Nissan 1F1 1F2 Forklift Service Manual – K21 K25 QD32 – PDF Download

Description

Nissan 1F1 1F2 Forklift Service Manual – K21, K25 & QD32

This is the full workshop service manual for the Nissan 1F1 and 1F2 series forklifts, covering both the North America manufactured models and general overseas market variants. It is written for the technician who actually turns wrenches on these trucks – lubrication schedules, valve clearance procedures, transmission teardown, brake adjustment, mast roller shimming and hydraulic troubleshooting are all laid out with figures, torque values and step-by-step sequences. Published by Nissan Motor Co., Ltd. and identified as document SM06E-F12G0, this manual covers gasoline, LPG and diesel powered 1F1 and 1F2 trucks in pneumatic, cushion and compact pneumatic tire configurations.

File Details

• Manual type: Forklift service / repair manual
• Brand: Nissan
• Models covered: 1F1 series (1 Ton), 1F2 series (2 Ton)
• Engines covered: K21 gasoline, K25 gasoline, QD32 diesel
• Document number: SM06E-F12G0
• Publisher: Nissan Motor Co., Ltd.
• Date: 2003
• Language: English
• File format: PDF
• Page count: 1,149 pages

Chapters Covered

• GI – General Information: How to use the manual, technical term definitions, identification information, vehicle model classification, general precautions, jacking and lifting, standard bolt tightening torques
• MA – Maintenance: Lubrication chart, maintenance schedule, engine maintenance, battery, tires and road wheels, brake system, steering, automatic transmission, loading mechanism, body electrical, hydraulics
• ER – Engine Removal: Joint removal of engine and transmission, control systems for clutch and torque converter models, piping and radiator, engine and transmission assembly, engine mounting
• CL – Clutch: Dry and wet clutch differences, clutch unit, clutch cover assembly, master cylinder, operating cylinder, clutch pedal adjustment, disc wear limit inspection
• MT – Manual Transmission: Construction, reduction ratios, removal and installation, disassembly, inspection, assembly, shifter case, output gear, input gear, mainshaft assembly
• AT – Automatic Transmission: Torque converter, control valve, input shaft assembly, oil pump assembly, oil pressure measurement, inching valve adjustment, stall speed testing
• ATC1 / ATC2 – Automatic Transmission, Cushion: Single speed and two speed cushion transmission specifications and service
• DF – Differential Carrier: Differential carrier service and adjustment
• DA – Drive Axle: Drive axle construction, removal and installation, disassembly
• SA – Steering Axle: Hub, kingpin, steering axle components, spindle details, service data and specifications
• RT – Road Wheel & Tire: Tire type and application, hub inspection and installation
• BR – Brake System: Construction, disassembly, inspection and adjustment, parking brake, shoe clearance, brake lining wear
• ST – Steering System: Steering wheel, column, PS valve, PS cylinder, free play and operating force
• HD – Hydraulic System: Hydraulic piping, oil pump, control valve, lift cylinder, tilt cylinder, hydraulic fluid replacement
• LM – Loading Mechanism: Fork inspection, lift chain tension, carriage roller, mast roller, mast operation, mast and tilt cylinder inspection
• FE – Fuel & Exhaust Systems: Accelerator wire and pedal, fuel system, exhaust system, LP tank swing bracket
• EC – Engine Control: System description, diagrams, inspection and trouble diagnosis, error code E35 troubleshooting, fail-safe function
• VC – Vehicle Control System: VCM setting, storage of settings, functional check, VCM-1 active test, ECM active test, diagnosis history, alarm code inspection
• BF – Body & Frame: Counterweight, frame, instrument frame, undercover, overhead guard, top panel, floor board, plastic cover, seat
• BE – Body Electrical: Wire harness, relay box, fuse box, combination meter, speedometer, switches, headlights

What This Nissan 1F1 1F2 Service Manual Gives You

Every major system on the truck is covered in its own section, which means you can go straight to the repair you are doing instead of reading around it. Engine work on the K21 and K25 gasoline engines is broken down to cylinder head tightening sequences, valve clearance measurement with the engine warm, compression pressure testing with the standard values and differential limits, fan belt deflection, oil and filter replacement, coolant service and spark plug gap. The QD32 diesel engine gets its own treatment with injection nozzle opening pressure testing and shim adjustment, fuel injection timing with plunger lift measurement, fuel filter replacement and fuel system bleeding with or without an air vent screw.

The driveline sections are just as detailed. Clutch coverage separates dry and wet clutch designs so you are not mixing procedures, and includes the clutch disc wear limit inspection that tells you when the operating cylinder can no longer absorb disc wear. The manual transmission section includes the forward-reverse two-stage speed change mechanism with synchronizer assembly and shim selection for the mainshaft bearings. Automatic transmission coverage extends through torque converter service, control valve disassembly, input shaft clutch pack measurement, oil pump clearance limits, oil pressure measurement at main, clutch and T/C inlet ports, and stall speed testing for K21, K25 and QD32 engines.

Chassis and hydraulic work is equally well supported. Brake coverage walks through shoe clearance adjustment with the automatic adjuster verification, brake lining wear limits, brake fluid level and pedal adjustment including push rod clearance. Steering axle, drive axle and differential carrier sections handle the running gear. The hydraulic section covers the pump, control valve, lift and tilt cylinders and the procedures for releasing a stuck mast, while the loading mechanism chapter handles fork wear calipers, fork capacity data, lift chain tension, carriage roller clearance and mast roller shim adjustment for 2W, 2F, 3F and 3V masts.

Models, Engines and Serial Numbers

The 1F1 series covers 1.0 to 2.0 ton trucks and the 1F2 series covers 2.0 to 4.0 ton trucks, with load capacity ratings spanning 1.5, 1.75, 2.0, 2.5, 2.75, 3.0, 3.25, 3.5 and 3.6 ton models. Tire configurations include pneumatic, cushion and compact pneumatic. Basic model codes split as 1F1 for the 1 Ton Series and 1F2 for the 2 Ton Series, with wheelbase options for standard, long, and inter wheelbase. Serial number designations are listed for each short model code including P1F1, CP1F1, AP1F1, CP1F2, CU1F2, CUG1F2, P1F2, U1F2, Y1F2, UG1F2, YG1F2, AP1F2 and UJ1F2, so you can confirm your truck falls in the covered range before you start a repair.

Service Bulletins Included

This file also carries a set of Nissan service bulletins covering tilt cylinder pin lubrication, cooling fan and engine rotation, transmission troubleshooting and warranty repair documentation, inching cable adjustment to prevent premature clutch plate wear, LPG low pressure switch diagnosis, transmission temperature sensor moisture issues, spark plug service guidelines for K21 and K25 engines, LPG injector error code E35 troubleshooting, load bearing clamp attachment safety compliance, and a seat change announcement with the ELR seat belt interlock switch setting. These bulletins supplement the main sections and address known field issues directly.

Why This Manual Belongs in Your Workshop

Forklift repairs go wrong when a torque value is guessed, a clearance is left out of spec, or a wear limit is missed. This Nissan 1F1 1F2 forklift service manual gives you the actual tightening torques, repair limits and adjustment values the manufacturer specifies – from cylinder head bolt torque and valve clearance to carriage roller clearance and brake shoe clearance. It supports engine overhauls, clutch and transmission rebuilds, brake and steering repairs, hydraulic troubleshooting and mast service on both the 1F1 and 1F2 series trucks.

You get instant access as a PDF after checkout, with no shipping and no waiting. The file opens on any phone, tablet, laptop or desktop and every page can be printed for the shop floor, so you can keep the section you are working on next to the machine while the rest stays on file.

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