01_A2030-00000_En.

fm Page 1 Thursday, July 22, 2010 9:40 AM

OPERATOR’S MANUAL En (English)

(Original)

驾 驶 员 手 册 zh (中文 )
( 原始手册的翻译稿 )
01_A2030-00000_En.fm Page 2 Tuesday, July 20, 2010 2:14 PM

ENGLISH
BEFORE INITIAL OPERATION
CONTENTS • Please read this manual thoroughly. This
will give you a complete understanding of
unexpected accident. Always wear proper
clothing for safe operation.
Note to Operators and Administrators .................................................................................................. 2 Toyota industrial vehicles and permit you to
operate them correctly and safely. • Please keep away from live electric power
Before Initial Operation ........................................................................................................................ 2 lines. Know the locations of inside and out-
Proper handling of new vehicles promotes
Caution Plates ....................................................................................................................................... 5 performance and extends service life. Oper- side power lines and maintain sufficient dis-
Main Components................................................................................................................................. 5 ate with special caution while becoming tance.
Operating Controls and Instrument Panel............................................................................................. 6 familiar with a new vehicles. • Be sure to perform pre-operation check
In addition to the standard operating proce-
Instruments............................................................................................................................................ 6 dures, pay attention to the following safety and periodic maintenance. This will pre-
Switches and Levers ............................................................................................................................. 9 vent sudden malfunctions, improve work
items. efficiency, save money and insure safe work-
Body Components............................................................................................................................... 12 ing conditions.
• Please acquire thorough knowledge on
Pre-Operation Check........................................................................................................................... 15 Toyota industrial vehicle. Read the opera-
Before Garaging the Vehicle............................................................................................................... 21 • Always warm up the engine before start-
tor’s manual thoroughly prior to operating ing operation.
Weekly Maintenance........................................................................................................................... 21 the vehicle. Get to know its operation and
Self Servicing...................................................................................................................................... 23 components. Learn about the safety devices • Be sure to avoid forward tilt when the
and accessory equipment and their limits and loaded fork is raised. In the worst case, this
Frame Serial Number.......................................................................................................................... 27 precautions. Be sure to read the caution plate will cause overturning due to lack of stabil-
How to Read the Name Plate .............................................................................................................. 27 attached to the vehicle. ity resulting from forward shifting of the
Lubrication Chart ................................................................................................................................ 27 center of gravity.
Every time you see this safety alert sym-
Periodic Maintenance ......................................................................................................................... 28 bol in this book or on your vehicle, there is • Never attempt traveling with a loaded on
Periodic Replacement Table ............................................................................................................... 28 important safety information for you. It the lifted fork beyond the specified height.
Protect Your Investment with Toyota Genuine Parts.......................................................................... 28 means Pay attention! Look out! Your Traveling with a load on the fork lifted
Periodic Maintenance Table................................................................................................................ 29 safety is involved! beyond the specified height may cause over-
Service Data ........................................................................................................................................ 32 The word after the symbol will tell you turning due to upward shifting of the center
about the hazard or importance of the rule. of gravity. Keep the fork at 10 – 20 cm (5.9 –
Mast Specifications & Rated Capacities............................................................................................. 34 7.9 in.) above the ground when traveling.
Wheel & Tire ...................................................................................................................................... 36 Danger -- An extreme hazard that could
Vehicle Dimensions ............................................................................................................................ 37 kill you or cause very serious injury every • Please avoid overloading or uneven load-
time. ing. Overloading or uneven loading is dan-
Warning -- Not as serious as Danger, gerous. If the center of gravity is nearer to
NOTE TO OPERATORS AND ADMINISTRATORS but a hazard that could cause injury or death
if you don't follow the rules.
the front side even though the load is below
the maximum, limit the loading weight
This manual explains the proper operation and maintenance of Toyota industrial vehicles as well as Two other words will be used to help you according to the load table.
daily lubrication and periodic inspection procedures. find better ways to run your vehicle: • If you hear unusual noise or sense any-
Please read this manual thoroughly even though you may already be familiar with other Toyota Caution -- When you see this word, thing unusual, inspect and repair immedi-
industrial vehicles because it contains information which is exclusive to this series of vehicles. The there will be a message to help you avoid ately.
manual has been produced based on a standard vehicle. However, if you have questions on other damage to your vehicle.
types, please contact your Toyota industrial vehicle dealer (Toyota dealer). Note -- Ways to do your job right and easier • Be sure to observe the correct operating
and to keep your vehicle running well, fol- procedures and precautions for the han-
In addition to this manual, it is essential that you review the separate publication entitled dling of vehicles equipped with power
“Operator’s Manual for Safety Operation” for forklift truck operators. It contains important low this word.
steering and power brakes.
information about the safe operation of forklift trucks. Toyota reserves the right to make any changes • Please learn safe driving points and safety
or modifications of specifications in this manual without giving previous notice and without incur- management. Understand and maintain • If the engine stops during traveling, the
ring any obligation. working area traffic rules. Ask the work area operation will be affected. Stop the vehicle
This vehicle passed the type approval tests pursuant to “Ordinance for Special Equipment Safety administrator about any special working pre- in a safe place as described below. Steering
Inspection” and “Regulation for Special Equipment Quality Supervision & Safety Inspection.” cautions. operation becomes heavy because the power
device for the power steering becomes inef-
• Wear neat clothing for operation. fective. Operate the steering wheel more
Improper clothing for vehicle operation may firmly than usual.
interfere smooth operation and cause an

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• Please use only the recommended types of • Prior to operation, adjust the seat to the the horizontal position. Never tilt the masts • To move down on a steep slope, use the
fuel and lubricants. Low-grade fuel and proper position and properly wear the seat- backward in an elevated position after backward move so that cargo collapse and
lubricants will shorten service life. belt with the adjusting mechanism. scooping the cargo as the cargo may col- tip-over can be prevented. Never park or
lapse. stop the vehicle on a slope as there is a haz-
• Flammable and/or combustible materials • To get on or get off the vehicle, use the step ardous possibility that the vehicle might
can be damaged, and in some cases
ignited, by a hot exhaust system or hot
and do not hold the steering wheel. For the
vehicle with the assist grip (option), use the
• If the chains are loosened when a cargo is
unloaded, use the lift lever to slightly raise
accidentally start moving. En
exhaust gases. To minimize the possibility assist grip. the forks, check that the chains are not loos- • Turing the vehicle at higher speed results in
for such damage or fire, the operator ened, and then draw out the forks. smaller turning radius, making the vehicle
must obey the following recommended • Symmetrically set the forks relative to the more likely to tip over. Therefore, take care
practices: center of the vehicle and then apply the stop- • If a cargo is found displaced when any other not to excessively increase the speed.
pers. cargo is unloaded, immediately correct the
• Do not operate forklift truck over or near position of the displaced cargo.
flammable and/or combustible materials, • To adjust the distance between the forks,
including dried grass and paper scraps. lean your body to the backrest and move the • If the forks cannot be fully inserted, tempo- Precautions for checks
forks with your foot. Never try to widen the rarily move the forks to a possible position
• Park forklift truck with rear end at least forks with your hands. and then fully insert them. • During working with others, communicate
30 cm (11.8 in.) away from lumber, veneer with each other so that the other workers
board, paper products and other similar • If a metallic pallet is used, maintain the forks find what your are doing.
materials to avoid discoloration, deforma- Precautions for cargo handling in a low position and the masts in the back-
ward tilting position when moving the vehi- • If the forks cannot be lowered to the ground
tion or combustion of those materials. because of a failure, mark the forks and set
• Do not push or roughly move any cargo with cle with any cargo loaded, since the pallet is
slippery. up a fence, etc., so that any other vehicle or
the forks. worker collide against the forks. In addition,
Safety Information • To transport any cargo in bulk or unpack- put up a sign indicating that the vehicle is in
aged, place it on the center of the pallet and failure.
Precautions for operation Precautions for moving the vehicle
then fasten it with a rope, etc. Do not place • To check the raised forks, previously take
• On the operator's seat, do not place anything any cargo on a single fork alone. • When turning the vehicle during backward measures for preventing the forks and masts
that may actuate the pedal or the lever move, take care not to let the fork ends hit from falling down.
• When raising the forks, take care not to drop anything.
depending on the motion of the vehicle. the cargo, and take preventive measures if • Do not access any high-voltage part. If you
• Any modification of the vehicle is prohib- necessary. • Pay attention to the fact that the turning get an electric shock, receive medical atten-
ited. In particular, removal of the head guard radius becomes larger when the vehicle car- tion.
• If two cargos are stacked, the upper cargo ries a long cargo.
or the backrest creates a hazardous possibil- may slide off. To stack two cargos, fasten
ity that the cargo might drop and hit the • Do not use the masts in place of stairs.
them with a rope. • Do not get off or jump off the moving vehi-
operator.
cle. • When opening or closing the tow board, the
• Do not try to suspend any cargo with forks engine hood, the battery cover, etc., take
• In handling any attachment, follow the using a rope (the rope is slippery). • To temporarily leave the vehicle, lower the care not to get your fingers caught.
attachment manufacturer's instructions. cargo to the ground and then apply the park-
• When storing any cargo on a shelf, etc., take ing brake. • For any work that requires a license, e.g., in
• When working in a dark location or at night, care not to let the forks protruding from the
ensure the necessary illumination and turn handling compressed air, use licensed per-
pallet damage the wall of the shelf. • Moving the vehicle on a rough surface sonnel. In that case, adjust the pneumatic
ON the headlights. causes a higher noise level and leads to
• To take out one cargo from the stacked car- pressure of the compressor.
• Adjust the distance between forks in compli- deformations of the tires.
gos, move forward the vehicle at right angles • Do not touch the anti-freeze liquid with your
ance with the pallet size. Since the adjust- to that cargo and then carefully insert the • Never try sudden starting, braking, or turn-
ment of the forks involves a hazard of bare hand. Never drink the anti-freeze liquid
forks into its pallet. ing on a rough surface of irregular ground, as it is hazardous material. Keep children
getting fingers pinched by the forks, move
an alleyway, or a sloping road as the cargo away from the anti-freeze liquid when stor-
the fork from the opposite side by pushing it • If you tilt the masts forward or backward may collapse or the vehicle may tip over.
with your foot; never use your hands. After when any cargo is loaded, the anterior-poste- ing it.
the adjustment, check that the fork stopper is rior stability deteriorates, causing the vehicle • Do not place your foot on the inching pedal • Improper disposal of waste oil, etc., contam-
properly located in the groove. to tip over. Never try to tilt the masts. while the vehicle is moving. Use the inching inates soil, water, air, or the like. For proper
pedal for fine-tuning alone when loading a disposal, comply with the applicable law and
• Make a fire extinguisher always available in • To scoop any cargo in an elevated position,
the work area and familiarize yourself with cargo. ordinance.
tilt the forks forward in the vertical position
how to use it. and then raise them. Scoop the cargo and
then lower it while maintaining the forks in
• In handling cargos, basically use pallets.

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Precautions for transportation Key-lift interlock (Option*) Travel OPS functions OPS controller abnormality warning
• Lock the dock board at the center of the *: You can use this function only when you If the operator leaves the seat while the vehicle If the OPS system detects an abnormality, the
trailer. In order to prevent slip or any other select OPS system (option). is traveling, the OPS lamp will light up, and 2 OPS lamp will blink to inform the operator.
similar hazard, ensure that the surface of the With the ignition switch positioned at OFF, the seconds later, traveling will be stopped. How- If the OPS lamp starts blinking, the OPS system
dock board is free from grease and other oil. fork will not move down even if the lift lever is ever, this does not forcibly brake traveling. (If may have malfunctioned. Park the vehicle at a
Thoroughly wipe off grease or other oil if so operated. However, if you sit in the seat and the operator returns to normal seating position safe location and request an inspection by your
any. turn on the ignition switch, you can lower the within 2 seconds, traveling can be continued.) Toyota dealer.
• To fasten the vehicle on the trailer, use well fork. If the OPS system is activated during traveling In the following cases, park the vehicle in a safe
trained personnel. an upward slope, the traveling power is inter- location and have the vehicle inspected by your
rupted and consequently the vehicle slides Toyota dealer.
• Use hooks in specified locations. OPS system (Option) down. To avoid this problem, make sure to sit
on the seat for operation. • The OPS lamp does not light up even if the
• To fasten the vehicle on the trailer, use a The OPS (Operator Presence Sensing) system To deactivate this function, return the control operator leaves the seat.
rope that has sufficient strength. prevents traveling and load handling operations lever to the neutral position and sit on the seat • The OPS lamp does not turn off even if the
• Do not stretch the rope to any unfixed loca- when the operator is not seated in the operator’s again.
seat. operator is re-seated.
tion during transportation.
If the operator leaves the operator’s seat while
• In towing the vehicle, do not tie a rope to the vehicle is operating, the OPS lamp will light Load handling OPS function
any unfixed location. Never tow the vehicle up to warn the operator that the OPS system will
with a drawbar as such tow is dangerous. activate. If the operator leaves the operator’s If the operator leaves the seat during load han-
seat for longer than 2 seconds, the OPS system dling operations, the OPS lamp will light up,
will activate and traveling and load handling and 2 seconds later, load handling operations
Precaution for storage operations will be suspended. However, if the will be stopped. (If the operator returns to nor-
operator returns to a normal seating position mal seating position within 2 seconds, loading
• To store the vehicle for a long period of time within 2 seconds, the OPS system will not acti- can be continued.) If the operator leaves the seat
except for its pneumatic tires, float it with vate and will allow travel and load handling while operating the control lever, loading can be
wood blocks of 300 mm (11.8 inches) each operations to continue. continued for 2-4 seconds.
in height in order to reduce load on the tires. Again, if an abnormality occurs to the OPS sys- To release the stopped load handling operations,
• Park the vehicle in a specified location. Put tem, the OPS lamp will blink to warn the opera- return the tilt lever to the neutral position and sit
up a sign or set up signal lights around the tor. In this case, the OPS system may have on the seat again. 1 second later, the OPS system
vehicle as necessary. malfunctioned. Contact your Toyota dealer to will be released and load handling operations
request an inspection. will again become possible. (Please beware that
• When the vehicle must be temporarily stored if you reseat yourself without returning the tilt
due to its failure, park it in a location distant lever to the neutral position, the load handling
from the traffic area and put up a sign show- operations will start to move 1 second later.)
ing that the vehicle is in failure.

OPS operation functions

Precautions for electric parts
If the operator leaves the seat, the OPS lamp
• This forklift uses high-precision electric will light up and inform the operator that the
parts. The use of any electric part other than OPS system is active. If the operator returns to
the parts Toyota approved for the forklift normal seating position, the OPS lamp will turn
may affect accurate operation of the systems off.
for the vehicle. For the use of any electric
part other than the ones approved by Toyota,
consult with your Toyota dealer.
• When non-marking or color tires are used,
electric resistance becomes larger than when This forklift is equipped with an OPS (Operator
the standard tires are used. Therefore, attach Presence Sensing) system. Before operating the
an antistatic strap to the vehicle. forklift, check that each of the system’s func-
tions is working properly.

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CAUTION PLATES MAIN COMPONENTS

Caution plates are attached on a vehicle. Before operating it, please be sure to read them thoroughly.
1. Mast
(The sample shows those of an Chinese version.)
2. Chain
1 8 3. Fork En
4. Tilt cylinder
5. Rear axle
2 6. Engine hood
7. Operator’s seat
7
8. Head guard

6
3

4 5

9. Counter weight
13 10. Frame
12
11. Front axle
12. Lift cylinder
13. Steering wheel

About these marks

Warning! Please read this Operator’s Manual carefully
before use.

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OPERATING CONTROLS AND INSTRUMENT PANEL INSTRUMENTS

Combination meter
1. Control lever
1 2 3 4 5 6 7 Meter illumination lamp is provided for easy
2. Parking brake lever 1 2 meter reading at night. It comes on when the
3. Steering wheel light control switch is set to ON.
4. Horn button
5. Light control and turn signal switch 1. Water temperature gauge
6. Lift lever 2. Hour meter
7. Tilt lever 3. Sedimenter warning lamp
8. Combination meter (Diesel engine models)
4. Fuel gauge
9. Accelerator pedal
5. Glow indicator lamp
10. Brake pedal 4 6 7 8
(Diesel engine models)
11. Ignition switch
6. Engine oil pressure warning lamp
12. Inching and brake pedal Gasoline engine models 7. Charge warning lamp
13 12 11 10 9 8 13. Tilt steering adjust lever
8. OPS lamp (Option)

1 2

3 4 5 6 7 8

Diesel engine models

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(1) Each warning lamp check method Engine oil pressure warning lamp
Please check if all warning lamps come on Comes on to indicate low engine oil pressure
when the ignition switch is turned to ON. while the engine is running.

Note:
1. If normal, the lamp comes on when the
ignition switch is turned on and goes off
En
• Use the light control switch to check the when the engine starts.
meter-lighting lamp. 2. If the lamp comes on while the engine is
• The OPS lamp lights up after turning on the running, either the engine oil is insuffi-
ignition switch even for the OPS-less mod- cient or the lubrication system is faulty.
els, but the OPS lamp does not light up Stop the operation immediately and ask a
other than this situation. Toyota dealer for inspection and repair.
(1) ON Note:
Caution
The engine oil pressure warning lamp does not
• The glow indicator lamp (diesel engine indicate the oil level. Check the oil level using
models) is on for 2 seconds when the the oil level gauge before starting work.
engine coolant temperature exceeds
50°C (122°F).
• If a lamp does not light up, contact your
Toyota dealer to request an inspection.

Hour meter Sedimenter warning lamp

(Diesel engine models)
Only operates when the ignition switch is on. It
indicates the total number of vehicle operating The sedimenter is a device for separating water
hours. from the fuel.
The unit of the right most digit is 1/10 hour. 1. The warning lamp comes on to indicate
Please use this meter to grasp the timing for water in the sedimenter exceeds the pre-
periodic maintenance and record the operation determined level while the engine is run-
hours. ning.
2. If normal, the lamp comes on when the
ignition switch is turned on and goes off
when the engine starts.
3. If the lamp comes on while the engine is
running, drain water immediately. (See
the self service section for the draining
method.)

Caution
Continued operation with the lamp on may
cause seizure of the injection pump and
pump damage. If the warning lamp light up,
always make sure to drain the water.

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Glow indicator lamp OPS lamp (Option: OPS models)

(Diesel engine models) If the operator leaves the seat, the OPS lamp
Indicates heating of glow plugs. will light up, indicating that the OPS system
When the ignition switch is turned on, the (option) is operating. In such a situation, return
lamp comes on and glow plug heating begins. the control lever and lift lever to the neutral
The lamp goes off automatically when glow position, then sit on the seat again.
plug heating is complete. The engine will start Should an abnormality occur in OPS system,
easily once the glow plugs are heated. this lamp will blink.

Note: Caution
The glow indicator lamp is on for 2 seconds In the following cases, a malfunction may
when the engine coolant temperature exceeds have occurred to the OPS system. Park the
50°C (122°F). vehicle in a safe location and contact your
Toyota dealer to request an inspection.
• If the operator leaves the seat, the OPS
lamp does not light up.
Charge warning lamp • Even when the operator is re-seated, the
OPS lamp does not turn off.
1. This lamp comes on to indicate an abnor-
mality in the charging system while the Note:
engine is running. The OPS lamp lights up after turning on the
2. If normal, the lamp comes on when the ignition switch even for the OPS-less models,
ignition switch is turned on and goes off but the OPS lamp does not light up other than
when the engine starts. this situation.
3. If the lamp comes on while the engine is Water temperature gauge
running, stop the operation immediately,
inspect the fan belt for cuts or loosening, Indicates the temperature of the engine cooling
adjust it, and restart the engine. water.
If lamp does not go off, the generation 1. This gauge functions with the ignition
system may be faulty. switch ON, and displays the cooling
Please ask a Toyota dealer immediately water temperature from left to right in a
for inspection and repair. 10-stage gradation scale.
2. The operator will be notified when the
water temperature is 95°C (203°F) or
over (above 8th stage), as the final 2
stages at far right begin blinking.
3. Temporary overheating may be caused by
water leakage, insufficient engine coolant
level, loosened fan belt or other abnor-
mality in the coolant level, loosened fan
belt or other abnormality in the cooling
system.
Inspect the cooling system.

Caution
When the water temperature gauge indi-
cates any temperature in the warning zone,
decrease the engine speed and then allow
the vehicle to stand until the water tempera-
ture decreases.

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Fuel gauge SWITCHES AND LEVERS

Indicates the amount of remaining fuel in the Ignition switch
fuel tank in terms of a 10-stage gradation scale.
The operator will be notified that remaining { [OFF]........Engine stop position.
fuel level is low when the 2 stages at far left Key insertion and withdrawal En
start blinking. are performed in this position.
It takes some time for the indication to be sta- I [ON]......... Engine operation position.
bilized after the fuel is supplied and the igni- Located one position clock-
tion switch is turned on. wise from { [OFF] position.
OFF ON The intake heater is preheated before starting
Caution in the diesel engine model.
• If the road is not level, attention must be START
paid because the correct level may not be START ............ Engine start position.
indicated. Located one position clock-
wise from the I [ON] position.
• When the gauge begins blinking, replace After engine start, release the key and it will
the fuel as soon as possible. return to the I [ON] position automatically.
The engine does not start unless the control
• In case of diesel in particular, be sure to lever is at the neutral position.
refuel it before it runs out because once
it causes the engines to stop running it
becomes necessary to bleed air from the Caution
fuel supply system. • Never operate the ignition switch with-
out first sitting on the seat. Otherwise,
the forklift could start to move uncon-
trolled, causing an accident.
• Do not leave the switch in the ON posi-
tion when the engine is stopped. It may
cause overdischarge of the battery.
• Do not turn ON the ignition switch while
treading on the accelerator pedal as the
starting performance deteriorates.
• Do not turn the switch to the START
position while the engine is running.
• Do not operate the starter motor for
more than 30 seconds continuously.
Return the switch to the OFF position
and wait at least 30 seconds prior to
attempting restart.
• With the ignition switch OFF (engine
off), the fork will not move down even if
the lift lever is so operated. However, if
you sit in the seat and turn on the igni-
tion switch, you can lower the fork. Do
not operate the lift lever before getting
on the vehicle and starting up the engine.
(Key-lift interlock: option)
• When the OPS lamp (option) is lighted,
return each lever to the neutral position
and sit on the seat.
Then confirm that the lamp has gone off.

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Integrated light and turn signal Control lever

switch (1)
Lever for shifting between forward and
(1) This switch serves as both two-position light reverse.
control and turn signal switch. Forward .................................... Push forward
(3) Reverse..................................... Pull backward
Light control switch The neutral position is halfway between the
(2)
forward and reverse position.
Irrespective of a ignition switch position, this
switch allows you to turn on and off lighting. Note:
(1)
This switch has two positions. With the switch After the OPS system (option) operates, return
at each position, the lamp comes on as shown (2) the accelerator pedal to its fully released posi-
below. tion and the control lever to the neutral posi-
(3) tion, and sit on the seat to restart the operation.
Lamp name Step 1 Step 2 (Even though the operator sits on the seat, trav-
(1) Left turn (1) Forward eling is impossible unless the control lever is
Head lamps − { shifted to the neutral position.)
(2) Right turn Side clearance lamps, tail lamps (2) Neutral
(Option) { {
(3) Reverse Caution
Meter illumination lamp { { • The engine cannot be started unless the
control lever is at the neutral position.
Caution • Stop the vehicle before shifting between
Do not keep lamps such as head lamps kept forward and reverse.
on for a long time when the engine is
stopped. It may cause overdischarge of the
battery to make engine starting impossible.

Turn signal switch Horn button

Makes the turn signal lamps blink. Press the button in the center of the steering
Left turn ................................... Push forward (1) wheel to sound the horn.
The horn will sound even when the ignition
Right turn ................................ Pull backward switch off.
The signal switch will operate when the igni-
tion switch is ON.
The turn signal lever returns automatically to
the original position after making a direction
change.

(1) Press

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(1)
Lift lever (1)
Tilt lever
Raises and lowers the forks. Tilts the mast forward and backward.
Raise..........................................Pull backward Forward .................................... Push forward
Lower ......................................... Push forward Backward................................. Pull backward En
The lifting speed can be adjusted by the The forward or backward tilting speed can be
(2)
degrees of accelerator pedal depression and (2)
adjusted by the degrees of accelerator pedal
lever operating stroke. depression and lever operating stroke.
The lowering speed can be adjusted only by
the degree of lever operating stroke. Caution
• Always operate the tilt lever from a
Caution seated position.
• Always operate the lift lever while cor-
rectly seated. • After the OPS system (option) operates,
return the accelerator pedal to its fully
(1) Lower • As long as the ignition switch is off, the (1) Forward tilting released position and the tilt lever to the
fork does not move down even if so oper- neutral position, and sit on the seat to
(2) Raise ated. However, if you sit in the seat and (2) Backward tilting restart the operation. (If you sit on the
turn on the ignition switch, you can lower seat without returning the tilt lever to
the fork. (Key-lift interlock: option) the neutral position, the fork may
resume moving.)
• After the OPS system (option) operates,
return the accelerator pedal to its fully
released position and the lift lever to the
neutral position, and sit on the seat to
restart the operation. (If you sit on the
seat without returning the lift lever to Parking brake lever
the neutral position, the fork may
resume moving.) When park the vehicle, pull the parking brake
lever fully while depressing the brake pedal.
• On OPS models, if the operator returns To release the brake, pull the lever once and
to the seat while pushing the lift lever push the knob at the top of the lever grip to
forward, the fork will not descend due to return the lever to the original position.
the return to neutral function. (2) (1)
Caution
Key-lift interlock (Option) (3) • Be sure to depress the brake pedal when
operating the parking brake lever.
When the ignition switch is OFF, the fork will
not descend even if the lift lever is so operated. (4) • When operating the lever, hold only the
However, if the operator sits properly in the grip of the lever.
seat and turns the ignition switch ON, the fork
can be lowered even if the engine is off. • Always chock the wheels when parking
(1) Lock on a slope.
If the ignition switch cannot be turned ON for
whatever reason, loosen the lift lock release (2) Release • If you fail to release the parking brake
bolt located on the oil control valve beneath (3) Release knob and travel, it may deteriorate the brak-
the toe board, and operate the lift lever in the ing effect. Have the vehicle inspected at a
forward direction. (4) Grip Toyota dealer.
Note:
(1) Once the fork has been moved down with the
lift lock release bolt applied, do not fail to fas-
(1) Lift lock release bolt ten the bolt and recover its original condition.

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Tilt steering adjustment BODY COMPONENTS

1. The steering wheel position may be
adjusted back and forth while the tilt Operator’s seat
steering adjust lever is raised. The operator’s seat belt is provided for your
2. Lowering the lever at the proper position safety.
fixes the steering wheel at that position.
(3) 1. Seat slide lever
3. After the adjustment, try to move the Pull the slide lever to the right to adjust
steering wheel back and forth to see that the back-and-forth position of the seat.
it is fixed. The seat is secured in position when you
release the lever.
(2) Caution
2. Recliner adjust knob
• The steering wheel position must be Turn the knob to adjust the seat’s angle of
adjusted before starting the vehicle. recliner.
(1)
(2)
• Adjustment during traveling must be Forward............. Turn the knob counter-
(1) Tilt steering adjust lever avoided. (1) clockwise
(2) Raised Backward ....... Turn the knob clockwise
(1) Seat slide lever
Pedals
(2) Recliner adjust knob Caution
From the right: accelerator pedal, brake pedal (3) Seat belt • The seat position must be adjusted
and inching and brake pedal. before starting the vehicle.
Caution • After adjustment, lightly shake the seat
Do not turn ON the ignition switch while forward and backward to confirm that
treading on the accelerator pedal as the the seat is firmly locked in position.
starting performance deteriorates.
Note:
Accelerator pedal stays neutral even when con-
trol lever is shifted to forward-reverse, due to Seat belt
accelerator switch.
The vehicle will move only when accelerator To fasten your seat belt, insert the tab into the
pedal is depressed. buckle.
You will hear a click when the tab locks into
the buckle. Pull on the belt to make sure the
Rear working light switch (Option) buckle is securely latched.
Adjust the seat belt length to your size as nec-
This switch turns the rear working lamps on essary.
and off.
ON ......................................... Raise the switch Disconnecting method
ON OFF ..................................... Lower the switch Push the release button and pull out the belt
from the buckle.
OFF
Caution
When the operator leaves the seat, insert the
seat belt tab into the buckle.

(1)

(1) Rear working light switch

12
01_A2030-00000_En.fm Page 13 Tuesday, July 20, 2010 2:14 PM

Warning 1. Seat slide lever

Pull the slide lever to the left to adjust the
• Buckle up. Your seat belt can reduce the back-and-forth position of the seat. The
risk of serious injury or death in case of seat is secured in position when you
a vehicle tipover. Your chances for avoid- release the lever.
ing serious injury or death in a tipover
are better if you stay with the vehicle in
(4)
2. Recliner adjust lever (Option)
En
the operator’s compartment. Pull the lever on the left of the seat to
adjust the seat’s angle of recliner.
• Always fasten your seat belt when oper- (2)
ating the vehicle. The vehicle can be (3) 3. Weight adjust knob (Option)
tipped over if operated improperly. To Turn the knob on the right of the seat
protect operators from the risk of seri- clockwise to adjust for a heavier body
ous injury or death in the event of a weight. Turn the knob counterclockwise
tipover, it is best to be held securely in to adjust for a lighter body weight.
the seat. The seat belt will help to keep Adjustment can be made for body
(1) weights between 40 kg and 120 kg.
you safely within the vehicle and opera-
tor’s compartment. (1) Seat slide lever
In the event of a tipover, don’t jump, Caution
grip the steering wheel, brace your feet, (2) Recliner adjust lever (Option) • The seat position must be adjusted
lean away from the direction of tipover, (3) Weight adjust knob (Option) before starting the vehicle.
and stay with the vehicle. (4) Seat belt • After adjustment, lightly shake the seat
forward and backward to confirm that
Suspension seat (Option) the seat is firmly locked in position.
The seat suspension mechanism provides a
comfortable seating position according to the Pocket (Option: Suspension seat)
weight of the operator. The optimum driving
position can be set using the knob and levers. An operator’s manual and operator’s manual
for safety operation are located on the rear side
Caution of the seat. Make sure to open the seat back
• To prevent an accident, make sure to pocket with both hands. If your vehicle does
adjust the seat before operating the vehi- not have an operator’s manual and operator’s
cle. manual for safety operation, please contact
(your authorized Toyota dealer) to obtain cop-
• In order to prevent an accident, do not ies for your vehicle.
adjust the seat while traveling. The seat
may suddenly move, interfering with Note:
your operation and causing an accident. Make sure the pocket is closed securely.
• Adjust the position of the seat so that
you can fully reach all of the pedals while
you have your back against the back of Magazine box
the seat. (Option: Suspension seat)
• On OPS models, due to the seat switch, There is a box at the rear of the pocket for
the forklift cannot be driven and the small items such as sketch boards and work
fork cannot be raised or lowered unless gloves.
the operator is sitting on the seat. There- To prevent items in the pocket from falling out
fore, please sit on the seat before when opening and closing the engine hood or
attempting to operate the forklift. More- driving on bad road surfaces, secure firmly
over, do not operate it with an object with the belt.
placed on the seat.
• On OPS models, do not turn on the seat
switch by any method other than sitting
on the seat.

13
01_A2030-00000_En.fm Page 14 Tuesday, July 20, 2010 8:28 PM

Retractable seat belt Engine hood

(Option: Suspension seat)
Caution
To fasten your seat belt, pull it out of the In opening or closing the engine hood, take
retractor and insert the tab into the buckle. care not to get your fingers pinched.
You will hear a click when the tab locks into
the buckle. Pull on the belt to make sure the
buckle is securely latched. Opening
The seat belt length automatically adjusts to
your size. Caution
Disconnecting method • Before opening the engine hood, previ-
Push the release button and allow the belt to ously stop the engine.
retract. • When opening the engine hood, be sure
Note: to check if the seat belt tab is being
inserted into the buckle.
If the seat belt is locked and cannot be drawn
out any further, pull on the belt strongly once, 1. Unfasten the engine hood catch.
then loosen it, then draw it back out slowly. 2. Lift the engine hood.
3. Open the engine hood all the way, then
Warning shake the hood slightly to check that the
• Buckle up. Your seat and seat belt can hood damper has been securely fastened
reduce the risk of serious injury or death before letting go.
in case of a vehicle tipover. Your chances
for avoiding serious injury or death in a
tipover are better if you stay with the
vehicle in the operator’s compartment.
• Always fasten your seat belt when oper-
ating the vehicle. The vehicle can be
tipped over if operated improperly. To
protect operators from the risk of seri- (1)
ous injury or death in the event of a
tipover, it is best to be held securely in (1) Engine hood catch
the seat. The seat and seat belt will help
to keep you safely within the vehicle and Closing
operator’s compartment. 1. Lift up the engine hood and press the
In the event of a tipover, don’t jump, hood damper lock to release the lock.
grip the steering wheel, brace your feet,
lean away from the direction of tipover, 2. Close the engine hood quietly, and press
and stay with the vehicle. (1) down on the hood until you hear a click-
ing sound.

Caution
Operating the vehicle without firm locking
of the engine hood is very dangerous. Be
sure to check firm locking before operating
the vehicle.

(1) Press

14
01_A2030-00000_En.fm Page 15 Tuesday, July 20, 2010 2:14 PM

Forks PRE-OPERATION CHECK

Lift each fork stopper and turn to release so
that forks can be shifted left and right. Pre-operation check
Adjust the forks in the position most appropri- Pre-operation checks and weekly inspections
ate for the load. are the responsibility of the Toyota industrial En
(1) When adjusting the forks, make sure that the vehicle user.
center of gravity of the load corresponds to the Be sure to perform a pre-operation check
center of the vehicle. After adjustment, turn the before beginning work to ensure safety.
stoppers to lock the forks in place.
Item Inspection
Warning Previously detected Correct.
malfunctions
Make the forks are locked before carrying a
load. Exterior Vehicle body, oil leakage, water leakage,
loose parts, exterior damage.
Wheels Tire air pressure, wear or damage, rims
hub nuts.
(1) Fork stopper Lamps Lamp condition, damaged lamps.

Draw bar Hydraulic oil Oil level, contamination, consistency.

Radiator Coolant level, antifreeze requirement.
The draw bar is located at the back of the coun- Check the radiator for clogging and
terweight, and is used to pull the vehicle clean it.
should its tires drop into a gutter or become Engine Oil level, contamination, consistency,
stuck in mud. noise, exhaust.
It can also be used for loading the forklift onto Brake pedal Pedal play, braking effect.
a truck or another vehicle. Brake fluid Fluid level.
(1) Parking brake Lever travel and brake performance.
Caution
Steering wheel Looseness, play, vibration, veering.
The draw bar should not be used for towing
Horn Sound.
the forklift or for towing another vehicle
using the forklift. Instruments Functioning.
Load handling Parts, oil leakage, cracking, looseness.
system
Fuel Amount.
(1) Draw bar Operator restraint Cut, frays and deck latch OK, seat belt &
buckle.
Vehicle hoisting method Exhaust tube Check for dust and inflammable material
around the muffler, and clean it if any.
When hoisting the vehicle, use the lifting holes
near the top of the mast for the front side and
the holes on the upper side of the counter- Walk around inspection
weight for the rear position as shown in the
illustration. Vehicle uprightness
Does the vehicle lean to one side or the other?
Caution If so, check for a tire puncture or a problem
• Use wire cable which is sufficiently with the undercarriage.
strong.
Beneath the vehicle
• Never use the overhead guard to hoist
the vehicle. Check for any oil or water leakage on the
ground or floor where the vehicle was parked.
Check for loose parts or damage.
If any unusual condition is found, have the
vehicle inspected at a Toyota dealer.

15
01_A2030-00000_En.fm Page 16 Tuesday, July 20, 2010 2:14 PM

Tire inspection Lamp inspection

Tire inflation pressure Are the filaments intact? Is there any lens dam-
age?
1. Use a tire pressure gauge and measure the Always keep the lenses clean to insure proper
inflation pressure. Adjust it to the proper forward vision.
level.

Warning
Use a cage when you put air into a tire.

Caution
Before using the air compressor, adjust its
pneumatic pressure.
Note:
• See the service data section for the proper
inflation pressure.
• Do not raise the pressure beyond the proper Engine compartment inspection
level.
Engine coolant level check and
2. After the adjustment, check if air is not supply
leaking from the valve.
Level check and supply of engine coolant shall
be performed while the coolant is cool.
1. With the engine off, open the engine hood
and check the engine coolant level in the
Damage, crack and wear of tires and rims reservoir tank.
Check the tires for damage and wear, and the (1)
rims for bending. If the tires are damaged, or Note:
there is a marked difference in the wearing of The reservoir tank equipped to the radiator
tires between the front and rear or between the automatically supplies the engine coolant
left and right is perceived, or bent rims are when the coolant quantity in the radiator
found, ask a Toyota dealer for inspection. becomes insufficient.
(1) Reservoir tank
2. The coolant level is proper if it is between
the upper and lower limits. If the level is
Hub nut inspection below the lower limit, supply coolant to
the upper limit.
Check the tightness of the hub nuts. 3. The concentration of the long life coolant
Avoid uneven torque and tighten all of the nuts (LLC) in the engine coolant must be 30%
uniformly. Refer to service data for proper (or 50% in a frigid zone).
torque.
Note:
If no engine coolant remains in the reservoir
tank, be sure to check the coolant level in the
(1) radiator, too.

(1) Reservoir tank

16
01_A2030-00000_En.fm Page 17 Tuesday, July 20, 2010 2:14 PM

Checking the engine coolant level 4. If the oil level is insufficient, add oil.
in radiator (1) Spilled and splashed oil must be wiped
off thoroughly. Adjust the oil level so that
(3) it will fall within a range of 0 through
Warning +10 mm (0.4 in.) from the lift-high mark
When the engine is hot, it is very dangerous on the gauge as illustrated on the left side. En
to remove the cap. Coolant level check must
always be performed when the engine is Gauge Identifier Applicable Models
cold. 20, 25 FGZN20, 25
FDZN20, 25
(4)
Caution 28, 30, 35 FGZN30
FDZN30
When removing the radiator cap, use thick
(5)
cloth to prevent possible burns; the use of
gloves is prohibited.
(2) (6)
(1) 1. Remove the radiator cover.
(1) Radiator cover 2. Remove the cap and check the coolant (1) Oil cap
level from the filler port. (2) Level gauge
3. If the engine coolant is not visible (3) Gauge identifier
through the filler port, fill appropriately (4) Lift high 4,300~4,700 mm
diluted coolant (LLC) to the port. (169.3~185 in.)
Note: (5) Lift high 4,000 mm (157.5 in.)
To close and tighten the radiator cap, match the (6) Lift high 3,000 mm (118.1 in.)
pawl on the reverse side of the cap with the
notch on the filler port and turn the cap fully
clockwise while applying a downward force.

Checking hydraulic oil level Engine oil inspection

Always stop the engine and lower the fork to 1. Park the vehicle on a flat ground. If the
the ground before checking the level of the vehicle is inclined, the indicated level
hydraulic oil, while the vehicle is on level may be incorrect.
ground.
2. The oil level must be checked before
1. Open the engine hood and remove the oil starting the engine or at least 3 minutes
cap. after the engine is stopped.
2. Wipe the level gauge attached to the oil 3. Extract the oil level gauge and wipe it
cap with clean cloth, and insert it again with clean cloth. Insert it again and check
into the tank. if the oil level is between the F and L lev-
els.
Note:
The oil level must be checked with the 4. If the oil level is below the L line, add oil
(1) threaded part of the oil cap in contact with the to the F line.
retainer inlet.
(1) Oil cap 3. Extract the level gauge gently and check
if the oil adhesion is up to the level line.

17
01_A2030-00000_En.fm Page 18 Tuesday, July 20, 2010 2:14 PM

Adding engine oil Warning

1. To supply oil, remove the filler cap and • Never use any oil other than brake fluid.
pour oil through the filler port. Never let • Do not allow dirt to get into the reservoir
the oil level exceed the F line. tank. Even a small amount of dirt in the
2. The oil to be supplied must be appropri- brake fluid can prevent proper braking.
ate for the season. This is extremely dangerous.
SAE40 Ambient temperature 5 mm (0.2 in.)
• Check the small vent hole in the reser-
higher than 30°C (86°F) voir tank cap frequently to make sure
SAE30 Ambient temperature that it is not clogged with dirt.
0°C to 30°C (32°F-86°F)
SAE20 Ambient temperature
-10°C to 0°C (14°F-32°F)

Caution
Always use the same brand of oil if possible.
Brake pedal inspection
1. Depress the brake pedal fully, and check
Leakage inspection the floor clearance (clearance between
the pedal and floor).
Check the engine compartment for any oil or
fuel leakage. Note:
Clean the radiator if it is clogged and check if
there are any foreign objects, such as paper or See the service data section for the floor clear-
other, onto the radiator grill. ance.
2. Make sure that the pedal does not go any
further when it is kept depressed.
3. Also check that no abnormality is
(1)
observed with pedal depression and
return.
4. Manually depress the brake pedal to
check the play until a resistance is felt.
On board vehicle inspection
Note:
Brake fluid inspection See the service data section for the value of
With the engine off, check the level of the brake pedal play.
brake fluid in the reservoir tank. The level
should be within the range shown in the figure. Warning
If the level is below the lower limit, add brake Ask a Toyota dealer for inspection if the
fluid up to the proper level. play is excessive, pedal movement is abnor-
If the decrease in brake fluid is excessive, the mal or brake performance is improper.
brake system may be leaky. Ask a Toyota (2)
dealer for inspection as early as possible.

(1)

(1) Brake pedal

(1) Reservoir tank
(2) Brake pedal floor clearance

18
01_A2030-00000_En.fm Page 19 Tuesday, July 20, 2010 2:14 PM

Parking brake inspection Instrument inspection

Start with the parking brake in the released Start the engine and see that they operate prop-
position and count the number of clicks while erly.
pulling the parking brake lever. Refer to the
service data for the correct number of notches En
required for braking.
If the brake is not effective within the desig-
nated number of notches, have the vehicle
inspected at a Toyota dealer.

Warning
(1) If abnormality of the number of notch is
found, have the vehicle inspected at a Toy-
ota dealer.

(1) Parking brake lever

Inching and brake pedal inspection Fuel level check and supply
1. Manually depress the inching and brake 1. Observe the fuel meter to see if the fuel is
pedal to check the play until a resistance sufficient.
is felt.
Note:
Note: • After the end of daily operation, fill the
See the service data section for the value of tank with fuel to prevent the moisture in the
inching and brake pedal play. air in the tank from mixing into the fuel.
2. Depress the inching and brake pedal and • The fuel tank cap has a breather. Every
check that there is no destruction or time you supply fuel, check to see whether
abnormal resistance. the breather functions properly.
Caution 2. When supplying fuel, stop the engine,
(1) remove the fuel tank cap by turning it
Ask a Toyota dealer for inspection when any counterclockwise, and pour fuel through
abnormality is found. the fuel filler neck.
(1) Inching and brake pedal
3. After fueling, be sure to tighten the fuel
Inspection of OPS lamp (Option) tank cap.

Sit on the seat, start the engine, and check that Caution
the OPS lamp is not lighted. • To check the fuel level, do not use a
In the following cases, a malfunction to the match, etc., that may cause ignition.
OPS lamp may have occurred. Park the vehicle
at a safe location and contact your Toyota • Always stop the engine and keep any fire
dealer. source away before and during the fuel-
ing operation.
• The OPS lamp does not light up even when
the operator leaves the seat. (1) • Carefully prevent entrance of water and
dirt into the tank during fueling.
• The OPS lamp does not turn off even if the
operator properly is re-seated. (1) Fuel tank cap

19
01_A2030-00000_En.fm Page 20 Tuesday, July 20, 2010 2:14 PM

Engine inspection Steering wheel inspection

Start the engine and warm it up sufficiently. Note:
1. Check each meter and warning lamp to Perform the inspection after starting the
see there is no abnormality. engine.
2. Check if the engine is generating abnor- 1. Check the steering wheel play with the
mal sound or vibration. rear wheel set in the straight traveling
3. Check the exhaust gas color to see it is direction.
normal. Note:
Colorless or light blue exhaust indicates
complete combustion; black exhaust, See the service data section for the standard
incomplete combustion; and white play of steering wheel.
exhaust, burning oil as a result of oil get- 2. Turn the steering wheel in the circumfer-
ting into the cylinders. ential direction and also move it up and
down to check there is no looseness.
Warning 3. Press the horn button to check if the horn
• The exhaust gas is harmful. If you must sounds normally.
start the engine inside a building or 4. If any abnormality is found, ask a Toyota
enclosure, insure sufficient ventilation. dealer for inspection.
• The gasoline engine carburetor is
equipped with the automatic choke that While moving slowly
keeps the engine running at a relatively
high speed when cold. Clutch disengagement and slipping
The engine resumes normal speed when
it is fully warmed. Press the inching and brake pedal and check
clutch engagement while moving.
Load handling system Caution
1. Check the fork installation state, for Insure that the control lever operate prop-
cracks and bending. erly in each gear and then make above
2. Check for mast distortion, chain tension check while moving slowly.
and oil leakage from cylinders and pip-
ing. Brake effectiveness
3. Operate the lift and tilt levers to check
Inspect to see if there is anything unusual when
their operating state. the brake pedal is pressed or if the brake only
Note: work on one side.
Effect the parking brake and insure that the
• Be sure to perform full-stroke operation for vehicle can be stopped and that a parked condi-
each cylinder piston a few times before tion can be maintained.
starting daily operation.
• If anything unusual is found, have the vehi- Caution
cle inspected at a Toyota dealer. If anything feels even slightly unusual, stop
vehicle operation immediately and have the
vehicle inspected at a Toyota dealer.

Steering inspection
While moving the vehicle slowly in a safe
location, turn the steering wheel to the left and
right and check for any unusual movement.

20
01_A2030-00000_En.fm Page 21 Tuesday, July 20, 2010 2:14 PM

BEFORE GARAGING THE VEHICLE Air cleaner cleaning

Remove dirt from all vehicle components and The element can be taken out after removing
Caution the three catches fixing the element.
then perform the following.
Even a small malfunction can cause a serious
1. Inspect for oil or water leakage. accident. En
2. Inspect each component for warping, Do not operate the vehicle until repairs have
scratches, dents or cracks. been completed.
If you sensed anything unusual during opera-
3. Clean the air filter element and lubricate tion, notify the administrator.
parts as required.
4. Raise the forks all the way up and down to (1)
lubricate the inside of the lift cylinder.
Operate the mast front and rear tilt at the
same time.

(1) Element
WEEKLY MAINTENANCE
Element cleaning
Maintenance required for the below items are
mainly checking and addition. As oil or grease 1. Tap the element filter paper lightly with-
needs periodic replacement depending on the out causing any damage or blow dust off
degree of contamination, take proper action as with compressed air (7 kgf/cm2 or less)
required. from inside.
Never fail to perform pre-operation inspection
and weekly maintenance to maintain safe, Caution
comfortable operation. Before using the air compressor, adjust its
pneumatic pressure.
Weekly (40-hour) inspection items
Air cleaner - clean
Fan belt - inspect
Torque converter oil level - check
Battery electrolyte level - check
Bolts and nuts - retighten
Mast and steering linkage - grease
Chain Lubrication - engine oil
2. After element cleaning, remove any dust
in the evacuator valve.
Inspect the items above in addition to the pre- Note:
operation items. Have necessary adjustments • Always replace the element if the filter
or replacements performed at a Toyota dealer. paper is torn or damaged.
Please inspect the vehicles thoroughly to
insure safety and pleasant working conditions. • Wash the element if heavily contaminated.
• It is unnecessary to clean the inside ele-
ment when cleaning the double cyclone air
cleaner (option).
Only clean the outside element.
(1) It is essential to replace both outside and
inside elements, in time of replacement.

(1) Evacuator valve

21
01_A2030-00000_En.fm Page 22 Tuesday, July 20, 2010 2:14 PM

How to wash the element Note:

When the battery indicates any of the follow-
1. Soak the element in water containing ing conditions, consult with your Toyota dealer
neutral detergent for approximately 30 or the manufacturer:
minutes and then wash. Use care not to
scratch the filter paper. • Foul odors are produced.
2. After washing, rinse the element with • A terminal is dark-colored.
clean water (water pressure less than • The temperature of the battery electrolyte is
2.8 kgf/cm2). high.
3. Allow to dry naturally or use a dryer • The battery electrolyte decreases too fast.
(cold air). Never use compressed air or
flame.
Note:
The element should be replaced after washing
six times or after it is used for one year.

Fan belt inspection Torque converter oil inspection

Inspect the fan belt for cracks, fraying and ten- 1. Park the vehicle at a safe and level
sion. ground, and stop the engine.
If any abnormalities are found, have the belt
replaced or adjusted at a Toyota dealer. Caution
Refer to service data for tension. Inspect with the parking brake is effected
and the forks are lowered to the ground.
2. Open the engine hood and remove the toe
board.
3. Extract the level gauge and wipe it with
clean cloth.
4. Insert the level gauge back to the hole
4Y engine 1DZ-II engine (1)
from which it is removed, and extract it
again to check if the oil level is between
(1) Toe board the F and L lines on the level gauge.

Battery electrolyte check Note:

• Perform inspections using the COLD side
1. The battery electrolyte should be between of the level gauge before operating the
the upper and lower levels (10 to 15 mm vehicle.
(0.4 to 0.6 in.) from the top of the plates).
2. If the electrolyte level is below the lower • The level gauge contains the inscriptions
level, remove the cap and add distilled “COLD” and “HOT” on either side. Con-
water to the upper level through the water duct inspections using the “COLD” side
inlet port. before operating the vehicle and when the
oil temperature is 40°C (104°F) or under. If
you have operated the vehicle and the oil
Caution temperature is 60°C (140°F) or over, use
Be sure to use distilled water for battery the “HOT” side to conduct inspections after
electrolyte. Also, wear protective glasses 30 seconds and within 5 minutes after the
when working on the battery. engine is stopped.
• If the level is near or below the L line, add
oil to the F line.

22
01_A2030-00000_En.fm Page 23 Tuesday, July 20, 2010 2:14 PM

Retightening of bolts and nuts SELF SERVICING

Retighten each bolt and nut on the chassis and
load handling system. Jack setting position
Caution En
After jacking up the vehicle, never enter the
area under the fork and frame. Serious
Greasing mast and steering linkage injury may occur if the jack happen to be
removed accidentally.
Grease in accordance with the lubrication
table.

Caution Front
• Clean the grease fitting tips thoroughly
prior to greasing. 1. Park the vehicle on a level surface.
2. Apply the parking brake and chock the
• After greasing, wipe off excess grease. wheels.
3. Tilt the mast backward, raise the forks by
about 1 m (39.4 in.).
When the battery is dead 4. Insert the jack under the bottom surface
of the frame in the rear of a front tire.
(4) When a booster cable is available, it is possible
a
to start the engine using the battery of another
vehicle.
Connect the booster cable following the
(1)
sequence of the illustration.
Make sure of (+) and (-) terminals of the cable
b, c (2) when connecting.

Caution Rear
(3) • Connection (1): The (+) terminal of dead
e battery. Caution
d Be sure to use a jack whose capacity is 5.0
• Connection (4): Use a frame apart from ton or more.
the battery.
a. Dead battery 1. Park the vehicle on a level surface.
• Do not directly connect batteries to avoid
b. Engine hanger a danger of explosion. (An inflammable 2. Apply the parking brake and chock the
c. To frame gas generated from batteries may catch wheels.
fire.) Insert the jack under the counterweight
d. Booster cable (jack-up point).
e. Rescue battery Jack setting position
• Oil garage jack
Apply the jack under the center of the
counterweight.
• Portable oil jack
(2) Apply the jack to the jack-up point
(1) under the counterweight.

(1) Oil garage jack

(2) Portable oil jack

23
01_A2030-00000_En.fm Page 24 Tuesday, July 20, 2010 2:14 PM

Tire replacement Adding antifreeze 1. Remove the radiator cap. Loosen the
drain cock on the radiator and cylinder
Caution If the vehicle is left in an area where the tem- block and drain the cooling water.
perature is less than 0°C (32°F), the cooling 2. Flush out the radiator and cylinder block
• In the case of a wheel with a divided rim, water will freeze and may damage the radiator
do not loosen the rim bolts and nuts by adding clean water through the radia-
and/or cylinder block. In such cases, antifreeze tor inlet.
when loosening the hub nuts. When loos- coolant must be used.
ening the rim nuts or removing the rim When long-life coolant (LLC) is used, it must 3. After the water has drained out of the
bolts, be sure to completely remove the be changed once every 2 years. radiator and cylinder block, tighten the
air before loosening. Freezing temperature varies depending on the radiator and engine drain cocks.
Front • Refer to service data for hub nut tighten- amount of antifreeze added. 4. Add the proper amount of antifreeze to
(1) (2) (1) ing torque and tire air pressure. the radiator inlet and fill up the remaining
Antifreeze mixture (%) space with clean water.
• Tire air pressure is very high, so pay Freeze protection -12 -15 -24 -35 5. When warm weather arrives and there is
attention to rim deformation, cracks, etc. temperature (°C (°F)) (10.4) (5) (-11.2) (-31)
no longer any danger of freezing, drain
Never exceed proper air pressure. Mixture (%) 25 30 40 50 the cooling water containing the anti-
freeze (except LLC, LLC is every 2 years
1. Jack up the vehicle until the tires are Caution in replacement).
about to leave the ground and loosen the • The antifreeze fluid is flammable, so be Flush out the radiator and engine block
hub nuts. particularly careful to avoid flame. and fill with clean water.
2. Jack up the vehicle until the tires leave Prior to adding antifreeze, inspect the
(2 ton models) (3 ton models) the ground and completely remove the air radiator, water pump, piping and cylin-
pressure from the tire. der block for leaks.
3. Remove the hub nuts and then remove the The procedures for adding antifreeze are
Rear as follows.
(1) (2)
wheel.
4. To reinstall each wheel after replacing the • When removing the radiator cap, use
tires, operate in the reverse order of the thick cloth to prevent possible burns; the
procedure for removal. use of gloves is prohibited.
The hub nuts should be tightened evenly
in the sequence shown in the figure.
Note:
See the service data for the hub nut tightening Cleaning of pre-cleaner (Option)
torque.
(1) Hub nuts Inspect the pre-cleaner and clean it if dust has
Caution accumulated up to the white line.
(2) Rim nuts
(Never loosen without removing the air) Make the vehicle travel at a low speed a few
times in the forward and backward direc-
tions to inspect hub nuts for any loosing,
and retighten them as required.

5. After replacing the wheel, check and

adjust the tire air pressure.
(1)
Warning
Use a cage when you put air into a tire.

Caution
(1) Pre-cleaner
Before using the air compressor, adjust its
pneumatic pressure.

24
01_A2030-00000_En.fm Page 25 Tuesday, July 20, 2010 2:14 PM

Fuse replacement Caution

If a lamp does not come on or an electrical • Use the fuse having the same capacity as
device does not function, the corresponding that of the installed one.
fuse may be blown.
Check the fuse for each device. The fuse box is
• If the replaced fuse is blown again, ask a
Toyota dealer for inspection.
En
located in the front left as seen from the
opened engine hood. • Ask a Toyota dealer to replace the
GLOW or ALT fuse, if necessary.
Note:
(1) See the table below for the device correspond-
ing to each fuse. Air purge of the fuel system
(Diesel engine models)
(1)
When fuel has been completely depleted or
when maintenance has been performed on the
fuel system, be sure to perform air purge in the
(1) Fuse box following sequence.
Fuse assignment 1. Open the engine hood.
2. Operate the priming pump up and down
A 30A STA M 7.5A SPARE
to perform air bleeding.
B 40A AM1 N 7.5A HME
C – – O 7.5A ST
D 15A HORN P 10A GAUGE
E 7.5A ALT-S Q 10A BACK_LP
F 7.5A STOP R 7.5A SFT (1) Priming pump
G 7.5A TAIL S 7.5A TURN
H 7.5A ECU-B T 7.5A IGN (1)
Draining the sedimenter
I 15A WORK_LP U 15A SPARE
(Diesel engine models)
J 15A HEAD V 10A SPARE The sedimenter separates the water contained
K 40A AM2 W 10A ECU-IG in the fuel. It is integrated with the fuel filter.
L 30A SPARE
If the sedimenter warning lamp comes on,
immediately drain water according to the fol-
lowing procedure because the accumulated
Including optional accessories water in the sedimenter is above the specified
level:
The fuse check and replacement procedures 1. Place a water receiving container under
are as follows: (2) the open end of the drain hose under the
1. Set the ignition switch to the OFF posi- fuel filter.
tion. 2. Turn around the drain plug a time or two
(3) to loose it and operate the priming pump
2. Remove the fuse box cover and take off
the clip attached to the fuse box. up and down to drain the water in the sed-
(1) Priming pump imenter.
3. Apply the fuse clip to a fuse to remove (2) Drain plug
the fuse. 3. When light oil starts to flow out after the
(3) Drain hose end of water draining, firmly tighten the
4. The fuse is blown if its state is as shown drain plug.
at right in the left illustration. Replace it
with a spare fuse. Caution
Wipe the light oil cleanly from the adjacent
area.

25
01_A2030-00000_En.fm Page 26 Tuesday, July 20, 2010 2:14 PM

Maintaining the battery Cleaning the radiator fin

(1)
Terminals Clean the radiator and radiator fin. If debris is
trapped therein, this may cause over-heating.
1. A loose or corroding terminal causes fail-
ure in connection: Eliminate white pow-
der, if noticed on the terminal, by pouring Caution
warm water over it to disable and then • After stopping the engine, confirm that
grease the terminal. the engine has sufficiently cooled down
before conducting cleaning. Taking ade-
2. Remove the terminal, if it is extremely quate precautions may result in burns.
corroded, from the battery to brush off the
corrosion using a wire brush or sandpa- • When cleaning the radiator fin, take
per. Then connect the terminal tightly to care not to cause it to become deformed.
(1) Grease the battery and grease the terminal.
• When performing cleaning, always wear
Note: safety goggles and dust mask.
Remove the negative terminal (-) first, but
replace the same, second.
Caution
• Stop the engine when attempt to work on Fuel tank check
the battery and terminals.
Check fuel tank, tank covering, fuel inlet, and
• Be careful not permitting any foreign drain plug against possible fuel leak. Follow
matter to come into the battery by the steps below.
means of putting the lids tightly in place.
1. Try to smell leak.
• Be careful not causing a short circuit on 2. Look for leak.
the battery nor nearing fire, such as
smoking fire, because the battery-emit- 3. Touch possible leak.
ted gas is inflammable. See the nearest Toyota dealer upon finding
leak and have them repair tank immediately.
• Be cautious enough not to contact the
battery electrolyte. Caution
When it comes into contact with an eye
or skin, wash it off immediately with Never perform do-it-yourself welding or
plenty of water and then see a doctor. other repair work for it might cause explo-
sion or fire.
• Charge the battery with the lids off in a
well-ventilated area.
• When battery electrolyte is spilt, be cer-
tain to wash it off with water thoroughly
the spot and adjoining area.
Note:
When the battery indicates any of the follow-
ing conditions, consult with your Toyota dealer
or the manufacturer:
• Foul odors are produced.
• A terminal is dark-colored.
• The temperature of the battery electrolyte is
high.
• The battery electrolyte decreases too fast.

26
01_A2030-00000_En.fm Page 27 Tuesday, July 20, 2010 2:14 PM

FRAME SERIAL NUMBER LUBRICATION CHART

Frame serial number location 1. Chain I) Inspect every 8 hours (daily)
The frame serial number is stamped on the 2. Differential gear II) Inspect every 40 hours (weekly)
right-hand step of the vehicle. Please refer to
the frame serial number when making inquiries
3. Front wheel bearing III) Inspect every 250 hours (6 weeks) En
about your vehicle. 4. Brake and clutch master cylinder IV) Inspect every 1000 hours (6 monthly)
5. Torque converter case V) Inspect every 2000 hours (annually)
6. Rear wheel bearing {: Inspect and service
7. Steering knuckle king pin z: Replase
8. Oil tank A) MP grease
9. Engine crankcase B) Engine oil
(1)
10. Rear axle beam front pin C) Hypoid gear oil
11. Rear axle beam rear pin D) Hydraulic oil
12. Tilt steering locking mechanism E) Automatic transmission fluid
(1) Frame serial number location 13. Mast support bushing F) Brake fluid
14. Tilt cylinder front pin G) Molybdenum disulfide
15. Propeller shaft Note:
HOW TO READ THE NAME PLATE 16. Tie rod end pin In case of the hard operating condition, the ser-
17. Rear axle cylinder end pin vice interval of 170 hours or 1 month may be
The load capacity is engraved on the name recommendable.
plate.
Make sure of the load center and capacity
before starting the operation.
1. Vehicle type 14 G G 14
2. Special vehicle type, attachment type 1 B B 1
13 G G 13
3. Frame No.
3 A A 3
4. Vehicle weight
4 F F C C 2
5. Mast lifting height
12 A A 15
6. Front tread
7. Tire size E E 5
8. Tire air pressure 10 G D D 8
9. The year of manufacture 7 A B B 9
10. UL specification 6 A A 7
11. Load capacity 16 A A 6
12. Load center 17 A A 16
11 G A 17
I
II
III
IV
V

27
01_A2030-00000_En.fm Page 28 Tuesday, July 20, 2010 2:14 PM

PERIODIC MAINTENANCE PROTECT YOUR INVERSTMENT WITH TOY-

Periodic inspection and maintenance are neces-
sary to keep your Toyota industrial vehicle run-
If operation time exceeds 250 hours within 6
weeks use the number of hours as the guide for
OTA GENUINE PARTS
ning smoothly. The designated number of hours performing periodic inspection. Pre-operation Why gamble with your valuable assets? When your forklift needs periodic maintenance - as every
in the inspection cycle are as follows. checks and weekly inspections should prefera- forklift does - you need Toyota Genuine Parts.
Daily (pre-operation check) ....Every 8 hours bly be performed by the user. 6 weeks, 3-month, The same parts used on Toyota assembly lines - meeting the same tough Toyota standards for “PER-
6-month and annual inspection should be per-
Weekly .....................................Every 40 hours formed by a Toyota dealer since high-level tech- FORMANCE”, “DURABILITY”, and “SAFETY”.
6 weeks ...................................Every 250 hours nology and special tools are required. TOYOTA GENUINE PARTS
Refer to the periodic maintenance table to deter- IF YOU USE A NON-GENUINE ENGINE OIL FILTER:
3-month ..................................Every 500 hours mine inspection and maintenance items and Offer Excellent Dust-catching Performance 1. Clogging may result, which can lead to engine
6-month ...............................Every 1,000 hours inspection cycles. seizure.
on:
Annually..............................Every 2,000 hours Use only genuine Toyota parts for replacement e.g. Air element, Torque converter oil filter 2. The engine oil may become dirty faster,
parts, and use the recommended types of lubri- necessitating frequent oil changes.
Return oil filter, Engine oil filter 3. It can pass dirty oil to the engine, causing
cants. Fuel filter engine wear.

TOYOTA GENUINE PARTS

PERIODIC REPLACEMENT TABLE
REPLACEMENT PERIOD (Accumulated hours of operation EVERY 6 WEEKS 3 6 12 MONTHS Offer Supreme Durability on: IF YOU USE A NON-GENUINE RADIATOR HOSE:
or monthly periods of operation, whichever comes sooner.) EVERY 250 500 1000 2000 HOURS e.g. Clutch disc 1. The hose may wear out extremely rapidly.
Engine oil z ← ← ← Radiator hose 2. The hose may be susceptible to water
Engine oil filter z* z ← ← V belt leakage, necessitating frequent replacement.
Cooling water (except LLC, LLC is every 2 years) z ← ←
Air cleaner element z
Fuel filter z ← TOYOTA GENUINE PARTS
Torque converter oil z ←
Torque converter oil filter z ← Offer Added Safety on: IF YOU USE A NON-GENUINE BRAKE SHOE:
Differential gear oil z e.g. Lift roller 1. Braking performance may be excessive,
← insufficient, or erratic, which is dangerous.
Hydraulic oil z Lift chain
← 2. The brakes may drag wasting fuel or
Hydraulic oil filter z* z Tie-rod end battery power.
Wheel bearing grease z Brake shoe
Spark plugs z ←
Master cylinder, wheel cylinder cap and seals z
Brake fluid z ←
Power steering hose (Every 2 years)
Power steering rubber parts (Every 2 years) Call your Toyota authorized shop for after-sale service.
Hydraulic hose (Every 2 years)
Reserve tank hose (Every 2 years) With high quality TOYOTA genuine parts and superior service
Fuel hose (Every 2 years) technology, Toyota help keep customers forklifts in the best
Torque converter rubber hose (Every 2 years) condition for efficient work and higher productivity. We
Chain (Every 3years) deliver satisfaction to the customers with Toyota genuine part.
Hydraulic oil pump seal (Every 3 years or 6,000 hours)
*: For new vehicles
Note:
In case of the hard operating condition, the service interval of 170 hours or 1 month may be recom-
mendable.

28
01_A2030-00000_En.fm Page 29 Tuesday, July 20, 2010 2:14 PM

PERIODIC MAINTENANCE TABLE INSPECTION PERIOD (Accumulated hours of operation or

6
EVERY WEEKS 3 6 12 MONTHS
monthly periods of operation, whichever comes sooner.)
EVERY 250 500 1000 2000 HOURS
Periodic maintenance
POWER TRANSMISSION SYSTEM
INSPECTION METHOD Differential En
I: Inspect and correct and replace as required. T: Tighten C: Clean L: Lubricate M: Measure and cor- 1. Oil leakage ............................................................................................... I ← ← ←
rect and adjust as required. 2. Oil level.................................................................................................... I ← ← ←
3. Loose bolts ............................................................................................... Τ

INSPECTION PERIOD (Accumulated hours of operation or

6
EVERY WEEKS 3 6 12 MONTHS Torque converter and transmission
monthly periods of operation, whichever comes sooner.) 4. Oil leakage ............................................................................................... I ← ← ←
EVERY 250 500 1000 2000 HOURS
5. Oil level.................................................................................................... I ← ← ←
ENGINE 6. Operating mechanism function and looseness......................................... I ← ← ←
Basic components 7. Control valve and clutch function............................................................ I ← ← ←
1. Starting condition and unusual noise ....................................................... I ← ← ← 8. Inching valve function ............................................................................. I ← ← ←
2. Rotating condition during idling.............................................................. M ← ← ← 9. Stall test and oil pressure measurement ................................................... Μ ←
3. Rotating condition during acceleration.................................................... M ← ← ← Propeller shaft and axle shaft
4. Exhaust condition..................................................................................... I ← ← ← 10. Loosening of joint .................................................................................... Ι ← ←
5. Air cleaner element .................................................................................. C ← ← ← 11. Looseness at spline connection................................................................ Ι
6. Valve clearance ........................................................................................ M* Μ 12. Looseness at universal joint ..................................................................... Ι
7. Compression ............................................................................................ Μ 13. Twisting and cracks of axle shaft............................................................. Ι
8. Cylinder head bolt.................................................................................... Τ
RUNNING EQUIPMENT
9. Muffler rubber mount............................................................................... I
Wheels
Blow by gas reduction device
1. Tire air pressure ....................................................................................... M ← ← ←
10. Clogging and damage of PCV valve and piping...................................... I ← ← ←
2. Tire cuts, damage and uneven treads ....................................................... I ← ← ←
Governor
3. Loose rim and hub nuts............................................................................ T ← ← ←
11. Maximum no-load stabilized rotation speed............................................ M ← ← ←
4. Tread depth .............................................................................................. M ← ← ←
Lubrication system 5. Metal fragments, stones or other foreign objects in tires......................... I ← ← ←
12. Oil leakage ............................................................................................... I ← ← ← 6. Rim, side ring and disc wheel damage..................................................... I ← ← ←
13. Oil level.................................................................................................... I ← ← ← 7. Front wheel bearing unusual noise and looseness ................................... I ← ← ←
14. Clogging and fouling of oil filter ............................................................. I ← ← ← 8. Rear wheel bearing unusual noise and looseness .................................... I ← ← ←
Fuel system Front axle
15. Fuel leakage ............................................................................................. I ← ← ← 9. Housing cracks and damage..................................................................... I
16. Carburetor link mechanism operation...................................................... I ← ← ←
Rear axle
17. Fouling and damage of fuel filter element............................................... I ← ← ←
10. Beam cracks, damage and deformation ................................................... Ι
18. Injection timing........................................................................................ Μ ←
11. Axle beam forward and backward direction looseness............................ M* Μ
19. Injection nozzle injection pressure and condition.................................... Μ
20. Draining of sedimenter ............................................................................ Ι ←
STEERING SYSTEM
Cooling system Steering wheel
21. Radiator cooling water level and leakage ................................................ I ← ← ← 1. Play and looseness ................................................................................... I ← ← ←
22. Rubber hose deterioration ........................................................................ I ← ← ← 2. Operating condition ................................................................................. I ← ← ←

23. Radiator cap condition ............................................................................. I ← ← ← Steering valve

24. Fan belt tension and damage.................................................................... I ← ← ← 3. Oil leakage ............................................................................................... I ← ← ←
25. Radiator rubber mount ............................................................................. Ι 4. Mounting looseness ................................................................................. T ← ← ←

29
01_A2030-00000_En.fm Page 30 Tuesday, July 20, 2010 2:14 PM

6 6
INSPECTION PERIOD (Accumulated hours of operation or EVERY WEEKS 3 6 12 MONTHS INSPECTION PERIOD (Accumulated hours of operation or EVERY WEEKS 3 6 12 MONTHS
monthly periods of operation, whichever comes sooner.) monthly periods of operation, whichever comes sooner.)
EVERY 250 500 1000 2000 HOURS EVERY 250 500 1000 2000 HOURS
Power steering 5. Mast and lift bracket looseness ................................................................ I ← ← ←

5. Oil leakage ............................................................................................... I ← ← ← 6. Mast support bushing wear and damage.................................................. Ι

6. Mounting and linkage looseness.............................................................. I ← ← ← 7. Roller wear, damage and rotating condition ............................................ I ← ← ←

7. Power steering hose damage.................................................................... Ι 8. Roller pin wear and damage .................................................................... Ι
9. Mast strip wear and damage .................................................................... I ← ← ←
Knuckle
8. King pin looseness ................................................................................... I ← ← ← Chain and chain wheel
9. Cracking and deformation........................................................................ I 10. Chain tension, deformation and damage.................................................. I ← ← ←
11. Chain lubrication...................................................................................... I ← ← ←
BRAKING SYSTEM
12. Chain anchor bolt condition..................................................................... I ← ← ←
Brake pedal 13. Chain wheel wear, damage and rotating condition .................................. I ← ← ←
1. Play and reserve ....................................................................................... M ← ← ←
Various attachments (Option)
2. Braking effect........................................................................................... I ← ← ←
14. Abnormalities and mounting condition ................................................... I ← ← ←
Parking brake HYDRAULIC SYSTEM
3. Operating force ........................................................................................ I ← ← ←
Cylinder
4. Pull margin............................................................................................... I ← ← ←
1. Cylinder mounting looseness and damage............................................... T ← ← ←
5. Braking effect........................................................................................... I ← ← ←
2. Rod and rod screw and rod end deformation and damage....................... I ← ← ←
Brake pipe and hose
3. Cylinder operation ................................................................................... I ← ← ←
6. Leakage, damage and mounting condition .............................................. I ← ← ←
4. Natural drop and natural forward tilt ....................................................... M ← ← ←
Brake oil 5. Oil leakage and damage ........................................................................... I ← ← ←
7. Level ........................................................................................................ I ← ← ← 6. Pin and cylinder shaft support wear and damage..................................... I ← ← ←
Master cylinder or wheel cylinder 7. Lifting speed ............................................................................................ M ← ← ←
8. Function, wear, damage and mounting looseness.................................... Ι 8. Uneven movement ................................................................................... I ← ← ←
Brake drum and brake shoe Oil pump
9. Clearance between drum and lining......................................................... M ← ← ← 9. Oil leakage and unusual noise.................................................................. I ← ← ←
10. Shoe sliding portion and lining wear ....................................................... Ι Hydraulic oil tank
11. Drum wear and damage ........................................................................... Ι 10. Oil level and contamination ..................................................................... I ← ← ←
12. Shoe operating condition ......................................................................... Ι 11. Tank and oil strainer................................................................................. C ←
13. Anchor pin rusting ................................................................................... Ι 12. Oil leakage ............................................................................................... I ← ← ←
14. Return spring wear, etc. ........................................................................... Μ
Control lever
15. Automatic adjusting function operation................................................... Ι
13. Linkage looseness .................................................................................... I ← ← ←
Backing plate 14. Operation.................................................................................................. I ← ← ←
16. Deformation cracking and damage .......................................................... Ι
Oil control valve
17. Mounting looseness ................................................................................. Τ
15. Oil leakage ............................................................................................... I ← ← ←
LOAD HANDLING SYSTEM 16. Relief pressure measurement ................................................................... M
Forks 17. Relief valve and tilt lock valve function .................................................. I ← ← ←
1. Fork and stopper pin condition ................................................................ I ← ← ← Oil pressure piping
2. Left and right fork uniformity.................................................................. I ← ← ← 18. Oil leakage ............................................................................................... I ← ← ←
3. Cracks in fork base and welded portion................................................... Ι∗1 19. Deformation and damage......................................................................... I ← ← ←

Mast and lift bracket 20. Linkage looseness .................................................................................... T ← ← ←

4. Deformation, damage and cracks in welded portion ............................... I ← ← ←

30
01_A2030-00000_En.fm Page 31 Tuesday, July 20, 2010 2:14 PM

6 6
INSPECTION PERIOD (Accumulated hours of operation or EVERY WEEKS 3 6 12 MONTHS INSPECTION PERIOD (Accumulated hours of operation or EVERY WEEKS 3 6 12 MONTHS
monthly periods of operation, whichever comes sooner.) monthly periods of operation, whichever comes sooner.)
EVERY 250 500 1000 2000 HOURS EVERY 250 500 1000 2000 HOURS
ELECTRICAL SYSTEM OPS (Option)
Ignition system 10. Function ................................................................................................... I ← ← ← En
1. Distributor cap cracking........................................................................... I ← ← ← Seat
2. Spark plug burning and gap ..................................................................... I ← ← ← 11. Mounting looseness and damage ............................................................. I ← ← ←
3. Distributor side terminal burning............................................................. I ← ← ← 12. Damage to and/or operation of seat belts................................................. I ← ← ←
4. Distributor cap center piece wear and damage ........................................ I ← ← ← 13. Plate and buckle damage.......................................................................... I ← ← ←
5. Plug cord internal disconnection.............................................................. Ι 14. Operating condition of seat switch (Option)............................................ I ← ← ←
6. Ignition timing ......................................................................................... Μ ← Body
Starter 15. Frame, cross member, etc. damage and cracking..................................... Ι
7. Pinion gear meshing................................................................................. I ← ← ← 16. Bolt looseness .......................................................................................... Τ
Charger Rear-view mirror
8. Charging effect......................................................................................... I ← ← ← 17. Dirt, damage............................................................................................. I ← ← ←
Battery 18. Rear reflection status................................................................................ I ← ← ←

9. Battery electrolyte level ........................................................................... I ← ← ← Others

10. Specific gravity ........................................................................................ Μ ← 19. Lubrication............................................................................................... L ← ← ←
Electrical wiring
11. Wiring harness damage............................................................................ I ← ← ← *: For new vehicle
12. Fuses ........................................................................................................ I ← ← ←
*1: Fissure and crack detector
Preheater Note:
13. Glow plug heat coil breakage .................................................................. Ι ← In case of the hard operating condition, the service interval of 170 hours or 1 month may be recom-
mendable.
SAFETY DEVICES, ETC.
Head guard
1. Welded portion cracking .......................................................................... I ← ← ←
2. Deformation and damage......................................................................... I ← ← ←
Back rest
3. Mounting looseness ................................................................................. T ← ← ←
4. Deformation, cracking and damage ......................................................... I ← ← ←
Lighting system
5. Operation and mounting condition .......................................................... I ← ← ←
Horn
6. Operation and mounting condition .......................................................... I ← ← ←
Turn signals
7. Operation and mounting condition .......................................................... I ← ← ←
Instrument
8. Operation.................................................................................................. I ← ← ←
Back-up buzzer (Option)
9. Operation and mounting condition .......................................................... I ← ← ←

31
01_A2030-00000_En.fm Page 32 Tuesday, July 20, 2010 2:14 PM

SERVICE DATA
Adjustment value table
Item Models 2~2.5 ton 3 ton
Fan belt tension (98N (10 kgf [22 lbf]) pressure applied) mm (in.) 8~13 (0.31~0.51) ←
Spark plug gap mm (in.) 4Y 0.7~0.8 (0.028~0.031) ←
Spark plug type 4Y W9EXR-U ←
Ignition timing (BTDC) deg/rpm 4Y 7/750 ←
Ignition sequence 4Y 1-3-4-2 ←
Fuel injection timing (BTDC) deg 1DZ-II 0 (Static) ←
Fuel injection sequence 1DZ-II 1-3-4-2 ←
4Y 0 (Self adjusting) ←
IN.
1DZ-II 0.18~0.22 (0.007~0.009) ←
Valve clearance (When warm) mm (in.)
4Y 0 (Self adjusting) ←
EX.
1DZ-II 0.33~0.37 (0.013~0.015) ←
4Y 750 +50
0 ←
Idling speed rpm
1DZ-II 750 ± 30 ←
4Y 2400 ± 50 ←
No load maximum speed rpm
1DZ-II 2400 ± 50 ←
4Y 1226 (12.5) [178]/250 ←
Standard value
1DZ-II 2850 (29) [412]/260 ←
Engine compression kPa (kgf/cm2) [psi]/rpm
4Y 883 (9) [128]/250 ←
Limit
1DZ-II 1961 (20) [284]/260 ←
Divided rim 700 (7) [100] −
Front wheels
Tire air pressure kPa (kgf/cm2) [psi] Side ring rim − 700 (7) [100]
Rear wheels Divided rim 700 (7) [100] 775 (7.75) [110]
Steering wheel play (When idling) mm (in.) 20~50 (0.79~1.97) ←
Parking brake range notches 4~5 ←
Parking brake lever operating force N (kgf) [lbf] 150~250 (15~25) [33~55] ←
Lift 18.7 (191) [2710] ←
Oil control valve set pressure MPa (kgf/cm2) [psi]
Tilt 15.7 (160) [2275] ←
Brake pedal play mm (in.) 1~5 (0.04~0.20) ←
Brake pedal floor clearance mm (in.) 89 (3.5) or more ←
Inching and brake pedal play mm (in.) 1~3 (0.039~0.12) ←
Divided rim 117~392 (18~40) [130~289] −
Front wheels
Hub nut tightening torque N·m (kgf·m) [ft·lbf] Side ring rim − 294~588 (30~60) [217~434]
Rear wheels Divided rim 118~196 (12~20) [87~145] ←
Front wheels 118~176 (12~18) [87~130] −
Divided rim set bolt tightening torque N·m (kgf·m) [ft·lbf]
Rear wheels 49~68.5 (5~7) [36~51] ←
Battery electrolyte specific gravity at 20°C (68°F) 1.28 ←

32
01_A2030-00000_En.fm Page 33 Tuesday, July 20, 2010 2:14 PM

Lubricant capacities and types

Item 2~2.5 ton 3 ton Type
Gasoline 4Y 4.0 (1.06) ← API SL, SM
Engine oil L (US. gal)
Diesel 1DZ-II 7.9 (2.09) ← API: CF-4
Torque converter L (US. gal) 1 speed 5.0 (1.32) ← ATF GM Dexron II En
Differential gear L (US. gal) 5.8~6.4 (1.53~1.69) 7.8~8.6 (2.06~2.27)
API GL 4 Hypoid gear oil
Transmission L (US. gal) 3.6 (0.95) ←
Fuel tank L (US. gal) 60 (15.8) ←
Wheel bearings, chassis, tilt steering and mast and grease fittings Appropriate amount MP Grease
Brake line L (US. gal) 0.2 (0.05) ← Brake fluid 2500H

Engine cooling system 4Y 8.6 (2.27) ←

L (US. gal) L.L.C.*
(excluding reserve tank) 1DZ-II 7.3 (1.93) ←
Radiator reserve tank (at FULL mark level) L (US. gal) 0.6 (0.158) ←
Hydraulic oil L (US. gal) 36.3 (9.6) 37.3 (9.8) ISO VG 32

* L.L.C. = Long Life Coolant (Appropriately diluted with fresh water)

The hydraulic oil level pertains to the V-mast with a lift of 3,000 mm (118.1 in.).

33
01_A2030-00000_En.fm Page 34 Tuesday, July 20, 2010 2:14 PM

MAST SPECIFICATIONS & RATED CAPACITIES

D
L M

A C G

B Overall height G Free lift (Top of forks) J Single tire

T A D Extended
K N
Mast Maximum I Tilt range Load capacity at 500 mm (19.7 in.) LC
type fork height C H With standard load
Lowered E F Without load backrest backrest L M O P
With standard load
Without load backrest Forward Backward PN tire PSC tire
backrest

V FV FSV
Wide visible mast Wide visible full-free lift two-stage mast Wide visible full-free lift three stage mast

34
01_A2030-00000_En.fm Page 35 Tuesday, July 20, 2010 2:14 PM

Model: FGZN20/FDZN20
B G J
A D K N
T C H I
E F L M O P
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) kg (lbs) En
3000 (118) 1995 (78.5) 3720 (146.5) 4250 (167.3) 98 (3.9) 98 (3.9) 6 11 2000 (4410) 2000 (4410)
V
4000 (157.5) 2595 (102.2) 4720 (185.8) 5250 (206.7) 98 (3.9) 98 (3.9) 6 11 2000 (4410) 2000 (4410)
4300 (169) 1995 (78.5) 4910 (193.3) 5550 (218.5) 1425 (56.1) 775 (30.5) 6 6 1900 (4190) 1900 (4190)
FSV
4700 (185) 2145 (84.4) 5310 (209.1) 5950 (234.3) 1575 (62) 925 (36.4) 6 6 1850 (4079) 1850 (4079)
Note: Height of standard load backrest is 1220 mm (48.1 in.).

Model: FGZN25/FDZN25
B G J
A D K N
T C H I
E F L M O P
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) kg (lbs)
3000 (118) 1995 (78.5) 3720 (146.5) 4250 (167.3) 98 (3.9) 98 (3.9) 6 11 2500 (5513) 2500 (5513)
V
4000 (157.5) 2595 (102.2) 4720 (185.8) 5250 (206.7) 98 (3.9) 98 (3.9) 6 11 2500 (5513) 2500 (5513)
4300 (169) 1995 (78.5) 4910 (193.3) 5550 (218.5) 1425 (56.1) 775 (30.5) 6 6 2300 (5072) 2300 (5072)
FSV
4700 (185) 2145 (84.4) 5310 (209.1) 5950 (234.3) 1575 (62) 925 (36.4) 6 6 2000 (4410) 2000 (4410)
Note: Height of standard load backrest is 1220 mm (48.1 in.).

Model: FGZN30/FDZN30
B G J
A D K N
T C H I
E F L M O P
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) kg (lbs)
3000 (118) 2015 (79.3) 3780 (148.8) 4270 (168.1) 88 (3.5) 88 (3.5) 6 11 3000 (6615) 3000 (6615)
V
4000 (157.5) 2615 (103) 4780 (188.2) 5270 (207.5) 88 (3.5) 88 (3.5) 6 11 3000 (6615) 3000 (6615)
4300 (169) 2165 (85.2) 4960*2 (195.3*2) 5570 (219.3) 1550*3 (61*3) 945 (37.2) 6 6 2850 (6284) 2850 (6284)
FSV
4700 (185) 2265 (89.2) 5360*2 (211*2) 5970 (235) 1650*3 (65*3) 1045 (41.1) 6 6 2800 (6174) 2800 (6174)

Note: 1. Height of standard load backrest is 1220 mm (48.1 in.).

2. With A4 piping, extended overall height (without load backrest) increase in 25 mm (1 in.). (*2-marked portions)
3. With A4 piping, free lift (without load backrest) decrease in 25 mm (1 in.). (*3-marked portions)

35
01_A2030-00000_En.fm Page 36 Tuesday, July 20, 2010 2:14 PM

WHEEL & TIRE

J-Lug
Model Tire Arrangement Rim Size Tire Size J-Lug NON-Punk
Front
A 5.00S X 12 DT 7.00-12-12PR {

A 5.00S X 12 DT 7.00-12 z
FGZN20, 25
FDZN20, 25 Rear
A 4.00E X 9 DT 6.00-9-10PR {

A 4.00E X 9 DT 6.00-9 z
Front
B 7.00T X 15 IR 28X9-15-12PR {

B 7.00T X 15 IR 28X9-15 z
FGZN30
FDZN30 Rear
A 5.00F X 10 DT 6.50-10-10PR {

A 5.00F X 10 DT 6.50-10 z

A: Divided rim B: Side ring rim

{: Standard z: Option

36
01_A2030-00000_En.fm Page 37 Tuesday, July 20, 2010 2:14 PM

VEHICLE DIMENSIONS
FGZN20 FGZN25 FGZN30
FDZN20 FDZN25 FDZN30

A 1140
(44.9) ← 1255
(48.2) En
980 1030
B ←
(38.6) (40.6)
960 1010
C ←
(37.8) (39.8)

C: Tread

F: Tread
210 260
D ←
(8.3) (10.2)
D
A
B

105 130
E ←

E
(4.1) (5.1)
965
F ← ←
(38)
G
2200 2260 2400
G

H
(86.6) (89) (94.5)
2190 2225 2325
H (86.2) (87.6) (91.5)
4250 4270
I ←
(167.3) (168.1)
3020
J ← ←
(118.9)
1995 2020
K ←
(78.5) (79.5)
98 88
L ←
(3.9) (3.5)
1210 1215
M ←
(47.6) (47.8)
40 45
N ←
(1.6) (1.8)

O P O 6° ← ←
T
I

L: Fork lifting height

P 11° ← ←

420 415 450

Q (16.5) (16.3) (17.7)
K
J

S
1095 ← 1160
R (43.1) (45.7)
M

2130 2195
S ←
(83.9) (86.4)
N

1040
T ← ←
(40.9)
U V W X
1070
U ← ←
Y (42)
470 490
V ←
(18.5) (19.3)
1650 1700
W ←
(65) (66.9)
450 530 585
Unit: mm (in.) X (17.7) (20.9) (23)
2575 2650 2780
Y (101.4) (104.3) (109.4)

37
02_A2030-00000_Zh.fm Page 38 Tuesday, July 20, 2010 8:39 PM

中文
在驾驶之前
目录 y 仔细阅读本手册。它将让您充分了解丰田 y 操作时必须穿着整洁。穿着不适的服装进
工业车辆的性能，并且能够正确而安全地 行车辆驾驶会妨碍操作并引发意外的事
驾驶员和管理员 ................................................................ 38
进行操作。 故。所以必须穿着适合驾驶及操作的服
在驾驶之前 .................................................................... 38
正确的操作能够提高新车性能和延长其 装。
警告牌 ........................................................................ 41
使用寿命。新车磨合期间，应特别小心驾
主要零部件 .................................................................... 41 y 请避开带电的供电线。熟悉内外供电线的
驶。
驾驶控制器和仪表板 ............................................................ 42 位置，并保持充分距离。
除了标准操作方法之外，请注意下列安全
仪表 .......................................................................... 42
事项。 y 驾驶前的检查和定期保养。这将防止突然
开关和操纵杆 .................................................................. 45
车身组件 ...................................................................... 48 y 请充分了解有关丰田工业车辆的知识。在 故障，提高工作效率，节省费用并确保安
使用前的检查 .................................................................. 51 驾驶车辆之前，仔细阅读驾驶员手册。了 全的工作状态。
车辆开进车库之前 .............................................................. 57 解其操作方法及要领。掌握安全装置和附 y 开始操作之前，须预热发动机。
每周保养 ...................................................................... 57 属设备的限制和预防规定。请务必阅读贴
自行维修 ...................................................................... 59 在车辆上的警示牌。 y 在承载货叉升高时避免前倾。由于重心前
车架序号 ...................................................................... 63 移会导致车辆失衡而造成翻车。
名牌的阅读方法 ................................................................ 63 每当您在本书中或在您的车辆上发现
润滑表 ........................................................................ 63 此安全警示符号时，表明它是对您非常重 y 当载有负荷的货叉提升到超过规定的高
定期保养 ...................................................................... 64 要的安全信息。该符号意味着“请注意！ 度时，不要将其移动。在载有负荷的货叉
定期更换表 .................................................................... 64 当心！注意您的安全！” 提升到超过规定的高度时移动，会由于重
使用丰田牌纯正零件来保护车辆 .................................................. 64 该符号之后的内容将告知您具体的危险 心上移而造成翻车。移动时将货叉保持在
定期保养表 .................................................................... 65 或该项规定的重要性。 离地 10-20 cm （厘米）的高度。
维修数据 ...................................................................... 68 危险——每次出现都有可能致命或造 y 避免超载或承载不匀。超载或承载不匀是
门架说明书和额定容量 .......................................................... 70 成非常严重的人身伤害的极端危险。 危险的。如果重心太靠前侧，即使装载量
车轮和轮胎 .................................................................... 72
警告——没有 “危险”那么严重，但 低于最大值，也要根据载重表来限制承载
车轮尺寸 ...................................................................... 73
若您不遵守规定的话，它也有造成人身伤 重量。
害或死亡的危险。
y 如果听到任何异常噪音或感到有任何异
驾驶员和管理员 同时还将使用其他两个词语来帮助您以
常，都须立刻进行检查并修理。
更好的方式来驾驶您的车辆：
本手册对丰田工业车辆的正确操作、保养、日常润滑、定期检查等要领作了说明。
y 对于有助力方向盘和助力制动器的车辆，
即使您对其他丰田工业车辆已经了如指掌，也要仔细阅读本手册，因为其包含了本系列车辆 当心——当您看见这个词语时，将会
有一个消息帮助您避免对车辆造成损伤。 须遵守正确的操作程序以及预防措施。
特有的资料。本手册是在标准车辆的基础上编写的。万一您对其他车种有疑问，请与丰田工
业车辆经销店 （丰田经销店）联系。 注意——在此符号后将给出正确的操作 y 如果在移动中发动机停止，会影响操作。
要领，让您能够更轻松地找到更适合车辆 把车辆停在以下所述的安全地点。由于助
除了本手册之外，有必要进一步阅读为叉车驾驶员专门出版的 “驾驶员安全操作手册” 。该
运行的方法。 力转向器的助力装置失效而使转向操作
手册集中了关于叉车安全操作的重要信息。丰田公司保留在没有预先通知和不承担任何责任
的情况下对本手册中的技术参数进行改变和修改的权利。 y 请掌握安全驾驶要点和安全管理。了解和 变得困难。操作方向盘比平时更吃力。

本车辆通过了依照 “特种设备安全检查条例”和 “特种设备质量监督和安全检查章程”执行 遵守工作区的交通规则。有关特别的工作 y 只能使用所推荐的燃油和润滑剂。低级燃

的型式试验。 注意事项，请向工作区管理员查询。 油和润滑剂将会缩短使用寿命。

zh-38
02_A2030-00000_Zh.fm Page 39 Tuesday, July 20, 2010 8:39 PM

y 高温排气系统或高温排气会使可燃或易 y 上车或下车时应使用踏板，不得握住方向 y 卸货时 , 若发现货物有错位，应立即纠正 检查时的注意事项

燃的物质发生质变，并在某些情况下使之 盘。对于装有扶手 （选购件）的车辆，则 使其回复正确状态。
y 在与他人配合工作时，应注意相互交流，
着火。为了将着火的可能性降至最低，驾 应使用扶手。
y 若货叉未能完全插入，则应暂时将货叉移 让其他人员了解你在做的事情。
驶员必须遵守下列所推荐的常规：
y 将货叉相对于车辆中心对称地排列 , 并用 动至适当的位置，然后再完全插入。
y 因故障货叉无法降至地面时，应对货叉做
y 不要在可燃或易燃物质，包括干燥的气体 货叉销固定。
y 金属制的托盘易滑脱，所以在负载行走 标记并设置围栏，防止其他车辆或人员与
和废纸的上部或近旁操作叉车。
y 调整货叉间距时，要将身体靠在当货架 时，应将货叉放到较低的位置，门架应保 货叉发生碰撞。另外还应表示出该车发生
y 停放叉车时须离开木材、胶合板、纸制品 上，用脚移动货叉 , 切勿用手。 持在后倾状态。 了故障。
以及其他类似物品至少 30 cm （英寸），
装卸货物时的注意事项 行走时的注意事项 y 若要检查已升起的货叉时，应先采取防止
以避免这些物质发生质变或燃烧。
货叉和门架掉落措施后进行。
安全须知
y 切勿使用货叉推动或移动货物。 y 在倒车转弯时，应注意防止货叉末端击中 zh
其他物品。 y 切勿触动高压部件。触电时，应接受医生
y 在搬运散装或未包装的货物时，将其放在
驾驶时的注意事项 诊断。
托盘的中心处，用绳子或其他工具将其绑 y 搬运超常货物时 , 应注意到转弯半径会变
y 不要在驾驶座上放置与驾驶无关的物品， 牢。切勿用一只货叉载货。 大。 y 切勿使用门架来代替台阶。
防止其由于车辆的运动而触动踏板或操
y 在提升货叉时，应注意防止货物掉落，必 y 切勿在车辆移动途中下车或跳下。 y 在打开或关闭拖缆板、引擎罩、电池盖
作杆。
要时要采取防护措施。 时，应注意防止手指被夹住。
y 禁止对车辆改造。特别值得注意的是如果 y 若要暂时离开车辆，应将货物降至地面，
y 两层叠放的货物容易滑落。需要两层叠放 并拉紧停车制动闸。 y 对于需要许可的工作，应该由持有许可证
拆除护顶架或挡货架，落下的货物会有击
中驾驶员的危险。 时要用绳子将其绑牢。 的人来进行。像处理压缩空气时，应指派
y 在不平整的路面上行走时 , 会产生很大的
具备许可证的员工调整压缩机的气压。
y 在使用附属装置时，请遵循该附属装置厂 y 切勿使用绳索将货物悬挂在货叉上（绳索 噪音，还会导致轮胎变形。
易滑脱）。 y 请勿直接用手触摸防冻液。因其属于有害
商的说明。 y 切勿在路面状态不佳的石子路、小巷或斜
物质切勿饮用。在存放时应确保远离儿
y 在黑暗场所或在夜间工作时，要确保作业 y 将货物摆放至货架时，要注意从托盘上伸 坡上急速启动、急速刹车或急速转弯等， 童。
所需亮度并打开车大灯。 出的货叉不要碰伤货架墙壁。 否则有可能导致货物散落，车辆侧翻。
y 将废油等进行不当的处理、会导致土壤、
y 货叉间距应按托盘尺寸进行调整。在调整 y 从叠放的货物中取出一件货物时，车辆要 y 在车辆行走中切勿将脚放在微动踏板上。
水、空气等的污染。所以作为废物处理
货叉时会有手指被夹的危险，因此要用脚 正对货物行进 , 将货叉谨慎地插入托盘。 该踏板仅在装载货物过程中进行微调时 时、要遵循适应的法律正确处理。
推动对面的叉子 , 切勿用手推。在调整 使用。
y 若提升负重货叉并将门架前后倾斜的话，
后，要确认货叉固定销紧嵌于槽内。 前后的稳定性降低 , 有导致车辆翻倒的可 y 以倒车方式从陡坡上下行，可以防止货物
y 工作区内要常备灭火器，并熟知其使用方 能。切勿将门架前倾。 倾倒和车辆翻倒。切勿在斜坡上停驻，防
法。 止车辆失控滑行所带来的危险。
y 用货叉提取高位货物时，先将货叉前倾至
y 货叉式车辆通常使用托盘搬运货物。 垂直位后提升，提取货物后再将货叉垂直 y 车辆旋转时、速度过快旋转半径变小易造
降下。货叉取出货物后 , 切勿在高位将门 成车辆翻到，所以应注意避免速度过快。
y 在驾驶前先将座椅调整至合适的位置，并 架向后倾斜，否则货物有可能倾倒。
正确佩带安全带。
y 卸货时 , 若链条松弛，应使用升降杆将货
叉微微抬起，在确认链条没有松弛后，抽
出货叉。

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运输时的注意事项 y 若使用了无标记或彩色轮胎，则电阻较之 行程 OPS 功能 OPS 控制器异常报警

于使用标准轮胎时会变大。因此，应在车
y 将装货板锁在拖板车的中心处。为防止滑 如果车辆正在行驶时驾驶员离开座位，OPS灯 如果 OPS 系统检测出异常状况，OPS 灯将闪
辆上系上一根防静电皮带。
动或其他类似的危险，应确保装货板的表 将点亮，两秒后自动停车。但本功能不会强 烁，提醒驾驶员。
制制动停车（如果驾驶员在 2 秒内返回座位，
面没有油脂和其他任何油污。若有油污则 钥匙提升联锁装置 （选购件 *） 如果 OPS 灯启动闪烁，则此时 OPS 系统可能
应彻底擦净。 车辆将继续行驶）。 发生故障，将车停放在安全的地方，联系丰
*：您仅可以在选定了OPS系统时使用此功能。
如果在驾驶上坡时启动 OPS 系统，则驱动电 田经销店进行检查。
y 要将车辆拴在拖板车上，应指派训练有素 当发动机被关闭 （点火开关在 OFF 位置），
源会被中断而导致车辆滑下。为避免这种故 发生下列情况的，将车辆停在安全的地方，
的人员来完成。 即使升降杆被操作了，货叉仍不能向下移
障，务必要坐到座位上进行操作。 并联系丰田经销店进行检查。
动。但是，如果坐到座位上并打开点火开关，
y 在指定的位置使用钩子。
才有可能降下货叉。 搬运操作 OPS 功能 y 驾驶员离开座位后，OPS 灯不能点亮。
y 在拖板车上固定时，应使用有相当强度的
OPS 系统 （选购件） 如果驾驶员在货物搬运操作期间离开座位， y 驾驶员回到座位后，OPS 灯不能熄灭。
绳索。
则 OPS 灯将亮起，两秒钟后搬运操作将自动停
OPS（驾驶员存在感测）系统可以防止驾驶员
y 在运输过程中切勿将绳索拉长至任何不 止。（如果驾驶员在两秒内返回座位，则搬运
没有坐在驾驶位置时的移动和搬运操作。
固定的位置。 操作将继续进行）。如果驾驶员离开座位的同
若驾驶员在车辆运行过程中离开其座位，则 时也在操作控制杆，则搬运操作将持续 2-4
y 在牵引时，切勿将绳索系在任何不固定的 OPS 指示灯将亮起，以提醒驾驶员 OPS 系统即 秒。
位置上。用牵引杆来拖拉车辆是十分危险 将启动。若驾驶员离开其座位超过 2 秒，则
若要释放停止的货物搬运操作，应将倾斜杆
的切勿使用。 OPS系统将启动，同时车辆行驶和搬运作业将
返回空档位置，并重新坐到座位上。1 秒钟
取消。反之，若驾驶员在两秒内返回座位，
保管时的注意事项 后，OPS系统将被释放并且重新可以进行搬运
则 OPS 系统不会启动，车辆行驶和搬运作业
操作。（请注意：如果已重新就位，而没有将
y 长时期保管车辆（除充气轮胎外）时、应 将继续进行。
倾斜杆返回空挡位置，则搬运操作将在 1 秒
使用高度为 300 mm （毫米）的木块将车 此外，如果 OPS 系统发生异常，OPS 灯将启动 钟后重新开始移动。）
辆撑起。( 以避免对轮胎造成负荷 ) 闪烁，提醒驾驶员。此时 OPS 系统可能发生
故障，请联系丰田经销店进行检查。 OPS 操作功能
y 应将车辆停放在指定位置上。并应在车辆
周围酌情设置标志牌或信号灯。 如果操作员离开座位，OPS 灯将亮起，提醒驾
驶员 OPS 系统已激活。如果驾驶员在两秒内
y 当车辆由于故障而必须临时存放起来时， 返回座位，则 OPS 灯将自动熄灭。
应将其停放在远离行走通道的位置，设置
标志牌，标明该车辆目前处于故障中。

电气零件的注意事项
y 叉车上使用了高精度的电气零件。在该叉
车上使用丰田公司认可零件以外的任何
电气零件均可能影响车辆系统运行的准
确度。有关使用丰田公司认可零件以外的
任何电气零件的事项，请咨询您的丰田经
销商。 本叉车装备有 OPS（驾驶员存在感测）系统。
操作本叉车前，应检查此系统的各个功能均
运行正常。

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警告牌 主要零部件
车辆上贴有警告牌。在开始驾驶之前，请务必全部阅读。（以下是中文版的实例。）
1. 立柱
2. 链条
1 8
3. 货叉
4. 倾斜液压缸
2 5. 后轴

7 6. 发动机罩
7. 驾驶座
8. 顶部防护装置
zh
6
3

4 5

9. 配重
13 10. 车架
12
11. 前轴
12. 升降液压缸
13. 方向盘
9

关于此标记
警告！请在使用前仔细阅读 “驾驶员手册”。

11

10

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驾驶控制器和仪表板 仪表
组合仪表
1. 控制杆
1 2 3 4 5 6 7 仪表照明灯是为了能在夜间看清仪表而装
2. 停车制动杆 1 2 备的。当灯光控制开关被设定在 ON 时，此
3. 方向盘 灯发亮。
4. 喇叭按钮
5. 灯光控制和转向信号开关 1. 水温计
6. 升降杆 2. 计时器
3. 沉淀杯警告灯 （柴油机车型）
7. 倾斜杆
4. 燃油计
8. 组合仪表 4 6 7 8
5. 电热丝式指示灯 （柴油机车型）
9. 加速器踏板
6. 机油压力警告灯
10. 制动踏板 汽油机车型
13 12 11 10 9 8
7. 充电警告灯
11. 点火开关
8. PS 灯 （选购件）
12. 微动制动踏板
13. 倾斜转向调整杆
1 2

3 4 5 6 7 8

柴油机车型

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(1) 每个警告灯的检查方法 机油压力警告灯

检查当点火开关被转到 ON 时，是否所有的 发动机在运转中，此灯发亮表示机油压力过
警告灯都发亮。 低。
1. 正常情况下，当点火开关打开时，此灯
注意 :
发亮，当发动机启动时，此灯熄灭。
y 钐诞秹蜡叜阑动箵穾駛睊屯讨诞粒
2. 在发动机运转时，如果此灯发亮，不是
y 在启动点火开关后，OPS 灯将点亮，即使 机油不足就是润滑系统有故障。须立
对于非 OPS 机型也同样如此，但是 OPS 灯 即停止操作，委托丰田经销店进行检
在其他情况下将不会点亮。 查和修理。
(1) ON
小心 注意 :
zh
y 当引擎制冷剂温度超过摄氏 50 ℃时，电 “机油压力警告灯”不指示机油位。工作开
热丝式指示灯 （柴油机车型）将点亮 2 始之前，应先用油位计检查一下油位。
秒钟。

y 如果灯没点亮，请联系丰田经销店进行 沉淀杯警告灯
检查。 （柴油机车型）
沉淀杯是把水从燃油中分离出来的装置。
计时器
1. 发动机运转中，此灯发亮指示沉淀杯
只当点火开关接通时才工作。它指示车辆工 里的水超过预定水位。
作的总时数。 2. 正常情况下，当点火开关打开时，此灯
最右边的一位数的单位是１ /10 小时。 发亮，当发动机启动时，此灯熄灭。
请用这仪表来掌握定时保养的时间，并记录 3. 发动机运转中，如果此灯发亮，应立即
工作时数。 将水排放。（关于排放的方法，可参看
自行维修的部分。

小心
在灯发亮的状态下继续作业，会导致喷射泵
滞赛并损坏泵体。如果警告灯点亮，确保将
水排干。

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电热丝式指示灯 OPS 灯 （选购件：OPS 车型）

（柴油机车型） 如果驾驶员离开座位，OPS 灯将亮起，表明
预热塞在加热。 OPS 系统 （选购件）正在运行。在这种情况
当点火开关打开时，此灯发亮，预热塞开始 下，应将操纵杆和升降杆返回空档位置，然
加热。当预热塞加热结束，此灯自动熄灭。 后重新坐到座位上。
预热塞一旦被加热，发动机将很容易启动。 如果 OPS 系统发生故障，此灯将闪烁。
注意 : 小心
当发动机冷却剂温度超过 50 ℃时，电热丝
在下列情况下，OPS 可能发生故障。将叉车
式指示灯发亮２秒钟。
停驻在安全地点，联系丰田经销店进行检
查。

y 驾驶员离开座位时，OPS 灯没点亮。

充电警告灯 y 驾驶员回到座位后， OPS 灯不能熄灭。

1. 发动机运转中，此灯发亮表示充电系
注意 :
统异常。 在启动点火开关后，OPS 灯将点亮，即使对
2. 正常情况下，当点火开关打开时，此灯 于非 OPS 机型也同样如此，但是 OPS 灯在其
发亮，当发动机启动时，此灯熄灭。 他情况下将不会点亮。
3. 如果发动机运转中，此灯发亮，应立即
停止作业，检查风扇皮带是否断裂或
松动，调整后再启动发动机。
水温计
如果此灯不熄灭，发电系统可能发生 发动机冷却水的温度。
故障。 1. 该温度计工作时点火开关打开，从左
请立即委托丰田经销店进行检查和修 到右显示冷却水温度，分为10级刻度。
理。
2. 当水温在摄氏 95 ℃或以上 （第 8 级）
时，最右端的最后两级开始闪烁。
3. 暂时的过热可能是由于漏水、发动机
冷却剂不足、风扇皮带松动或冷却系
统的其它异常所造成的。
检查冷却系统。

小心
当水温计表明有任何温度处于警告范围内
时，应减慢发动机速度，让车辆暂停直至水
温下降为止。

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燃油计 开关和操纵杆
燃油箱内的剩余燃油量，有 10 级刻度。剩 点火开关
余燃油量过低时，最左端两级开始闪烁，提 { ［OFF］...发动机停止位置。在这个位
醒驾驶员。
置上，钥匙可以插入和拔出。
加油及点火开关打开后，要稍等一会儿指针
I ［ON］ .....发动机工作位置。可以从 {
才会稳定下来。
［OFF］位置向顺时针方向转
小心 OFF ON 动一个位置进入此位置。
y 如果道路不平，由于不能指示正确的油 START 起动柴油机车之前必须将进气加热器预热。
位，所以要特别注意。 START .......发动机起动位置。
可以从 I ［ON］位置向顺时 zh
y 燃油计开始闪烁时，尽快更换燃油。
针方向转动一个位置进入此
y 特别是柴油机，一旦导致发动机停止运 位置。
转，就必须对供油系统进行排气，所以 发动机起动之后，将钥匙释放，它将自动回
务必在停止运转之前加油。 到 I ［ON］位置。
除非控制杆在空档位置，否则发动机不启动。
小心
y 在 坐 到 座 位 上 之 前，切 勿 操 作 点 火 开
关。叉车有可能失控前行，引发事故。
y 当发动机停止时，切勿将开关置于 ON 位
置。会导致蓄电池过度放电。
y 当脚踏在加速器踏板上时切勿打开点火
开关，会导致启动性能降低。
y 当发动机运转时，切勿把开关转到 START
位置。
y 切勿让起动马达连续运转超过 30 秒。将
开关回到 OFF 位置后少等 30 秒钟再试着
起动。
y 当点火开关在 OFF（发动机关闭）时，即
使拉动升降杆，货叉也不能向下移动。
但如果坐到座位上并打开点火开关，才
有可能降下货叉。在上车和起动发动机
之前，不要拉动升降杆。（钥匙提升联锁
装置：选购件）
y 当 OPS 灯（选购件）亮起时，将各拉杆返
回空档位置，并坐到座位上。

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集中式灯光和转向信号开关 控制杆
(1)
此开关作用于两个位置的灯光控制和转向 在前进和倒车之间变换的拉杆。
(1)
信号。 前进 ...........................向前推
(3)
灯光控制 倒退 ...........................向后拉

不论点火开关处于哪个位置，此开关均可以 空档在前进档和倒档的中间位置。
(2)
打开或关闭灯光。 注意 :
(1)
此开关有两个位置。开关在不同的位置，灯 在 OPS 系统（选购件）运行后，将加速器踏
如下所示发亮。 (2) 板返回完全释放位置，也将控制杆返回空档
(3) 位置，然后坐到座位上重新进行驾驶操作。
灯名 阶段１ 阶段２ （即使驾驶员坐到座位上，如果控制杆未返
(1) 左转
大灯 − { (1) 前进 回空档位置也不能驾驶。）
侧车宽灯，尾灯 { {
(2) 右转 ( 选购件 ) (2) 空档
小心
仪表照明灯 { { (3) 倒退
y 除非操纵杆置于空档位置，否则发动机
不能起动。
小心
发动机停止后，切勿让大灯等灯光继续点 y 在前进档和倒档之间进行换档操作前将
亮。长时间照明会导致蓄电池过度放电，使 车辆停止。
发动机难以起动。

喇叭按钮
转向信号
按方向盘中心的按钮使喇叭鸣响。
使转向信号灯闪烁。 (1)
即使点火开关关闭，喇叭也能鸣响。
左转 .......................... 向前推
右转 .......................... 向后拉
点火开关打开后，信号开关将启动。
车辆转向后，转向信号杆将自动回到原来的
位置。

(1) 按

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(1)
升降拉杆 倾斜拉杆
提升和下降货叉
(1)
使门架向前和向后倾斜。
提升 .......................... 向后拉 前倾 ...........................向前推
下降 .......................... 向前推 后倾 ...........................向后拉
(2) 提升的速度可以根据加速器踏板的降低以 前后倾斜的速度可以根据加速器踏板的降
及操纵杆操作行程的程度来进行调整。 低以及操纵杆操作行程的程度来进行调整。
(2)
下降速度只能根据操纵杆操作行程的程度
小心
来进行调整。
y 操作倾斜拉杆时一定要坐下。
小心 zh
y 操 作 升 降 杆 时，驾 驶 员 要 在 座 位 上 坐 y 在 OPS 系统（选购件）运行后，将加速器
(1) 下降 好。 踏板返回完全释放位置，也将升降拉杆
(2) 提升 返回空档位置，然后坐到座位上重新进
y 点火开关关闭，货叉不能下降。如果坐 (1) 前倾 行驾驶操作。（就座时没有将倾斜拉杆
在座位上，打开点火开关，就可以降下 (2) 后倾 返回空档位置，货叉可能会重新移动。）
货叉了。（钥匙提升联锁装置：选购件）
y 在 OPS 系统（选购件）运行后，将加速器
停车制动杆
踏板返回完全释放位置，并将升降杆返
回空档位置，然后坐到座位上重新进行 在停车时，踩下制动踏板，并充分拉动停车
驾驶操作。（如果您在就座时没有将升 制动杆。
降杆返回空档位置，则货叉可能会重新 在释放制动杆时，拉住制动杆，并将制动杆
移动。） (2) (1) 手柄顶部的按钮按下，以将制动杆返回其初
y 在 OPS 车型上，驾驶员回到座位上、即使 始位置。
将升降杆向前推，则在 “返回空档”功 (3)
小心
能的影响下，货叉不会下降。
y 在操作停车制动杆时，务必踩下制动踏
(4)
板。
钥匙提升联锁装置 （选购件）
y 在 操 作 制 动 杆 时，要 紧 握 制 动 杆 的 手
点火开关关闭后，即使向前推动升降杆，货
(1) 锁定 柄。
叉也不会下降。但是，如果驾驶员按要求坐 (2) 释放
在座位上并打开点火开关，即使发动机熄 y 在斜坡上停车时，应在车轮下面垫上三
(3) 释放按钮
火，货叉仍可以下降。 脚楔块。
(4) 杆柄
如果点火开关不能打开，不论什么原因，均
y 若您未能释放制动器而进行移动，会影
应松开顶板下机油控制阀上的升降锁释放
螺栓，并将升降杆向前压。 响到制动器的性能。请到丰田经销店处
对车辆进行检查。
注意 :
(1) 货叉向下运动、且使用升降锁释放螺栓时，
不得松开螺栓并回到初始位置。
(1) 升降锁释放螺栓

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调整方向盘倾斜度 车身组件
1. 该调整装置向上提升时，方向盘位置 驾驶员座位
可以前后调整。
驾驶员座位的安全带是为了您的安全而提
2. 将方向盘固定在适当位置后、将调整 供的。
装置放回至该位置锁定。 (3)
1. 座位调整拉杆
3. 调整后，前后移动方向盘看是否被固 将拉杆向右拉动，调整座椅的前后位
定。 置。当您松开拉杆时座位将固定。

(2) 小心 2. 靠背调整旋钮
y 在起动车辆之前，必须先调整好方向盘 转动旋钮来调整座位靠背的角度。
(1) 的位置。 (2) 向前............. 逆时针转动旋钮。
(1) 倾斜转向调整杆 y 避免在移动中进行调整。 (1) 向后............. 顺时针转动旋钮。
(2) 提升
(1) 座位调整拉杆 小心
踏板 (2) 靠背调整旋钮 y 在启动车辆之前必须先对座椅位置进行
从右面起为：加速器踏板、制动踏板和微动 (3) 安全带 调整。
制动踏板
y 在 调 整 完 成 后，轻 轻 地 将 座 椅 前 后 摇
小心 晃，以确认座椅是否牢固地锁定在其位
当脚踩在加速器踏板上时不得开启点火开 置上。
关，否则会降低启动性能。

注意 : 安全带
即使在控制杆被换到前进——后退档位时，
在加速器开关的作用下，加速器踏板仍将处 要系上您的安全带，应将凸舌插入锁扣中。
于空档位置。 当凸舌锁定在锁扣中时，您将会听到咔嗒
只有踩下加速器踏板，车辆才会移动。 声。戴上安全带后确认锁扣被牢牢地闩住。
可根据需要依照您的身材尺寸调节安全带
的长度。
后部作业灯开关 （选购件）
松开的方法
此开关用于打开和关闭后部作业灯。 按下释放按钮，将安全带从锁扣中拉出。
ON .......................... 推上开关
ON 小心
OFF ......................... 推下开关
OFF 当驾驶员离开座位时，应将凸舌插入锁扣
中。

(1)

(1) 后作业灯开关

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警告 1. 座位调整拉杆
y 扣好安全带。您的安全带将能保护您在 将调整拉杆推到左侧，调节座位的前
叉车翻倒时减少严重受伤或死亡的危 后位置。将杆释放，座位就被固定在其
险。在翻车时最好留在叉车的驾驶室中 位置上。
(4)
以避免严重受伤或死亡。 2. 靠背调整旋钮 （选购件）
y 驾驶叉车时务必扣好您的座位安全带。 拉动左边的调整旋钮来调节靠背的倾
(2) 角。
如果操作错误，叉车将会翻倒。在翻车 (3)
事故中，为了保护驾驶员不至严重受伤 3. 重量调节旋钮 （选购件）
或死亡，最好的方法是紧紧地固定在座 顺时针方向转动座位右边的旋钮，调
位上。座位安全带将能够保护您在驾驶 节至适合较重的身体。逆时针方向转
室中的安全。
(1)
动旋钮，调节至适合较轻的身体。可以 zh
在翻车事故中，不要跳车，要紧握方向 在体重 40kg( 公斤 ) 至 120kg( 公斤 )
(1) 座位调整拉杆
盘，岔开双腿，向翻车的方向倾倒，并 之间进行调节。
(2) 靠背调整旋钮 （选购件）
留在叉车中。 (3) 重量调节旋钮 （选购件） 小心
(4) 安全带 y 在启动车辆前必须先调整座椅位置。

弹性元件支承式座位 （选购件） y 调节之后，轻轻地前后摇动座位以确认

座位被紧紧地锁定在其位置上。
座椅的弹性元件支承机制将根据驾驶员的
重量来提供舒适的乘坐位置。最适合的驾驶 椅背包
位置可以利用按钮和调节杆来设定。 （选购件：弹性元件支承式座位）
小心 驾驶员手册和驾驶员安全操作手册放在座
y 为防止出现事故，请确保在驾驶车辆之 位的后侧。必须使用双手来打开座位后面的
前先调整座位。 靠背袋。如果您的车辆没有驾驶员手册和驾
y 为防止出现事故，不得在运行过程中调 驶员安全手册，请联络 （授权丰田经销店）
获得复印件。
整座位。座位可能突然移动，干扰您的
操作，从而导致意外发生。 注意 :
确认将袋口紧紧地关闭。
y 调整座椅的位置，使您能够充分触及所
有踏板，同时始终将您的背部紧靠在座 杂志盒
椅靠背上。 （选购件：弹性元件支承式座位）
y 在 OPS 车型上，由于座位开关的作用，除 椅背包上有一个盒子用以存放如速写板、和
非驾驶员坐在座位上，否则叉车不会驱 工作手套之类的小物品。
动，货叉也无法被升起或降下。因此，在
当开启和关闭发动机罩以及在差的路面上
驾驶叉车之前先坐在座位上。另外，在
驾驶时，为了防止口袋中的物品掉出来，须
座位上放有物件时不得操作叉车。
用带子紧紧地固定。
y 在OPS车型上，除了坐到座位上这一方法
外，不要采用其他方式打开座位开关。

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可伸缩的座位安全带 发动机罩
（选购件：弹性元件支承式座位）
小心
将座位安全带从收缩器中拉出来，把凸舌插 在打开或关闭发动机罩时，请小心不要夹住
入锁扣系紧座位安全扣带。 手指。
当凸舌锁定在锁扣中时，会听到咔嗒声。戴 打开
上安全带以确认锁扣被紧紧地闩住。
座位安全带的长度将根据乘员的身材尺寸 小心
自动调节。 y 要打开发动机罩，应先关闭发动机。

松开的方法 y 在打开发动机罩时，务必确认座位安全
按释放钮让扣带缩回。 带的凸舌插在带扣之中。
注意 : 1. 打开发动机罩的卡扣。
如果座位安全带被锁住并且不能更进一步
地拉出，则用力再拉一次，使之松开，然后 2. 拉起发动机罩。
再慢慢将其拉出。 3. 将发动机罩完全打开，然后轻轻摇动
罩板，检查放手前挺杆是否可靠紧固。
警告
y 扣好安全带。您的座位和座位安全带将
能保护您在叉车翻倒时减少严重受伤或
死亡的危险。在翻车时最好留在叉车的
驾驶室中以避免严重受伤或死亡。

y 驾驶叉车时务必扣好您的座位安全带。
如果操作错误，叉车将会翻倒。在翻车 (1)
事故中，为了保护驾驶员不至严重受伤 (1) 发动机罩卡扣
或死亡，最好的方法是紧紧地固定在座
关闭
位上。座位安全带将能够帮助保护您在
驾驶室中的安全。 1. 拉起发动机罩，压下发动机罩挺杆锁，
在翻车事故中，不要跳车，紧握住方向 使其松开。
盘，岔开双腿，向翻车的方向倾倒，并 2. 轻轻关上发动机罩并往下压紧，直到
(1)
留在叉车中。 听到发动机罩锁上的喀哒声。

小心
不锁紧发动机罩就操作车辆是很危险的。操
作车辆之前，一定要检查是否锁紧。

(1) 按下

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货叉 使用前的检查
拉起货叉固定销并将其释放，使货叉能左右 使用前的检查
移动。
使用前的检查和每周检查由丰田工业车辆
将货叉调节至最适合装载的位置。 用户自行负责。
(1)
当调节货叉时，须确认负荷的重心相当于车 为了保证安全，在开始工作之前必须完成使
辆的中心。调节完毕后，转动固定销将货叉 用前的检查。
锁定在位置上。
项目 检查
警告 事先检测故障 矫正
搬运货物前，确保货叉锁紧。 外部 车身、漏油、漏水、零件松动、
外部损坏 zh
车轮 轮胎压力、磨损或损坏、轮辋、轮毂
螺母
(1) 货叉固定销 灯类 灯的状态、损坏的灯
液压油 油位、杂质、稠度
牵引杆 散热器 冷却剂液位、防冻液的加注
检查散热器的堵塞情况并清洗。
牵引杆位于配重后面，在车轮陷入沟槽或泥 发动机 机油位、杂质、稠度、噪音、排气
潭时，用此杆来牵引车辆。 制动踏板 踏板游隙、制动效果
制动液 液位
它也可以用来把叉车装到卡车或其他车辆
停车制动器 制动杆游移和制动性能。
上去。 方向盘 松动、游隙、振动、转向
(1) 喇叭 声音
小心 仪表 功能
牵引杆不能用于拖挂叉车或用叉车拖挂其 装卸系统 零件、漏油、破裂、松动
他车辆。 燃油 油量
操作员限制 切断、打磨和甲板闩锁确认，安全带
和带扣。
排气管 检查消音器周围是否存在灰尘和易燃
材料，若存在则清理干净。
(1) 牵引杆
环视检查
车辆提升方法
车辆直立性
在吊起车辆时，如图所示，使用门架顶部附
近的吊孔来提升前侧，用顶部防护装置上的 车辆是否偏向一侧或另一侧？
孔来提升后侧。 如果是的话，就要检查轮胎或车盘是否有问
题。
小心
y 要使用强度足够的钢索。 车辆下面
y 不要使用护顶架来提升车辆。 检查停过车的地面或地板上有没有漏油或
漏水。
检查零件是否松动或损坏。
如发现有任何异常情况，须委托丰田经销店
检查车辆。

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轮胎的检查 灯类的检查
轮胎充气压力 灯丝是否完好无损？车灯玻璃是否损坏？
经常保持车灯玻璃的洁净，保证前方视野良
1. 用胎压表测量充气压力，把它调整到 好。
适当的水平。

警告
在给轮胎充气时应使用一个安全笼。

小心
在使用空气压缩机之前，应调整其气压。

注意 :
y 关于适当的充气压力，可参看维修数据 发动机室的检查
的部分。
发动机冷却剂液位的检查和加注
y 不要把压力提高到超过适当的水平。
液位的检查和发动机冷却剂的加注要在冷
2. 调整以后，检查空气是否从气门泄漏。 却剂冷却后进行。
轮胎和轮辋的损坏，破裂和磨损 1. 关掉发动机，打开发动机罩，检查储液
检查轮胎是否损坏和磨损，轮辋是否弯曲。 箱内的发动机冷却剂液位。
如果轮胎损坏，或发现前后或左右轮胎磨损 (1)
注意 :
显著不同，或发现轮辋弯曲，须委托丰田经 当散热器中的冷却剂数量不足时，带有储液
销店进行检查。 箱的散热器将自动提供发动机冷却剂。

(1) 储液箱
轮毂螺母的检查
2. 如果冷却剂液位在上限和下限之间是
检查轮毂螺母松紧度。 适当的。如果液位低于下限，须将冷却
避免不均匀的扭矩，把螺母都均匀地拧紧。 剂加注至上限。
适当的扭矩，可参看维修数据。
3. 发动机冷却剂中的长效冷却剂 （LLC）
的浓度必须在 30% （或在寒冷地带为
50%）。

注意 :
如果储液箱中已没有发动机冷却剂，同样须
(1)
检查散热器中的冷却剂液位。

(1) 储液箱

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检查散热器中的发动机冷却剂液位 4. 如果机油位不足，则需加机油。溢出和
(1) 溅出的机油必须被全部擦拭干净。调
警告 节机油位，使之如左图所示从量表的
(3)
当发动机尚热时，取下盖子是很危险的。检 升程高度标记处下降至 0 至 +10 mm（毫
查冷却剂液位必须在发动机冷却后进行。 米）的范围内。

小心 量具代号 适用型号
FGZN20, 25
在取下散热器盖子时，应使用厚布以防止灼 (4) 20, 25 FDZN20, 25
伤；禁止使用手套。 FGZN30
28, 30, 35 FDZN30
1. 取下散热器盖。 (5)

(1)
2. 取下盖子并从加注孔中检查冷却剂液 (2) (6) zh
位。
(1) 散热器盖 3. 如果通过加注孔看不到发动机冷却 (1) 油盖
剂，须在孔中加注适当稀释的冷却剂 (2) 油位计
（LLC）。 (3) 量表识别标志
注意 : (4) 升高 4,300 ～ 4,700 mm （毫米）
盖上和拧紧散热器盖时，要使盖背面的棘爪 (5) 升高 4,000 mm （毫米）
对准加注孔的缺口，一面往下压，一面顺时
(6) 升高 3,000 mm （毫米）
针方向旋转到底。

机油的检查
1. 将车停在平坦处，如果车辆倾斜，将会
导致读数偏差。
液压油位的检查 2. 油位检查必须在起动发动机之前或在
发动机被关闭了３分钟以后再进行。
当车辆在平地上时，检查液压油位之前，须
停止发动机并把货叉降低到地面。 3. 抽出油位计并用干净的布擦拭后，将
其再次插入，然后抽出检查油位是否
1. 打开发动机罩并取下机油盖。
处于Ｆ和Ｌ线之间。
2. 用干净的布擦拭机油盖上的油位计，
4. 如果油位低于Ｌ线，必须将油加注到
然后再把它插入油箱。
Ｆ线。
注意 :
必须令机油盖的螺纹部分接触到注油孔的
方式来检查油位。
(1)
3. 轻轻地抽出油位计，检查粘附的机油
(1) 油盖 是否在油位线之上。

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加注机油 警告
y 切勿使用制动液以外的油类。
1. 要补充机油时，先取下加油口盖并将
机油从加油口注入，但切勿使油位超 y 不要让杂质进入储液箱。在制动液中即
过Ｆ线。 使存在少量的杂质也会影响正常的制
2. 所加的机油必须与季节相符合。 动，这是极其危险的。
5mm( 毫米 )
SAE40 的适用温度为：30 ℃以上
y 经常检查储液箱中的小通气孔，以便确
SAE30 的适用温度为：0 ℃～ 30 ℃
SAE20 的适用温度为：－ 10 ℃～ 0 ℃ 认通气孔没有被杂质堵塞。

小心
如有可能，要使用同一牌号的机油。

制动踏板的检查
泄漏的检查
1. 将制动踏板踩到底，检查底板间隙（踏
检查发动机室以查看是否有任何机油或燃 板与底板的间隙）。
油的泄漏。
如果散热器阻塞，要立刻进行清洗并检查是 注意 :
关于底板间隙，可参看维修数据的部分。
否有异物粘附在散热器的栅板上，诸如纸或
其它等。 2. 确认当处于制动状态时，被踩住的制
动踏板不会继续下滑。
3. 同时，也要确认踏板的下踩和回复无
(1) 任何异常。
4. 用手压下制动踏板以检查自由行程，
直至感到阻力。
上车检查车辆
注意 :
制动液的检查 关于制动踏板的自由行程值，可参看维修数
关闭发动机，然后检查储液箱中制动液的液 据的部分。
位。液位应处在图示范围之内。 警告
如果液位低于下限，则必须将制动液加注到
如果自由行程过大，踏板的运动异常或制动
适当的液位。
(2) 性能不良，须委托丰田经销店进行检查。
如果制动液的消耗过快，则制动系统可能漏
液，须尽快委托丰田经销店进行检查。
(1)

(1) 制动踏板
(1) 储液箱 (2) 制动踏板与地板的间隙

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停车制动器的检查 仪表的检查
先将停车制动机置于松开位置上，拉住停车 起动发动机并确认工作正常。
制动杆，计算咔嗒声的数目。请参阅服务数
据以查看制动所需凹槽的正确数目。
若在指定数目的凹槽内制动无效，则应在丰
田的经销店处对车辆进行检查。

警告
若发现凹槽数量存在异常，应委托丰田经销
(1)
店对车辆进行检查。
zh
(1) 停车制动杆
点动和制动器踏板检查 燃料的油位检查和加注
1. 用手压下点动和制动踏板以检查自由 1. 查看燃油表以确认燃油是否足够。
行程，直至感到阻力。
注意 :
注意 : y 日常使用结束后，应将燃油箱再加满，
关于点动和制动器的自由行程值，可参看维 以防止油箱内空气中的湿气混入燃油。
修数据的部分。
y 燃油箱盖上有一个通气孔。每次注入燃
2. 踩下点动和制动踏板，并检查是否有
油 后，应 检 查 该 通 气 孔 的 运 行 是 否 正
障碍和异常。
常。
(1) 小心 2. 加注燃油时，要关掉发动机，逆时针方
如果发现任何异常，委托丰田经销店进行修 向拧下燃油箱盖后，从加油口注入燃
(1) 点动和制动踏板 理。 油。
3. 加油后，一定要将燃油箱盖拧紧。

检查 OPS 灯 （选购件） 小心
y 在检查燃油液位时，不得使用火柴等易
坐到座位上，起动发动机，然后检查确认 (1)
OPS 灯没有亮起。 燃物，否则可能引起点燃。

在下列情况下，OPS 灯可能出现故障。将车 y 加油前和加油中，要关闭发动机，严禁

(1) 燃油箱盖
停放在安全区域，并联系丰田经销店。 烟火。

y 操作员离开座位后，OPS 灯不能点亮。 y 加 油 时，小 心 防 止 水 和 污 垢 进 入 油 箱

内。
y 操作员回到座位坐好后，OPS 灯仍不熄
灭。

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发动机检查 方向盘的检查
起动发动机并使之充分预热。 注意 :
1. 检查每一个仪表和警告灯，确认没有 起动发动机后，要进行如下检查：
异常。 1. 使后轮成直线行走状态，检查方向盘
2. 检查发动机是否发出异常噪音或振 的自由行程。
动。 注意 :
3. 检查排气颜色是否正常。 关于方向盘的标准自由行程，可参看维修数
无色或淡蓝色排气表示完全燃烧；黑 据的部分。
色排气表示不完全燃烧；而白色排气 2. 在圆周方向转动方向盘，并上下摇动
则表示机油已被吸入气缸并与燃油混 方向盘以检查其有无松动。
燃了。
3. 按下喇叭按钮，检查喇叭声音是否正
警告 常。
y 排气是有害的。如果必须在建筑物内或 4. 如发现异常，须委托丰田经销店进行
被围起的地方起动发动机，必须确保通 检查。
风良好。

y 汽油发动机化油器配有自动挡风门，是 慢速行车时
让发动机在冷态保持相当高速的运转。
离合器啮合和打滑的检查
当发动机充分预热后，将会回到正常的
运转速度。 在移动中踩下微动制动踏板，检查离合器的
接触情况。

负荷装卸系统 小心
1. 检查货叉安装状态，是否有裂缝和弯 确保控制杆在每个档位均工作正常，然后在
曲。 慢速移动中执行上述检查。

2. 检查是否有门架变形、链条过紧、以及 制动效果
液压缸和管道的漏油等现象。
在踩下制动踏板时，检查是否有任何异常或
3. 操作提升和倾斜杆，检查其运作状况。 处于单边工作状态。
注意 : 使用停车制动器，保证车辆停止运行并保持
y 在日常作业开始前，务必对每个油缸的 驻车状态。
活塞执行若干次的全行程操作。
小心
y 如发现任何异常，需委托丰田经销店对 哪怕是发现了再小的异常，也要立即停止操
车辆检查。 作车辆，并委托丰田经销店进行车辆检查。

方向的检查
在安全处慢速行驶车辆，左右转动方向盘，
检查是否有异常现象。

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车辆开进车库之前 空气滤清器的清洗
把所有车辆部件上的污垢去除干净，然后进 卸下固定滤芯的三个销子后，滤芯可以取出。
小心
行如下检查。 即使是很小的异常也会导致严重事故。
1. 检查是否漏油或漏水。 在完全修好以前，不要使用车辆。
如果您在操作中感觉到任何异常，请立即通
2. 检查各部件是否有变形、划伤、撞坏或
知管理员。
破裂。
3. 清理空气过滤器，并在必要时对零件进 (1)
行润滑。
4. 全程升降货叉以对提升液压缸进行润滑。
zh
同时以前倾和后倾方式操作门架。
(1) 滤芯
滤芯的清洗
每周保养 1. 在不导致任何损伤的条件下轻敲滤芯
下列项目所需的保养主要包括检查和添加。 过滤纸，或者用压缩空气从内侧吹掉
由于机油或油脂需要根据污染程度而定期 灰尘 （7kgf/cm2 [ 公斤力 / 厘米 2 ]
更换，应根据需要采取适当的措施。 或以下）。
务必执行操作前检查以及每周保养，以维持
安全和令人满意的运行。 小心
在使用空气压缩机之前，应先调节气压。
每周 （40 个工作时）检查项目
空气滤清器—清洗
风扇皮带—检查
液力变矩器油位—检查
蓄电池电解液液位—检查
螺栓和螺母—重新紧固 2. 清洗滤芯后，除去真空阀内的灰尘。
门架和转向连杆—润滑
链条润滑—机油
注意 :
y 如果过滤纸被撕破或损坏，就要更换滤
除操作前项目之外，还应检查上述项目。委
芯。
托丰田经销店执行必要的调整和更换。请彻
底检查车辆以确保其处于安全和令人满意 y 如果被严重污染，就要清洗滤芯。
的工作状态。
y 在清洗双旋式空气滤清器（选购件）时，
无需清洗内滤芯。
(1)
只清洗外滤芯。
在更换时，内外滤芯应一起更换，这是
非常重要的。
(1) 真空阀

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滤芯的清洗方法 注意 :
当电池呈现以下任意状态时，均应咨询您的
1. 把滤芯浸泡在含有中性洗涤剂的水中 丰田经销店或厂商。
约 30 分钟，然后清洗。注意不要划伤
y 发出臭味。
过滤纸。
2. 清洗后，用干净的水漂洗滤芯（水压低 y 一个端子呈黑色。

于2.8kgf/cm2 [ 公斤力 /厘米 2 ] ）。 y 电池电解液的温度较高。

3. 可以自然干燥，也可以用吹风机 （冷 y 电池电解液减少的过快。
风）吹干。切勿用压缩空气吹干或用火
烘干。
液力变矩器油的检查
注意 :
在滤芯清洗过６次或使用了１年后，应将其 1. 将车辆停放在安全平坦的地面，关闭
更换。 发动机。

小心
风扇皮带的检查 检查停车制动器是否工作正常，货叉是否降
低到地面上。
检查风扇皮带是否有破裂、磨损，并检查其
绷紧程度。 2. 打开发动机罩，取下搁脚板。
如发现任何异常，须委托丰田经销店更换或 3. 抽出油位计，用干净的布将其擦试干净。
调节皮带。
4. 把油位计由抽出的孔插回原处，并再
关于绷紧度，可参看维修数据。 (1) 次抽出检查油位是否在油位计的Ｆ和
(1) 搁脚板 Ｌ线之间。

注意 :
y 使用液位计的 “冷”侧进行检查。
4Y 发动机 1DZ-II 发动机
y 液位计由 “HOT”侧和 “COLD”侧组成。
开始检查前，如果油温在 40 ℃或 40 ℃以
蓄电池电解液的检查 下，使用 “COLD”侧。如果油温在 60 ℃
1. 蓄电池电解液应保持在上下限之间 或 60 ℃以上，使用 “HOT”侧。关闭发
（离极板顶端 10 ～ 15mm[ 毫米 ]）。 动机后开始检查，检查时间为 30 秒至 5
2. 如果电解液液位低于下限，请拧下盖 分钟。
子，将蒸馏水从进水口加到上限。 y 如果油位接近或低于L线，应将油加注到
F 线。
小心
蓄电池电解液一定要使用蒸馏水。并且，在
做这项工作时，一定要戴上 护目镜。

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螺栓和螺母的重新紧固 自行维修
把底盘和负荷装卸系统上的每个螺栓和螺 千斤顶设置位置
母都重新紧固。
小心
门架和转向连杆的润滑 在用千斤顶顶起车辆后，切勿进入货叉和车
架的下面。若千斤顶意外被移动，可能会造
按照润滑表加注润滑油。 成严重受伤。

小心
y 在润滑操作前，先把润滑油器的油嘴尖
前轮
彻底擦干净。
1. 将车辆停放在平坦处。 zh
y 在润滑操作后，擦去溢出的润滑油。 2. 拉上停车制动器，并用三脚楔块挡住
车轮。

当蓄电池放完电时 3. 将门架向后倾斜，升起货叉大约1 m（米）。

(4) 4. 将千斤顶插入前轮后部车架底部表面
有辅助电缆时，可以用另一台车辆的蓄电池
a 下方。
来起动发动机。
(1) 按图示方法连接辅助电缆。
连接时，不要接错电缆的正(+)负(-)端子。
b, c (2)
小心
y 连接(1)：放完电的蓄电池的正(+)端子。
(3) 后轮
e
y 连接 (4)：使用与电池分开的支架。
d 小心
y 不要直接连接蓄电池，以免发生爆炸的 务必使用一个载重达 5.0 吨以上的千斤顶。

a. 放完电的电池 危险。( 蓄电池发出的易燃气体可能会着 1. 将车辆停放在平坦处。

火。)
b. 发动机架 2. 拉上停车制动器，并用三脚楔块挡住
车轮。
c. 至车架
将千斤顶插入配重下面 （顶起点）。
d. 辅助电缆
千斤顶的定位
e. 备用蓄电池
(2) y 油压入库千斤顶
(1)
将千斤顶用在配重中心点的下方。

(1) 油压入库千斤顶 y 便携式油压千斤顶

将千 斤顶用 在配重 下方的 顶起点
(2) 便携式油压千斤顶 处。

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更换轮胎 加注防冻剂 1. 取下水箱盖，拧松水箱和气缸的排放

塞，把冷却水排出。
小心 如果在温度低于零度的地区停放车辆，冷却
水将会冻结而损坏水箱或气缸缸体。在此情 2. 从水箱进水口加注干净的水，冲洗水
y 如果是可拆式轮辋的车轮，在拧松轮毂
况下，必须使用防冻冷却剂。 箱和气缸缸体。
螺母时，不要拧松轮辋螺栓和螺母。在
拧松轮辋螺母或卸下轮辋螺栓时，在拧 使用长效冷却剂 （LLC）时，必须每两年更 3. 水被排出水箱和气缸后，把水箱和发
松之前一定要完全放走空气。 换一次。 动机的排放塞拧紧。
前轮 冻结温度因所添加防冻剂量的不同而不同。 4. 从水箱进水口注入适当量的防冻剂，
(1) (2) (1) y 关于轮毂螺母的拧紧力矩和轮胎空气压
剩余的部分加满干净的水。
力，可参阅维修数据的部分。 防冻剂添加量 （％）
防冻温度 （℃） -12 -15 -24 -35 5. 当气温升高而没有冻结的危险时，把
y 轮胎空气压力很高，因此必须注意轮辋 防冻剂 （％） 25 30 40 50 含有防冻剂 （LLC 除外，LLC 每两年更
的变形、破裂等。切勿超过正常的空气 换一次）的冷却水排放出来。
压力。 小心 冲洗水箱和发动机气缸，并注入干净
1. 用千斤顶顶起车辆，直至轮胎离开地 y 防冻剂是可燃性的，要特别注意避开火 的水。
面为止，拧下轮毂螺母。 花。
（2 吨车型） （3 吨车型） 在加注防冻剂以前，要检查水箱、水泵、
2. 用千斤顶顶起车辆，直至轮胎离开地
管道和气缸缸体，是否有泄漏。
面为止，将空气从轮胎中完全排净。
后轮 加注防冻剂的步骤如下：
(1) (2) 3. 卸下轮毂螺母，然后卸下轮胎。
y 在拆卸散热器盖子时，应使用厚布以防
4. 要在更换完轮胎后重新安装每个车
止灼伤；禁止使用手套。
轮，应按照与卸下时相反的顺序操作。
应用力均匀按照如图所示的顺序拧紧
轮毂螺母。

注意 : 预净机的清洗 （选购件）
参见维修数据部分，查看轮毂螺母拧紧的力 检查预净机。如果积灰达到白线水平，请清
(1) 轮毂螺母 矩。 洗。
(2) 轮辋螺母
（切勿在未排净空气前将其拧松） 小心
令车辆以较低的速度前后行驶几次，以检查
轮毂螺母是否存在松动，并根据需要重新将
其拧紧。
(1)
5. 在更换完轮胎后，检查并调整轮胎的
空气压力。

警告 (1) 预净机
在向轮胎内注入空气时，应使用一个安全
笼。

小心
在使用空气压缩机之前应先调节其气压。

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保险丝的更换 小心
y 使用与原来安装的保险丝同一规格的保
如果灯不亮或电气设备不能工作，可能是相
险丝。
应的保险丝被烧断了。
检查各种设备的保险丝。保险丝盒在打开的 y 如果换上的保险丝再烧断，须委托丰田
发动机室中的左前方。 经销店进行检查。
(1) 注意 : y 如果需要，委托丰田经销店更换 GLOW 或
关于各种保险丝所对应的设备，请参照下
ALT 保险丝。
表。

(1) 保险丝盒 燃油系统的空气净化 zh

(1)
（柴油机车型）
保险丝的分布
当燃油已经完全耗尽或进行燃油系统的保
养时，必须按下列程序进行空气净化。
A 30A STA M 7.5A SPARE
B 40A AM1 N 7.5A HME
1. 打开发动机罩。
C - - O 7.5A ST 2. 上下操作起动泵进行放气。
D 15A HORN P 10A GAUGE
E 7.5A ALT-S Q 10A BACK_LP
F 7.5A STOP R 7.5A SFT
G 7.5A TAIL S 7.5A TURN
H 7.5A ECU-B T 7.5A IGN
I 15A WORK_LP U 15A SPARE
(1) 起动泵
J 15A HEAD V 10A SPARE
K 40A AM2 W 10A ECU-IG
(1) 沉淀杯的排水
L 30A SPARE
（柴油机车型）
包括可选择附件 沉淀杯把燃油中所含的水分分离开来。它与
燃油过滤器成一整体。
保险丝的检查和更换顺序如下： 如果沉淀杯警告灯发亮，表示沉淀杯内的积
水超过了规定水位，须立刻按照下述方法进
1. 把点火器开关 置于 OFF （关）位置。
行排水：
2. 取下保险丝盒盖，拿掉保险丝盒上的
(2) 1. 把盛水容器放在燃油过滤器下边的排
夹子。
水软管开口处。
3. 用保险丝夹夹住保险丝，把它取下。
2. 把排泄阀转动一、二圈，将其拧松，上
(3)
4. 如果其状态如左图右侧所示，表示保 下操作起动阀，排出沉淀杯内的水。
险丝烧断。请更换新的保险丝。 (1) 起动泵
3. 当水被排净后，轻油开始流出时，拧紧
(2) 排泄阀 排泄阀。
(3) 排泄软管
小心
将周围的轻油擦拭干净。

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蓄电池的保养 清洗散热器片
(1)
接线端子 清洗散热器和散热片。如果积有异物，可能
导致过热。
1. 松动或腐蚀的接线端子会引起连接不
良：如果发现接线端子上有白色粉末， 小心
要泼上热水使之溶解加以去除，然后 y 关闭发动机后，确保发动机充分冷却后
用油脂润滑接线端子。 方可清洗。如果预防措施不足，可能导
2. 如果接线端子严重腐蚀，应将它从蓄 致烫伤。
电池上取下，用钢丝刷或砂纸除去腐
y 清洗散热片时，注意不要使其变形。
(1) 润滑油脂 蚀物。然后将接线端子紧紧地与蓄电
池连接，并涂上润滑油脂。 y 清洗过程中，一定要戴上护目镜和防尘
注意 : 罩。
先取下负极接线端子 （－），然后按同样方
法替换其它接线端子。
小心
燃油箱的检查
y 当要对蓄电池和接线端子进行保养时，
必须关闭发动机。 按照下列步骤检查燃油箱、箱盖、进油口和
排泄阀以查看是否漏油。
y 把盖子紧固定位，注意不要让任何异物
进入蓄电池。 1. 闻一下有无泄漏的气味。
2. 查看有无泄漏。
y 注意不要使蓄电池短路和接近烟火。因
为蓄电池所释放的气体是可燃的。 3. 用手触摸看有无泄漏。

y 充分注意不要沾到蓄电池的电解液。万 如发现泄漏，驾驶到最近的丰田经销店，立
刻要求修理油箱。
一电解液溅入眼睛或沾到皮肤上，应立
即用大量的水冲洗并让医生检查。 小心
y 在通风良好的地方，取下盖子，再进行 切勿擅自进行焊补或其它维修，因为有可能
蓄电池充电。 引起爆炸或起火。

y 如果蓄电池的电解液溅出，一定要用水
把该处和周围都洗干净。

注意 :
当电池呈现以下任意状态时，均应咨询您的
丰田经销店或厂商。
y 发出臭味。
y 一个端子呈黑色。
y 电池电解液的温度较高。
y 电池电解液减少的过快。

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车架序号 润滑表
车架序号的位置
1. 链条 I) 每８小时点检 （每天）
车架序号印在车辆的右手边的踏板上。查询
2. 差速器 II) 每 40 小时点检 （每周）
自己的车辆时请告知车架序号。 III) 每 250 小时点检 （６周）
3. 前轮轴承
4. 制动器和离合器总泵 IV) 每 1000 小时点检 （每６个月）
5. 变速箱 V) 每 2000 小时点检 （每年）
{: 检查和维修
6. 后轮轴承
z: 更换
7. 转向节主销
A) 多用途润滑脂
8. 油箱
B) 发动机油
9. 发动机曲轴 C) 准双曲面齿轮油
(1) 10. 后轴横梁前销 D) 液压油 zh
11. 后轴横梁后销 E) 自动传动液
12. 倾斜转向锁定装置 F) 制动液
13. 立柱支架衬套 G) 二硫化钼
(1) 车架序号位置 14. 倾斜液压缸前销 注意 :
15. 传动轴 在繁重的操作条件下，建议将保养周期设定
16. 横拉杆后销 为 170 小时或１个月。
名牌的阅读方法 17. 后轴液压缸后销
承载能力印刻在名牌上。
工作前，须确认负荷中心和能力。
1. 车辆型号
2. 特种车辆型，附属型
14 G G 14
3. 车架号
1 B B 1
4. 车辆重量 13 G G 13
3 A A 3
5. 立柱可提升高度
4 F F C C 2
6. 前轮距 12 A A 15
7. 轮胎尺寸
E E 5
8. 轮胎空气压力
10 G D D 8
9. 制造年 7 A B B 9
10. ＵＬ参数 6 A A 7
16 A A 6
11. 承载能力 17 A A 16
12. 负荷中心 11 G A 17
I
II
III
IV
V

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定期保养 使用丰田牌纯正零件来保护车辆
要让丰田工业车辆能够安全行驶，定期检查 如果６周的工作时间超过 250 小时，请用时 何必拿值钱的资产作赌注呢？正如每辆叉车一样当您的叉车需要定期保养时，须使用丰田牌
和维修是很重要的。检查周期的规定时数如 数作为进行保养的大致标准。交付使用前的 纯正零件。
下： 检查和每周的检查应由用户自行负责。而６ 和丰田装配线上所使用的零件一样符合丰田有关 “性能”，“耐用”和 “安全”的严格标准。
每天 （用前检查）..............每 8 小时 周，３个月，６个月和每年的检查因为需要
丰田牌纯正零件
每周 .........................每 40 小时 高级技术和专用工具，所以须由丰田经销店 如果使用非纯正机油过滤器：
６周 ........................每 250 小时 进行。 提供优质的集尘性能： 1. 会导致堵塞，从而造成发动机卡壳。
每３个月 ....................每 500 小时 参照期保养表来决定检查和维修的项目以及 例如：空气过滤器滤芯、液力变矩器油过滤 2. 机油会很快变脏，而需频繁换油。
每６个月 ...................每 1000 小时 检查周期。 器、回油过滤器、机油过滤器、燃油 3. 它会导致脏油流进发动机，从而导致发动机磨
每年 .......................每 2000 小时 只能使用纯正丰田牌零件进行更换，并使用 过滤器 损。
所推荐的润滑油类。
丰田牌纯正零件
定期更换表 如果使用非纯正水箱软管：
每 6周 3 6 12 个月
提供卓越的耐用性：
更换期限 （按操作累计时数或操作期间月数，以先到者为
准） 例如：离合器盘 1. 软管会很快磨损。
每 250 500 1000 2000 小时
z ← ← ← 水箱软管 2. 软管容易漏水，需要经常更换。
机油
机油过滤器 z* z ← ← Ｖ型皮带
冷却水 （LLC 除外，LLC 每２年１次） z ← ←
z
丰田牌纯正零件
空气滤清器部件
如果使用非纯正制动蹄：
燃油过滤器 z ←
具有极高的安全性： 1. 制动性能可能会过高、过低或不稳定，这是很
液力变矩器油 z ←
z ←
例如：提升滚柱 危险的。
液力变矩器油过滤器
差速齿轮油 z 提升链条 2. 制动器可能打滑，从而浪费燃油或蓄电池电
转向横拉杆端头 力。
液压油 z ←
液压油过滤器 z* z ← 制动蹄
车轮轴承润滑脂 z
火花塞 z ←
制动总泵，车轮制动分泵盖和密封 z
由丰田授权经销店提供售后服务
制动液 z ←
动力转向软管 （每２年） 通过使用优质的丰田牌纯正零件和高超的维修技术，丰田
动力转向橡胶零件 （每２年） 帮助用户将叉车保持在最佳状态，以便有效的工作和具有
液压软管 （每２年） 更高的生产率。丰田公司使用丰田牌纯正零件来满足用户
备用油箱软管 （每２年） 的要求。
燃油软管 （每２年）
液力变矩器橡胶软管 （每２年）
链条 （每 3 年）
液压油泵封口 （每３年或６千小时）
*: 对于新车型

注意 :
在繁重的操作条件下，建议将保养周期设定为 170 小时或１个月。

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定期保养表 检查期限 （按累计操作时数或月数为基准，以先到者为准。）

每
每
6周
250
3
500
6
1000
12
2000
个月
小时

定期保养 动力传递系统
检查方法 差速器
1. 机油泄漏................................................. I ← ← ←
Ｉ：根据需要进行检查、校正和更换。Ｔ：扭紧 Ｃ：清洁 Ｌ：润滑 Ｍ：根据需要进行测 2. 机油位................................................... I ← ← ←
量、校正和调整。 3. 螺栓的松动............................................... T
液力变矩器和变速器
每 6周 3 6 12 个月 4. 机油泄漏................................................. I ← ← ←
检查期限 （按累计操作时数或月数为基准，以先到者为准。）
每 250 500 1000 2000 小时 5. 机油位................................................... I ← ← ←
发动机 6. 操纵机构的功能和松动..................................... I ← ← ←

基本零部件 7. 控制阀和离合器的功能..................................... I ← ← ← zh
8. 点动阀的功能............................................. I ← ← ←
1. 起动状态和异常噪音 ...................................... I ← ← ←
9. 失速试验和机油压力的测定................................. M ←
2. 怠速时的转动状态 ........................................ M ← ← ←
3. 加速时的转动状态 ........................................ M ← ← ← 传动轴和驱动轴
4. 排气状态 ................................................ I ← ← ← 10. 接头的松动............................................... Ι ← ←

5. 空气滤清器部件 .......................................... C ← ← ← 11. 花键接头的松动........................................... I

6. 气门间隙 ................................................ M* M 12. 万向节的松动............................................. I

7. 压缩 .................................................... M 13. 驱动轴的扭曲和开裂....................................... I

8. 气缸盖螺栓 .............................................. T 行走设备
9. 消声器橡胶支座 .......................................... I
车轮
用气体减少装置排气 1. 轮胎气压................................................. M ← ← ←
10. 曲轴箱通风量控制阀以及管道的堵塞和损坏 .................. I ← ← ← 2. 轮胎切痕、损坏和胎面花纹不均匀........................... I ← ← ←
调速器 3. 轮辋和轮毂螺母的松动..................................... T ← ← ←
11. 最大无负荷稳定转速 ...................................... M ← ← ← 4. 胎面花纹的深度........................................... M ← ← ←

润滑系统 5. 轮胎内的金属片、石头或其他异物........................... I ← ← ←

12. 机油泄漏 ................................................ I ← ← ← 6. 轮辋、侧环和盘式车轮的损坏............................... I ← ← ←

13. 机油位 .................................................. I ← ← ← 7. 前轮轴承的异常噪音和松动................................. I ← ← ←

14. 机油滤清器的堵塞和淤塞 .................................. I ← ← ← 8. 后轮轴承的异常噪音和松动................................. I ← ← ←

燃油系统 前轴
15. 燃油泄漏 ................................................ I ← ← ← 9. 轴套的破裂和损坏......................................... I
16. 化油器连杆的机械操作 .................................... I ← ← ← 后轴
17. 燃油滤清器部件的淤塞和损坏 .............................. I ← ← ← 10. 横梁的破裂、损坏和变形................................... I
18. 喷油时间点 .............................................. M ← 11. 轴承横梁前后方向的松动................................... M* M
19. 喷嘴喷射压力和状态 ...................................... M
转向系统
20. 沉淀杯的排放 ............................................ I ←
方向盘
冷却系统 ← ← ←
1. 自由行程和松动........................................... I
21. 散热器冷却水的水位和泄漏 ................................ I ← ← ←
2. 工作状态................................................. I ← ← ←
22. 橡胶软管的劣化 .......................................... I ← ← ←
← ← ←
转向阀
23. 散热器盖的状态 .......................................... I
3. 机油泄漏................................................. I ← ← ←
24. 风扇皮带的张力和损坏 .................................... I ← ← ←
4. 装配松动................................................. T ← ← ←
25. 散热器橡胶支座 .......................................... I

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每 6周 3 6 12 个月 每 6周 3 6 12 个月
检查期限 （按累计操作时数或月数为基准，以先到者为准。） 检查期限 （按累计操作时数或月数为基准，以先到者为准。）
每 250 500 1000 2000 小时 每 250 500 1000 2000 小时
助力转向机构 5. 立柱和提升托架的松动..................................... I ← ← ←

5. 机油泄漏 ................................................ I ← ← ← 6. 立柱支架衬套的磨损和损坏................................. I

6. 装配和连杆的松动 ........................................ I ← ← ← 7. 滚柱的磨损、损坏和转动状态............................... I ← ← ←

7. 助力转向软管的损坏 ...................................... I 8. 滚柱销的磨损和损坏....................................... I

9. 立柱滑道的磨损和损坏..................................... I ← ← ←
转向节
8. 转向节主销的松动 ........................................ I ← ← ← 链条和链轮
9. 破裂和变形 .............................................. I 10. 链条的张力、变形和损坏................................... I ← ← ←
11. 链条的润滑............................................... I ← ← ←
制动系统 12. 链条地脚螺拴的状态....................................... I ← ← ←
制动踏板 13. 链轮的磨损、损坏和转动状态............................... I ← ← ←
1. 自由行程以及与底板间的间隙 .............................. M ← ← ←
各种附件 （选购件）
2. 制动效果 ................................................ I ← ← ←
14. 异常情况和装配状态....................................... I ← ← ←
停车制动器
液压系统
3. 操作力 .................................................. I ← ← ←
← ← ←
液压缸
4. 拉动极限 ................................................ I
1. 液压缸装配松动和损坏..................................... T ← ← ←
5. 制动效果 ................................................ I ← ← ←
2. 活塞杆、活塞杆螺钉以及活塞杆端的变形和损坏............... I ← ← ←
制动管道和软管 ← ← ←
3. 液压缸的工作............................................. I
6. 泄漏、损坏和装配状态 .................................... I ← ← ←
4. 自然下落和自然前倾....................................... M ← ← ←
制动油 5. 机油泄漏和损坏........................................... I ← ← ←
7. 油位 .................................................... I ← ← ← 6. 插销和液压缸轴承支架的磨损和损坏......................... I ← ← ←
制动总泵或车轮制动分泵 7. 提升速度................................................. M ← ← ←
8. 功能、磨损、损坏和装配松动 .............................. I 8. 不均匀运动............................................... I ← ← ←

制动鼓和制动蹄片 机油泵
9. 制动鼓和摩擦衬片的间隙 .................................. M ← ← ← 9. 机油泄漏和异常噪音....................................... I ← ← ←
10. 制动蹄的滑动部分和摩擦衬片的磨损 ........................ I 液压油箱
11. 制动鼓的磨损和损坏 ...................................... I 10. 油位和杂质............................................... I ← ← ←
12. 制动蹄的工作状态 ........................................ I 11. 油箱和机油滤网........................................... C ←
13. 蹄片支销的锈蚀 .......................................... I 12. 机油泄漏................................................. I ← ← ←
14. 回位弹簧的磨损等 ........................................ M
控制杆
15. 自动调整功能的工作 ...................................... I
13. 连杆的松动............................................... I ← ← ←
后板 14. 工作状态................................................. I ← ← ←
16. 变形、破裂和损坏 ........................................ I
控油阀
17. 装配松动 ................................................ T
15. 机油泄漏................................................. I ← ← ←
负荷装卸系统 16. 减压测量................................................. M
货叉 17. 减压阀和倾斜锁定阀的功能................................. I ← ← ←

1. 货叉和止动销的状态 ...................................... I ← ← ← 油压管道

2. 左右货叉的均匀性 ........................................ I ← ← ← 18. 机油泄漏................................................. I ← ← ←
3. 货叉基座和焊接部分的开裂 ................................ I*1 19. 变形和损坏............................................... I ← ← ←
20. 连杆的松动............................................... T ← ← ←
立柱和提升托架
4. 焊接部分的变形、损坏和开裂 .............................. I ← ← ←

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每 6周 3 6 12 个月 每 6周 3 6 12 个月
检查期限 （按累计操作时数或月数为基准，以先到者为准。） 检查期限 （按累计操作时数或月数为基准，以先到者为准。）
每 250 500 1000 2000 小时 每 250 500 1000 2000 小时
电气系统 OPS （选购件）
点火系统 10. 功能..................................................... I ← ← ←

1. 分电器盖的破裂 .......................................... I ← ← ← 座位
2. 火花塞的烧损和间隙 ...................................... I ← ← ← 11. 装配松动和损坏........................................... I ← ← ←
3. 分电器侧端子的烧损 ...................................... I ← ← ← 12. 座位安全扣带的损坏和 / 或操作............................. I ← ← ←
4. 分电器盖十字头的磨损和损坏 .............................. I ← ← ← 13. 座位安全扣带的损坏....................................... I ← ← ←
5. 插头电线内部断开 ........................................ I 14. 座位开关工作条件 （选购件）............................... I ← ← ←
6. 点火时间点 .............................................. M ← 车身
起动机 15. 车架、横梁等的损坏和开裂................................. I
7. 小齿轮的啮合 ............................................ I ← ← ← 16. 螺栓的松动............................................... T zh
充电器 后视镜
8. 充电效果 ................................................ I ← ← ← 17. 污垢，损坏............................................... I ← ← ←

充电器 18. 后部映现的情况........................................... I ← ← ←

9. 蓄电池电解液的液位 ...................................... I ← ← ← 其它
10. 比重 .................................................... M ← 19. 润滑油................................................... L ← ← ←

电气线路
11. 电线束的损坏 ............................................ I ← ← ← * ： 对于新车
12. 保险丝 .................................................. I ← ← ←
*1 ：裂纹和裂缝探伤仪
预热器
13. 预热塞电阻线圈的断裂 .................................... I ← 注意 :
安全装置等 在繁重的操作条件下，建议将保养周期设定为 170 小时或１个月。
顶部防护装置
1. 焊接部分的开裂 .......................................... I ← ← ←
2. 变形和损坏 .............................................. I ← ← ←

靠背
3. 装配松动 ................................................ T ← ← ←
4. 变形、破裂和损坏 ........................................ I ← ← ←

照明系统
5. 工作情况和装配状态 ...................................... I ← ← ←

喇叭
6. 工作情况和装配状态 ...................................... I ← ← ←

转向信号
7. 操作和安装条件 .......................................... I ← ← ←

仪表
8. 工作情况 ................................................ I ← ← ←

倒车蜂鸣器 （选购件）
9. 工作情况和装配状态 ...................................... I ← ← ←

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维修数据
调整值表
项目 车型 2~2.5 吨 3吨
风扇皮带张力 （施加 10kgf 公斤力） mm （毫米） 8~13 (0.31~0.51) ←
火花塞间隙 mm （毫米） 4Y 0.7~0.8 (0.028~0.031) ←
火花塞类型 4Y W9EXR-U ←
点火时间点 （上止点前） 度/转/分 4Y 7/750 ←
点火顺序 4Y 1-3-4-2 ←
喷油时间点 （上止点前） 度 1DZ-II 0 （静态） ←
喷油顺序 1DZ-II 1-3-4-2 ←
4Y 0 ( 自动调整 ) ←
进气
1DZ-II 0.18~0.22 (0.007~0.009) ←
气门间隙 （热车时） mm （毫米）
4Y 0 ( 自动调整 ) ←
排气
1DZ-II 0.33~0.37 (0.013~0.015) ←
4Y 750 +500 ←
怠速 转/分
1DZ-II 750±30 ←
4Y 2400±50 ←
最大无负荷速度 转/分
1DZ-II 2400±50 ←
4Y 1226 (12.5) [178]/250 ←
标准值
1DZ-II 2850 (29) [412]/260 ←
发动机压缩 公斤力 / 厘米 2/ 转 / 分
4Y 883 (9) [128]/250 ←
极限值
1DZ-II 1961 (20) [284]/260 ←
可拆卸式轮辋 700 (7) [100] −
前轮
轮胎气压 公斤力 / 厘米 2 固定边圈轮辋 − 700 (7) [100]
后轮 特殊单轮 700 (7) [100] 775 (7.75) [110]
方向盘自由行程 （怠速时） mm （毫米） 20~50 (0.79~1.97) ←
停车制动范围 凹槽 4~5 ←
停车制动杆操作力 牛 （千克力）[ 磅 ] 150~250 (15~25) [33~55] ←
提升 18.7 (191) [2710] ←
控油阀预置压力 公斤力 / 厘米 2
倾斜 15.7 (160) [2275] ←
制动踏板自由行程 mm （毫米） 1~5 (0.04~0.20) ←
制动踏板地板间隙 mm （毫米） 89 （3.5）或更高 ←
点动和制动踏板自由行程 mm （毫米） 1~3 (0.039~0.12) ←
可拆卸式轮辋 117~392 (18~40) [130~289] −
前轮
轮毂螺母扭紧力矩 公斤力 - 米 固定边圈轮辋 − 294~588 (30~60) [217~434]
后轮 特殊单轮 118~196 (12~20) [87~145] ←
前轮 118~176 (12~18) [87~130] −
可拆卸式轮辋固定螺栓扭紧力矩 公斤力 - 米
后轮 49~68.5 (5~7) [36~51] ←
蓄电池电解液比重 (20°C) 1.28 ←

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润滑剂容量和类型
项目 2~2.5 吨 3 吨 型式
汽油 4Y 4.0 (1.06) ← API SL, SM
发动机油 升 ( 美加仑 )
柴油 1DZ-II 7.9 (2.09) ← API: CF-4
液力变矩器 升 ( 美加仑 ) 速度 1 5.0 (1.32) ← ATF GM Dexron II
差速器 升 ( 美加仑 ) 5.8~6.4 (1.53~1.69) 7.8~8.6 (2.06~2.27)
API GL 4 准双曲线齿轮油
变速器 升 ( 美加仑 ) 3.6 (0.95) ←
燃油箱 升 ( 美加仑 ) 60 (15.8) ←
车轮轴承、底盘、转向和立柱的倾斜机构以及黄油嘴 适 量 多用途润滑脂
制动系统管路 升 ( 美加仑 ) 0.2 (0.05) ← 刹车油 2500H
发动机冷却系统 4Y 8.6 (2.27) ←
( 备用箱除外 ) 升 ( 美加仑 )
1DZ-II 7.3 (1.93) ←
L.L.C.*
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散热器备用箱 ( 水位在 FULL[ 满 ] 标记处时 ) 升 ( 美加仑 ) 0.6 (0.158) ←
液压油 升 ( 美加仑 ) 36.3 (9.6) 37.3 (9.8) ISO VG 32

* L.L.C = 长效冷却剂 （用净水适当地稀释）

液压油油位在升程为 3000 mm （毫米）的 V 型立柱上。

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门架说明书和额定容量

D
L M

A C G

B 车高 G 自由升降 （货叉顶部） J 单轮

D K N
T A 货叉伸展距离
H I 倾斜范围 装载容量为 500 mm （毫米）的 LC
门架类型 最大货叉高度 C 无负载时的工作支承 标准负载时的工作支
下降高度 E F 高度 承高度 L M O P
无负载时的工作支承 标准负载时的工作支 向前 后退 PN 轮胎 PSC 轮胎
高度 承高度

V FV FSV
宽外形门架 宽外形全自动提升双级门架 宽外形全自动提升三级门架

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型号 : FGZN20/FDZN20
B G J
A D K N
T C H I
E F L M O P
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) kg (lbs)
3000 (118) 1995 (78.5) 3720 (146.5) 4250 (167.3) 98 (3.9) 98 (3.9) 6 11 2000 (4410) 2000 (4410)
V
4000 (157.5) 2595 (102.2) 4720 (185.8) 5250 (206.7) 98 (3.9) 98 (3.9) 6 11 2000 (4410) 2000 (4410)
4300 (169) 1995 (78.5) 4910 (193.3) 5550 (218.5) 1425 (56.1) 775 (30.5) 6 6 1900 (4190) 1900 (4190)
FSV
4700 (185) 2145 (84.4) 5310 (209.1) 5950 (234.3) 1575 (62) 925 (36.4) 6 6 1850 (4079) 1850 (4079)
注意：标准挡货架的高度为 1220 mm （毫米）。

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型号 : FGZN25/FDZN25
B G J
A D K N
T C H I
E F L M O P
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) kg (lbs)
3000 (118) 1995 (78.5) 3720 (146.5) 4250 (167.3) 98 (3.9) 98 (3.9) 6 11 2500 (5513) 2500 (5513)
V
4000 (157.5) 2595 (102.2) 4720 (185.8) 5250 (206.7) 98 (3.9) 98 (3.9) 6 11 2500 (5513) 2500 (5513)
4300 (169) 1995 (78.5) 4910 (193.3) 5550 (218.5) 1425 (56.1) 775 (30.5) 6 6 2300 (5072) 2300 (5072)
FSV
4700 (185) 2145 (84.4) 5310 (209.1) 5950 (234.3) 1575 (62) 925 (36.4) 6 6 2000 (4410) 2000 (4410)
注意：标准挡货架的高度为 1220 mm （毫米）。

型号 : FGZN30/FDZN30
B G J
A D K N
T C H I
E F L M O P
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) deg deg kg (lbs) kg (lbs)
3000 (118) 2015 (79.3) 3780 (148.8) 4270 (168.1) 88 (3.5) 88 (3.5) 6 11 3000 (6615) 3000 (6615)
V
4000 (157.5) 2615 (103) 4780 (188.2) 5270 (207.5) 88 (3.5) 88 (3.5) 6 11 3000 (6615) 3000 (6615)
4300 (169) 2165 (85.2) 4960*2 (195.3*2) 5570 (219.3) 1550*3 (61*3) 945 (37.2) 6 6 2850 (6284) 2850 (6284)
FSV
4700 (185) 2265 (89.2) 5360*2 (211*2) 5970 (235) 1650*3 (65*3) 1045 (41.1) 6 6 2800 (6174) 2800 (6174)

注意：1. 标准挡货架的高度为 1220 mm （毫米）。

2. 采用 A4 管道，延长总高度 （除挡货架）增长 25 mm （毫米）。（*2 标记的部分）
3. 采用 A4 管道，自由升降 （除挡货架）缩短 25 mm （毫米）。（*3 标记的部分）

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车轮和轮胎
横向
车型 轮胎组合 轮辋尺寸 轮胎尺寸 横向 非 PUNK
前轮 {
A 5.00S X 12 DT 7.00-12-12PR

A 5.00S X 12 DT 7.00-12 z
FGZN20, 25
FDZN20, 25 后轮
A 4.00E X 9 DT 6.00-9-10PR {
A 4.00E X 9 DT 6.00-9 z
前轮 {
B 7.00T X 15 IR 28X9-15-12PR

B 7.00T X 15 IR 28X9-15 z
FGZN30
FDZN30 后轮
A 5.00F X 10 DT 6.50-10-10PR {
A 5.00F X 10 DT 6.50-10 z
A: 可拆式单轮辋 B: 边环轮辋
{: 标准 z: 选购

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车轮尺寸
FGZN20 FGZN25 FGZN30
FDZN20 FDZN25 FDZN30
1140 ← 1255
A (44.9) (48.2)
980 1030
B ←
(38.6) (40.6)
960 ← 1010
C (37.8) (39.8)

F: 轮距
C: 轮距 D 210 260 ←
(8.3) (10.2)
D
A
B

105 130 ←
E

E
(4.1) (5.1)

F 965 ← ←
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(38)
G
2200 2260 2400
G

H
(86.6) (89) (94.5)
2190 2225 2325
H (86.2) (87.6) (91.5)
4250 ← 4270
I (167.3) (168.1)
3020 ← ←
J (118.9)
1995 ← 2020
K (78.5) (79.5)
98 ← 88
L (3.9) (3.5)
1210 ← 1215
M (47.6) (47.8)
40 ← 45
N (1.6) (1.8)

O 6° ← ←
O P
T
I

L: 货叉提升高度

P 11° ← ←

420 415 450

Q (16.5) (16.3) (17.7)
J

S
1095 ← 1160
R (43.1) (45.7)
M

2130 ← 2195
S (83.9) (86.4)
N

1040 ← ←
T (40.9)
U V W X
1070 ← ←
U
Y (42)
470 ← 490
V (18.5) (19.3)
1650 ← 1700
W (65) (66.9)
450 530 585
单位 :mm（毫米） X (17.7) (20.9) (23)
2575 2650 2780
Y (101.4) (104.3) (109.4)

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