INTERNAL COMBUSTION POWERED LIFT TRUCKS. Lubricant Specification and Refill Capacity.. 3. Maintenance Parts 7. Maintenance Quick Guide..

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2 Index INTERNAL COMBUSTION POWERED LIFT TRUCKS Lubricant Specification and Refill Capacity.. 3 Maintenance Parts 7 Maintenance Quick Guide.. 9 ELECTRIC POWERED LIFT TRUCKS Lubricant Specification and Refill Capacity.. 14 Maintenance Parts 16 Maintenance Quick Guide

3 INTERNAL COMBUSTION POWERED LIFT TRUCKS 2

4 Lubricant Specification and Refill Capacity Lubricant Specification D(G)15S/18S/20SC-5 (A2300, V2403, G420F(E), G424I(E)) GC15S/18S/20SC-5 (DL08P, T4) LUBRICANT SPECIFICATION D(G)15/18G (V2403, G420F) G(C)20/25/30/33P-5, G35C-5 (G424F(E), G424P(E)) G(C)20/25/30/33E-5 G20/25/30/33P-5 Plus, G35C-5 Plus (G430FE) D20/25/30/33S-5, D35C-5 (B3.3, 4TNV98, 4TNE98, 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) D(G)20/25/30G (B3.3, 4TNV98, 4TNE98, 4TNE94L, G424F(E),G424P(E)) D(G)35/40/45S-5, D(G)50/55C-5 (DB58S, D439E, V3800, G643(E), PSI 4.3L) D35/40/45S-7, D50/55C-7 (D34) GC35S/40S/45S/50C/55C-5 (G643(E), PSI 4.3L) D(G)50/60/70S-5, D80/90S-5 (DB58S, D439E, V3800, G643(E)) D(G)60/70S-7,D80/90S-7 (D34, PSI 4.3L) D110/130/160S-5 (Shoe) (DE08TS, DL06) D110/130/160S-5 (OCDB) (DE08TS, DL06K) D100/120/140/160S-7 (OCDB) (DL06P) (DL08K. T3) Compartment or System Oil Specification C F Min Max Min Max SAE 5W SAE 10W Engine Crankcase (LP and Gasoline) API SJ/SL/SH/SG SAE 5W SAE 10W SAE 15W SAE 15W SAE 20W SAE 5W SAE 10W Engine Crankcase (Diesel) API CH4/CI4/CJ4, ACEA E5/E7/E9 SAE 5W SAE 10W SAE 15W SAE 15W SAE 20W API CD/TO-2 SAE 10W SAE SAE 10W API CD/TO-4 Power Shift Transmission SAE DEXRON III DEXRON III ZF POWERFLUID UTTO MOBILE FLUID Mobil

5 Lubricant Specification and Refill Capacity Lubricant Specification D(G)15S/18S/20SC-5 (A2300, V2403, G420F(E), G424I(E)) GC15S/18S/20SC-5 G(C)20/25/30/33P-5, G35C-5 (G424F(E), G424P(E)) G(C)20/25/30/33E-5 G20/25/30/33P-5 Plus, G35C-5 Plus (G430FE) D(G)20/25/30G (B3.3, 4TNV98, 4TNE98, 4TNE94L, G424F(E),G424P(E)) D(G)35/40/45S-5, D(G)50/55C-5 (DB58S, D439E, V3800, G643(E), PSI 4.3L) GC35S/40S/45S/50C/55C-5 (G643(E), PSI 4.3L) D110/130/160S-5 (Shoe) (DE08TS, DL06) (DL08K. T3) (DL08P, T4) Compartment or System LUBRICANT SPECIFICATION D(G)15/18G (V2403, G420F) D20/25/30/33S-5, D35C-5 (B3.3, 4TNV98, 4TNE98, 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) D35/40/45S-7, D50/55C-7 (D34) D(G)50/60/70S-5, D80/90S-5 (DB58S, D439E, V3800, G643(E)) D(G)60/70S-7,D80/90S-7 (D34, PSI 4.3L) D110/130/160S-5 (OCDB) (DE08TS, DL06K) D100/120/140/160S-7 (OCDB) (DL06P) Oil Specification C F Min Max Min Max ISO VG Hydraulic and Power Steering System ISO 6743/4 HM ISO VG ISO VG ISO VG Shoe Brake API GL-5 SAE 80W API GL-5 SAE 80W Drive Axle Disc Brake UTTO (API GL-4) SAE 80W API CD/TO-2 SAE 10W SAE Shoe Brake DOT3, DOT4 SAE J1703f ISO VG ISO VG Brake Reservoir Disc Brake (OCDB) ISO 6743/4 HM ISO VG ISO VG ISO VG ISO VG * For the detail information about the lubricant specification, see Lubricant Information section of Operation & Maintenance Manual. * The SAE grade number indicates the viscosity of oil. A proper SAE grade number should be selected according to ambient temperature. 4

6 Lubricant Specification and Refill Capacity Refill Capacity Model Compartment or System D15S/18S/20SC-5 (A2300, V2403) G15S/18S/20SC-5 (G420F(E)) G15S/18S/20SC-5 (G424I(E)) GC15S/18S/20SC-5 (G420F(E)) GC15S/18S/20SC-5 (G424I(E)) D(G)15/18G (V2403, G420F) D20/25/30/33S-5, D35C-5 (B3.3) D20/25/30/33S-5, D35C-5 (4TNV98,/ 4TNE98,/ 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) D20/25/30G (4TNE98, 4TNE94L) G20/25/30/33P-5, G35C-5 (G424F(E)) G20/25/30/33P-5, G35C-5 (G424P(E)) GC20/25/30/33P-5 (G424F(E)) G20/25/30E-5 (G424I(E)) G20/25/30E-5 (G420F(E)) GC20/25/30/33E-5 (G420F(E)) G20/25/30/33P-5 Plus, G35C-5 Plus (G430FE) G20/25/30G (G424F(E), G424P(E)) D35/40/45S-5, D50/55C-5, D40/45/50/55SC-5 (DB58S) D35/40/45S-5, D50/55C-5, D40/45/50/55SC-5 (D439E) D35/40/45S-7, D50/55C-7, D40/45/50/55SC-7 (D34) D35/40/45S-5, D50/55C-5, D40/45/50/55SC-5 (V3800) G35/40/45S-5, G50/55C-5, G40/45/50/55SC-5 (G643(E)) G35/40/45S-5, G50/55C-5 (PSI 4.3L) GC35S/40S/45S/50C/55C-5 (G643(E), PSI 4.3L) Engine Crankcase with Filter Cooling System with Coolant Recovery Bottle 6.5 (1.7) 9.8 (2.55) 4.2 (1.11) 8.5 (2.25) 5.1 (1.34) 8.5 (2.25) 4.0 (1.06) 9.5 (2.5) 5.1 (1.34) 9.5 (2.5) 9.5 (2.5) /4.2 (1.11) 8.4 (2.2) /8.5 (2.25) 7.5 (1.98) 11.0 (2.91) 7.6 (2.00) / 10.7 (2.83) 8.6 (2.27) 10.7 (2.83) 10.7 (2.83) 4.5 (1.19) 9.0 (2.38) 5.7 (1.56) 9.0 (2.38) 4.5 (1.19) 9.0 (2.38) 5.7 (1.51) 8.5 (2.25) 4.2 (1.11) 8.5 (2.25) 4.2 (1.11) 8.5 (2.25) 4.3 (1.14) 9.0 (2.38) 4.5 (1.19) 9.0 (2.38) 20.5 (5.41) 23 (6.1) 8.5 (2.25) 15 (4.0) 13.6 (3.59) 4.7 (1.24) 13.5 (3.57) 23 (6.1) 5.3 (1.4) 19.0 (5.0) 5.3 (1.4) 19.0 (5.0) 4.3 (1.1) 19.0 (5.0) Fuel Tank 42 (11.0) 42 (11.1) 51 (13.47) 51 (13.47) 51 (13.47) 50 (13.2) 51 (13.47) 51 (13.47) 40 (10.56) 51 (13.47) 51 (13.47) 40 (10.56) 51 (13.47) 50 (13.2) 90.0 (23.8) 90.0 (23.8) 90.0 (23.8) 90.0 (23.8) Power Shift Transmission 11.2 (3) 11.2 (3) 11.2 (3) 11.2 (3) 11.2 (3) 8.5 (2.24) (3.43) (3.43) (3.43) 7.0 (1.85) (3.43) (3.43) 11.2 (3.0) (3.43) (3.43) 11.2 (3.0) (3.43) 7.0 (1.85) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) (3.4) Hydraulic and Power Steering System 30 (7.9) 30 (7.9) 30 (7.9) 25 (6.6) 25 (6.6) 30 (7.9) 34 (8.98) 34 (8.98) 34 (8.98) 44 (11.6) 34 (8.98) 34 (8.98) 34 (8.98) 34 (8.98) 34 (8.98) 34 (8.98) 34 (8.98) 44 (11.6) 73.0 (19.3) 73.0 (19.3) 73.0 (19.3) 73.0 (19.3) 73.0 (19.3) 73.0 (19.3) 73.0 (19.3) Drive Axle Disc Brake 5.0 (1.3) 5.0 (1.3) 5.0 (1.3) 5.0 (1.3) 5.0 (1.3) 10.0 (2.64) 10.0 (2.64) Shoe Brake 5.0 (1.3) 5.0 (1.3) 5.0 (1.3) 7.5 (2.0) 8.0 (2.11) 8.0 (2.11) Brake Reservoir (If equipped) 1.0 (0.26) 1.0 (0.26) 5

7 Lubricant Specification and Refill Capacity Refill Capacity Model Compartment or System G50/60/70S-5 (G643(E)) G50/60/70S-7 (PSI 4.3L, 2 speed) D50/60/70S-5 (DB58S, 2 speed) D50/60/70/80/90S-5 (V3800, 2 speed) D50/60/70S-5 (D439E, 2 speed) D60/70S-7 (D34, 2 speed) D50/60/70/80/90S-5 (DB58S, 3 speed) D50/60/70/80/90S-5 ( V3800, 3 speed) D50/60/70/80/90S-5 (D439E, 3 speed) D50/60/70/80/90S-7 (D34, 3 speed) D110/130S-5 (Non Certi) (DE08TS) D160S-5 (Non Certi) (DE08TS) D110/130S-5 (Tier III, Tier IV) (DL06) D160S-5 (Tier III, Tier IV) ( DL06) D100/120S-7 (DL06P) D140/160S-7 (DL06P) DV180/200S-7 (DL08K) DV250S-7 (DL08K) DV180S-7 (DL08P, T4) DV250S-7 (DL08P, T4) Engine Crankcase with Filter 4.3 (1.1) 4.3 (1.1) 20.5 (5.41) 13.5 (3.56) 8.5 (2.25) 12.6 (3.32) 20.5 (5.41) 13.5 (3.56) 8.5 (2.25) 12.6 (3.32) 24 (6.34) 24 (6.34) 29 (7.66) 29 (7.66) 29 (7.66) 29 (7.66) 36 (9.5) 36 (9.5) 39 (10.3) 39 (10.3) Cooling System with Coolant Recovery Bottle 19.0 (5.0) 19.0 (5.0) 18.5 (4.89) 18.5 (4.89) 15 (4.0) 12.7 (3.35) 23 (6.08) 23 (6.08) 15 (4.0) 12.7 (3.35) 35 (5) 35 (5) 35 (5) 35 (5) 35 (5) 35 (5) 50 (13.2) 50 (13.2) 50 (13.2) 50 (13.2) Fuel Tank 140 (37) 140 (37) 140 (37) 137 (36.1) 140 (37) 140 (37) 140 (37) 137 (36) 170 (44.9) 300 (79.3) 170 (44.9) 300 (79.3) 200 (52.8) 250 (66) 280 (74) 380 (100) 300 (79.3) 400 (105.6) Power Shift Transmission 11 (2.9) 13 (3.4) 11 (2.9) 11 (2.9) 11 (2.9) 11 (2.9) 23 (6.08) 21 (5.5) 23 (6.08) 21 (5.5) 25 (6.6) 25 (6.6) 25 (6.6) 25 (6.6) 25 (6.6) 25 (6.6) 33 (8.7) 33 (8.7) 25 (6.6) 25 (6.6) Hydraulic and Power Steering System 117 (3) 117 (3) 117 (3) 117 (3) 117 (3) 117 (3) 117 (3) 117 (3) 117 (3) 117 (3) 180 (47.6) 180 (47.6) 180 (47.6) 180 (47.6) 180 (47.6) 180 (47.6) 180 (47.6) 300 (79.3) 180 (47.6) 180 (47.6) Drive Axle Disc Brake Shoe Brake 20 (5.3) 24.7 (6.5) 21 (5.5) 24.7 (6.5) 19 (5.02) 24.7 (6.5) 20 (5.3) 24.7 (6.5) 19 (5.02) 20 (5.3) 20 (5.3) 24 (6.3) 23 (6.08) 27.2 (7.2) Brake Reservoir (If equipped) 6

8 Maintenance Parts D15S/18S/20SC-5 ( A2300) D15S/18S/20SC-5 (V2403) D15/18G (V2403) G15S/18S/20SC-5 (G420F(E)) G15S/18S/20SC-5 (G424I(E)) GC15S/18S/20SC-5 (G420F) GC15S/18S/20SC-5 (G424I(E)) G15/18G (G420F) D20/25/30/33S-5, D35C-5 (B3.3) D20/25/30/33S-5, D35C-5 (4TNV98, 4TNE98, 4TNE94L) D20/25/30G (4TNE98, 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) G20/25/30/33P-5, GC20/25/30/33P-5 (G424F) G20/25/30/33P-5, GC20/25/30/33P-5 (G424P(E)) G20/25/30/33P-5 Plus, G35C-5 Plus (G430F(E)) G20/25/30/33E-5, GC20/25/30/33E-5 (G424F(E)) G20/25/30E-5 (G424I(E)) G20/25/30G (G424F, G424P(E)) Model Part Name Air Cleaner Element - Primary A A A A A A A A A A A Air Cleaner Element - Safety A A A A A A A A A A A Fuel Cartridge - Engine A A A A A A Engine Oil Filter A A A A A A A A A A A A A Suction Filter - Hydraulic D D A A A D A D A Return Filter - Hydraulic D D D D A D A Transmission Oil Filter A A A A A D A D A Fuel Filter - LPG (Repair Kit) D D D Timing Belt A A A A A A / Oxygen Sensor A A

9 Maintenance Parts D35/40/45S-5,D50/55C-5, D40/45/50/55SC-5 (DB58S) D35/40/45S-5, D50/55C-5, D40/45/50/55SC-5 (D439E) D35/40/45S-7, D50/55C-7, D40/45/50/55SC-7 (D34) D35/40/45S-5,D50/55C-5, D40/45/50/55SC-5 (V3800) G35/40/45S-5,G50/55C-5, G40/45/50/55SC-5 GC35S/40S/45S/50C/55C-5 (G643) G35/40/45S-5,G50/55C-5, G40/45/50/55SC-5 GC35S/40S/45S/50C/55C-5 (PSI 4.3L) G50/60/70S-5 (G643) G60/70S-7 (PSI 4.3L) D50/60/70S-5 (2 speed) (DB58S) D50/60/70S-5 (2 speed) (D439E) D60/70S-5 (2 speed) (V3800) D60/70/80/90S-5 (3 speed) (V3800) D50/60/70/80/90S-5 (3 speed) (DB58S) D50/60/70/80/90S-5 (3 speed) (D439E) D60/70/80/90S-7 (3 speed) (D34) D110/130/160S-5 (Non Certi) (DE08TS, Shoe) D110/130/160S-5(Tier III, Tier IV) (DL06, Shoe) D110/130/160S-5 (Non Certi)(DE08TS, OCDB) D100/120/140/160S-7 (DL06, Tier 4) DV180/200S-7 (DL08 Tier 3) DV250S-7 (DL08 Tier 3) DV180/250S-7 (DL08 Tier 4) Part Name Model Air Cleaner Element - Primary A A A A A A A A A Air Cleaner Element - Safety A A A A A A A A A Fuel Cartridge - Engine A A A A Engine Oil Filter A A A A A A B Suction Filter - Hydraulic A A A A A A A A A A Return Filter - Hydraulic D D D D D D D A A Transmission Oil Filter D D K A (A453462) A A K Fuel Filter - LPG (Repair Kit) D (D141186) D (D141186) Oxygen Sensor A A

10 Maintenance Quick Guide FREQUENCY WHAT TO DO HOW TO DO C CHECK I INSPECT Chg CHANGE A ADJUST L LUBRICATE P REPACK N CLEAN D DRAIN T TEST S RESET R EASSEMBLE O Oiling D(G)15S/18S/20SC-5 (A2300, V2403, G420F(E),G424I(E)) GC15S/18S/20SC-5 D(G)15/18G (V2403, G420F) G(C)20/25/30/33P-5, G35C-5 (G424F(E), G424P(E)) G(GC)20/25/30/33E-5 G20/25/30/33P-5,G35C-5 Plus (G430FE) D20/25/30/33S-5,D35C-5 (B3.3, 4TNV98, 4TNE98, 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) D(G)20/25/30G (B3.3, 4TNV98, 4TNE98,4TNE94L, G424F(E), G424P(E)) D(G)35/40/45S-5, D(G)50/55C-5 (DB58S, D439E, V3800, G643(E), PSI 4.3L) D35/40/45S-7, D50/55C-7 (D34) GC35S/40S/45S/50C/55C-5 (G643(E), PSI 4.3L) D(G)50/60/70S-5, D80/90S-5 (DB58S, D439E, V3800, G643(E)) D(G)60/70S-7, D80/90S-7 (D34, PSI 4.3L) D110/130/160S-5 (DE08TS, DL06) D100/120/140/160S-7 (OCDB) (DL06P) (DL08K) (DL08P, T4) WHEN REQUIRED Battery Terminal N I Brake Oil (OCDB Only) C Carriage Roller Extrusion A C Circuit Breaker T Draining the Water From the Fuel Filter C D Engine Valve Lash (Diesel Engine Only) C A Fuel Tank Filler Cap & Screen (If Equipped) N Fuse & Relay Fuses, Bulbs and Circuit Breaker & Relay S Chg Mast, Carriage, Lift Chain & Attachment I L Priming the Fuel System (Diesel Engine Only) Radiator Cap N Chg SCR Cleaning - DeSOx Seat, Hood Latch and Support Cylinder C L Steering Mechanism (Link Bearing) C L Test Fuel System for Leaks (LP and Dual Fuel Engine Only) T Transmission Cooler N Chg Transmission Display C Tires and Wheels (D, G-Series) I C Water Separator (Diesel Engine Only) D C Wheel Bolts I Air Cleaner Indicator C Air Intake System C Back-Up Alarm (If Equipped) T Brake Oil Level C Coolant Level C N Drive Axle Oil Level C DEF/AD-Blue Fluid Level C Engine Oil Level C EVERY 10 Exhaust Leaks C I HOURS or DAILY Fluid Leaks C I Foot Pedal Operation (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) T Hydraulic Oil Level C Inspect Acceleration Pedal Operation (G643E/ PSI 4.3L Only) I Mast Channels (Roller Mast Only) L Parking Brake I Transmission Oil Level C Thermostat Valve (If Equipped) C Walk-Around Inspection I Please refer to the latest revision of the Operation maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. 9

11 Maintenance Quick Guide FREQUENCY WHAT TO DO HOW TO DO C CHECK I INSPECT Chg CHANGE A ADJUST L LUBRICATE P REPACK N CLEAN D DRAIN T TEST S RESET R EASSEMBLE O Oiling D(G)15S/18S/20SC-5 (A2300, V2403, G420F(E),G424I(E)) GC15S/18S/20SC-5 D(G)15/18G (V2403, G420F) G(C)20/25/30/33P-5, G35C-5 (G424F(E), G424P(E)) G(GC)20/25/30/33E-5 G20/25/30/33P-5,G35C-5 Plus (G430FE) D20/25/30/33S-5,D35C-5 (B3.3, 4TNV98, 4TNE98, 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) D(G)20/25/30G (B3.3, 4TNV98, 4TNE98,4TNE94L, G424F(E), G424P(E)) D(G)35/40/45S-5, D(G)50/55C-5 (DB58S, D439E, V3800, G643(E), PSI 4.3L) D35/40/45S-7, D50/55C-7 (D34) GC35S/40S/45S/50C/55C-5 (G643(E), PSI 4.3L) D(G)50/60/70S-5, D80/90S-5 (DB58S, D439E, V3800, G643(E)) D(G)60/70S-7, D80/90S-7 (D34, PSI 4.3L) D110/130/160S-5 (DE08TS, DL06) D100/120/140/160S-7 (OCDB) (DL06P) (DL08K) (DL08P, T4) FIRST 50~100 HOURS FIRST 250 HOURS EVERY 250HRS or MONTHLY EVERY 500HRS or 3 MONTHS Drive Axle Oil N C Chg Engine Oil & Filter (Diesel Engine Only) Chg Parking Brake T A Transmission Oil & Oil Filter & Strainer N Chg C Brake Oil Tank and Strainer (OCDB) N Chg C Engine Valve Lash (Diesel Engine Only) C A Hydraulic Return Filter Chg Air Intake System C N Battery Terminal N I Brake Oil Level C Drive Axle Oil Level Chg Engine Oil & Filter Chg Fuel Filter (Diesel Engine Only) Chg Hydraulic Oil Level C Mast, Carriage, Lift Chains & Attachments I L PCV Valve System I N Steering Mechanism C L Wheel Bolts & Nuts C I Air Intake System C N Battery Terminal N I Belts C A Brake Cam Shaft & Slack Adjuster L Brake Oil Tank and Strainer (OCDB) Chg N Cabin Mounting I Carriage Side Rollers Thrust (If Equipped) L Carriage Side Rollers L Carriage Sideshifter (If Equipped) L Circulation Pump Belt (OCDB & LPG Engine Only) C A Crosshead Roller I Cylinder Rod Extension A Drive Axle Oil (OCDB) Chg Drive Axle Oil & Strainer C N Chg Electrical System (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) I Engine Oil & Filter(Diesel Engine Only) Chg Fuel Filter (Diesel Engine Only) Chg CAUTION Before performing any work, be sure to refer to and follow all recommended safety precautions set out in the applicable DOOSAN Maintenance Manual. In addition, DOOSAN recommends that all mechanics wear appropriate protective items, such as safety glasse Please refer to the latest revision of the Operation maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. 10

12 Maintenance Quick Guide FREQUENCY WHAT TO DO HOW TO DO C CHECK I INSPECT Chg CHANGE A ADJUST L LUBRICATE P REPACK N CLEAN D DRAIN T TEST S RESET R EASSEMBLE O Oiling D(G)15S/18S/20SC-5 (A2300, V2403, G420F(E),G424I(E)) GC15S/18S/20SC-5 D(G)15/18G (V2403, G420F) G(C)20/25/30/33P-5, G35C-5 (G424F(E), G424P(E)) G(GC)20/25/30/33E-5 G20/25/30/33P-5,G35C-5 Plus (G430FE) D20/25/30/33S-5,D35C-5 (B3.3, 4TNV98, 4TNE98, 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) D(G)20/25/30G (B3.3, 4TNV98, 4TNE98,4TNE94L, G424F(E), G424P(E)) D(G)35/40/45S-5, D(G)50/55C-5 (DB58S, D439E, V3800, G643(E), PSI 4.3L) D35/40/45S-7, D50/55C-7 (D34) GC35S/40S/45S/50C/55C-5 (G643(E), PSI 4.3L) D(G)50/60/70S-5, D80/90S-5 (DB58S, D439E, V3800, G643(E)) D(G)60/70S-7, D80/90S-7 (D34, PSI 4.3L) D110/130/160S-5 (DE08TS, DL06) D100/120/140/160S-7 (OCDB) (DL06P) (DL08K) (DL08P, T4) EVERY 500HRS or 3 MONTHS EVERY 1000HRS or 6 MONTHS Fuel Trim Valve - FTV(G420F(E) / G424F(E) / G424I(E) / G643E) I Governor Lever and Engine Speed Control (Diesel Engine Only) C A Horn & Lights (If Equipped) C Inching & Brake Control Shaft L Mast, Carriage, Lift Chains & Attachments I L Mast Hinge Pin L Operator Compartment (Cabin and Overhead Guard) I Overhead Guard I Parking Brake T A PCV Valve System I N Servicing Filter Element Steering Axle Support C O Steering Mechanism C L Steer Suspension I Tilt Cylinders C A L Transmission Oil & Filter (2speed only) Chg Universal Joint I L Vacuum Lines & Fittings(G420F(E) / G424F(E) / G424I(E) / G643E) C Water Separator (Diesel Engine Only) N Wheel Bolts & Nuts I Air Breather Chg Air Intake System Chg Brake Oil Tank and Strainer Chg C N Carburetor (LP - Gas Engine Only) A N Coolant Hoses I Drive Axle Oil Chg Engine Valve Lash (Diesel Engine Only) C A Fuel Filter Chg C N Fuel Lines & Fittings C Hydraulic High Pressure Filter Chg Hydraulic Strainer & Breather C Chg N Hydraulic Return Filter, Breather & Strainer C Chg N Lift Chains T C A LP Regulator/Converter Inspection(G420F(E) / G424F(E) / G643E) Mixer Assembly (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) I Strainer & Breather Chg C N Throttle Assembly (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) I Transmission Oil, Oil Filter & Strainer N C Chg Transmission Oil (2speed Only) Chg Transmission Oil, Oil Filter (3speed, ZF 3WG116) C Universal Joint I Please refer to the latest revision of the Operation maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. 11

13 Maintenance Quick Guide FREQUENCY WHAT TO DO HOW TO DO C CHECK I INSPECT Chg CHANGE A ADJUST L LUBRICATE P REPACK N CLEAN D DRAIN T TEST S RESET R EASSEMBLE O Oiling D(G)15S/18S/20SC-5 (A2300, V2403, G420F(E),G424I(E)) GC15S/18S/20SC-5 D(G)15/18G (V2403, G420F) G(C)20/25/30/33P-5, G35C-5 (G424F(E), G424P(E)) G(GC)20/25/30/33E-5 G20/25/30/33P-5,G35C-5 Plus (G430FE) D20/25/30/33S-5,D35C-5 (B3.3, 4TNV98, 4TNE98, 4TNE94L) D20/25/30/33S-7, D35C-7 (D24) D(G)20/25/30G (B3.3, 4TNV98, 4TNE98,4TNE94L, G424F(E), G424P(E)) D(G)35/40/45S-5, D(G)50/55C-5 (DB58S, D439E, V3800, G643(E), PSI 4.3L) D35/40/45S-7, D50/55C-7 (D34) GC35S/40S/45S/50C/55C-5 (G643(E), PSI 4.3L) D(G)50/60/70S-5, D80/90S-5 (DB58S, D439E, V3800, G643(E)) D(G)60/70S-7, D80/90S-7 (D34, PSI 4.3L) D110/130/160S-5 (DE08TS, DL06) D100/120/140/160S-7 (OCDB) (DL06P) (DL08K) (DL08P, T4) EVERY 1500HRS or 9 MONTHS EVERY 2000HRS or 12 MONTHS EVERY 2500HRS or 15 MONTHS EVERY 3000 HRS or 18 MONTHS Drive Axle Oil C Chg N Fuel Filter (G420F(E) / G424F(E) / G643E) Chg Fuel Injection (Diesel Engine Only) I N T Ignition System (G420F(E) / G424F(E) / G643E) I LP Fuel Filter Element (G420F(E) / G424F(E) / G643E) Chg Spark Plugs (G420F(E) / G424F(E) / G643E) I Chg Testing Fuel Lock-off Operation (G420F(E) / G424F(E) / G643E) T Transmission Oil & Filer(3 Speed, ZF 3WG94) T Air Intake System Chg Cooling System N Chg Drive Wheel Bearing (Power Shaft and Drive Wheel) R Engine Valve Lash (Diesel Engine Only) C A Exhaust System I Forks I Fuel Lines & Fittings C Hydraulic Oil Chg Steer Wheel Bearings R Transmission Oil & Filer(3 Speed, ZF 3WG94) Chg Inspect Battery System I Intake Leaks (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) C Hydraulic Oil C N Chg Oxygen Sensor (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) C PCV Valve and breather element (G420F(E) / G424F(E) / G643E) Chg Spark Plugs (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) I Chg TMAP Sensor (G420F(E) / G424F(E) / G424I(E) / G430FE / G643E) C Timing Belt (G420F(E) / G424F(E)) Chg Timing Belt for Counterbalance Shaft Chg DPF Maintenance N DEF Filter / Supply Module Filter Replacement (D34P Engine Only) Chg Fuel Injection Pump (Diesel Engine Only) C Replace Oxygen Sensor (G420F(E) / G424F(E) / G643E) Chg EVERY 4500 HRS DEF Filter / Supply Module Filter Replacement Chg EVERY 6000 HRS DEF Filter / Supply Module Filter (If SCR Equipped) Chg EVERY 8000 HRS Timing Belt (G424P(E) LP, Dual Fuel Engine Only) Chg or 48 Months NOTE 1: TIER II diesel engines of the following models only have engine oil every 500hrs though they must still have the first 50~100 hrs service. (Cummins B3.3, Yammar 4TNV98, DB58S, DL06, DE08TS) Please refer to the latest revision of the Operation maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. 12

14 ELECTRIC POWERED LIFT TRUCKS 13

15 Lubricant Specification and Refill Capacity Lubricant Specification Compartment or System LUBRICANT SPECIFICATION Oil Specification C F Min Max Min Max BR13/15/18S(J)-5, BR14/16JW-5 BR13/15/18S-7, BR20/25S-7 BR14/16JW-7 BR14/16JW-7 PLUS BR18/20SP-7 BR20/25S-5 B10/13/15/16R-5 B(C)15/18S-5, BC20SC-5 B15/18/20T-5 (AC) B15/18/20T-7, B18/20TL-7 (AC) B16/18/20X-5 (AC) B16/18/20X-7 (AC) B(C)20/25/30/32S-5, B20/25SE-5, BC25SE-5 BC20/25/30/32S-7, BC25SE-7 B22/25/30/35X-5 B22/25/30/35X-7 B40/45/50X-5 ISO VG Hydraulic and Power Steering System ISO 6743/4 HM ISO VG ISO VG ISO VG ISO VG API GL-5 SAE 80W/ Drive Axle API GL-4 SAE 80W SAE 10 W API CD/ TO-4 SAE Brake Reservoir ISO 6743/4 HM ISO VG * For the detail information about the lubricant specification, see Lubricant Information section of Operation & Maintenance Manual. * The SAE grade number indicates the viscosity of oil. A proper SAE grade number should be selected according to ambient temperature. 14

16 Lubricant Specification and Refill Capacity Refill Capacity REFILL CAPACITY (APPROXIMATE) Compartment or System BR13/15/18S(J)-5, BR14/16JW-5 BR13/15/18S-7 BR20/25S-7 BR14/16JW-7 BR18/20SP-7 BR20/25S-5 B10/13/15/16R-5 B(C)15/18S-5, BC20SC-5 B15/18/20T-5 (AC) B15/18/20T-7 (AC) B16/18/20X-5 (AC) B16/18/20X-7 (AC) B(C)20/25/30/32S-5, B20/25SE-5, BC25SE-5 BC20/25/30/32S-7, BC25SE-7 B22/25/30/35X-5 B22/25/30/35X-7 B40/45/50X-5 Hydraulic & Power Steering System (U.S. Gal) 16 (4.23) 16 (4.23) 18 (4.76) 16 (4.23) 20 (5.3) 18 (4.76) 18 (4.76) 20 (5.28) 18 (4.76) 18 (4.76) 18 (4.76) 18 (4.76) 32 (8.3) 32 (8.3) 55 (14.3) 32 (8.3) 55 (14.3) Drive Axle (U.S. Gal) 4.1 (1.1) 4.2 (1.11) 5 (1.32) 1.4 (0.29) 1.4 (0.29) 1.4 (0.29) 1.4 (0.29) 3.0 (0.79) 2.4 (4) 3.0 (0.79) Brake Reservoir (U.S. Gal) 0.5 (0.13) Transfer Case (U.S. Gal) 3.4 (0.9) 3.4 (0.9) 4.1 (1.1) 3.3 (0.87) 3.3 (0.87) 15

17 BR13/15/18S(J)-5, BR14/16JW-5 BR14/16JW-7 (PLUS) BR18/20SP-7 BR13/15/18S-7 BR20/25S-5 BR20/25S-7 B10/13/15/16R-5 B15/18S-5 B(C)15/18S-5, BC20SC-5 B15/18/20T-5, B15/18/20T-7, B18/20TL-7 (AC) B16/18/20X-5, B16/18/20X-7 (AC) B(C)20/25/30/32S-5, B20/25SE-5, BC25SE-5 B22/25/30/35X-5, B22/25/30/35X-7 B40/45/50X-5 Maintenance Parts Model Part Name Filter - Return Filter - Suction Strainer D D D D D D D D A D A

18 Maintenance Quick Guide FREQUENCY WHAT TO DO HOW TO DO C CHECK I INSPECT Chg CHANGE Charg CHARGE A ADJUST L LUBRICATE P REPACK N CLEAN D DRAIN T TEST S RESET R REASSEMBLE E REPLACE Dig DISCHARGE Exg EXCHANGE BR13/15/18S(J)-5, BR14/16JW-5 BR13/15/18S-7,BR20/25S-7 BR14/16JW-7 BR14/16JW-7 PLUS BR18/20SP-7 BR20/25S-5 B10/13/15/16R-5 B(C)15/18S-5, BC20SC-5 B15/18/20T-5 (AC) B15/18/20T-7, B18/20TL-7 (AC) B16/18/20X-5 (AC) B16/18/20X-7 (AC) B(C)20/25/30/32S-5, B20/25SE-5, BC25SE-5 BC20/25/30/32S-7, BC25SE-7 B22/25/30/35X-5 B22/25/30/35X-7 B40/45/50X-5 WHEN REQUIRED EVERY 10 HOURS or DAILY FIRST 25 HOURS Axle Oil Level C Carriage Roller Extrusion A Compact Display Keys Drive Axle Gear Boxes C Fuses E Greasing Point Power Module Dig Run Time Diagnostic Transfer case C Parking brake A Seat L Self Diagnostics T Wheel Bolts C Back-up Alarm (If Equipped) T Battery C Exg Charg Carriage Channels L Indicator C Mast Channels L Tires and Wheels I Walk-Around Inspection I Wheel Bolts C Transfer Case C Drive Axle Oil Chg FIRST 50~100 HOURS Parking Brake T Transfer Case Oil Level C FIRST 200 HOURS Transfer Case Oil Level Chg EVERY 250HRS or MONTHLY Battery Cell, Case & Battery Plug C N Brake Cam & Brake Spring C A Brake System, Brake Oil Level C Please refer to the latest revision of the Operation maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. 17

19 Maintenance Quick Guide FREQUENCY WHAT TO DO HOW TO DO C CHECK I INSPECT Chg CHANGE Charg CHARGE A ADJUST L LUBRICATE P REPACK N CLEAN D DRAIN T TEST S RESET R REASSEMBLE E REPLACE Dig DISCHARGE Exg EXCHANGE BR13/15/18S(J)-5, BR14/16JW-5 BR13/15/18S-7,BR20/25S-7 BR14/16JW-7 BR14/16JW-7 PLUS BR18/20SP-7 BR20/25S-5 B10/13/15/16R-5 B(C)15/18S-5, BC20SC-5 B15/18/20T-5 (AC) B15/18/20T-7, B18/20TL-7 (AC) B16/18/20X-5 (AC) B16/18/20X-7 (AC) B(C)20/25/30/32S-5, B20/25SE-5, BC25SE-5 BC20/25/30/32S-7, BC25SE-7 B22/25/30/35X-5 B22/25/30/35X-7 B40/45/50X-5 Control Valve Microswitch C Drive Axle Oil Level C Hydraulic Return Filter Chg Hydraulic System C EVERY 250HRS or MONTHLY EVERY 500HRS or 3 MONTHS Hydraulic Oil Level C Mast, Carriage, Lift Chains & Attachmemts I A L Parking Brake T Steer Angle Switches C N Steering System L Wheel Bolts C Axle Oil Chg Battery Cell, Case & Battery Plug C N Brake Cam & Brake Spring C A Control Panel N I Control Valve Microswitch C Crosshead Rollers C I Cylinder Rod Extension A Direction Control forward/reverse Switch C Directional Lever C Drive Axle Oil Chg Hydraulic and Power Steering System C Hydraulic System C Hydraulic Oil Check, Hydraulic Oil Level C Mast, Carriage, Lift Chains & Attachmemts I A L Mast Hinge Pins L Overhead Guard I Parking Brake T Steer Angle Switches C N Steering System, Steering Mechanism L Tilt Cylinder C A L Transfer Case Oil Level C Please refer to the latest revision of the Operation maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. 18

20 Maintenance Quick Guide FREQUENCY WHAT TO DO HOW TO DO C CHECK I INSPECT Chg CHANGE Charg CHARGE A ADJUST L LUBRICATE P REPACK N CLEAN D DRAIN T TEST S RESET R REASSEMBLE E REPLACE Dig DISCHARGE Exg EXCHANGE BR13/15/18S(J)-5, BR14/16JW-5 BR13/15/18S-7,BR20/25S-7 BR14/16JW-7 BR14/16JW-7 PLUS BR18/20SP-7 BR20/25S-5 B10/13/15/16R-5 B(C)15/18S-5, BC20SC-5 B15/18/20T-5 (AC) B15/18/20T-7, B18/20TL-7 (AC) B16/18/20X-5 (AC) B16/18/20X-7 (AC) B(C)20/25/30/32S-5, B20/25SE-5, BC25SE-5 BC20/25/30/32S-7, BC25SE-7 B22/25/30/35X-5 B22/25/30/35X-7 B40/45/50X-5 Air Breather Chg Drive Motor N I Electric Power Steering Motor N I Drive Axle Oil Chg EVERY 1000HRS or 6 MONTHS EVERY 1500HRS or 9 MONTHS EVERY 2000HRS or 12 MONTHS EVERY 2500HRS or 15 MONTHS Fork I Hydraulic Return Filter Chg Lift Chains T C A Tires and Wheels I C Parking Brake N T Pump Motor N I Transfer Case Oil Chg Air Breather Fork I Hydraulic Return Filter Chg Hydraulic Oil C Chg Hydraulic, Power Steering System Steer Wheel Bearings R Transfer Case C Hydraulic Oil C Chg NOTE 1: Please refer to the latest revision of the Operation & maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. CAUTION Before performing any work, be sure to refer to and follow all recommended safety precautions set out in the applicable Doosan Maintenance Manual. In addition, Doosan recommends that all mechanics wear appropriate protective items, such as safety glasse Please refer to the latest revision of the Operation maintenance Manuals for more comprehensive information. Changes can be made to the "Quick Guide" infomration without any notification. 19