Toyota 50-4FD100 User Manual

FOREWORD
This manual covers the service procedures of the TOYOTA FORKLIFT
50-4FD100~135, 50-4FDK150,160. Please use this manual for providing quick,
correct servicing of the corresponding forklift models.
This manual deals with the above models as of August 2008. Please
understand that disagreement can take place between the descriptions in the
manual and actual vehicles due to change in design and specifications. Any
change or modifications thereafter will be informed by Toyota Industrial
Equipment Parts & Service News.
For the service procedures of the mounted engine, read the repair manuals
listed below as reference together with this manual.
(Reference)
Repair manuals related to this manual are as follows:
TOYOTA INDUSTRIAL EQUIPMENT J08E-UM ENGINE
REPAIR MANUAL (No. )

Toyota 50-4FD100 Specifications

General

Model	50-4FD100
Type	Forklift
Power Source	Internal Combustion
Fuel Type	Diesel
Tire Type	Pneumatic
Load Capacity	10000 kg
Lift Height	3, 000 mm

Summary

FOREWORD

GENERAL VEHICLE INFORMATION

VEHICLE EXTERIOR VIEWS

Visual representations of the forklift's exterior designs.

VEHICLE MODELS AND IDENTIFICATION

Lists different forklift models, their specifications, and frame number details.

MANUAL USAGE AND TERMINOLOGY

Instructions on manual navigation, explanation methods, and key terms.

OPERATING TIPS AND SAFETY

Advice on safe and efficient operation of the forklift.

VEHICLE LIFTING AND SUSPENSION

Procedures for safely jacking, hoisting, and wire rope suspension.

VEHICLE AND COMPONENT WEIGHTS

Tables listing the weights of the vehicle and its components.

ELECTRICAL PARTS INSPECTION

Procedures and precautions for inspecting electrical components.

FASTENER AND HOSE TORQUE SPECIFICATIONS

Standard tightening torques for bolts, nuts, and hose fittings.

RECOMMENDED LUBRICANTS AND TYPES

Details on recommended lubricants and their quantities.

LUBRICATION CHART

Visual guide for lubrication points and schedules.

PERIODIC MAINTENANCE

Schedule and procedures for routine maintenance tasks.

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

Schedule for replacing parts and lubricants.

ENGINE SYSTEM

ENGINE OVERVIEW AND MECHANICAL COMPONENTS

Overview of engine general layout, features, connecting rod, and camshaft.

ENGINE CONTROL AND DIAGNOSTICS

System block diagram, EGR valve operation, and diagnosis codes.

ENGINE LUBRICATION AND COOLING SYSTEMS

Details of lubrication system, diagrams, and cooling system overview.

ENGINE ACCESSORY COMPONENTS

Identification and procedures for air cleaner, ducts, fan supports, and drive systems.

ENGINE EXHAUST AND INTAKE SYSTEMS

Information on intercooler, brake cooling oil cooler, torque converter oil cooler, and muffler.

ENGINE OPERATIONAL PROCEDURES

Procedures for fan belt adjustment, fuel system bleeding, and accelerator operation.

ENGINE ASSEMBLY AND DISASSEMBLY

Procedures for removing and installing the engine assembly.