Nissan F05 Series Forklifts OEM Service & Repair Manual

SERVICE MANUAL & TECHNICAL BULLETIN MODEL F05 SERIES

INTRODUCTION This service manual has been prepared to provide necessary information concerning the maintenance and repair work on the NISSAN FORKLIFT FOS series. Any changes effected in the series after publication of this service manual will be announced in a technical bulletin. It is, therefore, recommended that each relevant technical bulletin be inserted in front of each section and be used together with the service manual as a reference. If a new model requires different service method or has undergone a major change, revised sections will be issued to replace the applicable sections. Each revised section will include the description of how to service the parts for the former specifications. The publication of a revised section will be announced in the technical bulletin. This service manual consists of twenty-one sections as shown in the following table, which gives the updated symbols. When a revised service manual is issued, this "INTRO- DUCTION" sheet should be replaced with a revised one. Section Symbol GENERAL INFORMATION (GI) MAINTENANCE (MA) ENGINE TUNE-UP (FD6 ENGINE) (ET) ENGINE MECHANICAL (FD6 ENGINE) (EM) ENGINE LUBRICATION SYSTEM (FD6 ENGINE) (EL) COOLING SYSTEM (FD6 ENGINE) (CO) ENGINE FUEL (FD6 ENGINE) (EF) GOVERNOR SYSTEM (FD6 ENGINE) (GO) ENGINE ELECTRICAL (FD6 ENGINE) (EE) ENGINE REMOVAL (ER) AUTOMATIC TRANSMISSION (AT) PROPELLER SHAFT & DIFFERENTIAL CARRIER (PD) FRONT AXLE (FA) REAR AXLE (RA) BRAKE SYSTEM (BR) STEERING SYSTEM (ST) HYDRAULIC SYSTEM (HD) LOADING MECHANISM (LM) ENGINE CONTROL, FUEL & EXHAUST SYSTEMS (FE) BODY & FRAME (BF) BODY ELECTRICAL (BE) Printed in Japan Edition: October 1983 Printing: March 1994 (09) Publication No. SM4E.OF05GO

Revised November 2008 FOREWORD © 2010 NFE B.V. Printed in The Netherlands This manual contains maintenance and repair procedures. In order to assure your safety and the efficient functioning of the lift truck, this manual should be read thoroughly. It is especially important that the PRECAUTIONS in the GI section be completely understood before starting any repair task. All information in this manual is based on the latest product information at the time of publication. The right is reserved to make changes in specifications and methods at any time without notice. IMPORTANT SAFETY NOTICE The proper performance of service is essential for both the safety of the technician and the efficient functioning of the lift truck. The service methods in this Service Manual are described in such a manner that the service may be performed safely and accurately. Service varies with the procedures used, the skills of the technician and the tools and parts available. Accordingly, anyone using service procedures, tools or parts which are not specifically recommended by NISSAN must first be completely satisfied that neither personal safety nor the lift truck's safety will be jeopardized by the service method selected. No modifications or alterations to a powered industrial truck, which may affect, for example, capacity, stability or safety requirements of the truck shall be made without the prior written approval of NISSAN, its authorized representative, or a successor thereof. Contact an authorized NISSAN FORKLIFT dealer before making any modification or alteration to your industrial truck that may affect, for example braking, steering, visibility and the addition of removable attachments. After getting approval of NISSAN, its authorized representative, or a successor thereof, capacity plate, decals tags and operation and maintenance handbooks shall also be changed to the appropriate one. Only in the event that NISSAN is no longer in business and there is no successor in the interest to the business, the user may arrange for a modification or alteration to a powered industrial truck, provided, however, that the user shall: A. Arrange for the modification or alteration to be designed, tested and implemented by an engineer(s) expert in industrial trucks and their safety; B. Maintain a permanent record of the design, test(s) and implementation of the modification or alteration; C. Approve and make appropriate changes to the capacity plate(s), decals, tags and Instruction Handbook; D. Affix a permanent and readily visible label to the truck stating the manner in which the truck has been modified or altered together with the date of the modification or alteration, and the name and address of the organization that accomplished the tasks.

GENERAL INFORMATION (GI) MODEL F05 SERIES CONTENTS GENERAL ViEWS GI-2 MODEL VA R IATION G 1-3 IDENTIFICATION NUMBERS GI-5 EN GIN ESE R IA L NUMBER G 1-5 CHASSIS SERIAL NUMBER GI-5 LIFT TRUCK IDENTIFICATION PLA T E ......................................................... G 1-5 TRANSMISSION SERIAL NUMBER GI-5 LOAD CHART, G 1-5 LIFTING POINTS AND TOWiNG GI-6 APPROXIMATE WEIGHT , GI-6 LIFTING POINTS GI-6 LIFTING UP FORKLIFT TRUCK GI-7 TOWING GI-7 SPECIAL SERVICE TOOLS GI-7 TIGHTENING TORQUE OF STANDARD BOLT GI-8

GENERAL VIEWS GENERAL VIEWS Unit: mm (in) ~ ~ ~ ..- 0- ..- ~ ;:::< 0"": 0 ltlO'l ~ '" ~...!!!. ... <l) > 0 Front tread t~ 0° ~g i i 8;;;; r==-===::bJ 0"- M!: 2,250 E Wheelbase (88.6) Overall length G Unit: mm (in) ---- F05A/N50 F05A/N60 F05A/N70 A. Overall width 1,880 1,990 (78.3) (74.0) B. Overall height 2,505 2,510 (98.8) (98.6) C. Free height 155 (6.1) 160 (6.3) 170 (6.7) D. Min. ground clearance 205 (8.1) 210 (8.3) E. Front overhang 600 (23.6) 605 (23.8) F. Rear overhang 625 (24.6) 685 (27.0) 780 (30.7) G. Overall length 4,695 4,760 4,855 (184.8) (187.4) (191.1) H. Front tread 1,580 1,470(57.9) (62.2) GI-2 ltl- ,...It! MM 'O'l N_ FGI063

MODEL VARIATION MODEL VARIATION ,--, Q ,--, ,--, - - - '-' '-' '-' '-' 0::: 0:::,--, 0::: 0::: ~ ,--, ~ ~ <l) ~ <l) 00 <l) 01 N .~ 01 .~ - .~ - - .... - ... ' <l) Eo-< , lrl lrl_ lrl lrl <l) - - ..0 - .... - t:o .... ~ 6 1-< .;, ~ ' ;:l ;..; , 0 ~ o:l 0 lrl 0 o:l lrl 1-< 0 .~ <l) 01 1-< ~ Cl <l) ~ I.I.. f') ~o::: 00 I.I.. 00,-,0::: 00 ,--, e:: 0::: 0::: o:l .S - <l) ,--, - ,--, lrl ,--, ,.q '-' lrl 0\ lrl 01 - 01 ~ <l) .... - f') - tv"l ~ tv"l .~ <l) ~ v: v: ~ 01 01 "d </J ~ > '1' 01 '-' Eo-< '-' o:l .... \D Eo-< 0 0 0 ~ 0 I I ;..; 0 0\ v: 0\ 0::: 0 ~ '-' o:l v: lrl lrl 1-< <l) \D I.I.. 00 0::: \D * .~ .... 1-< ~ .~ 0\ <l) f') 1-< 1-< f') <l) 1-< 8 o:l ::r: U is ~ .:2 CZJ </J 0 </J lrl 's - </J I.I.. I:: CZJ o:l 01 1-< Eo-< <l) I:: 'bb f') f') f') I:: f') \D f') \D f') \D ~ Cl Cl Cl Cl Cl Cl CZJ I.I.. ~ CZJ I.I.. ~ CZJ I.I.. ~ • o:l <r:"d > > > > > > > > > • o:l CZJ I:: 0 0 0 0 0 0 0 0 0 ~u I I lrl lrl lrl I I \D \D \D I r- r- r- <r: z <r: <r: <r: <r: <r: z <r: 1-< "d lrl lrl lrl lrl lrl lrl lrl lrl lrl 0 I:: 0 0 0 0 0 0 0 0 0 I.I.. o:l I.I.. I.I.. I.I.. Cl I.I.. I.I.. I.I.. I.I.. I.I.. o:l Cl Cl ;:J I.I.. Cl ;:J Cl Cl ;:J "d 0 ::;:s ;:J 1-<"d ;:J ;:J ;:J ...s I:: o:l Eo-< Eo-< ;:J ;:J ;:J Eo-< Eo-< ;:J ;:J ;:J ;:J ;:J ;:J o:l "d 0 0 0 0 0 0 0 0 0 0 0 0 O' .... 0.< o:l lrl lrl lrl lrl lrl \D \D \D \D \D I r- r- r- ~ <r: z <r: z <r: <r: z <r: z <r: <r: z <r: <l) • o:l UCZJ U lrl lrl lrl lrl lrl lrl lrl lrl lrl lrl lrl lrl lrl ~ . 0 0 0 0 0 0 0 0 0 0 0 0 0 ~;:J I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. I.I.. ::;:s ::;:s Cl Cl ;:J ::;:s ::;:s Cl Cl ;:J Cl Cl ;:J .S .S .S 1-< '1' '1' '1' <l) 01 01 01 .... ~ --- --- --- <l) ::9 ::9 ::9 U "d 0 0 0 o:l 0 0 0 j 0" q 0" - f') lrl --- - - - » .t:; U e e e o:l 0. e e e o:l U 0 0 0 co 0 0 0 .S \D \D \D ;; --- --- --- I:: ~ I:: ....I 0 0 0 .... .... .... lrl \D r- GI-3 ....; I:: <l) e .9- ;:l • O"~ <l) <l) <l) "d,.q ~~ "d 1-< I:: <l) o:l .... .... ;:l </J 0 </J o:l "d </J ~ <l) o:l .~ 1-< .... <l) <l) I:: ::0 .S ;:l ,.q 0 .... "d 0 <l) ..0 </J 1-< ;:l ...s </J o:l "d "d <l) </J 0 ;:l e .~ I:: <l) 0 0. .... » ~ .... "d <l) ~ e o:l o:l I:: </J <l) 0 ,.q ... Eo-< \D *

MODEL VARIATION Prefix and suffix designations M F05 A 50 T U L Destination U Except U.S.A. and Canada V U.S.A. & Canada Turbocharger T With turbocharger o Without turbocharger (0 means no indication) Lifting capacity/Load center 50 5 ton/600 mm, 11,000 lb/24 in 60 6 ton/600 mm, 13,000 lb/24 in 70 7 ton/600 mm, 15,000 lb/24 in Transmission model A Power shift transmission N Automatic shift transmission Basic model code F05: 5-ton series Engine model M SD33 (Diesel) D FD6 (Diesel) U P (Gasoline) GI-4

IDENTIFICATION NUMBERS / LOAD CHART IDENTIFICATION NUMBERS ENGINE SERIAL NUMBER FD6 XXXXXX SD33 XXXXXT P KXXXXX CHASSIS SERIAL NUMBER DF05 XXXXXX MF05 XXXXXX UF05 XXXXXX ~065 LOAD CHART LIFT TRUCK IDENTIFICATION PLATE TRANSMISSION SERIAL NUMBER FGI013 GI-5

LIFTING POINTS AND TOWING LIFTING POINTS AND TOWING APPROXIMATE WEIGHT Unit: kg (lb) ~ Weight distribution Truck weight Front Rear DF05A50 3,620 (7,985) 3,955 (8,720) 7,575 (16,705) MF05A50 3,565 (7,860) 3,825 (8,435) 7,390 (16,295) UF05A50 3,550 (7,830) 3,785 (8,345) 7,335 (16,175) DF05A60 3,550 (7,830) 4,675 (.10,305) 8,225 (18,135) MF05A60 3,495 (7,705) 4,550 (10,035) 8,045 (17,740) UF05A60 3,485 (7,685) 4,500 (9,920) 7,985 (17,605) DF05A70 3,535 (7,795) 5,405 (11,920) 8,940 (19,715) UF05A70 3,470 (7,650) 5,230 (11,535) 8,700 (19,185) LI FTING POINTS FRONT SIDE 1. Place chocks behind rear wheels. 2. Lift outer mast with a hoist. 3. Place wooden blocks under both side frames. Gradually lower front end to ground. Be careful not to dislocate blocks while lowering. After supporting lift truck with blocks, swing it back and forth and left and right to see if it is safe. FGI069 GI-6 REAR SIDE 1. Place chocks in front of front wheels. 2. Jack up counterweight or lift counterweight with a hoist. FGI070

3. Place wooden blocks under counterweight. Graudally lower rear end to ground. Be careful not to dislocate blocks while lowering. After supporting lift truck with blocks, swing it back and forth and from side to side to see if it is safe. SPECIAL SERVICE TOOLS LIFTING UP FORKLIFT TRUCK When lifting the entire forklift truck, secure wire ropes to holes on both sides of the outer mast cross beam and to the hook on the counterweight, and then utilize a lifting device. WARNING: • Make sure that the wire ropes do not interfere with the overhead guard while lifting the truck. • Ensure that the wire ropes and lifting device are strong enough to support the lift truck safely, as the lift truck is extremely heavy. TOWING Before towing a lift truck, secure a wire rope to traction pin. Make sure parking brake is released. a. Do not attach towing rope to any points other than those designated. b. To prevent accidents, do not apply load to wire rope abruptly. FGI072 FGI045 SPECIAL SERVICE TOOLS Special Service Tools play very important role in the maintenance of lift truck. These are essential to the safe, accurate and speedy servicing. The working times listed in the column under FLAT RATE TIME in FLAT RATE SCHEDULE are com- pu ted based on the use of Special Serv- ice Tools. The identification code of maintenance tools is made up of 2 alphabeti- calletters and 8-digital figures. The heading two letters roughly classify tools or equipment as: GI-7 STOOOOOOOO: Special Tool KVOOOOOOOO: Special Tool GGOOOOOOOO: General Gauge LMOOOOOOOO: Garage Tool HTOOOOOOOO: Hand Tool

Nissan F05 Series Forklifts OEM Service & Repair Manual

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