Nissan F04 Series Forklift Internal Combustion & S6S Engine Diesel Gas/LPG TB45 GM 4.3L Workshop Service Repair Manual

SERVICE MANUAL & TECHNICAL BULLETIN SERVICE MANUAL & TECHNICAL BULLETIN GM 4.3 Engine Manual (LPG) Model F04 series

Foreword This service manual is a guide to servicing of Nissan forklift trucks. The instructions are grouped by system. The long, productive life of fork lift trucks depends upon correct servicing as described in this service manual. Carefully read the respective sections of this manual. Know all the components before attempting to test, repair or rebuild a part or system. Whenever a question arises regarding this engine, or this manual, consult your Nissan forklift truck dealer for the latest available information. Notes, Cautions, and Warnings NOTES, CAUTIONS, and WARNINGS are used in this manual to emphasize important and critical instructions. They are used for the following conditions: To highlight an essential operating procedure or condition. Operating procedures or practices that will result in damage to or destruction of the engine if not strictly observed. Operating procedures or practices that will result in serious injury or loss of life if not correctly followed. NOTE CAUTION ! WARNING !

WARNING ! WARNING ! The OPERATION & MAINTENANCE MANUAL outlines the proper and safe lubrication and maintenance for the machine, as recommended by Nissan. Read and understand the OPERATION & MAINTENANCE MANUAL before performing any lubrication or maintenance. Improperly performed lubrication or maintenance procedures are dangerous and could result in injury or death. Because the service mechanic may be unfamiliar with many of the systems on this machine it is important to use caution when performing service work. Knowledge of the system and/or components is important before the removal or disassembly of any component. Because of the size of some of the machine components, the service mechanic should check the weights noted in this Manual. Use proper lifting procedures when removing any components. Following is a list of basic precautions that should always be observed. 1. Read and understand all warning plates and decals on the machine before operating, lubricating or repairing the part or system. 2. Always wear protective glasses and protective shoes when working around machines. In particular, wear protective glasses when pounding on any part of the machine or its attachments with a hammer or sledge. Use welder's gloves, hood/goggles, apron and other protective clothing appropriate to the welding job being performed. Do not wear loose-fitting or torn clothing. Remove all rings from fingers when working on machinery. 3. Do not work on any machine that is supported only by lift jacks or a hoist. Always use blocks or jack stands to support the machine before performing any disassembly. 4. Lower the forks or other implements to the ground before performing any work on the machine. If this cannot be done, make sure the forks or other implements are blocked correctly to prevent them from dropping unexpectedly. Do not operate this machine unless you have read and understand the instructions in the OPERATOR’S MANUAL. Improper machine operation is dangerous and could result in injury or death. 5. Use steps and grab handles (if applicable) when mounting or dismounting a machine. Clean any mud or debris from steps, walkways or work platforms before using. Always face machine when using steps, ladders and walkways. When it is not possible to use the designed access system, use ladders, scaffolds, or work platforms to perform safe repair operations. 6. To reduce the risk of back injury, use hoist when lifting components which weigh 23 kg (50 lb.) or more. Make sure all chains, hooks, slings, etc., are in good condition and are of the correct capacity. Be sure hooks are positioned correctly. Lifting eyes are not to be side loaded during a lifting operation. 7. To reduce the risk of burns, be alert for hot parts on machines which have just been stopped and have hot fluids in lines, tubes and compartments. 8. Be careful when removing cover plates. Gradually back off the last two bolts or nuts located at opposite ends of the cover or device and pry cover loose to relieve any spring or other pressure before completely removing the last two bolts or nuts. 9. Be careful when removing filler caps, breathers and plugs on the machine. Hold a rag over the cap or plug to prevent being sprayed or splashed by liquids under pressure. The danger is even greater if the machine has just been stopped because fluids can be hot. 10. Always use tools that are in good condition and understand how to correctly use them before performing any service work. 11. Reinstall all fasteners with same part number. Do not use a lesser quality fastener if replacements are necessary. Do not mix metric fasteners with standard nuts and bolts. 12. If possible, make all repairs with the machine parked on a level, hard surface. Block the machine so it does not roll while working on or under it. 13. Disconnect battery and discharge any capacitors (electric trucks) before starting to work on the machine. Hang “Do Not Operate” tag in the Operator’s Compartment.

14. Repairs which require welding should be performed only with the benefit of the appropriate reference information and by personnel adequately trained and knowledgeable in welding procedures. Determine the type of metal being welded and select correct welding procedure and electrodes, rods or wire to provide a weld metal strength equivalent at least to that of parent metal. 15. Do not damage wiring during removal operations. Do not reinstall damaged wiring. Reinstall the wiring so it will not be damaged in operation by contacting sharp corners, or by rubbing against an object or hot surface. Do not connect wiring to a line containing fluid. 16. Be sure all protective devices, including guards and shields, are properly installed and functioning correctly before starting a repair. If a guard or shield must be removed to perform the repair work, use extra caution. 17. When the mast needs to be in the raised position during maintanance and repairs, always support the mast and carriage to keep the carriage or attachments raised. 18. Loose or damaged fuel, lubricant and hydraulic lines, or tubes and hoses can cause fires. Do not bend or strike high pressure lines or install ones that are bent or damaged. Inspect lines, tubes and hoses carefully. Do not check for leaks with your hands. Pin hole (very small) leaks can result in a high velocity oil stream that will be invisible upon close inspection of the hose. This oil can penetrate the skin and cause serious injury. Use cardboard or paper to locate pin hole leaks. 19. Tighten connections to the correct torque. Make sure all heat shields, clamps and guards are installed correctly to avoid excessive heat, vibration or rubbing against other parts during operation. Shields must be correctly installed if they protect against oil spray onto hot exhaust components in the event of a line, tube, or seal failure. 20. Relieve all pressure in air, oil or water systems before any lines, fittings or related items are disconnected or removed. Always make sure all raised components are blocked correctly. Be alert for possible pressure when disconnecting any device from a system that uses pressure. 21. Do not operate a machine if any rotating part is damaged or contacts any other part during operation. Any high speed rotating component that has been damaged or altered should be checked for balance before reusing. 22. Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health. If dust containing asbestos is present, there are several common sense guidelines that should be followed. a. Never use compressed air for cleaning. b. Avoid brushing or grinding asbestos containing materials. c. For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter. d. Use exhaust ventilation on permanent machining jobs. e Wear an approved respirator if there is no other way to control the dust. f. Comply with applicable rules and regulations for the work place. g. Follow environmental rules and regulations for disposal of asbestos. h. Avoid areas where asbestos particles may be in the air.

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Nissan F04 Series Forklift Internal Combustion & S6S Engine Diesel Gas/LPG TB45 GM 4.3L Workshop Service Repair Manual

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