WARRANTY COVERAGE AT A GLANCE

To Nissan Forklift Valued Customers

Your Nissan Forklift may be covered by one or more of the following warranty coverages, depending on your
location. Included in your delivery package with this Operator's Manual should be a separate Warranty Statement,
which will explain your coverage.

Basic Coverage* 12 months / 2,000 hours

Powertrain 24 months / 4,000 hours

Emission Control Warranty LSI 36 months or 2,500 hours (General Parts)

Emission Control Warranty LSI 36 months or 4,000 hours (Powertrain Parts)

Long-Term Emission Control Warranty LSI 60 months or 3,500 hours (General Parts)

Long-Term Emission Control Warranty LSI 60 months or 4,000 hours (Powertrain Parts)

Emission Related Warranty CI 60 months or 3,000 hours (General Parts)

LSI = Large Spark Ignited Engines above 25 HP (gas, LPG, LNG)

CI = Compression Ignited Engines (all Diesel)

The above warranty coverage applies to both U.S. EPA and CARB Emission Regulation standards only. These
warranty time periods are for units shipped in the United States and its territories.

For exclusion and limitations, see separate Warranty Statement included with start-up manuals.

*Warranty coverage for tires, battery, optional equipment, and hang on attachments are provided by the local
component manufacturer's representatives, directly.

For warranty coverage and statements outside of the U.S., please contact your local authorized Nissan Forklift dealer.

Jan-04
 MAINTENANCE SCHEDULE

MAINTENANCE SCHEDULE Periodic Maintenance and Lubrication

Schedule for Emission Control System
Maintenance
ENGINE FAMILY NAME: 7NSXB02.147C, 7NSXB02.548C
ENGINE MODEL: K21, K25
Before delivery of your new forklift, your dealer provides a pre-delivery inspection and adjustment service specified by the factory and designed
to ensure satisfactory performance. The following tables list the servicing required to keep your forklift operating at peak mechanical condition,
and should be attended to as indicated below, preferably by an authorized dealer.

MAINTENANCE OPERATION MAINTENANCE INTERVAL

Periodic maintenance should be Months 1 2 3 4 5 6 7 8 9 10 11 12 ...... 18
performed after specified intervals
have elapsed in months or hours, Hundreds of
2 4 6 8 10 12 14 16 18 20 22 24 ...... 36
whichever comes first. hours

ENGINE COMPARTMENT MAINTENANCE (EXCEPT LPG FUEL SYSTEM)

1. Intake & exhaust valve clearance
A A A A A A ...... A
(operating temp.)
2. Drive belt tension I I I I I I I I I I I I ...... I
3. Engine oil (1) R R R R R R ...... R
4. Oil filter (1) R R R R R R ...... R
5. Engine coolant (L.L.C.) R ......
6. Air cleaner element (1) C C C C C R C C C C C R ...... R
7. Spark plugs (1) I I I I I I I I I I I I ...... R
8. PCV valve (1) I I I I ...... I
ENGINE COMPARTMENT MAINTENANCE (LPG FUEL SYSTEM)
1. Piping or pipe connector portion for
I I I I I I I I I I I I I
gas leakage
2. Tar in vaporizer D D D D D D D D D D D D ...... D
3. Filter for LPG C C C R ...... C
NOTE: (1) More frequent maintenance is necessary under dusty or other dirty operating conditions.

Abbreviations: I = Inspect. Correct or replace if necessary. R = Replace A = Adjust C = Clean D = Drain

All items listed above must be maintained in order to meet and keep emission control systems operating at design levels. Failure to maintain
the systems could compromise the warranty.

For reference: Normal operating conditions and time is based on a clean and dry environment and 1,200 hours or less in one year.

For Units in the US:

CAUTION:
• Do not tamper with, destroy, remove or alter EPA/CARB label or valve (rocker) cover in any way. Doing
so could violate EPA/CARB regulations and possibly void the warranty on your Nissan Forklift.
• Valve (rocker) cover may be removed for maintenance checks but
the original cover must be installed as soon as maintenance
checks are completed.
• You must notify your local Authorized Nissan dealer if either the
Valve (Rocker) cover or label is damaged and needs to be
replaced.

MA-4
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLATION
REMOVAL AND INSTALLTION
REMOVAL AND INSTALLATION
 CLASS 1, 4 & 5 SERVICE BULLETIN
Nissan Forklift Corporation
240 North Prospect Street; Marengo, IL 60152

SB2009-306
POLICY
PAGE 1 OF 2

Date: October 26, 2009

To: All Dealer Principals

All Service Managers
All Warranty Managers
All CSS Managers

From: Technical Service Department

Subject: Transmission Troubleshooting and Warranty Repairs

Applied Model: L01/L02, 1F1/1F2 and 1F4 Models

NFC has noticed an increase in the number of technical inquires on the proper troubleshooting
procedures for transmissions. NFC strongly encourages the use of the transmission diagnostic
forms. NFC designed these forms for use with each specific transmission in each specific model.
The diagnostic form has a series of questions to complete that will help determine the transmis-
sion’s condition and failure area. The proper use of these diagnostic forms can save your dealer-
ship hours of unbillable time and improve your overall efficiency and profitability.

It is important to remember a few things when investigating transmission issues and/or requesting
technical assistance.

• Ensure the engine is performing to specifications. Many times we have investigated reports of
transmission or torque converter issues to learn that the root cause of the problem was due to
the engine not performing to specification and only needed some adjustments.
• Make sure the inching mechanism is properly adjusted by using the appropriate pressure gauge
to validate where the pressure starts to drop. You can NOT properly adjust the inching mecha-
nism without one. Refer to the appropriate Service Manual for adjustment specifications.
• Perform your transmission stall test. This is done by following the appropriate safety guidelines
and blocking the front wheels up off of the ground. Install a good quality tachometer and ensure
the wires are routed so they are not in jeopardy of being in the way. Next, apply the parking
brake and the service brake. Put the forklift in forward and fully accelerate the unit and make not
of the maximum RPM’s achieved. NOTE: Do not perform for more than 30 seconds at a time.
After waiting a few minutes of time to allow the transmission to cool down, perform the same
test in reverse.

The information provided in this bulletin is

not to be construed as a basis for any claims
against NFC, unless otherwise stated.
Phone: 815-568-1492 Fax: 815-568-0186
 SB2009-306
POLICY
PAGE 2 OF 2

• Once the stall test is complete it is time to perform the pressure test. NFC recommends install-
ing good quality liquid filled gauges in all the available test ports at one time. This will give you
a better picture of any potential issues by allowing you to see exactly how each clutch pack
assembly reacts independently of the other as the transmission is shifted from one direction to
the other. Once the gauges are installed, start the engine and inspect all of the pressures at
idle and document each in the appropriate space on the diagnostic form. Put the forklift in for-
ward, then in reverse and document those as well. Now accelerate the engine to approximately
2000 RPM’s and document the pressure readings in the same fashion as at idle.
• When all of the tests are complete and documented, please review the information you have
collected. Generally this information will point you in the general area of the issue or confirm
there is no issue with the transmission.

It is extremely important to remember that having a transmission failure during the warranty period
does not necessarily guarantee or indicate warranty coverage. NFC warrants our products against
defects in material or workmanship for a specific period of time depending on the warranty pro-
vided at time of purchase. If a transmission fails due to neglect, abuse, lack of maintenance or
improper adjustment, the expense for the repair would not be considered warrantable. Having an
operator riding the inching pedal and burning up the clutch plates would be one example of this.
Performing these tests and documenting them correctly could help prevent your dealership from
getting involved in an undesirable dispute with an end user.

Also, please be reminded that a completed transmission diagnostic form, prior to the repair, is
required documentation in support of any potential warranty claim.

Additionally, NFC highly recommends that a diagnostic form be completed after the transmission is
repaired to ensure that the transmission is performing back to specifications before returning it to
the customer.

Please encourage your Service Technicians to perform the above listed test procedures and utilize
the appropriate diagnostic forms and to document accordingly when troubleshooting. We are cer-
tain this will help reduce the risk of having issues with lost labor hours and potential warranty claim
issues.

Please insert a copy of this bulletin into your Dealership’s copy of the L01/L02, 1F1/1F2 and 1F4
Service Manuals behind tab Labeled AT.

Should you have any questions please contact the NFC Service Department at 815-568-1487.

Best Regards,
Nissan Forklift Corporation

James Clark
Chief Service Officer
CONSTRUCTION
CONSTRUCTION
CONSTRUCTION
CONSTRUCTION
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY AND ASSEMBLY
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Nissan Forklift Corporation, North America
240 N Prospect Street, Marengo, IL 60152

SB2010-313
HYDRAULIC
Date: October 18, 2010

To: All Dealer Principals, Service Managers, Training Managers

From: Customer Quality Service Department

SUBJECT: New ANSI/ITSDF B56.1 Safety Standard affecting load bearing clamp attachments

On October 7, 2009, a revision was released to ANSI/ITSDF B56.1-2009 SAFETY STANDARD

FOR LOW LIFT AND HIGH LIFT TRUCKS which affects the installation and operation of load
bearing clamp attachments. The standard states:

7.25.7 The manual operation or physical action of the control used to release a
load bearing clamp shall require two distinct motions or operations by the op-
erator before the clamp is opened and the load bearing force is released. For
example move the lever or handle to the left (or right) and then forward (or
down), or depress a button on the lever or handle and then move the lever or
handle forward (or down).

Compliance with this standard is mandatory starting October 7, 2010.

For trucks in the field, at your dealership’s service department waiting for attachment installation,
or attachments currently on order for a customer to do their own installation; NFC has worked
with Cascade Corporation to develop a system (without timer only) that can be installed to meet
this requirement.

Truck Voltage Cascade Part Number

12V 6806868
24~48V 6806869

Please ensure that the additional cost for both the kit and the installation are noted to all custom-
ers. A B56.1 Safety Standard change and can be reviewed on line at www.ITSDF.org.

And, as with any attachment change, the model (capacity) plate will also need to be
changed. Use NFC’s capacity plate request process.

For 1S1 Series trucks and/or units with the Fingertip Control option, contact NFC’s Service De-
partment at 815/568-1487 using the FTMR process for additional support. For new truck orders,
NFC will provide a TMR to meet this requirement. Contact NFC’s TMR Support at 815/568-
2134 for additional information.

Insert this bulletin into the HD tab of all current production Service Manuals.
Note: The information provided in this bulletin is not to be construed as a basis for any claims against NFCNA, unless otherwise stated.
HYDRAULIC PUMP
LIFT (MAST) CYLINDER
TILT CYLINDER
TILT CYLINDER
TILT CYLINDER
TROUBLE DIAGNOSIS AND CORRECTIONS
HYDRAULICS
HYDRAULICS
HYDRAULICS
HYDRAULICS
HYDRAULICS
HYDRAULICS
 CLASS 1
1,,4,5 SERVICE BULLE
SERV TI
BULLETIN
TIN
Nissan Forklift Corporation
240 North Prospect Street; Marengo, IL 60152

SB2008-286
MECHANICAL
Page 1 of 2
Date: April 8, 2008

To: All Dealer Principals

All Service Managers

From: Technical Service Support Department

Subject: LPG Low Pressure Switch

Applied Models: All L01/L02 and 1F1/1F2 Forklifts

NFC has received reported failures for the LPG fuel pressure switch; however, our testing and
analysis has identified that many of the returned LPG pressure switches as non-faulty switches.

NFC has determined that one of the main contributing factors that may affect the functionality
of the LPG pressure switch is the ambient temperature of the LPG fuel tanks.

As you are aware, LPG tanks are typically stored outdoors, and LPG tanks may drop below an
ambient temperature of 30° Fahrenheit during the winter months. This condition will cause the
LPG tank pressure to drop below the pressure switch’s opening pressure of 50 PSI, thus
causing the switch to remain illuminated. When the LPG tank achieves an ambient temperature
above 30° Fahrenheit, the switch should open and the Low LPG Fuel light will go off.

In addition, the adverse affect may occur during the warmer summer months, whereas the LPG
tank will maintain a higher vapor pressure; however the liquid petroleum within the LPG tank
remains low, causing the LPG fuel switch to provide a shorter illuminated warning period before
the truck runs out of fuel.

The information provided in this

bulletin is not to be construed as
a basis for any claims against
NFC, unless otherwise stated.

Phone Number: (815) 568-0061 Fax Number: (815) 568-0187

 SB2008-286
MECHANICAL
Page 2 of 2

To properly diagnose if the LPG switch has failed, please perform the following steps:

Above 30° Fahrenheit

1. Install a warm LPG tank (Above Fahrenheit) on the truck
2. Install a pressure gauge in the LPG regulator to read the tank pressure
3. Open the LPG tank valve and observe the pressure. The LPG low fuel lamp should NOT be
illuminated if the fuel pressure is above 51-55 PSI.
a. If the low fuel light stays illuminated, replace the LPG Pressure switch
b. If the low fuel light goes out, please go to step 4
4. Close the valve on the LPG tank
5. Start the truck.
6. Observe the pressure gauge and read the pressure when the low fuel light becomes illumi-
nated.
a. The LPG Low Fuel light should illuminate around 40 PSI. If the light does not illumi-
nate below a pressure of approximately 40 PSI, replace the LPG pressure switch.
b. If the LPG Low Fuel light illuminates around 40 PSI, the switch is operating correctly.

Please insert a copy of this bulletin into your Dealership's copy of the L01/L02 and 1F1/1F2 Service
Manuals behind Tab Labeled FE.

Should you have any questions, please contact NFC’s Technical Support Group at 815-568-1487

Best Regards,
Nissan Forklift Corporation

Hugh Wilson Jr.

Manager, Technical Services
MEMO
 CLASS 1, 4 & 5 SERVICE BULLETIN
Nissan Forklift Corporation
240 North Prospect Street; Marengo, IL 60152

SB2009-305
ELECTRICAL
PAGE 1 OF 3

Date: October 21, 2009

To: All Dealer Principals

All Service Managers

From: Technical Service Department

Subject: Troubleshooting for Error Code E35

Applied Model: K and TB Engines with LPG on 1F1/1F2 and 1F4 Models

1. INTRODUCTION:
This is to inform you of the troubleshooting procedures for error code E35 (LPG F/INJ open
circuit malfunction).

We have received some technical reports from the field that the engine would not start with the
error code E35 displayed on the meter panel. The problem has been solved by replace the LPG
injector.

Our investigation of the injectors shows that the injector itself has no prolem, however, there are
other causes, such as a loose connection and water contamination to the connectors and to the
LPG injector and ECM.

It is requested to follow the attached troubleshooting procedures for error code E35 in order to
avoid the unnecessary replacement of LPG injectors that may have no problem.

2. TROUBLESHOOTING PROCEDURES:
Please follow the attached troubleshooting for Error Code E35 and Inspection Procedures for
LPG injector.

The information provided in this bulletin is

not to be construed as a basis for any claims
against NFC, unless otherwise stated.
Phone: 815-568-1492 Fax: 815-568-0186
SB2009-305
ELECTRICAL
PAGE 2 OF 3
 SB2009-305
ELECTRICAL
PAGE 3 OF 3

Please insert of copy of this bulletin into your Dealerships copy of the 1F1/1F2 and 1F4 Chassis
Service Manuals, 2007 & 2009 K21_K25 and the 2009 TB45 Gasoline Engine Service Manuals
behind Tab Labeled EC.

If you have any questions or concerns regarding this bulletin please contact NFC’s Technical Ser-
vice Deparment at 815-568-1487

Sincerely,
Nissan Forklift Corporation

James Clark
Chief Service Officer
 TROUBLE DIAGNOSIS

Diagnosis Chart by Symptom (Cont’d)

Poor starting
Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving
stall

During surge and constant speed driving

Engine rpm does not increase smoothly.
Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge and acceleration
When engine is warming up
Fast idle is not effective
Description/notable
No initial combustion

When engine is cold

During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
characteristics of the symptom

High idle rpm

Low idle rpm

After-burn
Knocking
Backfire

Driving
At Idle
⊕: Highly possible
♦: Possible
∇: Not very possible
Improper bulb contact ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on contact
Compression

condition and the number of cylinders.

pressure

Worn piston ring ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ • Symptom varies depending on degree of

wear and the number of cylinders.

Clogged three-way catalytic ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • In some cases, after engine stall,

converter /exhaust system restarting is possible.

Low idle base speed ∇ ∇ ∇ ∇ ♦ ♦ ♦ ♦ • Engine stall may occur by power steering
load and cargo load during deceleration
or at idling.
Dragging of brakes ♦ ♦ ♦ ♦ • Tires/wheels are hot.

Belt tension too high (excessive ♦ ♦ ♦ ♦ ♦ —

tension)

High A/T load ∇ ∇ ♦ ∇ ♦ • Insufficient ATF amount, improper oil

Other

specification (This symptom may

especially occur in the cold.)
High HYD PUMP load (PS, Cargo) ∇ ∇ ∇ ♦ ♦ ∇ ∇ ∇ ♦ • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)

Foreign material in fuel tank (such ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • With low fuel, this may easily occur.
as dust)

Damaged fan, malfunctioning water ♦ • Noise

pump

Clogged/restricted radiator/ ♦ —
condenser

Also check the following items other than the above:

• Check harness tension.
• Check each connector connection.
• Check ground wire for looseness.
• Check battery connection for looseness or corrosion.
• Check water and oil condition.
• Check fan belts for looseness.

EC-34
 TROUBLE DIAGNOSIS

Description
• “When” a malfunction occurs that is caused by the sensors of
engine or the air-fuel ratio control, “{ }” of the meter panel
illuminates. Then, Diagnostic Trouble Code (DTC) is displayed
on the meter. At this time, the possible cause is displayed by
operating the button.
• For DTC, refer to Table of DTC (EC-36).
• When a malfunction has occurred, check the symptom and
perform the trouble diagnosis using “Diagnosis history”, “ECM
input/output monitor” and “Active test” in the meter.
NOTE:
• For “Diagnosis history”, refer to EC-36.
• For “ECM Input/Output Monitor”, refer to EC-48.
• For “ECM Active Test”, refer to EC-49.
• For “Screen flow”, refer to EC-46.

OBD-II Plug to connect generic scan tool.

Fail-Safe Function
When any of the critical sensors or systems sends a malfunction
message, the fail-safe function estimates the driving conditions with
other input signals and selects safer conditions for engine (vehicle)
control, based on data previously stored in ECM.
Engine
Related sensors Malfunction condition Fail-safe Warning
light

Mass air flow sensor Same as self-diagnosis • Selects fuel injection pulse width depending on engine speed and ON
malfunction detection throttle position so the vehicle can be driven. However, fuel injection
conditions. will be inhibited (fuel cut off) when engine speed exceeds
approximately 800 - 1,600 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with elapsed ON
temperature sensor time after start) to perform controls so the vehicle can be driven.
Accelerator pedal position • Fuel injection will be inhibited when 1 circuit is opened. Release ON
sensor valve mechanically until it can drive at low speed when disconnecting
connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. However, ON
fuel injection will be inhibited (fuel cut off) when engine speed
exceeds approximately 2,500 rpm.

EC-35
 CLASS I, IV, V SERVICE BULLETIN
Nissan Forklift Corporation, North America
240 N Prospect Street, Marengo, IL 60152

SB2010-309
POLICY
Date: July 29, 2010 Page 1 of 2
To: All Dealer Principals, Service Managers

From: Nissan Marketing Department

SUBJECT: New Seat Announcement

As part of our continuous improvement initiatives, Nissan Forklift is pleased to announce that
effective June 30, 2010, most NFC produced lift trucks will include a new full suspension seat
providing increased comfort and ergonomics.
This seat incorporates a patented suspension mechanism offering a softer more cushioned and
comfortable ride for operators of all sizes. Its adjustment levers are more ergonomically posi-
tioned for easier access, making the seat’s fore/aft adjustment lever, weight adjustment dial and
back tilt lever simpler to operate with reduced effort.
In addition to all the same great comfort features of our former seat, this new design incorpo-
rates an Emergency Locking Retractable (ELR) seat belt. This new ELR design prevents cinch-
ing when the operator is twisting/turning in the seat during normal operation, functioning similarly
to your car’s seat belt. And for enhanced comfort for the larger operator, the seat belt length has
been increased to 60”. Also, an orange high visibility seat belt is available as an option.
This new design will be standard on the following product families: All 1F1/1F2, 1F4 and
1B1/1B2 Cushion Series models. Currently not available on: All 1N1 Series, (new) 1Q2 Se-
ries 80 Volt, 1B1/1B2 pneumatics, any trucks that have fingertip controls, or models manufac-
tured for drive-in racking applications.
Attached are the Updated and New Pages for the previous and new seat types for your refer-
ence. Please review this bulletin with all your service personnel due to the new standard Emer-
gency Locking Retractor (ELR) Seat Belt and Warning Switch position change.
The new Seat Belt Interlock Switch position change is done in the Meter Panel Setting as fol-
lows:
Model New Seat From June 30, 2010 Former Seat Prior to June 30, 2010
1F1/1F2/1F4
(B1-17 Lower) NO NC
Refer to Page VC39 for 1F1/1F2 and Page VC41 for 1F4
1B1/1B2-Cushion
(Adjustment Mode 1-6, 17) NO NC
Refer to Page CS30

Note: The information provided in this bulletin is not to be construed as a basis for any claims against NFCNA, unless otherwise stated.
 SB2010-309
POLICY
Page 2 of 2

If any of the new seats are used on units manufactured prior to June 30, 2010 the service tech-
nician will need to go into the meter panel and change switch to NO (Normally Open) position as
stated on page 1.
Please keep a copy of this bulletin with your Dealership’s copy of the 1F1/1F2, 1F4 and 1B1/1B2
Service Manuals (refer to page 1 for Tab Section).
Please contact NFC’s Service Team to answer immediate questions at 815-568-1487. And
NFC’s Parts Distribution Center will provide full aftermarket support for all current and former
seat assemblies and components. Call 815-568-1488 if you have questions on aftermarket
needs.
 CLASS 1
1,,4,5 SERVICE BULLE
SERV TI
BULLETIN
TIN
Nissan Forklift Corporation
240 North Prospect Street; Marengo, IL 60152

SB2008-285R
REVISED ELECTRICAL
Page 1 of 2
Date: April 8, 2008 (Revised May 19, 2008)

To: All Dealer Principals

All Service Managers

From: Technical Service Support Department

Subject: Transmission Sensor - Temperature W

Temperature arning Light
Warning

Applied Models: All L01/L02 and 1F1/1F2 Forklifts

Part #25080-
NFC has received reported incidents for our transmission temperature sensors (Part
FK100
FK100) communicating a high transmission temperature condition; however, NFC has deter-
mined that the transmission sensors are being affected through heavy moist/wet conditions
and applications.

The issue occurs when the temperature sensor gets moist enough with water/moisture, which
allows the moisture to act as an electrical conductor between the electrical contactor and the
grounded sensor body. The affect of this issue will cause the Transmission Temperature
Warning light to illuminate on the dash, and the truck will enter into the “Limp” mode.

Transmission Sensor Locations by Transmission T

Transmission ype
Type
A Single-Wired sensor located within the following transmission list can be easily identified
within the following transmissions:
· C2-2.5 & A2 1 speed – (Transmission P/N 31010-FC300) Located on the right hand
side of transmission above drain plug.
· C1 1 speed – (Transmission P/N 31010-FW00A & FC000) Located on the right hand
side of transmission above drain plug.
· A1 1 speed – (Transmission P/N 31010-FD000) Located on the left hand side of
transmission above drain plug.
· C2.8-3.3 1 speed – (Transmission P/N 31010-FC600) Located on the left hand side
of transmission above drain plug.
· P1 & P2 1 speed – (Transmission P/N 31020-FJ200) Located on the left hand side
bottom of the transmission
· C3-3.6 2 speed – (Transmission P/N 31010-FL300) Located on the right hand side
front of transmission behind the differential

The information provided in this

bulletin is not to be construed as
a basis for any claims against
NFC, unless otherwise stated.

Phone Number: (815) 568-0061 Fax Number: (815) 568-0187

 SB2008-285R
ELECTRICAL
Page 2 of 2

NFC service has tested several aftermarket products to eliminate this issue with effective results.
NFC is recommending that all trucks either being delivered, and/or exists in a heavily moist/wet
outdoor condition, to take the following precautions or recommendations to alleviate this potential
issue during your next scheduled PM or during your PDI inspection:
1. Use one of the following aftermarket products:
· Loctite Superflex Non-Corrosive RTV Silicon (Loctite #51387) or
· Starbrite Liquid Electrical Tape (Starbrite #84158)
2. Generously apply the product between the electrical contactor and the hex portion of the
sensor body
3. Allow the product to appropriately cure before placing the truck back into service (use manu-
facturers recommendations)

Please insert a copy of this bulletin into your Dealership's copy of the L01/L02 and 1F1/1F2 Service
Manuals behind Tab Labeled BE.

Should you have any questions, please contact NFC’s Technical Support Group at 815-568-1487.

Best Regards,
Nissan Forklift Corporation
Hugh Wilson Jr.
Manager, Technical Services
HARNESS LAYOUT
HARNESS LAYOUT
LIGHTS
LIGHTS
LIGHTS
LIGHTS
LIGHTS
LIGHTS
LIGHTS
OTHER
OTHER
OTHER
 WARRANTY COVERAGE AT A GLANCE
To Nissan Forklift Valued Customers
Your Nissan Forklift may be covered by one or more of the following warranty coverages, depending on your
location. Included in your delivery package with this Operator's Manual should be a separate Warranty Statement,
which will explain your coverage.

Basic Coverage* 12 months / 2,000 hours

Powertrain 24 months / 4,000 hours

Emission Control Warranty LSI 36 months or 2,500 hours (General Parts)

Emission Control Warranty LSI 36 months or 4,000 hours (Powertrain Parts)

Long-Term Emission Control Warranty LSI 60 months or 3,500 hours (General Parts)

Long-Term Emission Control Warranty LSI 60 months or 4,000 hours (Powertrain Parts)

GI US-1
Emission Related Warranty CI 60 months or 3,000 hours (General Parts)

LSI = Large Spark Ignited Engines above 25 HP (gas, LPG, LNG)

CI = Compression Ignited Engines (all Diesel)

The above warranty coverage applies to both U.S. EPA and CARB Emission Regulation standards only. These
warranty time periods are for units shipped in the United States and its territories.

For exclusion and limitations, see separate Warranty Statement included with start-up manuals.

*Warranty coverage for tires, battery, optional equipment, and hang on attachments are provided by the local
component manufacturer's representatives, directly.

For warranty coverage and statements outside of the U.S., please contact your local authorized Nissan Forklift dealer.

Jan-04
 K21/K25 2007

EPA AND CARB EMISSION CONTROL LABEL

EPA

! CAUTION

For Units in the US:

• Do not tamper with, destroy
destroy,, remove or alter EPA/CARB label of valve (rocker) cover in any way
EPA/CARB way.. Doing so
could violate EP A/CARB regulations and possibly void the warranty on your Nissan Forklift.
EPA/CARB
• Valve (rocker) cover may be removed for maintenance checks but the original cover must be installed as soon
as maintenance checks are completed.
• You must notify your local Authorized Nissan dealer if either the Valve (Rocker) cover or label is damaged and
Valve
needs to be replaced.

Label for K21 LPG Engine:

4.4 inch (111 mm)

EMISSION CONTROL INFORMATION SEP

Line 1

2006
ENGINE FAMILY: 7NSXB02.548C, ENGINE DISPLACEMENT: 2.5 LITER OCT
Line 2 THIS ENGINE IS CERTIFIED TO OPERATE ON LPG. NOV
LIne 3 EXHAUST EMISSION CONTROL TYPE: TBI, TWC, HO2S DEC
2.3 inch (59.5 mm)

Line 4 USE IN VARIABLE-SPEED APPLICATIONS ONLY JAN

Line 5 IDLE SPEED NO OTHER ADJUSTMENTS NEEDED FEB
Line 6 VALVE LASH 0.38 mm (HOT) MAR
Line 7 SPARK PLUG GAP 0.9 mm APR
MAY Engine manufactured
NO OTHER ADJUSTMENTS NEEDED. JUN month shall be indicated
2007

Line 8
CARB EMISSION STANDARDS : HC+NOx=1.0, CO=8.3 g/bhp-hr JUL by perforating.
EPA Tier2 EMISSION STANDARDS : HC+NOx=1.3, CO=11.1 g/kW-hr AUG
SEP
Line 9 THIS ENGINE COMPLIES WITH CALIFORNIA AND U.S. EPA REGULATIONS OCT
FOR 2007 LARGE NONROAD SI ENGINES. NOV
Line 10 NISSAN MOTOR CO., LTD. K21 L DEC

This label is required by both California CARB and Federal EPA. This label can be misleading if you
are not aware of its intentions and meanings. Let’s take a closer look:
Line 1 - This identifies the engine family to CARB and Federal EPA as well as engine displacement.
Line 2 - This line defines the fuel type that the engine is certified to work with.
Line 3 - Exhaust emission control type defines the method used: TBI (throttle body injection),
TWC (three way catalyst), and HO2S (oxygen sensor).
Line 4 - Test mode defines whether the engine was emission tested at fixed speeds or variable
speeds.
Line 5 - Idle Speed - No other adjustments needed. This indicates that this is tamper proof.
Line 6 and Line 7 - Valve lash and spark plug gap should measure as noted, if not, adjust to
maintain.

05/07 GI US-7
K21/K25 2007
Line 8 - No other adjustments needed - once again indicates that all other components are tamper proof and
therefore do not need any adjustments.
Line 9 - This statement conveys to all who view it that this engine behind the label meets CARB and EPA Regulations
for Tier One (2004) or Tier Two (2007) Large Nonroad Spark Ignited Engines.
Line 10- This indicates the name of the company that holds the compliance certificate, Nissan Motor Company Ltd.
and the engine model and fuel type.

The date code on the right is to mark the date of manufacture of the engine.

Label for K21 Gasoline Engine:

4.4 inch (111 mm)

EMISSION CONTROL INFORMATION SEP

2006
Line 1 ENGINE FAMILY: 7NSXB02.147C, ENGINE DISPLACEMENT: 2.1 LITER OCT
Line 2 THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE. NOV
LIne 3 EXHAUST EMISSION CONTROL TYPE: MPI, TWC, HO2S DEC
2.3 inch (59.5 mm)

Line 4 USE IN VARIABLE-SPEED APPLICATIONS ONLY JAN

Line 5 IDLE SPEED NO OTHER ADJUSTMENTS NEEDED FEB
Line 6 VALVE LASH 0.38 mm (HOT) MAR
Line 7 SPARK PLUG GAP 0.9 mm APR
MAY Engine manufactured month
Line 8 NO OTHER ADJUSTMENTS NEEDED. JUN shall be indicated by

2007
CARB EMISSION STANDARDS : HC+NOx=1.0, CO=8.3 g/bhp-hr JUL perforating.
EPA Tier2 EMISSION STANDARDS : HC+NOx=1.3, CO=11.1 g/kW-hr AUG
SEP
Line 9 THIS ENGINE COMPLIES WITH CALIFORNIA AND U.S. EPA REGULATIONS OCT
FOR 2007 LARGE NONROAD SI ENGINES. NOV
Line 10 NISSAN MOTOR CO., LTD. K21 G DEC

Label for K21 Dual Fuel Engine:

4.4 inch (111 mm)

EMISSION CONTROL INFORMATION SEP

2006

Line 1 ENGINE FAMILY: 7NSXB02.147C, ENGINE DISPLACEMENT: 2.1 LITER OCT

Line 2 THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE AND LPG. NOV
LIne 3 EXHAUST EMISSION CONTROL TYPE: MPI, TBI, TWC, HO2S DEC
2.3 inch (59.5 mm)

Line 4 USE IN VARIABLE-SPEED APPLICATIONS ONLY JAN

Line 5 IDLE SPEED NO OTHER ADJUSTMENTS NEEDED FEB
Line 6 VALVE LASH 0.38 mm (HOT) MAR
Line 7 SPARK PLUG GAP 0.9 mm APR
MAY Engine manufactured month
Line 8 NO OTHER ADJUSTMENTS NEEDED. JUN shall be indicated by
2007

CARB EMISSION STANDARDS : HC+NOx=1.0, CO=8.3 g/bhp-hr JUL perforating.

EPA Tier2 EMISSION STANDARDS : HC+NOx=1.3, CO=11.1 g/kW-hr AUG
SEP
Line 9 THIS ENGINE COMPLIES WITH CALIFORNIA AND U.S. EPA REGULATIONS OCT
FOR 2007 LARGE NONROAD SI ENGINES. NOV
Line 10 NISSAN MOTOR CO., LTD. K21 D DEC

GI US-8 05/07
 K21/K25 2007
Label for K25 LPG Engine:
4.4 inch (111 mm)

EMISSION CONTROL INFORMATION SEP

2006
Line 1 ENGINE FAMILY: 7NSXB02.548C, ENGINE DISPLACEMENT: 2.5 LITER OCT
Line 2 THIS ENGINE IS CERTIFIED TO OPERATE ON LPG. NOV
LIne 3 EXHAUST EMISSION CONTROL TYPE: TBI, TWC, HO2S DEC
2.3 inch (59.5 mm)

Line 4 USE IN VARIABLE-SPEED APPLICATIONS ONLY JAN

Line 5 IDLE SPEED NO OTHER ADJUSTMENTS NEEDED FEB
Line 6 VALVE LASH 0.38 mm (HOT) MAR
Line 7 SPARK PLUG GAP 0.9 mm APR
MAY Engine manufactured
Line 8 NO OTHER ADJUSTMENTS NEEDED. JUN month shall be indicated

2007
CARB EMISSION STANDARDS : HC+NOx=1.0, CO=8.3 g/bhp-hr JUL by perforating.
EPA Tier2 EMISSION STANDARDS : HC+NOx=1.3, CO=11.1 g/kW-hr AUG
SEP
Line 9 THIS ENGINE COMPLIES WITH CALIFORNIA AND U.S. EPA REGULATIONS OCT
FOR 2007 LARGE NONROAD SI ENGINES. NOV
Line 10
NISSAN MOTOR CO., LTD. K25 L DEC

Label for K25 Gasoline Engine:

4.4 inch (111 mm)

EMISSION CONTROL INFORMATION SEP

2006
Line 1 ENGINE FAMILY: 7NSXB02.548C, ENGINE DISPLACEMENT: 2.5 LITER OCT
Line 2 THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE. NOV
LIne 3 EXHAUST EMISSION CONTROL TYPE: MPI, TWC, HO2S DEC
2.3 inch (59.5 mm)

Line 4 USE IN VARIABLE-SPEED APPLICATIONS ONLY JAN

Line 5 IDLE SPEED NO OTHER ADJUSTMENTS NEEDED FEB
Line 6 VALVE LASH 0.38 mm (HOT) MAR
Line 7 SPARK PLUG GAP 0.9 mm APR
MAY Engine manufactured
Line 8 NO OTHER ADJUSTMENTS NEEDED. JUN month shall be indicated
2007

CARB EMISSION STANDARDS : HC+NOx=1.0, CO=8.3 g/bhp-hr JUL by perforating.

EPA Tier2 EMISSION STANDARDS : HC+NOx=1.3, CO=11.1 g/kW-hr AUG
SEP
Line 9 THIS ENGINE COMPLIES WITH CALIFORNIA AND U.S. EPA REGULATIONS OCT
FOR 2007 LARGE NONROAD SI ENGINES. NOV
Line 10 NISSAN MOTOR CO., LTD. K25 G DEC

Label for K25 Dual Fuel Engine:

4.4 inch (111 mm)

EMISSION CONTROL INFORMATION SEP

2006

Line 1 ENGINE FAMILY: 7NSXB02.548C, ENGINE DISPLACEMENT: 2.5 LITER OCT

Line 2 THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE AND LPG. NOV
LIne 3 EXHAUST EMISSION CONTROL TYPE: MPI, TBI, TWC, HO2S DEC
2.3 inch (59.5 mm)

Line 4 USE IN VARIABLE-SPEED APPLICATIONS ONLY JAN

Line 5 IDLE SPEED NO OTHER ADJUSTMENTS NEEDED FEB
Line 6 VALVE LASH 0.38 mm (HOT) MAR
Line 7 SPARK PLUG GAP 0.9 mm APR
MAY Engine manufactured
Line 8 NO OTHER ADJUSTMENTS NEEDED. JUN month shall be indicated
2007

CARB EMISSION STANDARDS : HC+NOx=1.0, CO=8.3 g/bhp-hr JUL by perforating.

EPA Tier2 EMISSION STANDARDS : HC+NOx=1.3, CO=11.1 g/kW-hr AUG
SEP
Line 9 THIS ENGINE COMPLIES WITH CALIFORNIA AND U.S. EPA REGULATIONS OCT
FOR 2007 LARGE NONROAD SI ENGINES. NOV
Line 10 NISSAN MOTOR CO., LTD. K25 D DEC

05/07 GI US-9
K21/K25 2007
WHAT SERVICE PERSONNEL SHOULD KNOW ABOUT
GASES THAT EPA & CARB HAVE REGULATED

OSHA ST ANDARD IN THE WORK PLACE

STANDARD
The CO (carbon monoxide) level shall not exceed 50 PPM measured over an 8 hour period in the
work environment.

SERVICE NOTE:
NOTE: This is only for air quality in the workplace, not exhaust pipe emissions for
any internal combustion engine. With adequate ventilation, the customer
should be able to keep the carbon-monoxide levels below the OSHA
requirement in the workplace.

EP
EPAA & CARB ENVIRONMENT
ENVIRONMENTAL AL ST ANDARD
STANDARD
EPA and Carb regulate emissions to the atmosphere’s environment;
CO = Carbon Monoxide, HC = Hydrocarbon, NOx = Nitrates or Nitrogen.
The EPA/Carb standard is in (grams per brake, H.P. one per hour), not % or PPM (Part Per
Million.)

Because most gas analyzers read in % CO, how does parts per million (PPM) relate to
percentage numbers?

One million parts per million equals one hundred percent of the engines exhaust gases.
10% CO = 100,000 PPM .1% CO = 1,000 PPM
1% CO = 10,000 PPM .01% CO = 100 PPM
For each one one-hundredth of one percent you will have 100 PPM.
Example: .01% x 1,000,000 PPM CO - 100 PPM CO.
NFC STRONGLY RECOMMENDS TO USE ONLY A MULTI GAS EMISSION ANALYZER
FOR CORRECTLY DETERMINING EMISSION LEVELS.

Nissan Forklift Corporation ST ATEMENT of EMISSION COMPLIANCE

STA
The compliance statement is supplied as confirmation that Nissan Forklift and the LSI (Large
Spark Ignited) engines that are used in them and manufactured by NIEM (Nissan Industrial
Engine Manufacturing) Marengo, IL or by Nissan Kohki Co., Ltd., have met or exceeded the
compliance standard for the 2007 EPA and CARB emission regulations at the time of
manufacture and delivery to NFC’s dealers.

Any engine that has met the compliance standard for emission level will have a compliance label
displayed on the engine valve cover.

If you require more information on the EPA or CARB standards, we recommend you contact
these agencies: EP
EPA A CARB
Environmental Protection Agency California Air Resources Board
Ariel Rios Building 1001 “I” Street
1200 Pennsylvania Avenue, N.W. P.O. Box 2815
Washington, DC 20460 Sacramento, CA 95812
www.epa.gov webmaster@arb.ca.gov

GI US-10 05/07
 K21/K25 2007

These are NFC Standards set as reference for servicing engines.

Model Idle HC PPM NOx PPM

and Max RPM CO% Idle
RPM Idle Idle
Engine
K21 700 + 25 2700 0.1 or less 50 or less 250 or less
Gas

K21 700 + 25 2700 0.1 or less 50 or less 250 or less

LPG

K21 700 + 25 2700 0.1 or less 50 or less 250 or less

Dual

K25 700 + 25 2700 0.1 or less 50 or less 250 or less

Gas

K25 700 + 25 2700 0.1 or less 50 or less 250 or less

LPG

K25 700 + 25 2700 0.1 or less 50 or less 250 or less

Dual

SERVICE NOTE: All readings must be taken when the Operating Systems reach
normal operating temperatures, as listed below.

Test Standards
• Engine at operating temperature (80oC, 176oF).
• Hydraulics have been operating to bring fluid to operating temperature
(hydraulic tank warm to touch), (22oC, 72oF).
• Operator engine at maximum RPM (2700) for 1 - 1 1/2 minutes (this
will heat up the catalytic converter).
• Let engine go to idle speed, using a multi-gas Analyzer test emission
level, test emissions within 1 to 2 minutes of engine going to idle RPM
(approx. 700).
• Compare to standard listed above and record.

05/07 GI US-11
 CLASS 1
1,,4,5 SERVICE BULLE
SERV TI
BULLETIN
TIN
Nissan Forklift Corporation
240 North Prospect Street; Marengo, IL 60152

MENT
NT
SB 2007-273
POLICY

TME
Date: February 22, 2007
To: All Dealer Principals

ART
All Service Managers
All Warranty Administrators

DEPAR
AR
All CSS Managers
From: Customer Satisfaction Department - Technical Publications & Quality

TION DEP
Subject: 2007 EPA/CARB Replacement Parts
EPA/CARB

2007 EPA regulations require the manufacturer to keep records of all system changes and/or
adjustments, made in the field, by factory-authorized dealers with factory-trained personnel. In
accordance with this requirement your dealership must utilize the accompanying form when

ACTION
ordering the EPA/CARB compliant parts listed below.

Part Number Description

* Valve Rocker Cover

TISFAC
AC
* Compliant Label

*Customer Satisfaction will supply part by date of engine manufacture.

ATISF
Upon completion of this form fax it to the Customer Satisfaction Service Department at 815-
568-0187. The Service Department will record the adjustments as required based on the
information supplied and release the shipment of the required replacement parts to our Parts
Department. They will then ship accordingly.

SA
If you should have any questions about this EPA requirement please contact James Clark at
815-568-2125 or Wayne Wilde Sr. at 815-568-2140. TOMER S
CUSTOMER
Sincerely,
Nissan Forklift Corporation, N.A.

Customer Satisfaction Department

CUS

The information provided in this

bulletin is not to be construed as
a basis for any claims against
NFC, unless otherwise stated.

Phone Number: (815) 568-0061 Fax Number: (815) 568-0187

 MAIN SPECIFICATIONS

MAIN SPECIFICATIONS MAIN SPECIFICATIONS

Engine type K21

Engine control system Electronic controlled specifications

Fuel specification Gasoline LPG Combined
Total displacement (cc) 2,065
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x stroke mm (in) 89 x 83 (3.50 x 3.27)
Compression ratio 8.7 9.3 8.7
2
Compression pressure [kPa (bar, kg/cm , psi)/rpm] 1,226 (12.2, 12.5, 178)/ 1,275 (12.8, 13.0, 185)/ 1,226 (12.2, 12.5, 178)/
250 250 250
Engine speed control system Engine Control System, electronically controlled throttle
Fuel in use (Note 1) Unleaded regular
At 20P See the left column
gasoline
Maximum output [kW (PS)/rpm] 39.6 (53.8)/2,700 41 (55.7)/2,700 40.7 (55.3)/2,700
Maximum torque [N·m (kg-m)/rpm] 149 (15)/2,000 151 (15)/1,600 150 (15)/2,000
Valve opening/closing timing Intake open (ATDC) 4
(degree)
Intake close (ABDC) 40
Exhaust open (BBDC) 36
Exhaust close (ATDC) 0
Valve clearance mm (in) Intake (when engine is hot) 0.38 (0.0150)
Exhaust (when engine is hot) 0.38 (0.0150)
Firing order 1-3-4-2
Ignition timing (idling) degree (BTDC) 0
On board idle speed (rpm) ATM 700
MTM GOM 700
On board high-idle speed ATM 2,700
(rpm)
MTM GOM 2,700
Allowable maximum engine Instantaneous, no load 3,600
speed (rpm)
Continuous load 3,000
PTO system Silent chain-driven/side PTO
Engine oil (originally fitted) Specification 10W-30 (Class SL)
Amount (US qt, Imp qt) 3.7 (3.9, 6.6) (including oil filter)
Engine dimensions (length x width x height) (Note 2) mm (in) 732.7 x 562.9 x 743
(28.846 x 22.161 x 29.252)
Engine weight (w/o coolant, w/ oil) (Note 2) N (kg, lb) 1,353 (138, 304)

Note 1: Fuel
Gasoline: Use unleaded regular gasoline with an octane
rating of 91 or more.
LPG: Use a fuel of 30P or more in cold seasons. In ambient
temperature of -5°C (23°F) or less, use a 100P fuel .
Note 2: The engine dimensions and weight differs with the
customer specifications. The above data should be
deemed as reference.

Revised: February 2009 GI-12

 MAIN SPECIFICATIONS

Engine type K25

Engine control system Electronic controlled specifications

Fuel specification Gasoline LPG Combined
Total displacement (cc) 2,488
Shape of combustion chamber Bathtub
Valve mechanism OHV
Bore x stroke mm (in) 89 x 100 (3.50 x 3.94)
Compression ratio 8.7 9.2 8.7

Compression pressure [kPa (bar, kg/cm2, psi)/rpm] 1,226 (12.2, 12.5, 178)/ 1,275 (12.8, 13.0, 185)/ 1,226 (12.2, 12.5, 178)/
250 250 250
Engine speed control system Engine Control System, electronically controlled throttle
Fuel in use (Note 1) Unleaded regular
At 20P See the left column
gasoline
Maximum output [kW (PS)/rpm] 45.8 (62.2)/2,700 46.9 (63.7)/2,700 46.7 (63.5)/2,700
Maximum torque [N·m (kg-m)/rpm] 175 (18)/1,600 188 (19)/1,600 187 (19)/1,600
Valve opening/closing timing Intake open (ATDC) 4
(degree)
Intake close (ABDC) 40
Exhaust open (BBDC) 36
Exhaust close (ATDC) 0
Valve clearance mm (in) Intake (when engine is hot) 0.38 (0.0150)
Exhaust (when engine is hot) 0.38 (0.0150)
Firing order 1-3-4-2
Ignition timing (idling) degree (BTDC) 0
On board idle speed (rpm) ATM 700
MTM GOM 700
On board high-idle speed ATM 2,700
(rpm) MTM GOM 2,700
Allowable maximum engine Instantaneous, no load 3,600
speed (rpm)
Continuous load 3,000
PTO system Silent chain-driven/side PTO
Engine oil (originally fitted) Specification 10W-30 (Class SL)
Amount (US qt, Imp qt) 3.7 (3.9, 6.6) (including oil filter)
Engine dimensions (length x width x height) (Note 2) mm (in) 732.7 x 562.9 x 743
(28.846 x 22.161 x 29.252)
Engine weight (w/o coolant, w/ oil) (Note 2) N (kg, lb) 1,353 (138, 304)

Note 1: Fuel
Gasoline: Use unleaded regular gasoline with an octane
rating of 91 or more.
LPG: Use a fuel of 30P or more in cold seasons. In ambient
temperature of -5°C (23°F) or less, use a 100P fuel .
Note 2: The engine dimensions and weight differs with the
customer specifications. The above data should be
deemed as reference.

GI-13 Revised: February 2009

 CLASS 1
1,,4,5 SERVICE BULLE
SERV TI
BULLETIN
TIN
Nissan Forklift Corporation
240 North Prospect Street; Marengo, IL 60152

SB2007-282R
REVISED MECHANICAL

Date: August 23, 2007

To: All Dealer Principals

All Service Managers
All Trainers

From: Technical Publications & Training

Subject: Spark Plugs

Applied Models: K21/K25 Engines from 2004 used in L01/L02 Models

and K21/K25 Engines from 2007 used in 1F1/1F2
Models

Due to the increase in questions regarding spark plug service, NFC has compiled several spark
plug service guidelines to assist you in servicing and maintaining your K21/K25 engines.

l Spark plugs are to be inspected every 200 hours as per NFC's EPA/Carb compliant
recommended engine maintenance.
l Spark plugs should not be removed when engine/head is hot, due to the risk of thread
damage. Stop engine and carry out other PM checks before trying to remove plugs to
let engine and head cool down.
l Always clean and check gap on plug when removed. Adjustment 0.8-0.9mm or
.031-.035in.
l Do not use any type of anti-seize on threads, this may reduce the grounding effect of
spark plug to head and can cause a reduction in spark or a cylinder to misfire.
l Use only OEM spark plugs, part #22401-FU412, which have a special nickel plated
material to assist in reducing the possibility of seizing. Also, make sure the OEM spark
plugs are the correct length and will not let threads past head bore. (See photo
attached of standard OEM spark plug in head)
l Use of non-OEM spark plugs which do not have nickel plating and may be too long will
greatly increase the possibility of seizing and damaging the cylinder during removal.
Also, non-OEM plugs may not fire (spark) correctly causing engine not to maintain
correct emission levels.

The information provided in this

bulletin is not to be construed as
a basis for any claims against
NFC, unless otherwise stated.

Phone Number: (815) 568-0061 Fax Number: (815) 568-0186

 l If the head threads become damaged, a standard thread repair coil kit may be used without
affecting the EPA or Carb warranty.
l When installing new OEM spark plug you should check gap - check and clean threads - then
install plug and torque to 19.6-29.4 Nm or 14-22 ft/lbs.

If you should have any questions on spark plug removal/replacement or planned maintenance always
contact NFC's Service Department at 815-568-0061.

Please insert a copies of this bulletin into any K21/K25 Engine Service Manuals at your Dealership
behind Tab Labeled MA.

Nissan Forklift Corporation

Wayne Wilde Sr.

Director, Training and Technical Publications
 ENGINE INSPECTION AND ADJUSTMENT
Engine Body Related (Cont’d)
COMPRESSION PRESSURE INSPECTION
1. Warm up the engine sufficiently and then stop it.
• Release the fuel pressure. (Electronic controlled
specifications)
• Gasoline: fuel pressure should release back to fuel pump in
tank.
• LPG: fuel pressure should be locked off at fuel shutoff
valve.

CAUTION:
CAUTION:
• Always ensure fuel system is deactivated by removing
relays in blue box (reference BE-15).

2. Remove all spark plugs.

3. Apply a compression gauge correctly to the cylinder plug hole to
be measured.
4. Depress the throttle pedal to the fully-open position.
5. Crank the engine and read the gauge.
• Keep the engine speed at approximately 250 rpm.
• Finish the pressure measurement in as short a time as
possible.

Standard compression pressure

K21 1.45 MPa
SMA042 (14.51 bar, 14.8 kg/cm2, 210 psi)
K25 1.51 MPa
(15.10 bar, 15.4 kg/cm2, 219 psi)

6. The compression pressure differences between cylinders must

not exceed 98 kPa (1.0 bar, 1 kg/cm2, 14 psi) /250 rpm. If any
cylinder shows an extremely low compression pressure, put a
small amount of oil into the cylinder through the spark plug hole
and remeasure the pressure.
• If the pressure rises after filling oil, the piston ring is worn or
damaged.
• If the pressure remains unchanged even after filling oil, the
valve is stuck or inappropriately seated.
• If low compression pressure is observed in two adjacent
cylinders and the pressure is not restored even after filling
oil, the head gasket is leaking. In this case, oil and water
may enter in the combustion chamber.
• If the engine RPM is not in the specified range: Measure
the battery specific gravity.

Revised: February 2009 ET-12

TIGHTENING TORQUE
 ENGINE SERVICE

Engine Assembly (Cont’d)

• Install the sprocket and chain as an assembly.
Install the chain to the sprocket, and then install the chain
and sprocket assembly to the crankshaft and timing chain
housing.
• Remove any old grease from the oil pump spline and apply
new molybdenum grease.
• Install front cover.

EMM0351

• Install the bushing crankshaft pulley for the crankshaft

position sensor.
Before installing the front cover, apply liquid packing to the
cover as shown in the figure. (Refer to the rear oil seal
retainer installation procedure.)
M8 x 25 (thread length) 7T bolt:
: 20.6 - 26.5 N·m (2.1 - 2.7 kg-m, 15 - 20 ft-lb)

EMM0544

1. Installation of crankshaft pulley

(1) Set the crankshaft pulley by aligning the pulley claws to the
groove of the bushing.
(2) Attach the washer and tighten the crankshaft pulley bolt.
Crankshaft pulley bolt:
: 220.5 - 240.1 N·m (22.5 - 24.5 kg-m, 163 - 177 ft-lb)
2. Installation of cylinder head
(1) Both ends of cylinder block top
Drive in dowels into the head bolt holes (two positions).
(2) Place the head gasket on the block top with the copper side fac-
ing up.

EM-45 Revised: February 2009

 ENGINE SERVICE

Engine Assembly (Cont’d)

(3) Set the cylinder head. Apply engine oil to the cylinder bolts and
tighten them to the specified torque in the order shown in the left
figure.

CAUTION:
CAUTION:
• Check tightening angle with an angle wrench (SST) or a
protractor. Do not simply estimate tightening angle.
For the service purposes, the following substitution
torque may be used: 68.6 N·m (7.0 kg-m, 51 ft-lb).

(4) Assembly of push rod

3. Installation of rocker shaft assembly

MAM0147

(1) Securely set the push rod onto the holder of the valve lifter.

FEM058

(2) Assemble the rocker shaft assembly.

: 17.7 - 21.6 N·m (1.8 - 2.2 kg-m, 13 - 16 ft-lb)

CAUTION:
CAUTION:
• Tighten the rocker shaft retaining bolts evenly from inside
to outside.

FEM059

• For the electronic control models, install the spindle support

(left figure) to the distributor installation holes.

EMM0354

EM-46
 ENGINE SERVICE

Engine Assembly (Cont’d)

(3) Adjust the valve clearance.
Valve clearance:
Both intake and exhaust
0.38 mm (0.0150 in) (when engine is hot)

CAUTION:CAUTION:
• The valve clearance must be finally adjusted when the
engine is hot. However, preliminary adjustment in cold
EMM355 state will make the final adjustment easier.

(4) Assemble the rocker cover.

: 13.7 - 15.7 N·m (1.4 - 1.6 kg-m, 10 - 12 ft-lb)
4. Installation of engine accessories
• Install the oil pressure switch.
• Installing oil pump (all models) and distributor (carburetor
model)
(1) Set the crankshaft position to the compression TDC for cylinder
No.1.

EMM0356

(2) Locate the distributor so that the center of its flange long hole
aligns to the bolt hole on the cylinder block, and insert the dis-
tributor. (Do not turn the distributor to align the holes)

EMM0357

(3) Align the drive shaft groove of the engine lubricating oil pump.

EMM0358

EM-47
 ENGINE SERVICE

Engine Assembly (Cont’d)

(4) Align the distributor gear mark to the short mark on the housing.

CAUTION:
CAUTION:
• Do not align the gear mark to the gear installation pin or the
long mark.

(5) Tentatively tighten the retaining bolts.

(6) After installing the distributor gear, adjust the ignition timing by
EMM0359 using a timing light. Then, fully tighten the retaining bolts.
Idle speed and ignition timing (BTDC°/rpm) Electroni c controlled specifications
0°/700 rpm
Carburetor specifications
K21 2°/700 rpm
K25 0°/700 rpm

(7) Installation of oil pan

• Before installing the oil pan, apply liquid packing to the oil
pan flange as shown in the figure.

EMM0545

• Tighten the oil pan retaining bolts to the specified torque in

the order shown in the left figure.
• Tightening torque for oil pan retaining bolt:
: 8.43 - 10.8 N·m
(0.86 - 1.1 kg-m, 75 - 95 in-lb)
M6 x 12 (thread length) 7T bolt
(8) Installation of flywheel housing (or rear plate)
• Install flywheel housing.
• Tightening torque for housing retaining bolt
: 44.1 - 58.8 N·m (4.5 - 6.0 kg-m, 33 - 43 ft-lb)
EMM0361 (9) Installation of flywheel
• Install flywheel.

EMM0362

EM-48
 ENGINE SERVICE

Engine Assembly (Cont’d)

• Tightening torque for flywheel
(Apply engine oil to the bolt seat face and threads)
: 132 - 142 N·m (13.47 - 14.49 kg-m, 97 - 105 ft-lb)
• Check the flywheel runout with a dial gauge by turning the
crankshaft.
Measurement position Repair limit

Section A 0.1 mm (0.004 in)

EMM0363

5. Other parts
• Install the (fuel pump) and piping. (Carburetor model)
• Install the oil filter. For the installation procedure, refer to
page MA-10.
• Install oil level gauge.
(Carburetor model only)
• Install thermostat.

FEM061

• Install thermal transmitter, engine coolant temperature

sensor, and heater connector.
• Install spark plugs.
: 18 - 24 N·m (1.8 - 2.4 kg-m, 13 - 17 ft-lb)
• Installation of distributor vacuum control tube (carburetor
model)
• Installation of high-tension cord (or low-voltage distribution
cord for electronic control model)
• Remove from the engine attachment.
• Install engine mount bracket LH.
EMM0364 • Install engine mount bracket RH.
• Install the alternator and adjusting bar.
• Install the fan belt and fan.
• Adjust the fan belt. Refer to MA section for the adjustment
procedure.

EM-49
ENGINE SERVICE

EM-50
 CLASS 1, 4 & 5 SERVICE BULLETIN
Nissan Forklift Corporation
240 North Prospect Street; Marengo, IL 60152

SB2009-305
ELECTRICAL
PAGE 1 OF 3

Date: October 21, 2009

To: All Dealer Principals

All Service Managers

From: Technical Service Department

Subject: Troubleshooting for Error Code E35

Applied Model: K and TB Engines with LPG on 1F1/1F2 and 1F4 Models

1. INTRODUCTION:
This is to inform you of the troubleshooting procedures for error code E35 (LPG F/INJ open
circuit malfunction).

We have received some technical reports from the field that the engine would not start with the
error code E35 displayed on the meter panel. The problem has been solved by replace the LPG
injector.

Our investigation of the injectors shows that the injector itself has no prolem, however, there are
other causes, such as a loose connection and water contamination to the connectors and to the
LPG injector and ECM.

It is requested to follow the attached troubleshooting procedures for error code E35 in order to
avoid the unnecessary replacement of LPG injectors that may have no problem.

2. TROUBLESHOOTING PROCEDURES:
Please follow the attached troubleshooting for Error Code E35 and Inspection Procedures for
LPG injector.

The information provided in this bulletin is

not to be construed as a basis for any claims
against NFC, unless otherwise stated.
Phone: 815-568-1492 Fax: 815-568-0186
SB2009-305
ELECTRICAL
PAGE 2 OF 3
 SB2009-305
ELECTRICAL
PAGE 3 OF 3

Please insert of copy of this bulletin into your Dealerships copy of the 1F1/1F2 and 1F4 Chassis
Service Manuals, 2007 & 2009 K21_K25 and the 2009 TB45 Gasoline Engine Service Manuals
behind Tab Labeled EC.

If you have any questions or concerns regarding this bulletin please contact NFC’s Technical Ser-
vice Deparment at 815-568-1487

Sincerely,
Nissan Forklift Corporation

James Clark
Chief Service Officer
 TROUBLE DIAGNOSIS

Diagnosis Chart by Symptom (Cont’d)

Poor starting
Impossible
to start
Engine

Other
Symptoms Poor idle Poor driving
stall

During surge and constant speed driving

Engine rpm does not increase smoothly.
Inconsistent idle when engine is cold.

Engine over temperature (Overheat)

Inconsistent idle when warming up

Poor fuel consumption efficiency

During surge and acceleration
When engine is warming up
Fast idle is not effective
Description/notable
No initial combustion

When engine is cold

During a heavy load

During deceleration
Poor power output
Poor acceleration
Initial combustion
characteristics of the symptom

High idle rpm

Low idle rpm

After-burn
Knocking
Backfire

Driving
At Idle
⊕: Highly possible
♦: Possible
∇: Not very possible
Improper bulb contact ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ ♦ • Symptom varies depending on contact
Compression

condition and the number of cylinders.

pressure

Worn piston ring ∇ ♦ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ⊕ ♦ ♦ ♦ ♦ • Symptom varies depending on degree of

wear and the number of cylinders.

Clogged three-way catalytic ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • In some cases, after engine stall,

converter /exhaust system restarting is possible.

Low idle base speed ∇ ∇ ∇ ∇ ♦ ♦ ♦ ♦ • Engine stall may occur by power steering
load and cargo load during deceleration
or at idling.
Dragging of brakes ♦ ♦ ♦ ♦ • Tires/wheels are hot.

Belt tension too high (excessive ♦ ♦ ♦ ♦ ♦ —

tension)

High A/T load ∇ ∇ ♦ ∇ ♦ • Insufficient ATF amount, improper oil

Other

specification (This symptom may

especially occur in the cold.)
High HYD PUMP load (PS, Cargo) ∇ ∇ ∇ ♦ ♦ ∇ ∇ ∇ ♦ • Malfunctioning oil pressure relief valve,
improper oil specification (This symptom
may especially occur in the cold.)

Foreign material in fuel tank (such ∇ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ ♦ • With low fuel, this may easily occur.
as dust)

Damaged fan, malfunctioning water ♦ • Noise

pump

Clogged/restricted radiator/ ♦ —
condenser

Also check the following items other than the above:

• Check harness tension.
• Check each connector connection.
• Check ground wire for looseness.
• Check battery connection for looseness or corrosion.
• Check water and oil condition.
• Check fan belts for looseness.

EC-34
 TROUBLE DIAGNOSIS

Description
• “When” a malfunction occurs that is caused by the sensors of
engine or the air-fuel ratio control, “{ }” of the meter panel
illuminates. Then, Diagnostic Trouble Code (DTC) is displayed
on the meter. At this time, the possible cause is displayed by
operating the button.
• For DTC, refer to Table of DTC (EC-36).
• When a malfunction has occurred, check the symptom and
perform the trouble diagnosis using “Diagnosis history”, “ECM
input/output monitor” and “Active test” in the meter.
NOTE:
• For “Diagnosis history”, refer to EC-36.
• For “ECM Input/Output Monitor”, refer to EC-48.
• For “ECM Active Test”, refer to EC-49.
• For “Screen flow”, refer to EC-46.

OBD-II Plug to connect generic scan tool.

Fail-Safe Function
When any of the critical sensors or systems sends a malfunction
message, the fail-safe function estimates the driving conditions with
other input signals and selects safer conditions for engine (vehicle)
control, based on data previously stored in ECM.
Engine
Related sensors Malfunction condition Fail-safe Warning
light

Mass air flow sensor Same as self-diagnosis • Selects fuel injection pulse width depending on engine speed and ON
malfunction detection throttle position so the vehicle can be driven. However, fuel injection
conditions. will be inhibited (fuel cut off) when engine speed exceeds
approximately 800 - 1,600 rpm.
• Idle speed is 800 rpm.
Engine coolant • Uses the estimated engine coolant temperature (varies with elapsed ON
temperature sensor time after start) to perform controls so the vehicle can be driven.
Accelerator pedal position • Fuel injection will be inhibited when 1 circuit is opened. Release ON
sensor valve mechanically until it can drive at low speed when disconnecting
connector.
Throttle position sensor • Fixes output to a preset value so the vehicle can be driven. However, ON
fuel injection will be inhibited (fuel cut off) when engine speed
exceeds approximately 2,500 rpm.

EC-35
 STARTER MOTOR

STARTER MOTOR Specifications

Items Specification

Part type M000T65381 / M000T65585

Type Built in reduction gear
Output 1.2 kW

February 2009 EE-8

STARTER MOTOR

CAUTION:CAUTION:
• Before starting any electrical system service, make sure to
turn off they key switch and disconnect the battery cable.

Starter Motor Specification

Items Specification

Part type M000T65381

Type Built in reduction gear
Output 1.2 kW

Component Parts Location

Major components of starter motor
Symbol Description

(1) Front bracket

(2) Overrunning clutch
(3) Lever
(4) Internal gear
(5) Packing
(6) Shaft gear
(7) Gear assembly
(8) Packing
(9) Armature
(10) Yoke assembly
(11) Connector brush holder assembly
(12) Rear blanket
(13) Switch assembly
(14) Hexagon head bolt
(15) Flange screw

EE-9 February 2009