Nissan Forklift Internal Combustion L01 Series Service Repair Manual

INTRODUCTION

Thisservicemanualhasbeenpreparedtoprovidenecessaryinformationconcerningthe maintenanceandrepairproceduresfortheNISSANFORKLIFTL01andL02series.

Anychangeseffectedintheseriesafterpublicationofthisservicemanualwillbe announcedinatechnicalbulletin.Itis,therefore,recommendedthateachrelevanttechnical bulletinbeinsertedinfrontofeachsectionandbeusedtogetherwiththeservicemanualasa reference.

Ifanewmodelrequiresdifferentservicemethodorhasundergoneamajorchange,revised sectionswillbeissuedtoreplacetheapplicablesections.Eachrevisedsectionwillincludethe descriptionofhowtoservicethepartsfortheformerspecifications.Thepublicationofa revisedsectionwillbeannouncedinthetechnicalbulletin.

Thisservicemanualconsistsofeightsectionsasshowninthefollowingtable,whichgives theupdatedsymbols.Whenarevisedservicemanualisissued,this‘‘INTRODUCTION” sheetshouldbereplacedwitharevisedone.

SectionSymbol

GENERALINFORMATION(GI)

MAINTENANCE(MA)

ENGINEREMOVAL(ER)

CLUTCH(CL)

MANUALTRANSMISSION(MT)

AUTOMATICTRANSMISSION(AT)

DIFFERENTIALCARRIER(DF)

DRIVEAXLE(DA)

STEERINGAXLE(SA)

ROADWHEEL&TIRE(RT)

BRAKESYSTEM(BR)

STEERINGSYSTEM(ST)

HYDRAULICSYSTEM(HD)

LOADINGMECHANISM(LM)

ENGINECONTROL,FUEL&EXHAUSTSYSTEMS(FE)

VEHICLECONTROLSYSTEMS(VC)

BODY&FRAME(BF)

BODYELECTRICALSYSTEM(BE)

Edition:August2003

Printing:August2003(01)

Publication:SM03E-L012G0

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.

CONTENTS

1. CONSTRUCTION. . . . . . . . . . . . . . . .AT-2

(1) Automatic Transmission . . . . . . . . . .AT-2

(2) Torque Converter . . . . . . . . . . . . . .AT-4

(3)

2.

1. CONSTRUCTION

(1) Automatic Transmission

1. Input plate

2. Torque converter assembly

3. Oil pump assembly

4. Control valve

5. Input shaft (Shaft No. 1)

6. Idler shaft (Shaft No. 2)

7. Output flange (Shaft No. 3)

CONSTRUCTION

The automatic transmission is a single-stage speed change mechanism for both forward and reverse, and power shifting is accomplished with a hydraulic multiple-disc clutch. Furthermore, with the exception of the torque converter and control valve (modulation orifice), it is the same for vehicles ranging from 1 ton to 3.5 tons.

The transmission housing and torque converter housing are split types.

The torque converter is constructed of integrated welded sheet metal, thus, parts are replaced as a unit.

L01/L02

Type3 elements, 1 stage, 2 phases

(2) Torque Converter

1. Turbine runner

2. Stator assembly

3. Input plate

4. Pump impeller

5. Pump boss

6. Clutch hub

7. Drive cover

8. Turbine boss

9. Pilot boss

(3) Automatic Transmission Control

1. Selector lever

2. Inching pedal

3. Cable (inching)

4. Control valve assembly

ATT0210LÅ@X

(4) Automatic Transmission Circuit Diagram

REMOVAL AND INSTALLATION

2. REMOVAL AND INSTALLATION

(1) Removal

1. Remove the engine and transmission (as a unit) from the chassis.

CAUTION

• Refer to ER section for removal and installation of engine and transmission. When performing this task, drain the transmission oil, too.

2. Remove the tightening bolt for the input plate from the torque converter housing upper hole.

3. Disassemble torque converter and transmission assembly from engine.

(2) Installation

1. Join the torque converter and transmission assembly to the engine. Press in fully so that the distance from the end face of the torque converter housing to the mounting face of the input plate is 50 to 55 mm. After the components are joined to the engine, make sure that the clearance between the flywheel and input plate is approximately 1 to 5 mm. If there is no clearance, the engagement of the torque converter and pump gear or spline is unsatisfactory. In such a case, reassemble the components.

2. Using the bolts, join the flywheel and input plate from the torque converter housing upper hole.

CAUTION

• Tighten the bolts alternately, without applying unreasonable force.

3.

(1)

Order

DISASSEMBLY AND ASSEMBLY

Removal of Transmission Accessories

of disassembly

1. Mount LH

2. Mount RH

3. Oil temperature sensor

4. Speed sensor

5. Cable bracket

6. Drain plug (gasket)

7. Oil level gauge

8. Oil pipe, I-joint (gasket)

9. Output flange

10.Filter case, magnet strainer

11.Control valve (gasket)

(2) Removal of Torque Converter Assembly and Pump Assembly

Order of disassembly

Disassembly

• Not all of the oil can be drained into the torque converter, so have an oil pan on hand when removing the torque converter assembly.

• Remove all of the tightening bolts from the oil pump assembly when the removing pump assembly. Remove them as an assembly using the bolts (SST:NF67281-15400) and the extraction bolt holes (M10 x 1.25) of the stator shaft.

1 - 2: Remove as a set.

1. Torque converter assembly

2. Input plate

3. Pump assembly

4. O-ring

DISASSEMBLY AND ASSEMBLY

(3) Removal of Transmission Housing and Output Gear

Order of disassembly

Disassembly

1. Place the torque converter housing side downward, and then remove the mounting bolts from the transmission housing

2. Face the clutch housing surface downward.

3. Remove the servo case assembly. Then using the transmission housing's hoisting equipment screw hole and mounting screw hole, lift the housing with the hoisting equipment.

4. With the wire rope slightly taut, remove the transmission housing by pound74ing uniformly near the dowel pin hole with a plastic hammer.

CAUTION

• Do not remove the steel ball and sealing cap that were tapped into the transmission housing and torque converter housing.

• Inspect the oil seal that was tapped into the transmission housing. Do not disassemble if it appears normal.

1. Servo case assembly (oil seal)

2. Transmission housing (oil seal)

3. Output gear (ball bearing)

4. Torque converter housing

Order of disassembly

(5) Inspection after Disassembly

Transmission housing

• Wear on contact surfaces of seal ring

Magnetic strainer

• Clogging and damage

Idler shaft

• Spline wear and damage

Output flange

• Spline wear and damage

• Damage to sliding surfaces of oil seal

(4) Removal of Input Gear Assembly and Idler Shaft

1. Input gear assembly2. Idler shaft

(6) Assembly

DISASSEMBLY AND ASSEMBLY

Order of assembly

1. Torque converter housing

2. Input shaft assembly

3. Idler shaft

4. Output gear

5. Transmission housing

6. Servo case

7. Pump assembly

8. Control valve

9. Magnetic strainer

10.Output flange

11.Oil pipe

12.Other accessories (drain plug, oil temperature sensor, etc.)

13.Torque converter assembly

DISASSEMBLY AND ASSEMBLY

Note the following, and assemble in the reverse order of disassembly.

Applying grease

• Apply grease to the lip of the transmission housing's oil seal.

Installation of transmission housing

• Lift and assemble the transmission housing by using the same procedure used during removal. When doing so, assemble the transmission assembly with care, because the center of the input shaft will still be unstable.

Installation of oil pump assembly

1. After installing the transmission housing, set the assembly upright and place it in normal condition.

2. Since the input shaft assembly will not be completely in the transmission housing, drive it in from the torque converter housing side with a copper rod or similar instrument.

3. Tighten the torque converter housing's 2 mounting bolts.

4. Apply grease to the O-ring and install it to the torque converter housing. Then install the pump assembly.

Installation of torque converter

1. Aligning the grooves of the transmission stator shaft, input shaft spline, and pump drive gear, and install the torque converter.

2. After installing the torque converter, make sure that the distance from the end face of the torque converter housing to the mounting face of the input plate is within the standard.

• Distance from end face of housing to mounting face of input plate Standard (mm) : 50 - 55

ATT0216L

3. Since the torque converter is only inserted, use wire to tighten part of the input plate to the torque converter housing until the torque converter is installed to the engine.

Filling with transmission oil

• Before filling with transmission oil, mount the transmission and ensure that the engine is in a condition to be started up. Then fill.

• Check the oil level with the level gauge.

• After idling, stop the engine.

• Wait at least one minute after stopping the engine, and then check the level.

• Finish the confirmation procedure within 15 minutes after stopping the engine.

CONTROL VALVE

4.

(1)

Order of disassembly

ATT0217LÅ@W

CONTROL VALVE

Disassembly (1)

1. Solenoid valve

2. Breather

3. Plug (O-ring)

4. Plug (O-ring)

5. Spring pin

6. Inching rod plate

7. Inching lever (retainer, bushing)

8. Plug (O-ring)

9. Main orifice

10.Breather cover

11.Valve plate (gasket)

(2) Disassembly (2)

Order of disassembly

12.Strainer (O-ring)

13.Inching plug (O-ring)

14.Inching stopper

15.Inching spring

16.Inching rod

17.Inching valve spring

18.Inching valve

19.Return spring

20.Inching sleeve

21.Oil seal

22.Snap ring

23.Snap ring

24.Accumulator spring seat (O-ring)

25.Inner spring

26.Outer spring

27.Accumulator piston

28.Snap ring

29.Accumulator plug (O-ring)

30.Snap ring

31.Main spring seat (O-ring)

32.Main relief spring (thin)

33.Main relief spring (thick)

34.Regulator valve

35.Slug

36.Snap ring

37.Main relief plug

Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL.NOWAITING

NOTE:

If there is no response to click on the link above, please download the PDF document first and then clickonit.

CONTROL VALVE

(3) Inspection after Disassembly

Valve housing

• Check each oil hole for clogging.

Valve

• Check for wear and damage, and make sure that sliding surfaces are smooth.

• Check small holes for clogging.

Spring

• Check for fatigue and damage.

Oil seal

• Check the lip for damage.

(4) Assembly (1)

Order of assembly

1. Main relief plug

2. Snap ring

3. Slug

4. Regulator valve

5. Main relief spring (thick)

6. Main relief spring (thin)

7. Main spring seat (O-ring)

8. Snap ring

9. Accumulator plug (O-ring)

10.Snap ring

11.Accumulator piston

12.Outer spring

13.Inner spring

CONTROL VALVE

14.Accumulator spring seat (O-ring)

15.Snap ring

16.Snap ring

17.Oil seal

18.Inching sleeve

19.Return spring

20.Inching valve

21.Inching valve spring

22.Inching rod

23.Inching spring

24.Inching stopper

25.Inching plug (O-ring)

26.Strainer (O-ring)

• Thoroughly clean the valve housing's hydraulic lines. Assemble after confirming that there is no clogging.

•

plug