Toyota 50-4FD120 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 50-4FD120 Specifications

General

Brand	Toyota
Model	50-4FD120
Category	Forklifts
Language	English

Summary

FOREWORD

GENERAL INFORMATION AND OPERATION

VEHICLE EXTERIOR VIEWS

Illustrates external views of the forklift, including headguard and cabin models.

HOW TO USE THIS MANUAL

Explains manual structure, explanation methods, terminology, and abbreviations for effective use.

OPERATING TIPS

Provides guidance on safe and tactful operation, defect checking, and waste fluid disposal.

JACKING AND HOISTING PROCEDURES

Outlines safe procedures for jacking up and hoisting the vehicle, including support and precautions.

WEIGHT AND LOAD CAPACITY DATA

Lists member weights, safe load for wire ropes, and forklift weights.

ELECTRICAL AND TORQUE SPECIFICATIONS

Covers electrical inspection, bolt tightening torques, and hose fitting torques.

PERIODIC MAINTENANCE SCHEDULES

STEERING AND BRAKE SYSTEM MAINTENANCE

Details inspection and maintenance for steering and brake system components like valves, hoses, and wheels.

DRIVE UNIT AND TRANSMISSION MAINTENANCE

Covers maintenance for axles, wheels, transmission, torque converter, and differential.

ELECTRICAL AND HYDRAULIC SYSTEM MAINTENANCE

Outlines maintenance for electrical systems, battery, wiring, and hydraulic components.

MATERIAL HANDLING AND SAFETY SYSTEM MAINTENANCE

Details maintenance for mast, lift bracket, chains, and safety devices like horn and lighting.

PERIODIC REPLACEMENT OF PARTS AND LUBRICANTS

ENGINE OIL AND FILTER REPLACEMENT

Specifies replacement cycles for engine oil and oil filters for new and used vehicles.

COOLANT AND FUEL SYSTEM REPLACEMENT

Details replacement intervals for engine coolant, air cleaner element, and fuel filter/hose.

TRANSMISSION AND HYDRAULIC SYSTEM REPLACEMENT

Covers replacement cycles for transmission oil, filters, hoses, and hydraulic oil.

BRAKE SYSTEM REPLACEMENT

Outlines replacement schedules for brake system parts like hoses, air dryer, and cooling oil.

ENGINE SYSTEMS AND COMPONENTS

ENGINE OVERVIEW AND SPECIFICATIONS

Provides general information, features, and structure of the engine, including key components.

ENGINE SYSTEMS: LUBRICATION AND COOLING

Describes the engine's lubrication and cooling systems, including diagrams and component details.

ENGINE AIR INTAKE AND EXHAUST COMPONENTS

Covers air cleaner, intercooler, muffler, and related support structures.

ENGINE DRIVE AND FUEL SYSTEMS

Details fan belt adjustment procedures and bleeding air from the fuel system.

ENGINE ASSEMBLY AND MAJOR SUBSYSTEMS

Covers ducts, fan drive, coolers, accelerator, and the engine assembly removal/installation.