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.. 17 1
INTERNAL COMBUSTION POWERED LIFT TRUCKS 2
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 5W30-30 +30-22 +86 SAE 10W30-20 +40-4 +104 Engine Crankcase (LP and Gasoline) API SJ/SL/SH/SG SAE 5W40-30 +40-22 +104 SAE 10W40-20 +40-4 +104 SAE 15W40-10 +40 +14 +104 SAE 15W50-10 +50 +14 +122 SAE 20W50-5 +50 +23 +122 SAE 5W30-30 +30-22 +86 SAE 10W30-20 +30-4 +86 Engine Crankcase (Diesel) API CH4/CI4/CJ4, ACEA E5/E7/E9 SAE 5W40-30 +40-22 +104 SAE 10W40-20 +40-4 +104 SAE 15W40-15 +40 +5 +122 SAE 15W50-15 +50 +5 +122 SAE 20W50-10 +50 +14 +122 API CD/TO-2 SAE 10W -20 +22-4 +72 SAE 30 +10 +50 +50 +122 SAE 10W -20 +22-4 +72 API CD/TO-4 Power Shift Transmission SAE 30 +10 +50 +50 +122 DEXRON III DEXRON III -20 +50-4 +122 ZF POWERFLUID UTTO -30 +50-22 +122 - MOBILE FLUID Mobil 424-30 +50-22 +122-3
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 22-30 +20-22 +68 Hydraulic and Power Steering System ISO 6743/4 HM ISO VG 32-20 +30-4 +86 ISO VG 46-10 +40 +14 +104 ISO VG 68 0 +50 +32 +122 Shoe Brake API GL-5 SAE 80W 90-20 +50-4 +122 API GL-5 SAE 80W 90-20 +50-4 +122 Drive Axle Disc Brake UTTO (API GL-4) SAE 80W -20 +80-4 +176 API CD/TO-2 SAE 10W -20 +22-4 +72 SAE 30 +10 +50 +50 +122 Shoe Brake DOT3, DOT4 SAE J1703f -30 +50-22 +122 ISO VG 10-20 +30-4 +86 ISO VG 15-40 +10-40 +50 Brake Reservoir Disc Brake (OCDB) ISO 6743/4 HM ISO VG 22-30 +20-22 +68 ISO VG 32-20 +30-4 +86 ISO VG 46-10 +40 +14 +104 ISO VG 68 0 +50 +32 +122 * 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
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
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
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 A383526 A383526 A371682 A383526 A213939 A213939 A371682 400504-00193 A213939 A213939 A213939 A371682 Air Cleaner Element - Safety A218870 A218870 A371683 A218870 A213938 A213938 A371683 400504-00194 A213938 A213938 A213938 A371683 Fuel Cartridge - Engine A323029 A323029 A323029 A408491 A409559 A408254 400508-00064 Engine Oil Filter A293225 A383718 A383718 A403646 400404-00036 A403646 400404-00036 A403646 A408489 A408065 A408065 400404-00068A A408423 400405-00167 400405-00082 A403646 400404-00036 A413511 Suction Filter - Hydraulic D501397 D501397 A371159 A155222 A371159 D164457 A371153 D164457 A371153 Return Filter - Hydraulic D516976 D516976 D516976 D516975 A371159 D516975 A371159 Transmission Oil Filter A383013 A383013 A373605 A383013 A373605 D140182 A373605 D140182 A373605 Fuel Filter - LPG (Repair Kit) D141186 D141186 400403-00169 D700179 Timing Belt A403831 A403831 A403831 A413674 130204-00225 A403831 A413674 / 130204-00225 Oxygen Sensor A413502 A413502 7
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 A131768 400504-00170 A131768 400504-00170 400504-00260 A131768 A131768 A131768 A131768 A131768 A131768 400504-00170 A147202 400504-00054 Air Cleaner Element - Safety A131769 400504-00171 A131769 400504-00171 400504-00261 A131769 A131769 A131769 A131769 A131769 A131769 400504-00171 A147203 400504-00055 Fuel Cartridge - Engine 65.12503-5016 A453975 400508-00064 400508-00055 65.12503-5016 A453975 400508-00055 400508-00055 65.12503-5016 A453975 400504-00115 65.12503-5016 65.12503-5026 65.12503-5016 400504-00078 65.12503-5033A Engine Oil Filter 65.05510-5028 A433754 400504-00115 400508-00056 A232028 400405-00225 A232028 400405-00225 65.05510-5028 A433754 400508-00056 400508-00056 65.05510-5028 A433754 400508-00064 65.05510-5022 65.05510-5032 5016 65.05510-5032A 65.05510-5026B 400508-00092 Suction Filter - Hydraulic A235011 A135050 A135050 A135050 A135050 A135050 A135050 A145025 A235011 A235011 Return Filter - Hydraulic D516974 D501696 D501696 D501696 D501696 D501690 D501690 A145088 A145088 400504-00076 Transmission Oil Filter D140182 400409-00003 400409-00003 D140182 400409-00003 K1029612 A138746 (A453462) A453462 400405-00072 A138746 400405-00034 K1029612 Fuel Filter - LPG (Repair Kit) D700179 (D141186) 400403-00152 D700179 (D141186) 400403-00152 Oxygen Sensor A413502 301308-00159 A413502 301308-00159 8
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
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
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
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 changes @ 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
ELECTRIC POWERED LIFT TRUCKS 13
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 15-40 +10-40 +50 Hydraulic and Power Steering System ISO 6743/4 HM ISO VG 22-30 +20-22 +68 ISO VG 32-20 +30-4 +86 ISO VG 46-10 +40 +14 +104 ISO VG 68 0 +50 +32 +122 API GL-5 SAE 80W/90-20 +50-4 +122 Drive Axle API GL-4 SAE 80W -20 +80-4 +176 SAE 10 W -20 +22-4 +72 API CD/ TO-4 SAE 30 +10 +50 +50 +122 Brake Reservoir ISO 6743/4 HM ISO VG 10-30 +50-22 +122 * 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
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
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 D500261 400504-00082 400504-00221 D516976 D516976 D516975 D516976 D144020 D516975 D516974 A155222 D512992 A235011 16
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
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
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