service repair manual

1. INTRODUCTION
This service manual has been prepared to provide necessary information concerning the
maintenance and repair work on the NISSAN FORKLIFT F03 series.
For H30 and SD33 engines, refer to the NISSAN FORKLIFT SERVICE MANUAL &
TECHNICAL BULLETIN MODEL J15, H20, H30, 5022, 5033 ENGINE.
Any changes effected in the series after publication of this service manual will be an-
nounced 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, re-
vised 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 publica-
tion 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 "INTRODUC-
TION" sheet should be replaced with a revised one.
Section Symbol
GENERAL INFORMATION (GI)
MAINTENANCE (MA)
ENGINE TUNE-UP (P ENGINE) (ET)
ENGINE MECHANICAL (P ENGINE) (EM)
ENGINE LUBRICATION SYSTEM (P ENGINE) (EL)
COOLING SYSTEM (P ENGINE) (CO)
FUEL SYSTEM (P ENGINE) (EF)
GOVERNOR SYSTEM (P ENGINE) (GO)
ENGINE ELECTRICAL (P ENGINE) (EE)
ENGINE REMOVAL (ER)
AUTOMATIC TRANSMISSION (AT)
DIFFERENTIAL CARRIER (DF)
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 AND FRAME (BF)
BODY ELECTRICAL (BE)
Printed in Japan
Printing: November 1996 (11)
Publication No. SMOE.FOS2GO

2. ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM
-p Engine-
(EL)
CONTENTS
SERVICE DATA AND SPECIFICATIONS EL-2
TROUBLE DIAGNOSES AND CORRECTIONS EL-3
ENGINE LUBRICATION SySTEM EL-4
LUBRICATION CiRCUiT EL-4
01 L PUMP EL-5
OIL FILT ER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. EL-6
SPECIAL SERVICE TOOL EL-6

3. Service Data and Specifications - ENGINE LUBRICATION SYSTEM
SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Lubrication method Pressedfeed flow
Oil pump type Spur gear type
Oil filter type Full flow and cartridge type
Oil capacity Q (US qt, Imp qt)
With oil filter 5.0 (5-1/4,4-3/8)
Without oil filter 4.3 (4-1/2,3-314)
TIGHTENING TORQUE
Unit N.m kg-m ft-Ib
Oil pump mounting
o ,
bolts
25 - 34 '.'0. 2.5 - 3.5 18 - 25
Oil pump cover bolt 7-9 0.7 - 0.9 5.1 - 6.5
Oil pan drain plug 20 - 39 2.0-4.0 14 - 29
Oil pan bolt 8 -14 0.8 - 1.4 5.8 -10.1
INSPECTION AND ADJUSTMENT
Oil pump Unit: mm (in)
Pump gear to pump body clearance
Pump gear backlash
Pump gear vertical clearance
Lessthan 0.26 (0.0102)
Lessthan 0.51 (0,0201)
Lessthan 0.115 (0.0045)
EL-2
SLC136

4. ENGINE LUBRICATION SYSTEM - Trouble Diagnoses and Corrections
TROUBLE DIAGNOSES AND CORRECTIONS
Condition Probable cause Corrective action
Oil leakage Damaged or cracked pump body cover. Replace.
Oil leakage from gasket and oil seal. Replace.
Oil leakage from regulator valve. Tighten or replace.
Oil leakage from blind plug. Replace.
Decreased oil Lack of oil in engine oil pan. Correct.
pressure Dirty oil strainer. Clean or replace.
Damaged or worn pump rotors/gears. Replace.
Malfunctioning regulator. Replace.
Use of poor quality engine oil. Replace.
Warning light Decreased oil pressure. Previously mentioned.
remains "on" - Oil pressure switch unserviceable. Replace.
engine running
Electrical fault. Check circuit.
Noise Excessive backlash in pump rotors. Replace.
EL-3

5. EngineLubricationSystem- ENGINE LUBRICATION SYSTEM
ENGINE LUBRICATION SYSTEM
LUBRICATION CIRCUIT
El.4
./l---, Oil gallery in
......- cylinder block
...... - - Oil splash
.....- Oil passage
SLC132

6. ENGINE LUBRICATION SYSTEM - Engine Lubrication System
5.0 (5.1/4, 4.3/8)
4.3 (4-1/2, 3.3/4)
Unit: Q (US qt, Imp qt)
Without oil
filter
With oil filter
6. Insert distributor, meshing dis.
tributor drive slit and driven slit.
7. Refill engine with oil.
(2) Insert and turn oil pump spindle
clockwise.
(3) Confirm that slit on oil pump
spindle deflects as shown.
Oil capacity
////0 C;I~d:r
~I~C~/
/////
I
SLC146
SLC145
//UJ/JIi~d;:~I~CYL/J//
1-200
5. Install oil pump spindle as
follows:
(1) Set oil pump spindle as shown.
~ - 2::://~
~- / SLC133
OIL PUMP
REMOVAL
1. Remove oil pan drain plug, and
allow oil to drain.
2. Remove distributor and oil pump
spindle.
3. Remove oil pan.
4. Remove oil pump body.
DISASSEMBLY AND ASSEMBLY
INSTALLATION
1. Before installing oil pump in
engine, turn crankshaft so that No.1
piston is at T.D.C.
2. Install oil pump on cylinder
block.
[f:l : Oil pump mounting bolts
25 -34 N'm
(2.5 • 3.5 kg-m,
18 - 25 ft-Ib)
3. Install oil pan.
[f:l : Oil pan bolt
8-14 N.m
(0.8 - 1.4 kg-m,
5.8 - 10.1 ft-Ibl
4. Rotate oil pump shaft with a con-
ventional screwdriver as shown.
Oil pump
drive
shaft set
v~
t-t!l 25 - 34
(2.5 - 3.5,
18-25) ~.
Regulator.., ~'. Oil pump
valve / . strainer
(!) Pin~Washer assembly
, Spring
~.
Regulator valve set t!l: N.m (kg-m, ft-Ib)
SLC135
EL.5

7. Special Service Tool- ENGINE LUBRICATION SYSTEM
INSPECTION
1. Inspect the following for wear or
damage.
• Pump body and cover
• Pump gears
• Drive spindle
Pump gears and body are not
serviced separately. If pump gears or
body are damaged or worn, replace
drive shaft set or entire oil pump
assembly.
2. Using a feeler gauge, check the
following clearance.
If it exceeds the limit, replace drive
shaft set or entire oil pump assembly.
Pump gear to pump body:
less than 0.26 mm (0.0102 in)
Pump gear backlash
less than 0.51 mm (0.0201 in)
Pump gear vertical clearance
less than 0.115 mm (0.0045 in)
3. Check oil pressure regulator valve
sliding surface and valve spring.
If damaged, replace valve set or
pump assembly.
rPin
I
~
.--..c::;egUlator v~ve
i~spnng
iJ ~r"'"
SLC137
OIL FILTER
REPLACEMENT
1. Remove oil pan drain plug, and
allow oil to drain.
2. Using Tool, remove oil filter.
3. Wipe oil filter mounting surface
with clean rag.
4. Check oil pressure relief valve for
cracks or breaks.
If necessary. remove valve by pry-
ing it out with a screwdriver.
Install a new valve by tapping it in
place.
5. Smear a little engine oil on rubber
gasket of oil filter.
6. Install oil filter.
Hand-tighten ONLY.
DO NOT use a wrench to tighten
the filter.
7. Refill engine with oil.
Oil capacity:
5.0 liters
(5-1/4 US qt, 4-3/8 Imp qt)
8. Run engine for a few minutes, and
check for leaks.
Tool number
SPECIAL SERVICE TOOL
Tool name
ST19320000
EL-6
Oil filter wrench

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