Toyota 50-4FDK160 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 50-4FDK160 Specifications

General

Model	50-4FDK160
Load Capacity	16000 lbs
Mast Type	3-Stage
Overall Length	158.9 in
Overall Width	82.7 in
Overall Height	98.4 in
Weight	22928 lb
Fuel Type	Diesel
Transmission	Automatic
Tire Type	Pneumatic
Load Center	24 in
Power Type	Internal Combustion

Summary

GENERAL

Vehicle Lifting and Hoisting Procedures

Instructions and safety precautions for jacking up and hoisting the vehicle.

Wire Rope Suspension and Load Data

Electrical Parts Inspection Methods

Bolt Tightening Torque and Strength Identification

Information on judging tightening torque based on bolt strength class and diameter.

High Pressure Hose Fitting Torque

Lubricant Recommendations and Chart

List of recommended lubricants, types, quantities, and a lubrication chart.

Periodic Maintenance Schedule

Schedule for inspection, repair, and replacement of steering, brake, and drive unit components.

ENGINE

Engine System Block Diagram

Illustrates the electrical and control system connections for the engine ECU.

EGR Valve Operation and Control

Engine Lubrication System Description and Diagram

Explains oil flow, pressure control, safety valves, and provides a lubrication system diagram.

Cooling System Overview and Components

Oil Coolers and Muffler Components

Accelerator Components and Fan Belt Adjustment

Fuel System Air Bleeding Procedure

Engine Assembly Removal and Installation

Detailed steps for removing and installing the engine assembly, including specific operations.