Toyota 50-4FD100, 50-4FDK150, 160 Repair 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. )

SECTION INDEX

NAME SECTION

GENERAL ENGINE TORQUE CONVERTER & TRANSMISSION PROPELLER SHAFT FRONT AXLE & DIFFERENTIAL REAR AXLE STEERING BRAKE BODY MATERIAL HANDLING SYSTEM MAST

CYLINDER OIL PUMP OIL CONTROL VALVE HYDRAULIC PIPING OPS APPENDIX

GENERAL

0-1

Page

VEHICLE EXTERIOR VIEWS

VEHICLE MODEL........................................................... 0-4

FRAME NUMBER........................................................... 0-4

HOW TO USE THIS MANUAL .................................... 0-5

EXPLANATION METHOD ............................................... 0-5

TERMINOLOGY............................................................... 0-6

ABBREVIATIONS ............................................................ 0-6

OPERATING TIPS.......................................................... 0-7

GENERAL........................................................................ 0-7

JACKING UP ................................................................... 0-8

HOISTING THE VEHICLE ............................................... 0-9

WIRE ROPE SUSPENSION ANGLE LIST ...................... 0-10

SAFE LOAD FOR EACH WIRE ROPE

SUSPENSION ANGLE.................................................. 0-11

MEMBER WEIGHTS........................................................ 0-11

ELECTRICAL PARTS INSPECTION............................... 0-14

...................................... 0-2

BOLT & NUT TIGHTENING TORQUE ...................... 0-15

BOLT STRENGTH CLASS IDENTIFICATION

METHOD AND TIGHTENING TORQUE ....................... 0-15

HEXAGON FLANGE BOLT TIGHTENING TORQUE ..... 0-17

PRECOATED BOLTS (BOLTS WITH

SEAL LOCK AGENT COATING ON

THREADS)..................................................................... 0-17

HIGH PRESSURE HOSE FITTING

TIGHTENING TORQUE ............................................. 0-18

RECOMMENDED LUBRICANT

QUANTITY & TYPES.................................................. 0-19

LUBRICATION CHART................................................. 0-20

PERIODIC MAINTENANCE......................................... 0-21

PERIODIC REPLACEMENT OF PARTS AND

LUBRICANTS ............................................................... 0-26

0-2

VEHICLE EXTERIOR VIEWS

HEADGUARD MODEL

CABIN MODEL

0-3

0-4

VEHICLE MODEL

Payload Vehicle model Standard load center Engine model

10 ton 50-4FD100

11.5 ton 50-4FD115

12 ton 50-4FD120

13.5 ton 50-4FD135

15 ton 50-4FDK150

16 ton 50-4FDK160

FRAME NUMBER

Vehicle model Punching format

50-4FD100

4FD120-5001150-4FD115

50-4FD120

50-4FD135

4FDK160-5001150-4FDK150

600 mm (23.6 in)

J08E-UM

50-4FDK160

Punching position

Upper LH side of frame

HOW TO USE THIS MANUAL

EXPLANATION METHOD

1. Operating procedure

Description example

0-5

DISASSEMBLY

•The numbers may partially be omitted in the

illustration.

•INSPECTION•REASSEMBLY

Tightening torque unit → N•m (kgf•cm) [ft•lbf]

T = 46.1 to 48.1

(470 to 490) [34.0 to 35.4]

Disassembly Procedure

1 Remove the cover. [Point 1]

2 Remove the bushing. [Point 2]

3 Remove the gear.

Point Operations

[POINT 1]

Disassembly:

Make match marks before removing the pump cover.

[POINT 2]

Inspection:

Measure the bushing inside diameter.

Limit: 19.12 mm

Explanation of operation point with illustration

Operation to be explained

Explanation of abbreviations used for

point operations Removal Reassembly Installation Adjustment Disassembly Inspection

0-6

2. Matters omitted from this manual This manual omits descriptions of the following jobs, but perform them in actual operation:

(1) Cleaning and washing of removed parts as required

(2) Visual inspection (partially described)

TERMINOLOGY

Caution: Important matters, negligence of which may cause accidents. Be sure to observe them.

Note: Important matters, negligence of which may cause failures, or matters in operation procedure requiring special attention. Standard: Value showing the allowable range in inspection or adjustment. Limit: The maximum or minimum value allowed in inspection or adjustment.

ABBREVIATIONS

Abbreviation Meaning Abbreviation Meaning

ASSY Assembly SAE

LH Lefthand SAS System of Active Stability

LLC Long Life Coolant SST Special Service Tool

L/ Less STD Standard

M/T Manual Transmission T/C Torque Converter & Transmission

OPT Option T= Tightening Torque

O/S Oversize T Number of teeth ( T)

PS Power Steering U/S Undersize

RH Righthand W/ With

Society of Automotive Engineers

(USA)

OPERATING TIPS

GENERAL

1. Safe operation

(1) After jacking up, always support the vehicle with wooden blocks and rigid stands.

(2) When hoisting the vehicle, use wire ropes with sufficient reserve in load capacity.

(3) Always disconnect the battery plug before the inspection or servicing of electrical parts.

(4) The operator must always extract and carry the engine key when entering the area under the

vehicle.

(5) When 2 or more persons work as a group, always assign an instructor and operate according to his

instructions.

2. Tactful operation

(1) Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure

gauge, etc.) and SSTs before starting operation.

(2) Check the cable color and wiring state before disconnecting any wiring.

(3) When overhauling functional parts, complicated sections or related mechanisms, arrange the parts

neatly to avoid confusion.

0-7

(4) When disassembling and inspecting a precision part such as the control valve, use clean tools and

operate in a clean location.

(5) Always follow the specified operation steps for disassembly, inspection, reassembly and

adjustment.

(6) Always replace gaskets, packing, O-rings, self-locking nuts and cotterpins with new ones whenever

they are disassembled.

(7) Use genuine Toyota parts for replacement.

(8) Use specified bolts and nuts and observe the specified tightening torque when reassembling.

(Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the "standard tightening torque table".

3. Defect status check Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect.

4. Waste fluid disposal Always use a proper container to collect draining waste fluid from the vehicle. Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort them well, and ask specialized companies for appropriate disposal.

0-8

JACKING UP

When jacking up the vehicle, always observe the following instructions.

• When the fork is loaded, unload it and park the vehicle on a flat surface. Do not park on an inclined or rough ground.

• Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous.

• Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the vehicle only with the jack is very dangerous.

• Never, under any circumstances, put any part of the body (including hands and feet) under the jackedup vehicle.

Reference weight

kg (lb)

Vehicle model

Vehicle overall weight

Front axle load W/mast ASSY

Rear wheel load W/mast ASSY

Flat spaces for front axle installation

50-

4FD100

13570

(29916)

6860

(15124)

6710

(14793)

50-

4FD115

14650

(32297)

6970

(15366)

7680

(16931)

50-

4FD120

15120

(33334)

6950

(15322)

8170

(18012)

Main frame

50-

4FD135

16040

(35362)

7750

(17086)

8290

(18276)

50-

4FDK150

18070

(39837)

8630

(19026)

9440

(20811)

50-

4FDK160

18630

(41072)

8580

(18915)

10050

(22156)

Front axle center portion

Rear ends of counterweight

: Jack-up point

: Positions for supporting with stands

0-9

When the mast ASSY is installed on the vehicle, it is also possible to jack up the front side of the vehicle as follows:

1. Lift the lift bracket to a height not obstructing operation.

2. Place wooden blocks and a plate under the outer mast.

3. Tilt the mast forward to raise the front of the vehicle.

Plate Wooden block

4. Support the flat spaces of the front axle mounting portion with stands.

HOISTING THE VEHICLE

Always hoist the vehicle as specified in the specified position. Never hoist by any other attachment section as it is very dangerous.

Caution: Hoist the vehicle only for loading/unloading at the time of vehicle shipment. Do not hoist the vehicle while ordinary servicing jobs.

0-10

WIRE ROPE SUSPENSION ANGLE LIST

Lifting

angle

0°

30°

Tension

1.00 time

1.04 time

Com-

pression

Suspension

method

Lifting

angle

0 time 90°

1 tf

2 t

30°

0.27 time

2 t

120°

Tension

1.41 time

2.00 time

Com-

pression

1.00 time

1.73 time

Suspension

method

90°

2 t

120°

2 t

60°

1.16 time

0.58 time

60°

2 t

SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE

0-11

Unit: N (tf) [lbf]

Rope

diameter

6 mm

(0.24 in)

8 mm

(0.32 in)

10 mm (0.4 in)

12.5 mm (0.5 in)

14 mm

(0.56 in)

Cutting

load

21380

(2.18)

[4807]

31480

(3.21)

[7078]

49230

(5.02)

[11.69]

76880

(7.84)

[17387]

96400

(9.83)

[21675]

Single-rope suspension

(0.31)

[683.6]

(0.45)

[992.3]

(0.71)

[1565.6]

10980

(1.12)

[2469.5]

13730

[3087]

MEMBER WEIGHTS

Two-rope suspension Four-rope suspension

0° 0° 30° 60° 90° 0° 30° 60° 90°

3040

4410

6960

(1.4)

6080

(0.62)

[1367]

8830

(0.9)

[1985]

14020

(1.43)

[3153]

21570

(2.2)

[4851]

27460

(2.8)

[6174]

5880

(0.6)

[1323]

8530

(0.87)

[1918]

13440

(1.37)

[3021]

21280

(2.1)

[4631]

26480

(2.7)

[5954]

5200 (0.53) [1169]

7650 (0.78)

[1720]

11770

(1.2)

[2646]

18630

(1.9)

[4190]

23540

(2.4)

[5292]

4310

(0.44)

[970]

6280 (0.64) [1411]

9810

(1.0)

[2205]

14710

(1.5)

[3308]

18630

(1.9)

[4190]

12160

(1.24)

[2734]

17650

(1.8)

[3969]

27460

(2.8)

[6174]

43150

(4.4)

[9702]

54920

(5.6)

[12348]

11770

(1.2)

[2646]

17060 (1.74) [3937]

26480

(2.7)

[5954]

41190

(4.2)

[9261]

52960

(5.4)

[11907]

10400

(1.06)

[2337]

15300

(1.56)

[3440]

23540

(2.4)

[5292]

37270

(3.8)

[8379]

47070

(4.8)

[10584]

8630

(0.88)

[1940]

12550

(1.28)

[2322]

19610

(2.0)

[4410]

29420

(3.0)

[6615]

37270

(3.8)

[8379]

Vehicle weight

kg (lb)

Weight

Specifications

Headguard Mast V mast, lifting height: 3000 Fork length: 1220 mm Attachment A31

Weight increase when the attachment is installed

50-

4FD100

13420

(29585)

50-

4FD115

14500

(32000)

50-

4FD120

14970

(33000)

50-

4FD135

15890

(35030)

50-

4FDK150

17920

(39510)

50-

4FDK160

18480

(40740)

kg (lb)

Weight

Attachment type

50-4FD100 50-4FD115 50-4FD120 50-4FD135

A35 110 (243) 150 (331) 150 (331) 160 (353) 100 (220) 100 (220)

E3 490 (1080) 530 (1168) 530 (1168) 590 (1300) 450 (992) 450 (992)

E3A35 530 (1168) 560 (1235) 560 (1235) 620 (1367) 480 (1058) 480 (1058)

50-

4FDK150

50-

4FDK160

Weight increase when the cabin air conditioner is installed: 230 kg

0-12

Mast weight (including lift bracket and excluding the fork)

kg (lb)

Mast type

Lifting height

mm (in)

3000 (118)

3300 (130)

3500 (138)

3700 (146)

4000 (157)

4500 (177)

5000 (197)

5500 (217)

6000 (236)

Mast ASSY weight

50-4FD100 50-4FD115 50-4FD120 50-4FD135

2560

(5644)

2620

(5776)

2660

(5864)

2700

(5952)

2760

(6085)

2930

(6459)

3050

(6724)

3160

(6967)

3230

(7121)

2650

(5842)

2720

(5997)

2770

(6107)

2820

(6217)

2890

(6371)

3070

(6768)

3240

(7143)

3380

(7452)

3500

(7716)

2650

(5842)

2720

(5997)

2770

(6107)

2820

(6217)

2890

(6371)

3070

(6768)

3240

(7143)

3380

(7452)

3500

(7716)

2920

(6437)

3000

(6614)

3060

(6746)

3100

(6834)

3200

(7055)

3360

(7407)

3570

(7870)

3720

(8201)

3850

(8488)

50-

4FDK150

3730

(8223)

3830

(8444)

3900

(8598)

3940

(8686)

4130

(9105)

4280

(9436)

4540

(10009)

4690

(10340)

4830

(10648)

50-

4FDK160

3730

(8223)

3830

(8444)

3900

(8598)

3940

(8686)

4130

(9105)

4280

(9436)

4540

(10009)

4690

(10340)

4830

(10648)

FSV

3000 (118)

3500 (138)

4000 (157)

4500 (177)

5000 (197)

4000 (157)

5000 (197)

6000 (236)

2610

(5754)

2730

(6019)

2850

(6283)

2990

(6592)

3180

(7011)

3080

(6790)

3310

(7297)

3710

(8179)

3550

(7826)

3800

(8377)

4220

(9303)

3550

(7826)

3800

(8377)

4220

(9303)

3810

(8400)

4080

(8995)

4520

(9965)

Fork weight

0-13

kg (lb)

Fork length

mm (in)

1220

(48.0)

1370

(53.9)

1520

(59.8)

1670

(65.7)

1820

(71.7)

2440

(96.1)

50-4FD100 50-4FD115 50-4FD120 50-4FD135

370

(816)

390

(860)

410

(904)

430

(948)

450

(992)

600

(1323)

Member weights

Member name

50-

4FD100

Engine ASSY 520 (1146)

Torque converter & transmission ASSY

Front axle

Counterweight

455 (1000)

1075

(2370)

3860

(8510)

Cabin ASSY 550 (1212)

410

(904)

430

(948)

450

(992)

470

(1036)

500

(1102)

670

(1477)

4FD115

4720

(10405)

Weight (for 2 forks)

410

(904)

430

(948)

450

(992)

470

(1036)

500

(1102)

670

(1477)

470

(1036)

500

(1102)

520

(1146)

550

(1213)

570

(1257)

730

(1609)

50-

4FDK150

470

(1036)

500

(1102)

520

(1146)

550

(1213)

570

(1257)

730

(1609)

50-

4FDK160

520

(1146)

550

(1213)

580

(1279)

610

(1345)

630

(1389)

810

(1786)

kg (lb)

Weight

50-

←←←←←

←←←←

50-

4FD120

5180

(11420)

50-

4FD135

5420

(11950)

50-

4FDK150

6640

(14640)

50-

4FDK160

7080

(15610)

←

Rear axle ASSY 710 (1565) ←←←←←

Tilt Cylinder 40 (88)

Lift Cylinder 90 (198)

Oil pump 35 (77)

Oil control valve 75 (165)

←←←←← ←←←←← ←←←←← ←←←←←

0-14

ELECTRICAL PARTS INSPECTION

1. Always disconnect the battery plug before inspecting or servicing electrical parts.

2. Pay sufficient attention when handling electronic parts.

(1) Never subject electronic parts, such as computers

and relays, to impact.

(2) Never expose electronic parts to high temperature or

moisture.

(3) Do not touch connector terminals, as they may be

deformed or damaged due to static electricity.

3. Use a circuit tester that matches the object and purpose of measurement.

Analog type: This type is convenient for observing movement during operation and the operating

condition. The measured value is only for reference or guideline.

Digital type: A fairly accurate reading is possible. However, it is difficult to observe operation or

movement.

1 Difference between results of measurement with analog and digital types

* The results of measurements using the analog type and the digital type may be different. Use the circuit tester according to its instruction manual. Differences between the polarities of the analog type and the digital type are described below.

(1) Analog circuit tester

Forward Reverse

Black tester probe

Red tester probe

(2) Digital circuit tester

Forward Reverse

Red tester probe

Black tester probe

Example of measurement result Tester range: kΩ range

Forward direction: Continuity 11 kΩ Reverse direction: No continuity ∞

Black tester probe

Example of measurement result Tester range: 2 MΩ

Forward direction: Continuity 2 MΩ Reverse direction: No continuity

Red tester probe

0-15

BOLT & NUT TIGHTENING TORQUE

Standard bolt & nut tightening torque

Tightening torques of standard bolts and nuts are not indicated throughout the manual. Use the charts and table below to judge the standard tightening torque.

1. Judge the tightening torque for the hexagon head bolt, welded bolt or stud bolt having the standard bearing surface according to the tightening torque table by identifying the bolt strength class from the table below.

2. Judge the tightening torque for the hexagon flange bolt based on the threading diameter.

3. The nut tightening torque can be judged from its corresponding bolt type.

BOLT STRENGTH CLASS IDENTIFICATION METHOD AND TIGHTENING TORQUE

Identification by actual part

Type Shape and class Class

4 = 4T 5 = 5T

Number in relief or hallmark on the head

6 = 6T 7 = 7T 8 = 8T

No mark 4T

Hexagon head bolt (standard)

Welded bolt 4T

Stud bolt

Bolt with two raised lines on head 5T

Bolt with three raised lines on head 7T

Bolt with four raised lines on head 8T

No mark 4T

2 mm groove(s) on one/both edge(s) 6T

+ 39 hidden pages