SERVICE MANUAL & TECHNICAL BULLETIN Model L01/L02 series
INTRODUCTION This service manual has been prepared to provide necessary information concerning the maintenance and repair procedures for the NISSAN FORKLIFT L01 and L02 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 eight 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)
ENGINE REMOVAL
(ER)
CLUTCH
(CL)
MANUAL TRANSMISSION
(MT)
AUTOMATIC TRANSMISSION
(AT)
DIFFERENTIAL CARRIER
(DF)
DRIVE AXLE
(DA)
STEERING AXLE
(SA)
ROAD WHEEL & TIRE
(RT)
BRAKE SYSTEM
(BR)
STEERING SYSTEM
(ST)
HYDRAULIC SYSTEM
(HD)
LOADING MECHANISM
(LM)
ENGINE CONTROL, FUEL & EXHAUST SYSTEMS
(FE)
VEHICLE CONTROL SYSTEMS
(VC)
BODY & FRAME
(BF)
BODY ELECTRICAL SYSTEM
(BE) Edition: August 2003 Printing: August 2003 (01) Publication: SM03E-L012G0
Printed in Japan
FOREWORD 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.
Š 2010 NFE B.V.
Printed in The Netherlands
Revised November 2008
ëçÅ@ê‡ AUTOMATIC TRANSMISSION ÉÅÉìÉeÉiÉìÉX ÉGÉìÉWÉìíEíÖ SECTION ÉNÉâÉbÉ` É}ÉjÉÖÉAÉãÉgÉ ÉIÅ[ÉgÉ}É`ÉbÉN ÉfÉtÉ@ÉåÉìÉVÉ ÉtÉçÉìÉgÉAÉNÉ ÉäÉÑÉAÉNÉXÉã ÉçÅ[ÉhÉzÉCÅ[É ÉuÉåÅ[ÉLÉVÉXÉ ÉXÉeÉAÉäÉìÉOÉ ÉnÉCÉhÉçÉäÉb ÉçÅ[ÉfÉBÉìÉOÉ
AT
CONTENTS
1. CONSTRUCTION . . . . . . . . . . . . . . . .AT- 2 (1) Automatic Transmission . . . . . . . . . .AT- 2 (2) Torque Converter . . . . . . . . . . . . . .AT- 4 (3) Automatic Transmission Control . . . .AT- 5 (4) Automatic Transmission Circuit Diagram . . . . . . . . . . . . . . . .AT- 6 2. REMOVAL AND INSTALLATION . . . .AT- 7 (1) Removal . . . . . . . . . . . . . . . . . . . . .AT- 7 (2) Installation . . . . . . . . . . . . . . . . . . . .AT- 7 3. DISASSEMBLY AND ASSEMBLY . . .AT- 8 (1) Removal of Transmission Accessories. . . . . . . . . . . . . . . . . . .AT- 8 (2) Removal of Torque Converter Assembly and Pump Assembly . . . . . . . . . . . .AT- 9 (3) Removal of Transmission Housing and Output Gear . . . . . . . . . . . . . . . . . .AT-10 (4) Removal of Input Gear Assembly and Idler Shaft . . . . . . . . . . . . . . . . . . . .AT-11 (5) Inspection After Disassembly . . . . . .AT-11 (6) Assembly . . . . . . . . . . . . . . . . . . . .AT-12
4. CONTROL VALVE . . . . . . . . . . . . . . . AT-14 (1) Disassembly (1) . . . . . . . . . . . . . . . AT-14 (2) Disassembly (2) . . . . . . . . . . . . . . . AT-15 (3) Inspection After Disassembly . . . . . AT-16 (4) Assembly (1) . . . . . . . . . . . . . . . . . AT-17 (5) Assembly (2) . . . . . . . . . . . . . . . . . AT-19 5. INPUT SHAFT ASSEMBLY . . . . . . . . AT-21 (1) Disassembly . . . . . . . . . . . . . . . . . . AT-21 (2) Inspection After Disassembly . . . . . AT-23 (3) Assembly . . . . . . . . . . . . . . . . . . . . AT-24 6. OIL PUMP ASSEMBLY . . . . . . . . . . . AT-27 (1) Disassembly . . . . . . . . . . . . . . . . . . AT-27 (2) Assembly . . . . . . . . . . . . . . . . . . . . AT-28 7. INSPECTION AND ADJUSTMENT . . AT-29 (1) Measurement of Oil Pressure . . . . . AT-29 (2) Adjustment of Pedal . . . . . . . . . . . . AT-31 (3) Adjustment of Inching Valve . . . . . . AT-32 (4) Stall Speed . . . . . . . . . . . . . . . . . . . AT-33
GI MA ER CL MT AT DF DA SA RT BR ST HD LM FE
é‘óºêßå‰ÉVÉXÉ É{ÉfÉBÅ[ÅïÉtÉå É{ÉfÉBÅ[ìdëï
VC BF BE
CONSTRUCTION
1. CONSTRUCTION (1) Automatic Transmission
ATT0207LÃ…@X
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)
AT-2
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 Type
3 elements, 1 stage, 2 phases Transmission route
Speed stage
AT-3
F (Forward)
a
cde
R (Reverse)
b
e
F (Forward)
32 61 33 X 30 = 1.972
R (Reverse)
61 30 = 2.033
CONSTRUCTION (2) Torque Converter
ATT0208LÃ…@W
1. Turbine runner 2. Stator assembly 3. Input plate
4. Pump impeller 5. Pump boss 6. Clutch hub
AT-4
7. Drive cover 8. Turbine boss 9. Pilot boss
CONSTRUCTION (3) Automatic Transmission Control
ATT0209LĂ…@V
1. Selector lever 2. Inching pedal
3. Cable (inching) 4. Control valve assembly
AT-5
CONSTRUCTION (4) Automatic Transmission Circuit Diagram
ATT0210LÃ…@X
AT-6
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.
AT-7
DISASSEMBLY AND ASSEMBLY
3. DISASSEMBLY AND ASSEMBLY (1) Removal of Transmission Accessories
ATT0211LÃ…@W
Order 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)
AT-8
DISASSEMBLY AND ASSEMBLY (2) Removal of Torque Converter Assembly and Pump Assembly
ATT0212LÅ@V
Order of disassembly 1 - 2: Remove as a set. 1. Torque converter assembly 2. Input plate
3. Pump assembly 4. O-ring
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.
ATT0240L
AT-9
DISASSEMBLY AND ASSEMBLY (3) Removal of Transmission Housing and Output Gear
ATT0213LÅ@V
Order of disassembly 1. Servo case assembly (oil seal) 2. Transmission housing (oil seal)
3. Output gear (ball bearing) 4. Torque converter housing
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.
AT-10
DISASSEMBLY AND ASSEMBLY (4) Removal of Input Gear Assembly and Idler Shaft
ATT0214LÅ@V
Order of disassembly 1. Input gear assembly
2. Idler shaft
(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
AT-11
DISASSEMBLY AND ASSEMBLY (6) Assembly
ATT0215LÃ…@X
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
AT-12
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.
AT-13
CONTROL VALVE
4. CONTROL VALVE (1) Disassembly (1)
ATT0217LĂ…@W
Order of disassembly 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)
AT-14
CONTROL VALVE (2) Disassembly (2)
ATT0218LĂ…@V
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
AT-15
Thank you very much for your reading. Please Click Here. Then Get COMPLETE MANUAL. NO WAITING
NOTE: If there is no response to click on the link above, please download the PDF document first and then click on it.
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.
AT-16
CONTROL VALVE (4) Assembly (1)
ATT0219LÃ…@Y
AT-17
CONTROL VALVE Order of assembly 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)
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
Assembly • Thoroughly clean the valve housing's hydraulic lines. Assemble after confirming that there is no clogging. • Inching plug Tightening torque [N•m (kg-m)]: 39.2 - 49.0 (4.0 - 5.0) • Strainer Tightening torque [N•m (kg-m)]: 19.6 - 24.5 (2.0 - 2.5)
AT-18