NISSAN Forklift P01 P02 PO1 PO2 series Workshop Service Manual

NISSAN FORKLIFT SERVICE MANUAL & TECHNICAL BULLETIN MODEL P01 & P02 SERIES

( INTRODUCTION This service manual has been prepared to provide necessary information concerning the maintenance and repair procedures for the NISSAN FORKLIFT POI and P02 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 fourteen sections as shown in the following table, which gives the updated symbols. When a revised service manual is issued, this "INTRODUCTION" sheet should be replaced with a revised one. Section Symbol GENERAL INFORMATION (GI) MAINTENANCE (MA) CONTROL SYSTEM (CS) BATTERY & CHARGER (Be) ELECTRICAL SYSTEM (EL) MOTOR MECHANISM (MM) DIFFERENTIAL CARRIER (DF) FRONT AXLE (FA) REAR AXLE (RA) BRAKE SYSTEM (BR) STEERING SYSTEM (ST) HYDRAULIC SYSTEM (HD) LOADING MECHANISM (LM) BODY & FRAME (BF) Printed in Japan Edition: February 1996 Printing: March 2001 (03) Publication No. SM6E.POI2GO

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 SECTION G I CONTENTS HOW TO USE THIS MANUAL 2 Outline of This Manual 2 Technical Term Definitions 3 Manual Illustrations 5 HOW TO READ WIRING DIAGRAMS 6 Description 8 IDENTIFICATION INFORMATION 10 Vehicle Model Classification Number 10 Vehicle Identification Number 11 Identification Plate 11 GENERAL PRECAUTIONS 12 JACKING, TOWING AND L1FTING 15 Jacking 15 Towing (Freeing a stuck vehicle) 16 Lifting 16 TIGHTENING TORQUE OF STANDARD BOLTS 18

HOW TO USE THIS MANUAL \ Outline of This Manual Section Section title Topics symbol How to use this manual, identification information, general GI General information precautions, jacking, lifting, towing and tightening torque of standard bolts. MA Maintenance Inspection, adjustment, part replacement and lubricant replen- ishment Precautions, controller unit inspection and adjustment, meter CS Control system panel, LCD letter display mode description, trouble diagnostic procedures, trouble diagnoses for controller and battery charg- ing systems. BC Battery and battery charger Precautions, battery and battery charger. Precautions, electrical component parts, location of electrical EL Electrical system units, harness layout, fuses, lighting system, meter panel, mis- cellaneous electrical parts and location of optional parts. Service data and specifications, trouble diagnoses and MM Motor mechanism corrections, precautions and preparation, traction motor, hydraulic pump motor, power steering motor and motor inspection. Service data and specifications, trouble diagnoses and DF Differential carrier corrections, precautions and preparation, construction, removal, disassembly, inspection, assembly and installation. Service data and specifications, trouble diagnoses and FA Front axle corrections, precautions and preparation, construction, component parts, hub and axle housing. Service data and specifications, trouble diagnoses and RA Rear axle corrections, precautions and preparation, construction, component parts, removal, inspection, installation and adjustment. Service data and specifications, trouble diagnoses and BR Brake system corrections, precautions and preparation, construction, brake assembly, brake pedal, master cylinder, brake piping and park- ing brake. Service data and specifications, trouble diagnoses and ST Steering system corrections, precautions and preparation, steering wheel, steering column assembly, steering gear box, power cylinder and steering linkage. Service data and specifications, trouble diagnoses and HD Hydraulic system corrections, precautions and preparation, hydraulic piping system, hydraulic pump (gear pump), control valve, control lever, tilt cylinder, lift (mast) cylinder and oil tank. Service data, trouble diagnoses and corrections, precautions LM Loading mechanism and preparation, construction, backrest, lift chain, carriage assembly and mast assembly . . Service data, precautions, construction, removal, installation, BF Forklift body and frame body parts and accessories. This Manual contains the essential information required to perform effective forklift maintenance procedures. All forklift units are included. Informational configuration in the CS (control system) section differs from that of other sections. The CS section introduces how to utilize information in the section. GI-2 )

HOW TO USE THIS MANUAL Outline of This Manual (Cont'd) MAIN TEXT ENTRIES Main text entries describe unit removal, unit disassembly, inspection, unit reassembly, unit installation and adjustment procedures. Step-by-step descriptions are provided for all of these procedures. Together with the step-by-:-step descriptions, other important information is. provided. This information includes service points and tips, basic units and values, required specified tightening torques and required special service tools. Information pertaining to common tools generally found in all maintenance facilities is generally omitted. This information is included in the exploded part views and other drawings as required. OTHER ENTRIES The following information is included at the beginning of all sections as a supplement to the main text. Service data and specifications Adjustment values, part selection information and specified tightening torque values are shown for all procedures described in the main text. Trouble diagnoses and corrections Individual symptoms, probable causes and remedial measures indicated by these symptoms are described. Precautions and preparation • Precautionary and reference information related to the entire section is provided. • Special service tools are required for some maintenance procedures. Special service tool name, tool number and tool application information as well as illustrations depicting tool shapes are included. Technical Term Definitions SPECIFIC TERMS WARNING: Warns you of instructions that must be followed to prevent severe personal injury and/or fatal accident. CAUTION: Warns you of instructions that must be followed to prevent personal injury and/or damage to some parts of the vehicle. NOTE: Provides helpful information to perform a smooth and effective service procedure. Standard value or specifications: The allowable range for a given measured value during inspection and adjustment. Limit value: The maximum or minimum acceptable measured value during inspection and adjustment. GI-3

HOW TO USE THIS MANUAL Technical Term Definitions (Cont'd) MEASURING UNITS AND VALUES Specified torque, pressure, force and other values used in this Manual are primarily expressed as the SI unit (International System of Unit). The values following the SI unit and enclosed in parentheses ( ) are expressed in the metric system and in the yard/pound system. Example: Tightening torque: 9 - 12 N.m (0.9 - 1.2 kg-m, 6.5 - 8.7 ft-Ib) I I I 51 unit Metric system Yard/pound system Main unit conversions Metric Yard/pound Conversion 51 unit factor to 51 system system unit Torque and kg-m - 9.807 N'm moment - ft-Ib 1.356 kg - 9.807 Force N - Ib 4.448 kg/cm 2 - 98.07 kPa - psi 6.895 Pressure kg/cm 2 - 0.0981 MPa - psi 0.0069 NOTE: Converting the unit in metric system or yard/pound system to SI unit is shown below. Unit in metric system or yard/pound system x conversion factor = SI unit GI-4 )

HOW TO USE THIS MANUAL Manual Illustrations EXPLODED VIEWS These contain part names, tightening torques, lubrication points and other information necessary to perform removal, disassembly, repair, reassembly and installation procedures. (See example below.) Backplate Primary shoe ~ : Always replace after every disassembly (OJ : N'm (kg-m, ft-Ib) ~ : Nissan Genuine Liquid Gasket or equivalent EEi!I: Nissan rubber grease .. : Brake grease point Symbols used in exploded views Shoe spring BRTOO05 Symbol Meaning Symbol Meaning Specified tightening torque is required for part (OJ installation. When a torque range is given, use ~ Always replace after every disassembly. the average figure as the standard. EEi!I Should be lubricated with specified grease. * Select parts of proper thickness. f] Should be lubricated with oil. * Adjustment is required. D Sealing point GI-5

:@H E@ C736 H;C;?9 6;39C3>D + KD@J) o o 9H o Jc >@'<N8CFB<'*. o h ) (" ) DWlh dSYW &( o I@>D8B h 9 IM@J:? 7% h 9;'7I3>A=')+ ) CCC (K ("B((0 CC I> BoCFB @ h "!' B> ff+XX[ GG!?; FEM<H FEI@J@ED 5 H<B8O ** o F """"""#' """" 4'FI * , 2 CEJEH :EDJHEBB<H 7 7% ? () 1* f ff JJ f J B' 9 (Jc<B'<N8CFB +!!!!!!!!!!!!!!!!!!!!!!!!!" ''R ppo HWXWf hc cdh[cbS_ gd_[UW( @ @ @ @ ( @ & @ & @ & +- B RR + / F+ ( F*+ acVW_g 74 F*, acVW_g FfWUWV[bY dSYW ... ../ Z[_7 o9 c ,18,1+4 ,1/1./ 6 >@C***, 9;'.

:@H E@ C736 H;C;?9 6;39C3>D @[_SYXKV][VSMO F*+ acVW_g F*, acVW_g >@C***- +*8 a "!' h5A ,1* b >9=5@ K :@; o +*8 a "!' =(:)>I $Q@% B @ ,')" @ B o7 +o@:[__ B @ !V B +,2* ; 9;'/

NISSAN Forklift P01 P02 PO1 PO2 series Workshop Service Manual

You're Reading a Preview

Recently Viewed