Toyota 8FG40N User Manual

TABLE OF CONTENTS
TABLEOFCONTENTS
1 FOREWORD ..................................................................................................................en4
2 SAFEUSE......................................................................................................................en5
3 MAINCOMPONENTS....................................................................................................en6
4 OPERATINGCONTROLS .............................................................................................en7
5 HOWTOREADTHENAMEPLATE ..............................................................................en8
6 WARNINGLABELS.......................................................................................................en9
6.1 Recycling/discarding...........................................................................................en11
7 SASFUNCTION...........................................................................................................en12
7.1 PrecautionsonSAS ...........................................................................................en12
7.2 DescriptionofSASfeatures ...............................................................................en12
8 OPSFUNCTION ..........................................................................................................en15
8.1 TravelOPSfunction ...........................................................................................en15
8.2 LoadhandlingOPSfunction...............................................................................en15
8.3 OPSoperationinformationfunction....................................................................en15
8.4 Returntoneutral ................................................................................................en15
8.5 Parkingbrakeonwarning...................................................................................en16
8.6 Parkingbrakeoffwarning...................................................................................en16
9 MAINFUNCTIONS ......................................................................................................en17
9.1 Travelcontrolfunction .......................................................................................en17
9.2 Engineautostopfunction ...................................................................................en17
9.3 Ecomode ...........................................................................................................en17
10 SWITCHESANDLEVERS ..........................................................................................en18
10.1 Ignitionkeyswitch ..............................................................................................en18
10.2 Directioncontrollever.........................................................................................en19
10.3 Parkingbrakelever.............................................................................................en19
10.4 Liftlever ..............................................................................................................en20
10.5 Manualloweringvalve ........................................................................................en20
10.6 Tiltlever ..............................................................................................................en20
10.7 Tiltleverknobswitch ..........................................................................................en21
10.8 Clampreleasebutton(Option) ...........................................................................en21
10.9 Integratedlightandturnsignalswitch ................................................................en22
10.10 Keyoffheadlightoffsystem(Option) ................................................................en23
10.11 Torqueconverterinterlockfunction(Option) ......................................................en23
10.12 Tiltsteeringadjustlever......................................................................................en23
10.13 Pedals.................................................................................................................en24
10.14 EZpedal(Option) ...............................................................................................en24
10.15 Hornbutton.........................................................................................................en24
10.16 Rearassistgripwithhornbutton(Option) ..........................................................en24
10.17 Rearworkinglight(Option).................................................................................en25
10.18 Minilever(Option) ..............................................................................................en25
10.19 Joystick(Option)................................................................................................en27
10.20 Armrest(MinileverorJoystickmodels)............................................................en28
11 BODYCOMPONENTS ................................................................................................en30
11.1 Operator'sseat ...................................................................................................en30
11.2 Swivelseat(Option) ...........................................................................................en31
11.3 Seatbelt .............................................................................................................en32
11.4 Enginehood(ExceptMinileverorJoystickmodels) .........................................en32
11.5 Enginehood(MinileverandJoystickmodels) ..................................................en33
11.6 Drawbar .............................................................................................................en34
11.7 Liftingpoints .......................................................................................................en34
11.8 Overheadguard..................................................................................................en34
11.9 Loadbackrestextension.....................................................................................en34
11.10 Mast....................................................................................................................en34
11.11 Forks...................................................................................................................en35
11.12 Rearviewmirror(Option) ...................................................................................en35
12 INSTRUMENT ..............................................................................................................en36
12.1 Combinationmeter .............................................................................................en36
12.2 Multifunctiondisplay(Option) ............................................................................en41
13 LPGDEVICE(OPTION)...............................................................................................en48
13.1 Switches .............................................................................................................en48
13.2 LPGrelatedparts ...............................................................................................en49
13.3 Enginehood .......................................................................................................en50
13.4 OperatingLPGpoweredforklift ..........................................................................en50
13.5 Refuelingyourtruck............................................................................................en51
13.6 ImportantinformationaboutLPG .......................................................................en55
13.7 SafetyprecautionsonLPGpoweredforklifts .....................................................en55

Toyota 8FG40N Specifications

General

Model	8FG40N
Category	Forklifts
Load Capacity	4000 kg
Power Source	Internal Combustion
Turning Radius	2400 mm

Summary

SAFE USE

Before Starting Operation

Essential precautions and knowledge required before operating the forklift.

Safety Requirements

Specific safety guidelines and requirements related to forklift operation.

OPERATING CONTROLS

WARNING LABELS

SAS FUNCTION

Precautions on SAS

Important safety considerations and warnings for operating trucks with SAS.

Description of SAS features

Explains the functionalities and purpose of various SAS features.

OPS FUNCTION

Travel OPS function

Details the operation of the Operator Presence Sensing system during travel.

Load handling OPS function

Explains how the Operator Presence Sensing system affects load handling.

MAIN FUNCTIONS

Travel control function

SWITCHES AND LEVERS

Ignition Key Switch and Basic Lever Operations

Operation of the ignition key switch and fundamental lever controls.

Direction Control and Parking Brake Levers

How to operate the direction control lever and parking brake lever.

Lift, Lowering, and Tilt Lever Operations

Using the lift, manual lowering, and tilt levers for fork and mast control.

Tilt Knob Switch, Clamp Release, and Integrated Lights

Pedals, Horns, and EZ Pedal Operation

Rear Working Light and Mini Lever Direction Control

Mini Lever Fork, Mast, and Attachment Controls

Joy Stick Direction and Load Handling Levers

Joy Stick Fork Leveling, Attachment, and Arm Rest Controls

BODY COMPONENTS

Operator's Seat and Adjustments

Adjusting the operator's seat position and reclining angle for comfort and safety.

Seat Belt Usage and Safety

Proper fastening, disconnecting, and safety warnings for the seat belt.

INSTRUMENT

Combination Meter and Warning Lamps

Identifies gauges and warning lamps on the combination meter.

Water Temperature, Hour Meter, and Fuel Gauges

Indicator Lamps and Warnings

System Status and Warning Indicators

Details on engine oil, charging system, OPS, and diagnosis indicators.

OK Monitor System and Brake Indicator

Functionality of OK monitor, air cleaner, coolant level, and brake indicators.

Multi-function Display Overview and Screens

Display Screens: Status, Speedometer, and ODO/TRIP

Maintenance, Diagnosis, and Setting Indicators

Load Meter and Parking Brake Warnings

Torque Converter and Over-Speed Alarms

LPG DEVICE (OPTION)

LPG Device Switches

Refueling and Parking Procedures

LPG Refueling and Tank Removal

Installing LPG Tank and Safety Information

LPG Safety Precautions

Critical safety measures for operating LPG-powered forklifts to prevent fire.

PRE-OPERATION CHECK

Walkaround Inspection Items

Visual inspection of the truck's exterior, wheels, and beneath the unit.

Tire and Hub Nut Inspection

Engine Compartment Checks

Inspecting engine coolant levels in the reservoir and radiator.

Hydraulic Oil and Engine Oil Inspection

Checking hydraulic oil and engine oil levels for proper operation.

Fluid and Leakage Checks

Adding engine oil, checking for leaks, and LPG leakage inspection.

On Board Truck and Pedal Inspections

Parking Brake, OPS, and Instrument Checks

Fuel, Chain Tension, and Load Handling Checks

Steering, SAS, and Slow Movement Checks

SELF SERVICING

Refueling Procedures and Fuel Types

Tire Changing and Fuse Replacement

EMERGENCY PROCEDURE

Using Jumper Cables

Instructions for jump-starting a truck with a discharged battery using jumper cables.

Lifting the Truck

Cautions and procedures for safely lifting the forklift truck.

PLANNED MAINTENANCE

Storage and Weekly Maintenance

Detailed Periodic Maintenance Table