service repair manual

1. SERVICE MANUAL &
TECHNICAL BULLETIN
SERVICE MANUAL &
TECHNICAL BULLETIN
MODEL Q02 SERIES
SERVICEMANUAL
TECHNICALBULLETIN
MODEL
DX
SERIES

2. INTRODUCTION
This service manual has been prepared to provide necessary information concerning the maintenance
and repair procedures for the NISSAN FORKLIFT Q02 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 sec-
tions will be issued to replace the applicable sections. Each revised section will include the descrip-
tion 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! INFORMA! nON! (GI)
MAINTENANCE (MA)
CONTROL SYSTEM (CS)
BATTERY & CHARGER (BC)
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 The Netherlands
Edition: July 1997
Printing: August 1997 (01)
Publication No. SM7E-Q020GO

3. 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.

4. STEERING SYSTEM
SECTIONST
CONTENTS
SERVICE DATA AND SPECIFICATIONS 2
TROUBLE DIAGNOSES AND CORRECTIONS 4
PRECAUTIONS AND PREPARATION 6
Precautions 6
Special Service Tools 6
b7
STEERING WHEEL 8
Removal. 8
Inspection 8
Installation 8
STEERING COLUMN ASSEMBLy 9
Construction 9
Removal. 9
PS Piping 10
Disassembly 11
Inspection 11
Assembly 12
Installation 12
ORBITROL.. 13
Construction 13
Removal and Installation 14
Disassembly 14
Inspection , 15
Assembly 16
POWER CYLINDER 17
Removal and Installation 17
Disassembly 19
Assembly 20
OIL PUMP (for power steering) 21
Construction 21
Oil pump for power steering 22
Removal. 22
Disassembly 23
Inspection 23
Assembly 25
Installation '" 26

5. SERVICE DATA AND SPECIFICATIONS
GENERAL SPECIFICATIONS
Type
Turns 01 steering wheel
(Lock to lock)
Reliel set pressure
kPa (bar, kgl/cm2
, psi)
Orbitrol
Type
Discharge
me (US II oz, Imp II oz)/rev
Power Cylinder
Fully hydraulic
power steering
4.5
9,317 (90, 95,1,351)
UBS090A08ZHD
69 (2.3, 2.6)
Inner diameter
Outer diameter
Piston rod diameter
Stroke
mm (in)
mm (in)
mm (in)
mm (in)
60 (2.36)
72 (2.83)
40 (1.57)
196 (7.72)
Tightening Torque
N.m kgl-m ft-Ib
Steering wheel nut 26 - 32 2.7 - 3.3 20 - 24
Steering column to instru-
27 - 36 2.8 - 3.7 20 - 27
ment Irame
Steering column bracket to
15.7-21.6 1.6 - 2.2 11.6 - 16.0
ORBITROL
Steering column to column
15.7 - 21.6 1.6 - 2.2 11.6 - 16.0
bracket
Connecting steering col-
16 - 21 1.6 - 2.1 12 - 15
umn with steering shaft
ORBITROL to lront cross
68.6 - 78.4 7.0 - 8.0 50.8 - 58.1
member
Power cylinder attaching
137 - 186 14 - 19 101 - 137
bolt
Connecting PS hose &
39 - 59 40 - 60 28.9 - 43.7
pipes
Connector at ORBITROL 34 - 39 3.5 - 4.0 25 - 29
Pressure switch 24 - 34 2.5 - 3.5 17.8 - 25.2
Tilt steering handle
7.7 - 10.5 0.79 - 1.07 5.5 - 7.5
(Left hand threads)
ORBITROL cap screws 21 2.1 16
ST-2

6. SERVICE DATA AND SPECIFICATIONS
Oil pump (for power steering)
Applied model
Pump type
Drive type
Gear system
Normal discharge
me (US II oz, Imp II oz)/rev.
Maximum pressure
MPa (bar, kg/cm2
, psi)
002 series
Gear (1SX060)
Direct-coupled to motor
Dual
6.0 (0.20, 0.21)
9.0 (090, 88.2, 1305)
INSPECTION AND ADJUSTMENT
Hydraulic oil type and capacity
Applied model
Hydraulic oil type
TIGHTENING TORQUE
002 series
All models
I.S.O. VG32
Part name N.m (kgl-m, ft-Ib)
Pump assembly mounting bolt 46 - 51 (4.7 - 5.2, 34 - 38)
Pump assembly-to-pump motor securing bolts 24.5 - 31.4 (2.5 - 3.2, 18.6 - 23.8)
Oil pump Intake connector 78.4 - 88.2 (8.0 - 9.0. 59.5 - 67.0)
Discharge pipe connector 39.2 - 44.1 (4.0 - 4.5, 29.7 - 33.5)
Discharge pipe Ilare nut 29.4 - 58.8 (3.0 - 6.0, 22.3 - 44.6)
ST-3

7. TROUBLE DIAGNOSES AND CORRECTIONS
CAUTION:
The following tables list only typical examples. To perform an accurate diagnosis, carefully listen to the
user's complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur .
• The steering system is directly related to the rear axle, be sure to diagnose the steering system by referring to
RA section.
Condition Probable cause Corrective action
Shaking, shocking or • Improper tire pressure • Adjust.
unstable steering wheel • Improperly adjusted or worn wheel bearing • Check and adjust preload or replace wheel
bearing.
• Worn king pin thrust bearing • Replace.
• Deformed or unevenly worn tires or road • Correct or replace.
wheels
• Improperly adjusted wheel alignment • Adjust toe-in .
Heavy steering wheel • Improper tire pressure • Adjust.
operation • Improperly lubricated king pin • Apply grease or replace .
• Improperly adjusted or worn wheel bearing • Check and adjust preload or replace wheel
bearing.
• Improperly adjusted wheel alignment • Adjust toe-in .
• Insufficient gear oil or dirt in oil. • Replenish or change .
• Insufficient oil in tank. • Replenish.
• Air in system. • Bleed air.
• Hydraulic oil leakage at connection or blocked • Replace or clean.
passage.
• Low hydrualic oil pressure. • Refer to item Low oil pressure.
• Control valve seized or damaged. • Clean or replace.
• Power cylinder piston seal damaged. • Replace.
Vehicle swerves to right • Loose wheel nuts • Tighten.
or left • Unequal right and left tire pressure • Adjust.
• Different type tire or wheel on right and left • Replace.
• Improper alignment (toe-in) • Check and adjust.
• Differently worn right and left tires • Check and replace.
• Improperly adjusted spindle stopper • Adjust.
• Improperly adjusted brakes • Adjust.
Low hydraulic oil pres- • Hydraulic oil leakage at connection or blocked • Replace or clean.
sure passage.
• Inoperative oil pump. • Refer to section HD.
ST-4

8. TROUBLE DIAGNOSES AND CORRECTIONS
Condition Probable cause Corrective action
Unstable driving in • Improper alignment (toe-in) • Check and adjust.
straight-ahead direction • Improperly adjusted or worn wheel bearing • Check preload and adjust or replace wheel
bearing .
• Loose wheel nuts • Tighten.
• Deformed or unevenly worn tires or road • Correct or replace.
wheels
Excessive steering • Wheel bearing improperly adjusted • Adjust.
wheel play
Poor returnability of • Improper alignment (toe-in) • Check and adjust.
steering wheel • Improper tire pressure • Adjust.
Hydraulic oil leakage • Faulty oil seal or O-ring • Replace.
• Deformed contact surface of spacer plate, etc .• Replace .
Hydraulic oil pressure • Excessive internal leakage • Replace as an assembly.
does not build up • Improper adjustment of relief valve • Readjust to specified pressure using pressure
gauge.
• Hydraulic oil leaking through orbitrol • Replace faulty parts.
• Air in the system • Retighten suction side piping .
CAUTION:
The following table lists only typical examples. To perform an accurate diagnosis, carefully listen to the
user's complaints and check the actual vehicle to fully understand under what conditions the symptoms
occur.
For problems closely related to pump motor, refer to MM section for diagnosis.
OIL PUMP
Condition Probable cause Corrective action
No oil supplied from oil • Low oil level in tank • Fill up oil to specified level.
pump • Clogged suction pipe or filter • Clean. If oil is dirty, replace with new .
Low oil pump pressure • Worn gear shaft bushing or faulty packing • Replace with new one .
ring
• Improperly adjusted relief valve • Readjust to specified pressure using pres-
sure gauge .
• Air in the system • Retighten suction side piping .
• If oil level in tank is too low, add oil to speci-
fied level.
• Do not operate pump until air bubbles in tank
are removed .
Abnormal noise caused by • Cavitation due to crushed suction hose or • Remove foreign matter and repair crushed
oil pump clogged filter hose.
• Air sucked from lose suction side joint • Retighten each joint.
• Excessive viscosity of oil • Replace with new oil having proper viscosity .
• Air bubbles in hydraulic oil • Discharge air, remove foreign matter and
replace oil.
Oil leakage from oil pump • Faulty oil seal or body seal • Replace seal with new one .
• Worn sliding surfaces of gears (Increased • Replace oil pump with new one .
inner leakage)
ST-5

9. Tool number
Tool name
ST27180000
Steering wheel puller
PRECAUTIONS AND PREPARATION
Precautions
CAUTION:
• Be extremely careful when hoisting and moving heavy
objects. These can be extremely dangerous operations.
• Always clean working area to prevent foreign matter from
getting into parts being assembled or serviced.
• Use a paper rag rather than a cloth when wiping clean parts.
Use of a cloth rag may leave lint or other foreign matter on
parts being wiped.
• When disassembling or servicing units or parts of a vehicle,
park it on solid and level ground and chock the wheels.
Failure to do so may cause the vehicle to move unexpect-
edly. Also, be sure to disconnect battery plug in advance.
• When disassembling or servicing the steering ORBITROL
and power steering cylinder assembly, always perform with
clean hands. It is important to prevent the parts from becom-
ing contaminated by dirt or other foreign matter.
• When removing or installing any unit, make sure that the
vehicle is placed in the straight-ahead driving position.
• After tightening castle nut, be sure to install and clinch a
new cotter pin.
NOTE:
• This ST section describes inspection and maintenance proce-
dures for the mechanism of the steering system.
• For troubleshooting and maintenance of electrically controlled
power steering system, refer to CS section.
• Refer to EL section for meter panel and turn signal lamp lever
switch.
• Refer to RA section for servicing rear axle assembly.
• When disassembling or servicing designated parts, be sure to
use special service tools.
• Refer to CS section for control of pump motor.
Special Service Tools
Description
Removing steering wheel
sn0002
ST-6

10. PRECAUTIONS AND PREPARATION
Precautions
CAUTION:
• When performing removal or installation procedures, be
sure to turn key switch to OFF, disconnect battery plug and
discharge remaining pressure in pipes using control lever.
• To prevent foreign matter from entering, always maintain a
clean workplace.
• When disconnecting pipes, cover the surrounding area with
rag and ensure oil does not contaminate other parts.
• Never allow foreign matter to enter pipes when connecting.
• Put disassembled parts on clean paper or rag and use care
not to contaminate, scratch or dent them.
• When handling heavy parts, two people should perform the
work.
NOTE:
• For the removal, installation and service of pump motor, refer to
MM section.
• For the removal of instrument counterweight, refer to SF section.
ST-7

11. ST27180000
sn0004
STEERING WHEEL
Removal
1. Remove horn button.
2. Remove steering wheel nut and washer. Using special service
tool (ST27180000), remove steering wheel.
COMPONENT PARTS
1Knob
p-KnObshatt
~
Koro ""h"gL
Hornbrush
sn0005
Inspection
• Check steering wheel for deformities, cracks or damage. If
necessary, replace with a new one.
• Check serrations on steering wheel and steering shaft sides. If
necessary, replace steering wheel or steering shaft.
Installation
To install, reverse the order of removal. Observe the following:
Steering wheel nut:
rPJ: 26 - 32 Nom (2.7 - 3.3 kgf-m, 20 - 24 ft-Ib)
CAUTION:
• Apply a coat of multi-purpose grease to sliding section of
horn contact.
.ST.8

12. ~ 68.6 -78.4
(7.0 - 8.0, 50.8 - 58.1)----.
STEERING COLUMN ASSEMBLY
Construction
m :Apply grease
~ : N.m (kgf-m, ft-Ib)
Floor
~
/ 15.7 _21.6 (1.6 _2.2,11.6 _16.0) ? 34 - 39 (3.5 - 4.0, 25 - 29)
V
0rbitrol ~dV' 24 - 34 (2.5 - 3.5,17.8 - 25.2)
@I?"(Q)II
Of ,Q:
@1 <) ~ ~ Pressure switch
View ~
STM0012
Removal
1. Remove steering wheel. Refer to "STEERING WHEEL".
2. Remove the following parts from steering column assembly.
Refer to EL and CS sections.
• Meter panel
• Turn signal lamp switch
• Forward-reverse lever and FR switch
• Harnesses of above-mentioned units and horn switch
3. Remove instrument panel inner cover and pullout steering cover
upward.
4. Remove floor mat and floor panel. Refer to SF section.
5. Remove bolts securing steering column clamp to instrument
frame. Then remove steering assembly.
ST-9

13. STEERING COLUMN ASSEMBLY
PS Piping
Connector
24 - 34 (2.5 - 3.5, 17.8 - 25.2)
ORBITROL
~ : N.m (kgf-m, ft-Ib)
ST-10
o
Hydraulic tank
To power cylinder
STM0013

14. STEERING COLUMN ASSEMBL V
Disassembly
Bushing
~ 4.3-5.9
(0.44 - 0.60, t3.1 - 4.2)
~ ~ /
/ f~ Tilt lock plate
~ / Washer ~~ Steenng column clamp
~ Washer
r ~Adjusting nut
~ 7.7 - 10.5 (0.79 - 1.07, 5.5 - 7.5)
(left hand threads) Steenng column adjusting lever
!i5!I :Apply grease
~ : N.m (kgf-m, ft-Ib)
STM0014
i. Remove tiit iock iever from steering column ciamp.
2. Loosen pinch bolt of steering shaft upper joint and remove steer-
ing shaft.
3. Remove steering column from steering column bracket.
4. Remove snap ring on lower side of steering column. Then draw
out column bearing and steering column shaft from column.
CAUTION:
When drawing out steering column shaft from steering column,
be careful not to damage bushing on column upper end with
shaft end serration.
5. Remove steering column clamp from steering column bracket.
Inspection
Clean disassembled parts and carefully check for cracks or damage.
If necessary, repair or replace with new ones.
ST-11

15. STEERING COLUMN ASSEMBLY
Inspection (Cont'd)
STEERING SHAFT
• Check shaft for bending or twisting. If necessary, replace.
• Check universal joint for unsmooth operation or backlash. If
necessary, replace.
• Check serrations for deformities or damage. If necessary,
replace.
COLUMN BEARING
Check bearing for wear, damage or backlash. If necessary, apply
grease or replace.
STEERING COLUMN, STEERING COLUMN BRACKET
AND STEERING COLUMN CLAMP
Check for deformities or damage. If necessary, replace.
BOOT
Check for cracks or damage. If necessary, replace.
Assembly
To assemble, reverse the order of disassembly. Observe the follow-
ing:
Steering shaft upper joint pinch bolt:
~: 16 - 21 Nom(1.6 - 2.1 kgf-m, 12 - 15 ft-Ib)
Steering column bracket securing bolt:
~: 16 - 21 Nom(1.6 - 2.1 kgf-m, 12 - 15 ft-Ib)
Tilt lock lever securing bolt:
~: 21 - 27 Nom(2.1 - 2.8 kgf-m, 15 - 20 ft-Ib)
CAUTION:
• Install steering column so that horn harness is positioned on
the right side.
• When installing steering shaft to steering column, apply
grease to serration on steering shaft side.
• Install tilt lock lever so that the lever is placed in the lock
position with its serration seated in place. Then tighten
securing bolts to the specification. After installation, release
lever to make sure that bracket smoothly slides in entire
tilting range without interfering adjacent parts.
Installation
To Install, reverse the order of removal. Observe the following:
Steering column clamp securing bolt:
~: 27 - 36 Nom(2.8 - 3.7 kgf-m, 20 - 27 ft-Ib)
CAUTION:
When inserting shaft on steering ORBITROL side into steering
shaft, be sure to apply grease to serration.
ST-12

16. SECTION B
ORBITROL
Construction
DETAIL (j)
SECTION A
~ 21 (2.1,16)
1 SCREW, CAP 6
[[
2 SCREW, RETAINER ASS'Y 1
3 SCREW, RETAINER (1)
4 SPRING, PIN (1)
5 BALL 1
6 CAP,END 1
7 GERATOR 1
10 PLATE, SPACER 1
11 DRIVE 1
12 CONTROL PARTS ASS'Y 1
Cf
13 HOUSING (1)
14 SLEEVE (1)
15 SPOOL (1)
16 PIN 1
17 SPRING, CENTERING 4
18 SPRING, FLAT 2
19 PLUG, ADJUST (1)
20 O-RING (1)
21 SPRING (1)
22 POPPET (1)
23 COLLAR (1)
24 RACE, BEARING 2
25 BEARING, NEEDLE 1
26 O-RING 1
27 SEAL, QUAD RING 1
28 SEAL, DUST 1
29 RING, RETAINING 1
30 BUSHING, SEAL GLAND 1
31 O-RING 2
32 O-RING 1
33 PLUG 1
34 O-RING 1
35 NAME PLATE 1
36 RIVET 2
ST-13
~ Nom (kgf-m, ft-lb)
STM0015

17. ORBITROL
Removal and Installation
1. Disconnect battery ground cable.
2. Remove floor board.
3. Remove arbitral with steering column from steering column
bracket.
4. Installation is in the reverse order of removal.
Disassembly
Before diassembling, completely clean outer periphery of
orbitrol, especially contact areas or ports and areas around
shafts.
1. Lightly clamp the housing of arbitral with a vise using pads and
remove screws from end cap.
2. Remove end cap, gerotor, spacer plate and drive shaft.
Be careful not to drop start gear.
FST288
3. Remove retaining ring from housing.
ST-14

18. FST289
ORBITROL
4. Remove seal gland bushing.
5. Remove race bearing and needle thrust bearing from spool
sleeve assembly.
FST290
Centering pin
c:=£
FST291
FST333
6. Draw out spool, centering springs, centering pin and sleeve as a
unit from end side of housing.
7. Draw out centering pin and separate spool and sleeve.
Inspection
Thoroughly clean all parts in cleaning solvent and dry with com-
pressed air. Check parts for evidence of deformation or other dam-
age.
ST-15

19. FST275
ORBITROL
Inspection (Cont'd)
Oil seal and O-ring
Do not reuse oil seals and O-ring once they have been removed.
Other compartment parts
• Replace parts if they are deformed, cracked, or their sliding sur-
faces are worn excessively.
• Always replace control parts assembly and gerotor set as a unit,
since all of these are constructed precisely finished parts.
Assembly
Assembly in the reverse order of disassembly, noting the following
instructions:
• Match centering pin channel direction.
Cap screw
~: 21 N.m (2.1 kgf-m, 16 ft-Ib)
• After assembling, check the following items:
1. Ensure that spool turns smoothly without binding.
2. Twist spool until it reaches stopper and release. It should return
properly to Neutral.
ST-16

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21. /
POWER CYLINDER
Removal and Installation
1. Jack up counterweight and support truck body with wooden
blocks or safety stands.
2. Remove rear tires.
3. Remove tie-rod bars.
FST335
4. Disconnect PS piping connectors and remove power cylinder
attaching bolts, and then draw out power cylinder from axle cen-
ter.
5. Install power cylinder in the reverse order of removal.
ST-17

22. POWER CYLINDER
Removal and Installation (Cont'd)
Installation of cylinder rod end
L
Dimension "L"
626.5 - 627.5 mm (24.67 - 24.70 in)
Power cylinder attaching bolt
~: 137 - 186 N.m
(14 - 19 kgf-m, 101 - 137 ft-Ib)
ST-18
SMT0016

23. POWER CYLINDER
Disassembly
II
@@ @ 4 @CDCV (J) @
CD Cylinder tube assembly
CD Piston rod assembly
CD Cylinder head
8) Bushing
CD Snap rin
@ U-ring
CD Back-up ring
o Wiper ring
CD O-ring
@ Piston
@ O-ring
@ Slipper seal
STM0017
1. Using a chisel or similar tool, straighten lock plate driven into
groove in guide assembly at tube end.
FST337
FST318
2. Rotate cylinder head and remove it from cylinder.
ST-19