Toyota 30-7FBCHU25, Owner'S Manual

Page 1: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 2: ...rements a Warning and Informational Decals a Controls Switches Instruments Data Platelcapacities IV DAILY OPERATION 49 Daily Inspection Pre Operation Checks Driving and Operating a Brakes Lifting and...

Page 3: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 4: ...fy ways you can carry out your responsibilities and the sections relating to safety information point out hazards that you can eliminate from the workplace as well as ideas that can be incorporated in...

Page 5: ...is right for you Clamp Truck with Audible and Visual Alarms This highly specialized truck works in close spaces with a high noise level and many pedestrians The owner choses audible and visual alarms...

Page 6: ...the workplace rules specific to your operation This book and the National Safety Council publications listed at the end of this section will help you develop your rules Many injuries related to lift t...

Page 7: ...so your operators will not have to recognize and avold them while also concentrating on their job The section on operator rules is for you also It will help you set up work rules suited to your workpl...

Page 8: ...familiar with the operating maintenance and safety instructions contained in these publications General Industry Standards OSHA 2206 OSHA Safety and Health Standards 29 CFR 191O Subpart N Materials Ha...

Page 9: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 10: ...fety information for you It means PAY ATTENTION LOOK OUT YOUR SAFETY IS INVOLVED The word after the asymbol will tell you about the hazard or importance of the rule aDANGER An extreme hazard that will...

Page 11: ...ibility for Contact your Toyota dealer and battery manufacturer for help in putting together a training course suited to your operation and think about the following areas as they apply to the work yo...

Page 12: ...s a starter to develop workplace rules that keep your plant safe Call meetings with your people to explain your rules post them where they can be read and enforce them Gloves 1 r I Hard hats 1 OPERATO...

Page 13: ...aired Don t risk injury by trying to fix it Truck Application Know the ways your truck can operate safely Don t try to operate on rough ground with a cushion truck or push a rail car with the carriage...

Page 14: ...wheels if there is any question about the truck moving Key Switch Turn the key switch off when you park LIFTING Operating Position Operate the truck only when sitting in the operator s seat Never sta...

Page 15: ...n weigh over 8 tons 17 600 Ib Elevators floors ramps or hiuhwav trucks mav not be able to s u p o r t this WORKPLACE HAZARDS weight Ask your o o t a dealer if you are not sure what your truck weighs W...

Page 16: ...l to take up the slack before you move the truck Forks or rails may be caught or jammed Never put your hands in the mast Ask your Toyota dealer to inspect and re air I An empty truck can tip over easi...

Page 17: ...centrate or damage your hearing Noise and hearing protectors make it harder for pedestrians to notice you If you need light to be seen or to work properly your Toyota dealer can supply a truck mounted...

Page 18: ...ny shifting or movement moves forward the dock board or lift truck can fall Trailers without a tractor Portable Ramps If using a portable ramp to load a trailer make sure it is must be supported under...

Page 19: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 20: ...nd Informational Decals Controls Switches Instruments Data Platelcapacities MAIN COMPONENTS 18 LIFT TRUCK DESCRIPTION 19 PRECAUTIONS TO BE TAKEN WHEN USING SAS MODELS 20 OPS SYSTEM 23 WARNING AND INFO...

Page 21: ...ast 2 Chain 3 Forks 4 Lift cylinder 5 Tilt cylinder 6 Overhead guard 7 Frame 8 Counteiweight 9 Battery hood 10 Steering wheel 11 Operator s seat and seat belt 12 Drive axle 13 Steer axle P r o p e r t...

Page 22: ...nce and repairs do not attempt it without asking your dealer for the proper instructions and manuals OSHA requires it Decals and plates that give you information about safe operation are on your truck...

Page 23: ...Before operating a truck equipped with SAS familiarize yourself with the SAS feature or features and be sure that the SAS warning lamp is not illuminated and or the SAS alarm buzzer is not operating E...

Page 24: ...ever knob switch will cause the mast to suddenly stop moving Avoid this operation Under some conditions suddenly stopping the mast while tilting forward may cause the truck to tip forward Some special...

Page 25: ...t the backward tilt speed of the mast is not controlled If the mast is tilted backward at low lift with the tilt lever knob switch pressed the backward tilt speed is controlled slowed down as long as...

Page 26: ...e displayed on the screen and powered travel will be stopped after 2 seconds However the OPSS will not apply the brakes to stop coasting or prevent rolling back on inclines The operator can continue m...

Page 27: ...your memory often 1111111111111111111lllllllllllllllllllllllllllllllllllllll lllllllllllllllllllllllll1llllllllllllllllllllllllllllllll aWARNING 1111111111111111111llllllllllllllllllllllllllllllllllll...

Page 28: ...y of people around you is your responsibility A minor adjustment of the brake is easily made to keep it working properly Use the brake whenever you leave the truck and keep twell adjusted x m If you c...

Page 29: ...Ill KNOW YOUR TRUCK Batteries can be very dangerous if you do not follow the safety rules in this book P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 30: ...splay 13 14 15 16 6 Key switch 11 Tilt lever 15 Accelerator pedal 7 Turn signal switch Option 12 Attachment lever 16 Tilt steering adjust lever 8 Light control switch 13 Tilt steering lock release 17...

Page 31: ...he indicator is not caused t o go out by releasing the parking brake stop the operating the truck and ask the Toyota dealer for inspection 1111111111111111111llllllllllllllllllllllllllllllllllllllll T...

Page 32: ...SS indicator T h i s OPSS i n d i c a t o r i n f o r m s t h e operator that the OPSS will soon be activated This indicator is displayed o n the screen when the operator is out of the operator s seat...

Page 33: ...ndicator Three traveling modes are available from a selection switch on the mult ple display H High performancs mode P Productivity mode S Sav ng mode Note Continuous use of H high power mode increase...

Page 34: ...mally Note Use it for selection of the set mode YES or NO on the clock setup selection screen Power select switch This switch selects the clock setup selection screen Press it for 2 seconds or more to...

Page 35: ...switch ON hours are integrated and its result is displayed in units of 0 1 hour up to 99999 9h While the hour meter is in operation the sandglass mark of the display blinks The next screen travelinglm...

Page 36: ...screen lap hour meter will be displayed When the operator presses the power select switch 0 the ordinary screen will reappear Lap hour meter Trip meter 0 Maintenance hour meter Lap hour meter Key swit...

Page 37: ...screen will be displayed Caution Be sure to operate the switch panel with fingers Warning sound When a wrong operation is performed a warning sound will be output to inform the operator of an error s...

Page 38: ...while the key switch is turned off IIIIHIIII111111111111111111III11111111111111111lllllllllli Directional control lever This lever allows forward and reverse directional changes to be made Forward Pu...

Page 39: ...ntrolled by the amount you move the lever Caution After activation of the OPSS return the direction control lever and the lift and tilt levers t o their neutral positions and sit in the seat so that l...

Page 40: ...hown when operator is out of the normal operating position is shown when operator 1 s in the normal operating position Icon is shown on display screen and does not go off when operator returns to the...

Page 41: ...1II1111III1I11111III1111111111 WARNING Do not adjust the wheel position while the truck is moving IIIIIIII111111111111II111111111111111111II11111111111111111 rake pedal Accelerator pedal Forward Rearw...

Page 42: ...off At this time return all levers to their neutral positions Caution Always pull the parking brake lever before parking the truck Note To tow the truck the seat switch brake must be released Please a...

Page 43: ...A specially designed operator s seat and seat belt are provided for your safety Get in the habit of using the seat belt whenever you sit on the truck An Operator s and Owner s Manual is located behin...

Page 44: ...e seat is secured in position when you release the lever O Recliner adjust lever Option Pull the lever on the left to adjust the seat s angle of recline O Weight adjust knob Option Turn the knob on th...

Page 45: ...Lumber adjust knob Suspension seat Option Adjusting the pointer on the weight scale to the operator s weight to obtain the most comfortable suspension matching the operator s weight The optimum drivin...

Page 46: ...1111111111111111111111 WARNING Always wear your seat belt when driving the truck The truck can tip over if operated improperly To protect operators from the risk of serious injury or death in the even...

Page 47: ...ing the hood untll it is locked to the position 3 Pull the steering wheel backward to return it to the original position 4 Make sure the hood latch is securely engaged and the manual catches are latch...

Page 48: ...or from falling objects Load backrest extension When properly maintained the load backrest extension will help stabilize the load and prevent parts of a load from falling back into the operator s comp...

Page 49: ...shifted left and right Adjust the forks in the position most appropriate for the load and as wide as possible When adjusting the forks make sure that the weight of the load is centered on the truck A...

Page 50: ...tor 7 Make sure you always perform the before operation and after operation inspections Ill KNOW YOUR TRUCK UL TYPE EE SPECIFICATION TRUCKS These trucks are classified by Underwriters Laboratories Inc...

Page 51: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 52: ...llllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllllll item Inspection Previously detected Correct malfunctions Exterior Body oil leakage water leakage loose part...

Page 53: ...e tires for damage and wear and the rims for bending If the tires are damaged or there is a marked difference in tire wear between front and rear or between left and right or bent rims are found you s...

Page 54: ...fluid in the reservoir tank The level should be within the range shown in the figure If the level is below the lower limit add brake fluid up to the proper level 1111111111111111111llllllllllllllllll...

Page 55: ...lllllllllllllllllllllllllllllllllllll WARNING Ask your Toyota dealer to inspect your truck if play is excessive pedal movement is a problem or brake performance is improper 1111111111111111111llllllll...

Page 56: ...lllllllllllllllIlllllllllllllIlll WARNING All chargers do not operate the same Follow the instructions in the Charger Operation Manual and your employer s rules 1111111111111111111llllllllllllllllllll...

Page 57: ...ervice Data Section for the standard steering wheel play 2 Rotate the steering wheel and also move it up and down to check that there is no looseness 3 If any problems are found ask your Toyota dealer...

Page 58: ...ased and direction control lever is in FORWARD or REVERSE position with key switch ON Driving 1 Shifting the direction lever to forward or reverse in trucks equipped with power steering will start the...

Page 59: ...1111111111I WARNING Never park on an incline if you have a choice If you must park on a slope the wheels must be chocked 1111111111111111111lllllllllllllllllllllllllllllIllllllllll Don t t l t the mas...

Page 60: ...rfaces PRECAUTIONS ON ELECTRIC FORKLIFTS Do not turn on the key switch with the direction lever shifted to forward or reverse position and the accelerator pedal depressed Avoid over discharging If the...

Page 61: ...a load and its load center must not be greater than the truck s capacity If the load is greater than the truck s capacity the rear wheels can lift and create an extremely dangerous condi tion Overload...

Page 62: ...information at the beginning of this section Read the Operator s and Owner s Manual and the warning decals on your truck Stow the manual behind the seat when you finish Ask questions if you don t und...

Page 63: ...vel in REVERSE if the load blocks your view Stacking loads requires patience and practice Put the truck in position before raising the mast and lower loads only when stopped and as close to the shelve...

Page 64: ...your work area but here are some things to remember Motor or motors stop while traveling Stop the truck as soon as possible If steering motor stops steering will take much more force to operate than...

Page 65: ...guard Loss of brakes while traveling Pump the brakes Set parking brake Steer around hazards Shift direction control lever to the opposite direction Forks mast or attachments hang up If you see a slac...

Page 66: ...ATTERY USAGE Do not overdischarge the battery Continued use of the battery until the truck will no longer run will shorten the battery life If the voltage drops into 20 level when the fork is raised w...

Page 67: ...nce depend on the kind of handling and inspection given to it daily Be sure that the battery is properly checked and serviced so that it will always be maintained in top cond tion a DANGER Batteries a...

Page 68: ...Maximum battery clearance must be less than 112 inch total in any direction Avoid battery damage Always keep battery adequately charged Change or charge battery if the battery capacity indicator begin...

Page 69: ...ect the battery plug before you attempt to replace a fuse Replace fuses with the same capacity as the bad fuse Fuse specifications are found in the Service Data Section If the fuse tends to burn out f...

Page 70: ...or to the wheels coming up off the ground and loosen the hub nuts Jack up until the wheels come off the ground then remove the hub nuts and remove the wheel To reinstall the wheel after changing a tir...

Page 71: ...t be injured by trying to use it 1 Determine parking brake force from service data section 2 Attach a spring scale to the center of the brake lever grip 3 Pull straight back and measure force 4 Adjust...

Page 72: ...k on a tilt trailer or make sure that dock levelers or plates of the proper capacity are used if loading from a dock Center the truck left and right lower the forks or the attachments set the parking...

Page 73: ...strong Never use the upper part of the overhead guard 1111111111111111111llllllllllllllllllllllllllllllllIlllllll The draw bar is located at the back of the counterweight and is used to pull the truc...

Page 74: ...nder a truck supported by any hydraulic jack SPECIAL SPECIFICATION PARTS 11111111111111111111111111111111111111111111111111111I11111111111111111111111III11111II111111111111111111111111111111 A WARNING...

Page 75: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...

Page 76: ...e manual will remind you of the areas that must be inspected and the replacement intervals for various components It is not meant to be a substitute for the mechanic training OSHA requires If you deci...

Page 77: ...working conditions Lack of proper lubrication and servicing will quickly show up in increased troubles and shortening of truck life Set up a certain day and make it a rule to inspect on that day Recor...

Page 78: ...eight battery See Data Plate Maximum battery clearance must be less than 112 inch total in any direction Avoid battery damage Always keep battery adequately charged Change or charge battery if the bat...

Page 79: ...t to the full forward position or remove the seat assembly 1 5 3 2 ton models Move the seat to the full backward position or remove the seat assembly 3 5 5 5 ton models 4 Release the latch and catches...

Page 80: ...ta dealer since high level technology and special tools are required Refer to the Periodic Maintenance Table to determine the inspection and maintenance items and inspection cycles Use only genuine To...

Page 81: ...wire looseness I Micro switch Operating condition and timing I c t t Damage and looseness of installing parts I t t c Direction lever Operating condition damage I c c 6 on operatng hours or months wh...

Page 82: ...der or brake valve and wheel cyl nder Function wear damage mounting looseness Brake drums and brake shoes Clearance between drum and lrnlng Shoe sl dtng posttion and lhning wear Drum wear and damage O...

Page 83: ...l t t t l t t c C c l c t t l t t e M l c c t l t t t l c t t T t t c l c c t l t t e T c c t I C t t I t INSPECTION PERIOD Accompl sh based on operatlng hours or months whichever IS soonest EVERY 6W...

Page 84: ...US gal Drlve unlt oil I I I Hipoid gear 011 SAE75 80W API GL 4 GL 5 F2B For pump motor No 2 A 1F3 For PS contactor A 75 1 t 1 I 1 325 3 5 5 5 ton 4 5 1 1 I8 US gal 1 5 1 8 ton 15 5 1 4 09 US gal 2 0...

Page 85: ...by referring to the table below Always use a case allowing fixation of the battery stopper Compartmentdimensions Necessary mm in Maximum minimum battery weight battery weight with case with case kg I...

Page 86: ...front pin 14 Rear axle beam rear pin 15 Swing lock cylinder crank and rod pin I Inspect every 8 hours daily II lnspect every 40 hours weekly Ill lnspect every 250 hours 6 weeks IV lnspect every 1000 h...

Page 87: ...pin 15 Swing lock cylinder crank and rod pin I lnspect every 8 hours daily II lnspect every 40 hours weekly Ill lnspect every 250 hours 6 weeks IV lnspect every 1000 hours 6 monthly V lnspect every 20...

Page 88: ...E SERIAL NUMBER Frame serial number location The frame serial number is stamped on the front cross plate Refer to the frame serial number when making inquiries about your truck P r o p e r t y o f A m...

Page 89: ...P r o p e r t y o f A m e r i c a n A i r l i n e s...