnormal sound or
vibration. Check the color of the exhaust gas to make sure it is normal. Colorless or slightly
blue exhaust gas indicates complete combustion, black exhaust gas indicates incomplete
combustion and white exhaust gas indicates

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combustion of oil as a result of oil entering the cylinders.

Warning
Exhaust gas is harmful. If you must run the engine inside a building or in an enclosed area, ensure adequate
ventilation. The carburetor of a gasoline engine is equipped with an automatic choke that keeps the engine running
at a relatively high RPM for a period of time. However, don't worry if the engine runs at normal speed after it's warmed
up enough.

Cargo management system

Check the condition of the forks for cracks and bent spots. Check for mast distortion, chain tension
and oil leakage from cylinders and pipes. Operate the lift and tilt levers to check the working
condition. If anything abnormal is found, have the vehicle checked by a Toyota dealer.

Steering wheel check

Note:
Carry out the check after starting the engine. Check the steering wheel for play when the rear
wheels are in the straight ahead position.

Note:
See operating data section for standard steering wheel play. Turn the steering wheel in a circular
direction and also move it up and down to check that it is not loose. Press the horn button to confirm
that the horn is sounding normally. If any abnormality is found, have your Toyota dealer check.

When moving slowly

Clutch engagement and slip
Depress the engine crank pedal and check to see if the clutch engages while driving.
Brake performance
Check to see if there is anything unusual when you press the brake pedal and if the brakes are working on only one side.
Apply the parking brake and make sure that the truck can be stopped and that the parking brake can hold it in place.

Warning
If you feel anything out of the ordinary, stop using the vehicle immediately and have it checked by your Toyota dealer.

Steering check
While the vehicle is moving slowly in a safe place, turn the steering wheel left and right and check for any unusual movements.

Warning
If there is any sign of a malfunction, or if the malfunction indicator lamp turns on or flashes, or an error code appears
on the hour meter display, immediately stop all work on the loader and contact your Toyota dealer for inspection. (In
the case of trucks equipped with diesel engines, the malfunction indicator may turn on during engine warm-up after
a cold start, but this is not a malfunction.)

BEFORE PARKING THE VEHICLE IN THE GARAGE

Remove dirt from all vehicle components, and then do the following. Check for oil or water leakage. Check each component
for deformation, scratches, concavities or cracks. Clean the air filter element and lubricate the parts as required. Raise the
forks all the way up and down to lubricate the inside of the lift cylinder.

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WEEKLY MAINTENANCE
Check the items below in addition to the pre-operational check items. Have any necessary adjustments or replacements
carried out by your Toyota dealer. Please check your vehicle carefully to ensure a safe and pleasant working environment.
Weekly check items (40 hours) Air cleaner - clean Fan belt - check Torque converter oil level - check

Check battery electrolyte level. Bolts and nuts - tighten. Mast and rudder joint - lubricate. Chain Lubrication - Engine Oil

Cleaning the air cleaner

The element can be taken out after removing the three latches securing the element.
Tap the filter paper lightly without causing any damage, or blow out the dirt with compressed
air (7 kg/cm or less) from the inside.
After cleaning the element, remove all dust from the suction valve.
Note:
Always replace the element if the filter paper is torn or damaged.
Rinse the element if it is heavily soiled.
Immerse the element in water containing neutral detergent for approximately 30 minutes
and then rinse. Be careful not to damage the filter paper. After rinsing, rinse the element
with clean water (water pressure less than 2.8 kg/cm). Dry normally or use a hair dryer
(cold air). Never use compressed air or fire.

Note:
The element must be replaced after six washings or after use.
him for one year.

There is no need to clean the inner element when cleaning the double cyclone air cleaner.
(Optional) Clean the outer element only. It is important to replace both the outer and inner
elements during replacement.

(1) Suction valve

Checking the fan belt

Check the fan belt for cracks, fraying and tension. If any abnormality is found, replace
the fan belt or have it adjusted by your Toyota dealer. Refer to service data for tension
information.

Engine 4Y Engine 1DZ-II, 2Z

Battery electrolyte check

1. The battery electrolyte must be between the upper and lower levels (10 - 15 mm from
the top of the plates).
2. If the electrolyte level is below the low level, remove the cap and add distilled water to
the high level through the water fill hole.

Warning
Be sure to use distilled water for the battery electrolyte. Also wear
protective goggles when working on the battery.

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Checking the torque converter oil

1. Park the loader in a safe place on a level surface and stop the engine.

Warning
Carry out the inspection with the parking brake applied and the
pitchfork land

2. Open the engine hood and remove the outer shield.

3. Remove the level indicator and wipe it with a clean cloth.
4. Insert the level indicator back into the hole from which it was removed and remove it
again to check if the level is between lines F and L on
(1) Outer shield level indicator.
Note:
• Before driving, inspect using the COLD (cold) mark.
level meter.
• There are "COLD" and "HOT" marks on each side of the level meter. Inspection using the
"COLD" mark of the level meter should be carried out before driving at a working fluid
temperature of 40 ° C or below. If at the end of the movement the temperature of the
working fluid is higher than or equal to 60 ° C, then
check the level at the "HOT" mark, waiting from 30 seconds to 5 minutes after the engine has stopped.
5. If the level is near line L, then add oil to line F.

Tightening bolts and nuts

Tighten every bolt and nut on the chassis and load control system.
Mast and steering joint lubrication
Lubricate according to the lubrication chart.

Warning
• Thoroughly clean grease fitting tips before lubricating.
• Wipe off excess grease after lubrication.
When the battery is low
If there is a connecting cable, it is possible to start the engine using the battery of another
vehicle.
Connect the connection cable in the sequence shown in the figure. Be sure to match the (+)
and (-) terminals when connecting the cable.

Warning
• Connection (1): To the terminal (+) of the discharged battery.
• Connection (4): Use the case instead of the battery.
• Do not connect batteries directly to avoid fire hazard. (Combustible gas generated by batteries
a. vehicle with
discharged battery may ignite.)

b. Engine Mount
c. To the body
d. Connection cable
e. Auxiliary
accumulator battery

INDEPENDENT MAINTENANCE
Tire change

Warning
Take proper safety precautions when jacking up the vehicle. Never crawl under

fork or body.
For a compound rim wheel, do not loosen the rim bolts and nuts.
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while loosening the hub nuts. When loosening the rim nuts or removing the rim bolts, be sure to
completely bleed air before loosening.
Refer to service data for hub nut torque and tire pressure.

Tire pressure is very high, so pay attention to rim deformation, cracks, etc. Never exceed the correct tire
pressure.
Do not change any wheel without turning on the ignition switch before jacking up the vehicle. After
replacement is complete, return the ignition switch to the OFF position.
(SAS models).

Front wheels
1. Unload the vehicle, place it on a level surface
2. Apply the parking brake, put blocks under the wheels. The jacking point is located on
the bottom of the frame behind the front wheel. Insert the jack securely in there.
Make sure the jack is positioned correctly.
3. Jack up until the wheels are off the ground and loosen the hub nuts.

4. Jack up until the wheels are off the ground. Release all air pressure from the tire,
(1, 3, J3.5-ton (2-ton models)
then remove the hub nuts and
models) remove the wheel.

5. To reinstall the wheel after changing a tire, follow the removal steps in reverse
order. The hub nuts must be evenly tightened in the sequence shown in the figure.

6. After changing the wheel, check and adjust the air pressure in the tire.

(3-ton models)

(1) Hub nut

(2) Rim nut
(Never loosen without releasing the air)

rear wheels
1. Position the vehicle on a level surface.
2. Apply the parking brake and chock the wheels, then install
jack under counterweight.

Warning
Never loosen the compound rim nuts. If any nuts are found to be loose or otherwise
abnormal, deflate the tires and then loosen the hub nuts to remove the tires.
(1, 2, 3, J3.5 ton
models)

(1) Hub nut

(2) Rim nut
(Never loosen without releasing the air)

Jacking position
Place the jack on the jacking point located under
counterweight

Warning
Make sure the lifting capacity of the jack you are using is 5.0 tons or more.

1. Jack up until the wheels are off the ground and loosen the hub nuts.
(1) Garage jack (not available for 1
ton models)
(2) Heart rate jack 21
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2. Jack up until the wheels are off the ground. Release the air pressure completely from the tire and
then remove the hub nuts and remove the wheel.
3. To reinstall the wheel after changing a tire, follow the removal steps in reverse order.

The hub nuts must be tightened evenly in the same sequence as

for the front wheels.
4. After changing the wheel, check and adjust the air pressure in the tire.

Adding antifreeze
If the vehicle is left in a place where the temperature is below 0°C, the cooling water will freeze and may damage the radiator and/or
engine block. In such cases, a coolant with antifreeze must be used. If Long Life Coolant (LLC) is used, it should be replaced every two
years. The freezing point varies depending on the amount of antifreeze added.

Antifreeze mixture (%)

Frost protection temperature (°C) -12 -15 -24 35

Blend (%) 25 30 40 50

Warning
Antifreeze fluid is flammable, so be especially careful to avoid flames. Before adding antifreeze, check
the radiator, water pump, piping and cylinder block for leaks. The procedures for adding antifreeze will
be as follows.
1. Remove the radiator cap. Open the drain cocks on the radiator and cylinder block and drain the coolant
water
2. Flush the radiator and cylinder block by adding clean water through the radiator inlet.
3. After the water is drained from the radiator and cylinder block, close the radiator and engine drain cocks.
4. Add the proper amount of antifreeze through the radiator inlet and fill the remaining space with clean water.

Replacing fuses
If the light does not turn on or the electrical appliance does not function, then the corresponding
fuse may have blown.
Check the fuse for each appliance. The fuse box is located on the front left when viewed through
the open hood
the engine.

Note:
(1) Fuse box See the table below to determine the appropriate device for each fuse

fuse.

Purpose of fuses

A 25A BLR O 15A Heater

B 30A STA P 15A Headlight
C 20A Rear Q 15A HEAD
wiper

D 20A Front R 40A AM2

wiper

E 40A AM1 S 30A Reserve

F 15A Alert T 7.5A Reserve
G 15A CDS U 7.5A Meter
H 15A EFI:4Y-E At 7.5A Starter
DPF:1DZ,2Z W 10A Dimensions
I 7,5A ALT-S X 10A Rear light

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J7,5A Stop signal Y 7,5A SFT

K 7,5A ACC-B Z 7.5A Turns
L 7,5A TAIL a 7,5A IGN:4Y-M
M 7,5A ECU-B 15A IGN:4Y-E
N 15A E-THRQ: 4Y-E b 15A Reserve
ECU-B2: 4Y d 10A e Reserve
7,5A
M,1DZ,2Z 10A ECU-IG
Including equipment on request
The fuse check and replacement procedure is as follows:
1 Turn the ignition key to the OFF position.

2 Remove the cover of the fuse box and take the clip
attached to the fuse box.
3 Put the clip on the fuse to remove the fuse.
4 The fuse is blown if its condition is as shown on the right side of the figure on the left.
Replace it with a spare fuse.

Warning
Use a fuse with the same capacity as the one that was installed.
If the replaced fuse blows again, have your Toyota dealer check it.
Have your Toyota dealer replace the GLOW or ALT fuse if necessary.

Purge air from the fuel system

(Models with diesel engine)
When the fuel runs out completely or when the fuel system has been repaired, be sure to
purge air in the following sequence.
1 Open the engine hood
2 Operate the starter pump up and down to evacuate the air

Draining water from the sedimenter

(Models with diesel engine)
The sedimenter separates the water contained in the fuel. It is integrated with the fuel filter. If
the sedimenter warning light turns on, drain the water immediately according to the following
procedure because the accumulated water in the sedimenter has exceeded a certain level.

1 Place a container to receive water under the open end of the drain hose, under the fuel
filter.
2 Turn around the drain cock once or twice to loosen it and operate the starter pump up and
(1) Start pump down to drain any water in the sediment.
(2) Drain plug
3 When fuel begins to pour out after the water has finished draining, tighten the drain cock
(3) Drain hose
securely.

Warning
Wipe fuel clean from adjacent areas.

Battery Care
Terminals
1. A loose or rusty terminal will cause an interruption in the connection. Remove white
deposits if formed on the terminal by pouring warm water on it to remove it, then lubricate
the terminal.
2. Remove the terminal, if it is severely rusted, from the battery to remove corrosion using a
wire brush or sandpaper. Then firmly connect the terminal to the battery and lubricate
the terminal.
(1) Grease
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Note:
Remove the negative (-) terminal first, but replace it with the second.

Warning
Stop the engine if you want to work on the battery and terminals.
Be careful not to let any foreign object get into the battery by making sure that the covers are firmly in place.

Be careful not to cause a short circuit of the battery or fire near it, such as a fire when smoking, as the battery emits
flammable gas.
Be careful not to come into contact with the battery electrolyte. If it gets into the eyes or on the skin, wash it off
immediately with plenty of water and then see a doctor.
Charge the battery with the covers removed in a well-ventilated area.
If battery electrolyte is spilled, be sure to thoroughly wash it off with water from the spilled area and surrounding
areas.

Radiator core cleaning

Clean the radiator and its core. The accumulation of debris in them can lead to overheating of the engine.

Warning
Stop the engine and make sure the engine is cool before cleaning. Failure to take sufficient precautions may result
in burns.
When cleaning the radiator core, care must be taken not to damage it.
Use protective goggles and a respiratory mask during the cleaning process.

FUEL TANK CHECK

Check the fuel tank, tank cap, fuel inlet and drain plug for possible fuel leakage. Follow the steps below.

1 Try to smell the leak.

2 Check for leaks.
3 Feel for potential leaks.
If a leak is found, contact your Toyota dealer and have the fuel tank repaired immediately.

Warning
Never attempt welding or other repairs yourself as this may result in an explosion or fire.

FRAME SERIAL NUMBER

Frame serial number location
The frame serial number is stamped on the front cross plate. Please refer to the frame
serial number when making inquiries about your vehicle.

(1) Frame serial number location

HOW TO READ THE NAMEPLATE

Load capacity engraved on nameplate
Be sure to check the load center and load capacity before starting work.
1 vehicle type
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2 Special vehicle, attachment type 3 Frame no.

4 Vehicle weight 5 Mast height

6 Front track 7 Tire size 8
Air pressure 9 Year
of manufacture
10 UL specification 11
Load capacity 12
Load center

LUBRICATION CHART 1
Chain 2
Differential 3 Front
wheel bearing 4 Brake and clutch
master cylinder 5 Transmission housing 6
Rear wheel bearing 7
Steering knuckle pin 8 Oil tank
9 Engine crankshaft 10 Rear axle
beam front kingpin
11 Rear axle beam rear kingpin
12 Mechanism steering tilt lock 13 Mast support bushing
14 Tilt cylinder front king pin 15 Propeller shaft 16 Swing
lock cylinder 17 Tie rod lock pin 18 Rear axle cylinder lock
pin

I) Check every 8 hours (daily)

II) Check every 40 hours (weekly)
III) Check every 250 hours (6 weeks)
IV) Check every 1000 hours (every six months)
V) Check every 2000 hours (yearly)

ÿ Inspection and maintenance Replacement

A) Grease MP
B) Engine oil
C) Hypoid gear oil
D) Hydraulic oil
E) Hypoid gear oil
F) Brake fluid
G) Lubricating grease containing molybdenum disulphide

PERIODIC MAINTENANCE Periodic inspection and maintenance are essential to keep your
Toyota industrial vehicle in good working order. The required number of hours for the test cycle will be: Daily (pre-operational
check) .................................................. ............Every 8 hours Weekly .................................. ..........Every 40 hours Once
every 6
weeks................................... ......Every
250 hours Every 3 months .................................. ...Every
500 hours

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Once every 6 months ....................................... Every 1000 hours

Annually................................................. Every 2000 hours
If the operating time exceeds 250 hours in 6 weeks, use the number of hours as a guideline for periodic inspection. Pre-operation checks and weekly inspections
should preferably be carried out by the user. Pre-operation checks and weekly inspections should preferably be carried out by the user. The 6-week, 3-month, 6-
month and yearly inspections should be done by a Toyota dealer as they require high technology and special tools. Refer to the periodic maintenance chart for
inspection and maintenance items and inspection cycles.

Use only genuine Toyota replacement parts, and use the recommended lubricants.

PERIODIC REPLACEMENT TABLE

REPLACEMENT PERIOD (Accumulated hours of operation or monthly EVERY 6 WEEKS 3 EVERY 250 6 12 MONTHS
periods of operation, whichever comes first) 500 1000 2000 HOURS

• • • •
Engine oil Engine oil
filter Cooling water (except LLC, • *1 • • •

• • •
LLC every 2 years) Air cleaner element Fuel filter Torque converter oil Torque
•
converter oil filter Differential oil
• •
Hydraulic oil Hydraulic oil
• •
filter Wheel bearing lubrication
• •

• •

• *1 • •

Spark plug • •

•
Seals and cover for master cylinder, wheel brake cylinder Brake fluid Power steering hose
• •

(Every 2
years)
Power Steering Rubber Parts Hydraulic Hose Reserve Tank Hose (Every 2 years)
Fuel Hose (Every 2 years)
(Every 2 years)
(Every 2 years)
Torque Converter Rubber Hose Chain Hydraulic Oil (Every 2 years)
Pump (Every 3 years)
Seal (Every 3 years or 6000 hours)

*1: For new vehicles

Note:
In case of severe operating conditions, the interval between maintenance cycles can be recommended 170 hours or 1 month.

PROTECT YOUR MONEY WITH

GENUINE TOYOTA PARTS
Why risk your valuable property? When your forklift needs periodic maintenance - like every forklift - you need genuine Toyota parts. The same parts are used on
Toyota's assembly lines - meeting Toyota's stringent standards for "PERFORMANCE", "LIFE" and "SAFETY".

GENUINE TOYOTA PARTS

Provide excellent dust-collecting performance:
For example air cleaner element,
Torque converter oil filter,
Drain oil filter,
engine oil filter,
Fuel filter.
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GENUINE TOYOTA PARTS

Provide the highest service life:
e.g. radiator hose,
V-belt.

GENUINE TOYOTA PARTS

Provide additional security:
e.g. lifting lifting drum,
chain,
traction tip,
Brake shoe

IF YOU ARE USING A GENUINE ENGINE OIL FILTER:

1. The filter may become clogged, causing the engine to seize.
2. Engine oil can get dirty faster, requiring frequent oil changes.
3. It can let dirty oil into the engine, causing engine wear.

IF YOU ARE USING AN UNGENUINE RADIATOR HOSE:

1. The hose can wear out extremely quickly.
2. The hose may leak water and require frequent replacement.

IF YOU ARE USING AN UNGENUINE BRAKE SHOE:

1. Braking performance may be excessive, insufficient or unstable, which is very
dangerous.

2. Brakes may slip, consuming fuel or battery power.

Call your authorized Toyota store for warranty service.

With high quality genuine TOYOTA parts and advanced maintenance technology, Toyota will help keep
customers' forklifts in top condition for efficient operation and higher productivity. We satisfy customers
with genuine Toyota parts.

LPG (Liquefied Petroleum Gas) DEVICE

NAMES OF COMPONENTS OF THE LPG DEVICE
1. Tank strap 2 Control pin 3. Tank 6 Tank bracket
bracket stopper 4. LPG 7. LPG switch
tank 5. Tank latch 8. Filter
9. Solenoid valve
10. Regulator

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SWITCHES
Fuel switches
This switch is used to turn the LPG or petrol dispenser on and off.
OFF … Horizontal position
The engine cannot be started because fuel will not be supplied.
LPG … Low position
GAS … High position
Note:
• When the ignition switch is set to OFF, fuel will not be delivered even if
Fuel switch is set to LPG or GAS.
• To stop an LPG engine, set the fuel switch to the OFF position and allow the engine to stop naturally. After
stopping the engine, remove the fuel tank, close the outlet

fuel valve, turn off the ignition and remove the key.

LPG TANK AND RELATED PARTS

Exhaust valve
This valve controls the flow of LPG fuel from the LPG tank to the regulator.
To open the valve, turn it counterclockwise.
To close the valve, turn it clockwise.

Inlet valve
LPG fuel is poured into the tank through this valve. The tank must be filled by
the service personnel of the LPG filling station. Make sure this valve
tightly closed always after use.

(1) Inlet valve

Pipe valve
When it is necessary to disconnect the fuel hose for changing the tank, etc., close this
valve to prevent fluid from flowing out of the hose. During normal operation, this valve is
always open.
To open the valve ... turn it counterclockwise.
To close the valve ... turn it clockwise.

(1) Pipe valve

Safety valve
This valve prevents an explosion that can occur when the LPG pressure rises above normal
levels or when the hose becomes worn.

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(1) Safety valve

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OPERATION OF FORKLIFT POWERED BY

LPG

1. Turn the tank outlet valve counterclockwise to open it.

2. Make sure the pipe valve is open.
Warning
Never depress the accelerator pedal repeatedly or keep it pressed all the way
down during starting. The engine will be difficult to start.

3. Wait until the initial ignition of the engine and lightly press the accelerator pedal. Wait
(1) Open
until the engine starts and turn the ignition switch to the "I" (ON) position.

4. Let the engine idle for 5-6 minutes.

Warning
Never fully depress the accelerator pedal. This will supply too much LPG
and its hot fumes will stall the regulator, damaging the engine.

(1) Open

Starting the Engine (Petrol/LPG Models)

If the ambient temperature is high enough, start the engine in the same way as you start an LPG model engine. If the
temperature is very low and it is difficult to start the engine on LPG fuel, set the fuel supply switch to GAS and start the engine.
Change the position of the fuel supply switch to the LPG position after the engine has warmed up (stop the engine first).

1. Set the fuel supply switch to the GAS position.

2. Start and warm up the engine in the same way as you start a conventional gasoline
engine. See operator's manual for engine starting procedures.

3. Set the fuel switch to the OFF position and allow the engine to stop naturally.

4. Set the fuel switch to the LPG position and start the engine again in the same way
as you start an LPG model engine.

Warning
Never change the fuel switch setting from GAS to LPG
while the engine is running. This will drastically increase the engine RPM and cause severe engine damage.

To prolong engine life, refrain from rough handling and driving, especially when it is new.

Stop
1. Stop for a short time
(1) Set the fuel supply switch to the OFF position.
(2) Allow the engine to stop naturally so that all LPG fuel exits the piping system. Turn the ignition switch to the "O" (OFF)
position and remove the key.
2. Stop for a long time
(1) Turn the LPG tank outlet valve clockwise to shut off the fuel supply.
(2) Allow the engine to stop naturally so that all LPG fuel exits the piping system. Turn the fuel switch and ignition switch to the
"O" (OFF) position and remove the key

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Replacement of LPG tanks

Warning
Under no circumstances, no matter what happens, the replacement of an LPG tank should not be carried
out near a lit cigarette, a lit match, a gas stove burner, an electric heater, an electric motor, or any other
electrical equipment that emits sparks, flames, or any other type of fire (related to collectively to "fire"
below).

Warning
To avoid serious injury from fire or explosion, you must observe the following rules:

Turn off the ignition switch and lights.

Replace tanks only in a well-ventilated, favorable area. fire or flame
prohibited.

Check all connections for damage or missing parts. Check for leaks.
Do not restart the engine until the smell of gas disappears.
If the loader will not start, have a mechanic check it.
Filling tanks requires special procedures. Be sure to ask someone to explain them to you.

Removing the LPG tank

1. Stop the engine in accordance with the instructions for the section "Stopping for a long time"
(1) Turn the LPG tank outlet valve clockwise to shut off the fuel supply
(2) Let the engine stop naturally. Turn the fuel switch and ignition switch to the "O" (OFF) position

2. Turn the pipe valve clockwise to close it

3. Disconnect the pipeline from the LPG tank (turn the screw counterclockwise).

4. Raise the tank bracket stopper to the left tank bracket and unlock
Castle.

(1) Bracket stopper

30
Machine Translated by Google

5. Disconnect the control pin (upper part) located on the right side of the tank bracket by
lifting it up, rotate the bracket back and reinstall the pin.

(1) Control pin (Top)

6. Pull the control pin (bottom) located on the bottom of the tank bracket to unlock it. The
tank bracket will fall. Lower the bracket and fix the pin.

Warning
• When unlocking the tank bracket control pin, never enter the area under
the tank bracket. Pay special attention to how the bracket lowers under its
own weight.
• Never unlock the control pin when the tank is full. Otherwise, the tank
(1) Control pin (Bottom) bracket will fall rapidly, causing a dangerous situation.

7. Pull the tank latch towards you and unlock the tank straps.

8. Lift the tank straps away from you and remove the LPG tank.

Installing the LPG tank

1. Install the LPG tank on the bracket.

(1) The exhaust valve must face the right or top side of the vehicle.

(2) The tank must be placed with the right side up. Find the label on the tank.
It should be facing up or back.

(1) Bullet

31
Machine Translated by Google

2. Install the tie-down bands on top of the tank, hook the latches onto the tie-down bands,
and push the latches up to secure the tank.

3. Unlock the tank bracket by pulling the control pin (bottom) under
tank bracket. Raise the bracket and fix the pin.

Warning
Unloading the control pin without load (tank) is dangerous because the
bracket can jump up due to the force of the spring. Unlock the control pin
when the tank is installed on the bracket. Remove the control pin, rotate the
tank bracket along the axis of rotation and accurately install the bracket stop
knob.
(1) Control pin (Bottom)

(1) Control pin (Top)

4 Connect the tubing to the tank outlet valve (turn the screw counterclockwise)

5 Wet the pipe-to-tank connection with soapy water or neutral detergent. Open the bleed
valve and pipe valve and check the connection for any gas leaks. Wipe off the soapy
water or detergent after the test is completed

Important information regarding the properties of LPG

LPG usually contains a substance that gives it a noticeable color at an air concentration of 1/200 or more. If a large amount
of LPG is leaking from the system's tank, this can be detected by the smell. LPG does not contain carbon monoxide and is
not poisonous, although it is explosive.
• LPG is a highly compressed gas and leaks easily.
Vapors have a volume 250 times that of liquefied gas and their density is twice that of air. Hence, they congregate in low
places.
• The LPG pressure rises as the temperature rises.

Safety Precautions When Using LPG Forklifts

32
Machine Translated by Google

• LPG is combustible. A small spark can cause a fatal explosion if handled carelessly. It is very important that the following
precautions be observed as strictly as possible in order to avoid hazards.
• All LPG powered forklifts must be operated and serviced (including changing the LPG tank)
only certain individuals.

• Never stop an LPG powered forklift near a fire.

• Whenever possible, do not stop or park an LPG powered forklift in direct sunlight. Sheltering it under an awning is highly
recommended. And make sure the vehicle is well ventilated.

• Do not operate an LPG powered forklift near a fire.

• When operating or inspecting an LPG powered forklift, display a large DANGER
FIRE" and make sure that persons using fire do not have access to the vehicle.
• Remove the ignition key from the LPG powered forklift truck after it has been stopped or parked in a garage,
so that an unauthorized person cannot operate it.
• Use only soapy water or neutral detergent to check the vehicle for gas leaks. Do not use any other liquid.

If the gas leak test is to be carried out at night with a flashlight, turn on the flashlight away from the vehicle and approach it.
The flashlight may spark when turned on and cause an accident.

• If a gas leak is detected, extinguish any fire immediately, ventilate the area and keep the area completely free of fire. Then
call a qualified Toyota dealer or service station.

• Store LPG tanks in a strictly fire-proof place with a gas detector at all times.
• Refueling of LPG tanks should only be done by LPG filling station service personnel.
• Use LPG of the correct chemical composition according to the climate. Use LPG in hot climates
with a relatively high content of butane; in cold climates, use LPG with a relatively high propane content.

REGULATOR MAINTENANCE
(1) Hose
(2) Oil basin
(3) Drain cock (Optional)

Removing tar from the regulator

Tar tends to collect in the regulator and must be removed regularly on a weekly basis after
the day's work has ended. Let the engine cool down and
remove the tar as described below
1 Set the fuel supply switch to the "O" (OFF) position and open the hood
the engine
2 Connect the hose to the drain cock located under the regulator.
3 Place an oil bowl under a drain cock. Open the drain cock and allow the tar to drain into the oil bowl.
4 After removing all the tar from the regulator, close the drain cock and disconnect the hose
Warning
If the tar sticks to the vehicle, it must be completely wiped off with
fabrics.

INSPECTION AND MAINTENANCE OF HA LPG FORKLIFTS

Check and maintain LPG powered forklifts in the same way as standard forklifts. In addition, check and maintain them as
described below.
• Check before operation
• LPG leak test
• After finishing the gas leak test, wipe off the soapy water or neutral detergent from the wet parts.
• If a gas leak is found, extinguish any fire immediately, ventilate the area and contain it.
33
Machine Translated by Google

place completely liberated from fire. Then call a qualified Toyota dealer or service station.

Warning
Never test for LPG gas leaks near a fire. Make sure there's no one around
fire sources during the leak test.
Warning
To avoid serious injury from fire or explosion, you must follow these rules:
ÿ Turn off the ignition and lights.
• Check for leaks only in well-ventilated, favorable locations.
• No smoking, fire or flames allowed.
• Apply water to all connections with a brush, bubbles will indicate a leak. Never use
any other liquids or open flame to check for leaks.
• Do not start the engine until the smell of gas has disappeared.
• If any gas leak is found, report it to the inspector immediately for repair by a qualified mechanic or your
Toyota dealer. If a leak is detected, the truck must not be operated.

1. Turn the LPG tank outlet valve counterclockwise to open it.

2. The pipe valve must also be open.
3. Set the ignition switch to the "I" (ON) position.
4. Reset the fuel supply switch to the "I" (ON) and "O" (OFF) positions several times and finally
account, leave it in the "O" (OFF) position.
5. Moisten the hose connections to the LPG tank and regulator with soapy water or neutral detergent. Check for gas leaks.

6. Press the fuel test rod attached to the regulator several times outward from
vehicle.
7. Moisten the hose connections to the regulator and carburetor with soapy water or neutral detergent. Check for gas leaks

ÿ Inspections and maintenance once a month

Item

Leakage of gas from pipes and joints (connections)

Damage to pipes and joints (connections)
Adjustment of the regulator

Cracking, damage or leaking gas from the tank

Loose or damaged tank bracket
Damage to wiring, loose contacts
Fluid drain cock rotation
Gas leak from regulator housing

ÿ Inspection and maintenance every three months

Carburetor and adapter

Regulator operation (disassembly and repair every year)
Solenoid valve

Filter

34
Machine Translated by Google

LUBRICANT AND COOLANT

Engine oil
Use SAE 30 engine oil (SAE 20 in cold weather). Change oil once a month.
Coolant
Use a mixture of equal parts water and long life coolant. Replace cooling water every two years.

ENGINE SPECIFICATIONS
Engine - 4Y
1.0-2.5t 3.0-3.5t

Max power PS/rpm 48/2400 52/2600

Max Torque Advance Setting kg/rev, min 15/1600 15/1600

BTDC° / o6 per min 7°/750 7°/750

ignition

Idle Speed Max RPM No Load rpm 750 750

rpm 2600 2800

MAST SPECIFICATIONS AND RATED LOADS

T
The overall height G Free lift J Single tire Q Dual tire
Mast type

K N R U
D Extended state
A S H I Limit slope Load capacity at 500 mm O R Slope limit Load capacity at
Maximum In lowered E F Without protective With Pneumatic Solid 500 LC
L M T
fork height able Without protective With frames protective frame cast Pneumatic/
Forward back S Forward Back
frames protective frame tires tires solid tires

35
Machine Translated by Google

Model: 32-8FG10/62-8FD10
IN G J Q

A D TO N R
T S H I IN
AND F L M O P S T

mm mm mm mm mm mm city city kg kg city city kg

2700 1820 3145 3920 140 140 7 10 1000 1000 7 10 1000

3000 1970 3445 4220 140 140 7 10 1000 1000 7 10 1000

3300 2120 3745 4520 140 140 7 10 1000 1000 7 10 1000

3500 2220 3945 4720 140 140 7 10 1000 1000 7 10 1000

IN
3700 2380 4145 4920 140 140 7 10 1000 1000 7 10 1000

4000 2570 4445 5220 140 140 7 10 1000 1000 7 10 1000

4500 2820 4945 5720 140 140 7 5 950 1000 7 10 950

5000 3070 5445 6220 140 140 7 10 950 1000 7 5 950

3000 1970 3595 4245 1400 750 7 10 1000 1000 7 10 1000

3300 2120 3895 4545 1550 900 7 10 1000 1000 7 10 1000

FV 3500 2220 4095 4745 1650 1000 7 10 1000 1000 7 10 1000

3700 2380 4295 4945 1810 1160 7 10 1000 1000 7 10 1000

4000 2570 4595 5245 2000 1350 7 10 1000 1000 7 10 1000

3700 1770 4240 4920 1230 550 7 5 950 950 7 5 950

4000 1870 4540 5220 1330 650 7 5 900 900 7 5 900

4300 1970 4840 5520 1430 750 7 5 900 900 7 5 900

4500 2040 5040 5720 1500 820 7 5 900 900 7 5 900

4700 2120 5240 5920 1580 900 7 5 900 900 7 5 900

FSV
5000 2220 5540 6220 1680 1000 7 5 850 900 7 5 850

5500 2380 6040 6720 1840 1160 7 5 850 900 7 5 850

6000 2570 6540 7220 2030 1350 7 5 700 800 7 5 800

6500 2820 7040 7720 2280 1600 - - - -

7 5 700

7000 3070 7540 8220 2530 1850 - - - -

7 5 650

Model: 32-8FG15/62-8FD15
IN G J Q

A D TO N R
T S N I IN
Well F L M O R S T

mm mm mm mm mm mm city city kg 11 1500 1500 kg city city kg

2700 1845 3145 3920 145 145 6 7 10 1500

3000 1995 3445 4220 145 145 6 11 1500 1500 7 10 1500

3300 2145 3745 4520 145 145 6 11 1500 1500 7 10 1500

3500 2245 3945 4720 145 145 6 11 1500 1500 7 10 1500

IN
3700 2405 4145 4920 145 145 6 11 1500 1500 7 10 1500

4000 2595 4445 5220 145 145 6 11 1500 1500 7 10 1500

4500 2845 4945 5720 145 145 6 6 1450 1500 7 10 1450

5000 3095 5445 6220 145 145 6 11 1300 1400 7 5 1300

3000 1995 3560 4210 1430 710 6 11 1500 1500 7 10 1500

3300 2145 3860 4510 1580 710 6 11 1500 1500 7 10 1500

FV 3500 2245 4060 4710 1680 710 6 11 1500 1500 7 10 1500

3700 2405 4260 4910 1840 710 6 11 1500 1500 7 10 1500

4000 2595 4560 5210 2030 710 6 11 1500 1500 7 10 1500

3700 1795 4235 4915 1260 580 6 6 1400 1400 7 5 1400

4000 1895 4535 5215 1360 680 6 6 1400 1400 7 5 1400

FSV 4300 1995 4835 5515 1460 780 6 6 1400 1400 7 5 1400

4500 2065 5035 5715 1530 850 6 6 1350 1400 7 5 1350

4700 2145 5235 5915 1610 930 6 6 1350 1400 7 5 1350

36
Machine Translated by Google

5000 2245 5535 6215 1710 1030 6 6 1250 1350 7 5 1300

5500 2405 6035 6715 1870 1190 6 6 950 1050 7 5 1250

6000 2595 6535 7215 2060 1380 6 6 700 800 7 5 1100

6500 2845 7035 7715 2310 1630 - - - -

7 5 900

7000 3095 7535 8215 2560 1880 - - - -

7 5 650

Model: 32-8FG18/62-8FD18
IN G J Q

A D TO N R
T S N I IN
Well F L M O R S T

mm mm mm mm mm mm city city kg kg city city kg

2700 1845 3320 3920 145 145 6 11 1750 1750 7 10 1750

3000 1995 3620 4220 145 145 6 11 1750 1750 7 10 1750

3300 2145 3920 4520 145 145 6 11 1750 1750 7 10 1750

3500 2245 4120 4720 145 145 6 11 1750 1750 7 10 1750

IN
3700 2405 4320 4920 145 145 6 11 1750 1750 7 10 1750

4000 2595 4620 5220 145 145 6 11 1700 1750 7 10 1700

4500 2845 5120 5720 145 145 6 6 1600 1700 7 10 1600

5000 3095 5620 6220 145 145 6 11 1550 1650 7 5 1550

3000 1995 3560 4210 1430 780 6 11 1750 1750 7 10 1750

3300 2145 3860 4510 1580 930 6 11 1750 1750 7 10 1750

FV 3500 2245 4060 4710 1680 1030 6 11 1750 1750 7 10 1750

3700 2405 4260 4910 1840 1190 6 11 1750 1750 7 10 1750

4000 2595 4560 5210 2030 1380 6 11 1700 1750 7 10 1700

3700 1795 4235 4915 1260 580 6 6 1600 1600 7 5 1600

4000 1895 4535 5215 1360 680 6 6 1600 1600 7 5 1600

4300 1995 4835 5515 1460 780 6 6 1550 1600 7 5 1550

4500 2065 5035 5715 1530 850 6 6 1500 1600 7 5 1500

4700 2145 5235 5915 1610 930 6 6 1500 1600 7 5 1500

FSV
5000 2245 5535 6215 1710 1030 6 6 1450 1550 7 5 1450

5500 2405 6035 6715 1870 1190 6 6 1100 1200 7 5 1400

6000 2595 6535 7215 2060 1380 6 6 850 950 7 5 1200

6500 2845 7035 7715 2310 1630 - - - -

7 5 850

7000 3095 7535 8215 2560 1880 - - - -

7 5 600

Model: 32-8FG20/62-8FD20
IN G J Q

A D TO N R
T S H I IN
AND F L M O P S T

mm mm mm mm mm mm city city kg kg city city kg

2700 1845 3375 3920 145 145 6 11 2000 2000 6 11 2000

3000 1995 3675 4220 145 145 6 11 2000 2000 6 11 2000

3300 2145 3975 4520 145 145 6 11 2000 2000 6 11 2000

3500 2245 4175 4720 145 145 6 11 2000 2000 6 11 2000

IN
3700 2405 4375 4920 145 145 6 11 2000 2000 6 11 2000

4000 2595 4675 5220 145 145 6 11 2000 2000 6 11 2000

4500 2845 5175 5720 145 145 6 6 1950 2000 6 11 1950

5000 3095 5675 6220 145 145 6 6 1850 2000 6 6 1900

3000 1995 3560 4175 1395 780 6 11 2000 2000 6 11 2000

3300 2145 3860 4435 1545 970 6 11 2000 2000 6 11 2000

FV 3500 2245 4060 4635 1645 1070 6 11 2000 2000 6 11 2000

3700 2405 4260 4835 1805 1230 6 11 2000 2000 6 11 2000

4000 2595 4560 5135 1995 1420 6 11 2000 2000 6 11 2000

37
Machine Translated by Google

3700 1795 4275 4910 1220 580 6 6 2000 2000 6 6 2000

4000 1895 4575 5210 1320 680 6 6 1950 1950 6 6 1950

4300 1995 4875 5510 1420 780 6 6 1900 1900 6 6 1950

4500 2065 5075 5710 1490 850 6 6 1850 1850 6 6 1900

4700 2145 5275 5910 1570 930 6 6 1850 1850 6 6 1900

FSV
5000 2245 5575 6210 1670 1030 6 6 1450 1600 6 6 1850

5500 2405 6075 6710 1830 1190 6 6 1200 1350 6 6 1800

6000 2595 6575 7210 2020 1380 6 6 850 1000 6 6 1600

6500 2845 7075 7710 2270 1630 - - - -

6 6 1550

7000 3095 7575 8210 2520 1880 - - - -

6 6 1200

Model: 32-8FG25/62-8FD25
IN G J Q

A D TO N R
T S N I IN
AND F L M O R S T

mm mm mm mm mm mm city city kg kg city city kg

2700 1845 3375 3920 150 150 6 11 2500 2500 6 11 2500

3000 1995 3675 4220 150 150 6 11 2500 2500 6 11 2500

3300 2145 3975 4520 150 150 6 11 2500 2500 6 11 2500

3500 2245 4175 4720 150 150 6 11 2500 2500 6 11 2500

IN
3700 2405 4375 4920 150 150 6 11 2500 2500 6 11 2500

4000 2595 4675 5220 150 150 6 11 2500 2500 6 11 2500

4500 2845 5175 5720 150 150 6 11 2150 2300 6 11 2450

5000 3095 5675 6220 150 150 6 11 1700 1850 6 6 2400

3000 1995 3560 4175 1400 785 6 11 2500 2500 6 11 2500

3300 2145 3860 4435 1550 975 6 11 2500 2500 6 11 2500

FV 3500 2245 4060 4635 1650 1075 6 11 2500 2500 6 11 2500

3700 2405 4260 4835 1810 1235 6 11 2500 2500 6 11 2500

4000 2595 4560 5135 2000 1425 6 11 2500 2500 6 11 2500

3700 1795 4270 4910 1225 585 6 6 2500 2500 6 6 2500

4000 1895 4570 5210 1325 685 6 6 2500 2500 6 6 2500

4300 1995 4870 5510 1425 785 6 6 2300 2300 6 6 2500

4500 2065 5070 5710 1495 855 6 6 2000 2000 6 6 2450

4700 2145 5270 5910 1575 935 6 6 2000 2000 6 6 2450

FSV
5000 2245 5570 6210 1675 1035 6 6 1500 1650 6 6 2400

5500 2405 6070 6710 1835 1195 6 6 1250 1400 6 6 2050

6000 2595 6570 7210 2025 1385 6 6 900 1050 6 6 1700

6500 2845 7070 7710 2275 1635 - - - -

6 6 1550

7000 3095 7570 8210 2525 1885 - - - -

6 6 1200

Model: 32-8FG30/62-8FD30
IN G J Q

A D TO N R
T S N I IN
AND F L M O R S T

mm mm mm mm mm mm city city kg kg city city kg

2700 1865 3440 3920 135 135 6 11 3000 3000 6 11 3000

3000 2015 3740 4220 135 135 6 11 3000 3000 6 11 3000

3300 2165 4040 4520 135 135 6 11 3000 3000 6 11 3000

3500 2265 4240 4720 135 135 6 11 3000 3000 6 11 3000

IN
3700 2425 4440 4920 135 135 6 11 3000 3000 6 11 3000

4000 2615 4740 5220 135 135 6 11 3000 3000 6 11 3000

4500 2865 5240 5720 135 135 6 6 3000 3000 6 11 3000

5000 3115 5740 6220 135 135 6 6 2600 2750 6 6 3000

38
Machine Translated by Google

3000 2015 3655 4260 1400 795 6 11 3000 3000 6 11 3000

3300 2165 3955 4515 1550 990 6 11 3000 3000 6 11 3000

FV 3500 2265 4155 4715 1650 1090 6 11 3000 3000 6 11 3000

3700 2425 4355 4915 1810 1250 6 11 3000 3000 6 11 3000

4000 2615 4655 5215 2000 1440 6 11 3000 3000 6 11 3000

3700 1915 4315 4920 1300 695 6 6 3000 3000 6 6 3000

4000 2015 4615 5220 1400 795 6 6 3000 3000 6 6 3000

4300 2165 4915 5520 1550 945 6 6 3000 3000 6 6 3000

4500 2215 5115 5720 1600 995 6 6 3000 3000 6 6 3000

4700 2265 5315 5920 1650 1045 6 6 3000 3000 6 6 3000

FSV
5000 2425 5615 6220 1810 1205 6 6 2600 2750 6 6 2950

5500 2615 6115 6720 2000 1395 6 6 1900 2050 6 6 2650

6000 2865 6615 7220 2250 1645 6 6 1500 1650 6 6 2050

6500 3115 7115 7720 2500 1895 - - - -

6 6 1600

7000 3365 7615 8220 2750 2145 - - - -

6 6 1200

Model: 32-8FGJ35/62-8FDJ35
IN G J Q

A D TO N R
T S N I IN
Well F L M O R S T
mm mm mm mm mm mm city city kg kg city city kg
2700 2000 3560 3920 140 140 6 11 3500 3500 6 11 3500

3000 2120 3860 4220 140 140 6 11 3500 3500 6 11 3500

3300 2300 4160 4520 140 140 6 11 3500 3500 6 11 3500

3500 2400 4360 4720 140 140 6 11 3500 3500 6 11 3500

IN
3700 2500 4560 4920 140 140 6 11 3500 3500 6 11 3500

4000 2750 4860 5220 140 140 6 11 3500 3500 6 11 3500

4500 3000 5360 5720 140 140 6 6 3500 3500 6 11 3500

5000 3250 5860 6220 140 140 6 6 3300 3450 6 6 3400

3000 2120 3660 4145 1395 910 6 11 3500 3500 6 11 3500

3300 2300 3960 4395 1575 1140 6 11 3500 3500 6 11 3500

FV 3500 2400 4160 4595 1675 1240 6 11 3500 3500 6 11 3500

3700 2500 4360 4795 1775 1340 6 11 3500 3500 6 11 3500

4000 2750 4660 5095 2025 1590 6 11 3500 3500 6 11 3500

3700 2030 4425 4910 1305 820 6 6 3500 3500 6 6 3500

4000 2180 4725 5210 1455 970 6 6 3500 3500 6 6 3500

4300 2230 5025 5510 1505 1020 6 6 3500 3500 6 6 3500

4500 2280 5225 5710 1555 1070 6 6 3400 3400 6 6 3400

4700 2440 5425 5910 1715 1230 6 6 3400 3400 6 6 3400

FSV
5000 2630 5725 6210 1905 1420 6 6 3300 3300 6 6 3300

5500 2880 6225 6710 2155 1670 6 6 2700 2850 6 6 3200

6000 3130 6725 7210 2405 1920 6 6 2000 2150 6 6 2400

6500 3380 7225 7710 2655 2170 - - - -

6 6 1650

7000 3630 7725 8210 2905 2420 - - - -

6 6 900

39
Machine Translated by Google

WHEELS AND TIRES

durable durable Not reliable
Model Tire arrangement Rim size Tire size tire type tire type broken

J-Lug Long Life J-Lug tires

8FD/G10 Front Single A 4.00EX 9 DT 6.00-9-10PR O •

A 5.00FX 10 DT 6.50-10-10PR • •

ÿ 4.00E X 9 DT 6.00-9 •

• •
Twin C 3.50DX 12 DC 4.50-12-8PR
ÿ 3.00D X 12 SDC 4.50-12 •

ÿÿÿÿÿÿ ÿ 3.00 X 8 DT 5.00-8-8PR O •

F 3.00 X 8 TV 5.00-8-8PR • •

ÿ 3.00 X 8 DT 5.00-8 •

F 3.00 X 8 TV 5.00-8 •

8FD/G15 Front Single A 5.00FX 10 DT 6.50-10-10PR O •

A 5.00FX 10 DT 6.50-10 •

At 6.00 X 9 TV 21X8-9-10PR • •

At 6.00 X 9 TV 21X8-9 •

• •
Paired With 3.50DX 12 DC 4.50-12-8PR With 3.00DX 12 SDC 4.50-12
•

ÿÿÿÿÿÿ ÿ 3.00 X 8 DT 5.00-8-8PR about

•

F 3.00 X 8 TV 5.00-8-8PR • •

ÿ 3.00 X 8 DT 5.00-8 •

F 3.00 X 8 TV 5.00-8 •

8FD/G20 Front Single A 5.00SX 12 DT 7.00-12-12PR about

•

A 5.00SX 12 DT 7.00-12 •

• •
Paired With 4.50EX 15 SDC 5.50-15-8PR With 4.50E X 15 SDC 5.50-15
•

D 5.00S X 12 TB 7.00-I2-12PR • •

D 5.00S X 12 TB 7.00-12 •

ÿÿÿÿÿÿ Is 4.00E X 9 DT 6.00-9-IOPR about

•

Is 4.00EX 9 DT 6.00-9 •

F 4.00E H 9 TV 6.00-9-10PR • •

F 4.00E X 9 TV 6.00-9 •

8FD/G30 Front Single A 5.00SX 12 DT 7.00-12-12PR O •

A 5.00SX 12 DT 7.00-12 •

• •
Twin C 4.50EX 15 SDC 5.50-15-8PR
ÿ 4.50E X 15 SDC 5.50-15 •

D 5.00SX 12 TB 7.00-12-12PR • •

D 5.00S X 12 TB 7.00-12 •

ÿÿÿÿÿÿ Is 4.00E X 9 DT 6.00-9-10PR O •

Is 4.00EX 9 DT 6.00-9 •

Is 5.00FX 10 DT 6.50-10 •

F 4.00E H 9 TV 6.00-9-I0PR • •

F 4.00E X 9 TV 6.00-9 •

8FD/G25 Front Single B 7.00TX 15 IR B 7.00TX 15 IR 28X9-15-12PR about

•

28X9-15 •

• •
Paired with 4.50EX 15 SDC 6.00-15-10PR
ÿ 4.50E X 15 SDC 6.00-15 •

D 6.00SX 15 IS 28X8-15-12PR • •

D 6.00SX 15 IS 7.00-15/6.00 •

ÿÿÿÿÿÿ ÿ 5.0OF X 10 DT 6.50-10-1OPR about

•

Is 5.00FX 10 DT 6.50-10 •

F 5.00F X 10 TB 6.50-10-10PR • •

F 5.00F X 10 TB 6.50-10-12PR • •

40
Machine Translated by Google

F 5.00F X 10 TB 6.50-10 •

8FD/G J35 Front Single B 7.00TX 15 IR B 7.00TX 15 IR 250-15-16PR about

•

250-15/7.00 •

• •
Paired with 4.50EX 15 SDC 6.00-I5-10PR
ÿ 4.50E X 15 SDC 6.00-15 •

D 6.00SX 15 IS 28X8-15-12PR • •

D 6.00SX 15 IS 7.00-15/6.00 •

ÿÿÿÿÿÿ F 5.00F X 10 TB 6.50-10-12PR about

•

F 5.00F X 10 TB 6.50-10 •

A: One split rim B: One side ring C: Standard twin D: Special twin E: Split F: Side ring

PERIODIC MAINTENANCE CHART

Periodic maintenance
METHOD OF CHECKS

I Check, repair and replace if necessary T Tightening C Cleaning L Lubrication M Measuring,

correction and adjustment if necessary

CHECK PERIOD (Perform based on hours of work or elapsed months, whichever EVERY 6 WEEKS
3 6 12 MONTHS
comes first) EVERY 250
500 1000 2000 HOURS
ENGINE
Main Components

1 Starting condition and abnormal noise 2 Rotation I I I I

condition during idling 3 Rotation condition during acceleration 4 Exhaust MMMM

gas condition MMMM

I I I I

5 Air cleaner element 6 Valve clearance 7 S With S C

Compression 8 Cylinder M* M

head stud 9 Silencer M

rubber mount T
I

10 Clogged and damaged pressure reducing valve and piping Regulator I I I I

11 Maximum steady rotation speed without load Lubrication system MMMM

12 Oil leak I I I I

13 Oil level 14 Clogged I I I I

and dirty oil filter Fuel system I I I I

15 Fuel leak I I I I

16 Operation of the carburetor link mechanism 17 I I I I

Dirty and damaged fuel filter element 18 Injection control 19 Injection nozzle, I I I I

injection pressure and condition 20 MM

Draining water from the sedimenter Cooling system M

I I

21 Coolant level and radiator leak 22 Worn rubber hose 23 Radiator cap I I I I

condition 24 Fan belt tension and I I I I

damage 25 Radiator rubber support I I I I

I I I I

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Forklift Movement and Loading/Unloading Control Device (Optional)

26 Stepper Motor Damage 27 Accelerator Pedal I I I

Sensor and Switch Damage 28 Speed Sensor Damage POWER TRANSMISSION I I I

SYSTEM I

Traction
1 Clutch pedal free play 2 Abnormal noise and ÿMMM

operating condition (engaging) 3 Clutch booster operation and oil leakage 4 Oil I I I I

clutch operation and oil leakage 5 Fluid level Manual transmission I I I I

I I

I I I I

6 Oil leak I I I I

7 Oil level 8 Gear operation I I I I

and unusual noise Differential I I I I

9 Oil leak I I I I

10 Oil level 11 Loose bolts I I I I

Torque converter and transmission

12 Oil leak I I I I

13 Oil Level 14 Actuator I I I I

Function and Looseness 15 Control Valve and Clutch Function 16 Engine Slow Crank I I I I

Valve Function 17 Damping Test and Oil Pressure Measurement Driveshaft and Axle I I I I

Shaft I I I I

MM

18 Loose joint 19 Spline joint play 20 I I I

Universal joint play 21 Axle warp and cracks I

UNDERCARRIAGE I

wheels

1 Tire pressure 2 Tire cuts Damaged or ÿMMM

uneven tread 3 Loose rim and hub nuts 4 Tread depth 5 Metal debris, stones I I I I

or other foreign objects in the tires 6 Damage to the T TT T

rim, lug and wheel rim 7 Unusual MMMM

noise and play in the front wheel bearing 8 Unusual noise and rear wheel bearing play Front axle I I I I

I I I I

I I I I

I I I I

9 Cracks and damage to the body Rear axle I

10 Cracks, damage and deformation of the beam 11 Play of the I

bridge beam in the forward and backward directions M* M

STEERING SYSTEM

steering wheel
1 Play and looseness 2 Working I I I I

condition I I I I

Steering valve
3 Oil leak I I I I

4 Loose fastening T TT

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Power Steering
5 Oil leak I I I I

6 Loose mounting and connection 7 Damaged power steering hose I I I I

Pin I

8 Kingpin play 9 Cracking and deformation I I I I

BRAKING SYSTEM I

brake pedal
1 Free play and headroom 2 Braking MMMM

efficiency Parking brake I I I I

3 Operating force 4 Braking I I I I

efficiency 5 Loose and damaged linkage and I I I I

cable Brake pipes and hoses I I I I

6 Leakage, damage and mounting condition Brake fluid I I I I

7 Level Master I I I I

cylinder or wheel brake cylinder

8 Function wear, damage and loosening Brake drum and brake shoe I

9 Gap between drum and lining 10 Sliding part of shoe and MMMM

wear of linings 11 Wear and damage of drum 12 Working condition of I

shoe 13 Rust of support pin 14 Wear of return spring I

15 Operation of automatic adjustment function I

Support plate I

] 6 Deformation cracking and damage 17 Loose fastening LOAD I

MANAGEMENT SYSTEM T

Pitchfork

1 Condition of forks and lock pins 2 Uniformity of left and right I I I I

forks 3 Cracks in fork base and welds Mast and lifting I I I I

bracket I*1

4 Deformation, damage and cracks at the welding points 5 Looseness of the mast and I I I I

lifting bracket 6 Wear and damage of the mast support sleeve 7 Wear and tear of I I I I

the drum Damage and rotation condition 8 Wear and damage of the drum I

kingpin 9 Wear and damage of the mast rack Chain and sprocket I I I I

I I I I

10 Tension deformation and chain damage 11 Chain lubrication 12 Chain I I I I

anchor bolt condition 13 I I I I

Wear damage and sprocket rotation condition I I I I

Miscellaneous accessories (Optional) 1 I I I

14 Abnormality and mounting condition HYDRAULIC SYSTEM I I I I

Cylinder

1 Loose mounting and damage to the cylinder T TT T

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2 Deformation and damage to the rod, rod screw and the bottom of the hydraulic cylinder
I I I I

3 Cylinder operation 4 Natural I I I I

lowering and natural forward tilt 5 Oil leakage and damage 6 Wear and damage to MMMM

cylinder shaft bearing and pin 7 Lifting speed I I I I

8 Irregular motion Oil pump I I I I

MMMM
I I I I

9 Oil leakage and unusual noise Hydraulic oil I I I I

tank
10 Oil level and contamination 11 Tank and I I I I

oil filter 12 Oil leakage C C

I I I I

Control lever
13 Linkage play 14 Operation I I I I

I I I I

Oil control valve

15 Oil leak I I I I

16 Burst pressure measurement 17 Relief valve M

and shut-off valve function

I I I I
the slope

Oil discharge pipe

18 Oil leak I I I I

19 Deformation and damage 20 Loose I I I I

connection ELECTRICAL SYSTEM T TT T

Ignition system

1 Cracking of the ignition distributor cap 2 Gap and oxidation of the spark I I I I

plugs 3 Oxidation of the side contact of the ignition I I I I

distributor 4 Wear and damage to the central part of the distributor cap I I I I

I I I I
ignition

5 Internal spark plug wire disconnection 6 Ignition advance setting Starter I

motor MM

7 Drive gear engagement Charging rectifier I I I I

8 Charging effect I I I I

Rechargeable battery
9 Battery electrolyte level 10 Specific gravity Wiring I I I I

MM

11 Damaged wire bundles 12 Fuses Preheater I I I I

I I I I

13 Glow plug heating coil failure 14 Integral heater open circuit I I

DPF muffler (Optional) I I

15 Filter 16 In- I I

line filter (for backpressure sensor) SAFETY DEVICES, ETC. I I I

protective roof
1 Weld cracking 2 Deformation and damage I I I I

I I I I

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seat back

3 Loose fastening 4 Deformation T TT T

cracking and damage Lighting system I I I I

5 Mounting operation and status Horn I I I I

6 Operation and mounting status Instruments I I I I

7 Work I I I I

Reverse Horn (Optional)

8 Operation and condition of the mount I I I I

SAS (Optional)
9 Work I I I I

10 Looseness and/or damage to sensor fittings 11 Deformation damage and/or oil I I I I

leakage in system functions and loose connections 12 Loose and/or damaged electrical wiring 13 Interlock
I I I I
cylinder and/or accumulator performance 14 Rust or
corrosion in load control sensor OPS system I I I I

15 System function Seat I I I I

16 Backlash and damage to the anchorage 17 I I I I

Damage and/or operation of the seat belts 18 Function of the seat switch 1 I I I

Body I I I I

19 Damage and cracking of the cross beam frame, etc. 20 Loose bolts I

Cabin (Optional)
21 Deformation, damage and cracking 22 Cracking of welds 23 I I I I

Cracking and loss of performance of seals and I I I I

silicone sealants
I

24 Cracking and damage to the material of the rubber mounts of the cab Rear-view mirror (Optional) I

25 Dirt damage 26. Rear reflection I I I I

conditions Other I I I I

27 Lubrication L LL L

*: For new vehicle

* 1: Crack and tear detector

Note:

In case of severe operating conditions, the interval between maintenance cycles may be
recommended 170 hours or 1 month.

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PERFORMANCE DATA
Item Models 1-1.5 tons 2-2.5 tons 3 tons J3.5 tons

Fan belt tension (10 kg pressure

mm 8-13 8-13 8-13 8-13
applied) Spark plug gap Spark plug
type mm 4Y 0,7-0,8 0,7-0,8 0,7-0,8 0,7-0,8
4Y W9EXR-U W9EXR-U W9EXR-U W9EXR-U

Ignition advance setting (BTDC) deg/rpm Ignition sequence Fuel injection 4Y 7/750 7/750 7/750 7/750
control (BTDC) Fuel injection sequence 4Y 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
town 1DZ-II-2Z 0 (Static) 0 (Static) 0 (Static) 0 (Static)
1DZ-II-2Z 1-3-4-2 1-3-4-2 1-3-4-2 1-3-4-2
4Y 0 (Self-adjustment) 0 (Self-adjustment) 0 (Self-adjustment) 0 (Self-adjustment)
INSIDE 1D2-II 0,18-0,22 0,18-0,22 0,18-0,22 0,18-0,22
2Z 0,15-0,25 0,15-0,25 0,15-0,25 0,15-0,25
Valve clearance (when warm) mm
4Y 0 (Self-adjustment) 0 (Self-adjustment) 0 (Self-adjustment) 0 (Self-adjustment)
EXTERNAL 1DZ-II 0,33-0,37 0,33-0,37 0,33-0,37 0,33-0,37
2Z 0,31-0,41 0,31-0,41 0,31-0,41 0,31-0,41
4Y 750 ±30 750 ±30 750 ±30 750 ±30
idle speed rpm
1DZ-II, 2Z 750 ±25 750 ±25 750 ±25 750 ±25
4Y 2570,00 2570,00 2570,00 2570,00
Maximum speed without load rpm 1DZ-II 2600,00 2600,00 2600,00 -

2Z -
2400,00 2400,00 2400,00
4Y 12,5/250 12,5/250 12,5/250 12,5/250
Standard
1DZ-II 29/260 29/260 29/260 29/260
meaning
kg/sq.cm /rv 2Z 33/260 33/260 33/260 33/260
Engine compression
i 4Y 9,0/250 9,0/250 9,0/250 9,0/250
Limit IDZ-II 20/260 20/260 20/260 20/260
2Z 20/260 20/260 20/260 20/260
Front Single Double 7,00 7,00 7,00 8,50
wheels Composite 7,00 7,00 7,00 7,00
Tire pressure kg/cm rim Beaded rim 8,00 7,00 7,75 -

ÿÿÿÿÿÿ
Special single 8,00 7,00 7,75 9,00
wheels
- -
9,00 -

Steering wheel play (when idling) Set pressure

mm 20-60 20-60 20-60 20-60

Climb 182,00 191,00 191,00 191,00

kg/sq.cm
oil control valve Slope 120,00 150,00 150,00 150,00
Free play of the brake pedal Gap between mm 1-5 1-5 1-5 1-5

the brake pedal and the floor Free play of the grinding mm 90 or more 90 or more 90 or more 90 or more
pedal
mm 1-3 1-3 1-3 1-3
engine cranking

Item Models 1-1.75 tons 2-2.5 tons 3 tons J3.5 tons

Composite rim 12-20 18-40 - -

Front Single 18-40 18-40 30-60 30-60

Machine Translated by Google

Item Models 1-1.5 tons 2-2.5 tons 3 tons J3.5 tons

Composite rim 12-20 18-40 - -

front Single 18-40 18-40 30-60 30-60

wheels Rim with sides Internal External 18-40 18-40 30-60 30-60
Hub nut tightening torque kg-m Double
18-40 18-40 30-60 30-60
ÿÿÿÿÿÿ Composite rim Side 9-16 12-20 12-20
wheels ring rim 9-16 18-40 12-20 12-20

Tightening torque of the compound Front wheels Rear 5-7 12-18 - -

kg-m
rim set bolt wheels 3-4,5 5-7 5-7 -

Parking brake force Specific gravity of battery kg 18-22 18-22 18-22 23-27
electrolyte (20°C)
1,28

Capacities and types of lubricants

Item 1-1.5 tons 2-2.5 tons 3 tons J3.5 tons Type

Gasoline 4Y 4,00 4,00 4,00 4,00 API SL, SM
Engine oil l 1DZ-II 7,90 7,90 7,90 -

Diesel API: CF-4

2Z -
9,00 9,00 9,00
1-speed 2-speed 9,00 9,00 9,00 9,00
Hydrotransformer l ATF GM Dexron 11
12,00 12,00 12,00 12,00
API GL 4 Hypoid
Clutch Model 5,80 6,10 8,20 8,20
Differential l transmission oil

Model with torque converter 5,80 6,10 8,20 8,20 API GL 5 Hypoid

Transmission l 3,60 3,60 3,60 3,60 transmission oil

Fuel tank l 45,00 60,00 60,00 60,00
Wheel bearings, chassis, steering
tilt control, Appropriate Quantity Grease MP

mast and grease fittings

Brake and clutch lines l 0,20 0,20 0,20 0,20 SAEJ-1703DOT-3
Model with clutch Model with 8,20 8,30 8,30 8,30
4Y torque
8,40 8,50 9,70 9,70
converter Model with clutch
Model with torque converter 6,80 7,00 7,00 -

Engine cooling system (except reserve tank)

l 1DZ-II Model with L.L.C.*
7,00 8,40 8,40 -

clutch Model with torque

converter -
7,90 7,90 7,90
2Z
-
8,10 9,30 9,30

Spare radiator tank (at the level of the FULL mark)

l 1,55 1,55 1,55 1,55

Hydraulic oil l 30,00 33,00 34,00 34,00 ISO VG 32

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VEHICLE OVERALL DIMENSIONS

32(62)- 32(62)- 32(62)- 32(62)- 32(62)- 32(62)- 32(62)-
8FG(FD)10 8FG(FD)15 8FG(FD)18 8FG(FD)20 8FG(FD)25 8FG(FD)30 8FGJ(FDJ)35
A 1045 1070 1070 1150 1150 1240 1290

IN 920 920 92 92 92 1070 1070

S 885 885 885 885 885 1010 1060

D 200 200 200 200 200 200 280

Well 100 100 100 100 100 100 140

F 895 895 895 965 965 965 965

1910 1990 2010 2200 2280 1910 2490

Mr. N 1975 2010 2020 2140 2210 2305 2350

I 4220 4220 4220 4220 4220 4220 4220

J 3000 3000 3000 3000 3000 3000 3000

TO 1970 1995 1995 1995 1995 2015 2120

L 140 145 145 145 150 135 140

M 920 920 920 920 920 1070 1070

N 30 35 35 36 40 40 50

ABOUT 7 6 6 6 6 6 6

R 10 11 11 11 11 11 11

Q 285 285 285 310 310 335 335

R 1070 1065 1060 1095 1090 1130 1130

S 2080 2080 2080 2110 2110 2170 2180

T 1055 1055 1055 1055 1055 1055 1055

IN 770 920 920 920 1070 920 920

IN 405 410 410 455 465 500 515

In 1485 1485 1485 1650 1650 1700 1700

X 355 395 420 455 520 595 650

AND 2245 2290 2315 2560 2635 2795 2865

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