Challenge for Excellence

DP20~35N3

Maintenance & Inspection

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 Maintenance & Inspection
Schedule overview

The operators are responsible for the performance of the daily Pre-Start
inspection.
The operators also responsible for those items listed under Every 50 Service
Hours or Weekly, Whichever Comes First to keep your truck in a proper
working condition.
For periodic inspection and periodic replacement of rubber parts, however,
rely on the expert knowledge of the dealer’s well-trained mechanics.

Periodic Inspection Time Intervals

The Periodic inspection time intervals is below 6 basic times.
▪ Every 50 service hours or Weekly, whichever comes first
▪ One month (30 days) or 200 service hours after delivery of
a new forklift truck, whichever comes first
▪ Every 500 service hours or 3 months, whichever comes first
▪ Every 1000 service hours or 6 months, whichever comes first
▪ Every 2000 service hours or 12 months, whichever comes first
** The details for maintenance refer to the OMM.
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 Maintenance & Inspection
Every 10 service hours or Daily (Pre-Operation)
This is a pre-operation inspection to ensure safe and proper tuck operation.
Important is checking the safety features for proper operation such as both
interlock systems, the seat- & seatbelt switches.
But also wheels / tyres and the brake system.
(check service manual for details)

Every 50 Service hours or Weekly

Check the Cooling-, Fuel-, Hydraulic- and Exhaust systems, air
cleaner and universal joint for proper operation.
(check service manual for details)

One Month (30 days) or 200 Service hours

Check the Brake-, Cooling-, Fuel-, Electrical-, Intake-, Hydraulic and Driving
systems, Mast & Forks, Front Axle, Rear Axle & Steering System, and the
Engine.
(check service manual for details)
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 Maintenance & Inspection
Every 500 Service hours or 3 Months
Check the Brake-, Cooling-, Electrical- and Fuel System, Engine, Frame &
Chassis, Mast & Forks, Front Axle, Rear Axle and Steering System.
(check service manual for details)

Every 1000 Service hours or 6 Months

Check the Brake-, Electrical-, Intake and Driving System and Engine.
(check service manual for details)

Every 1500 Service hours or 9 Months

Check the Engine.
(check service manual for details)

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 Maintenance & Inspection
Every 2000 Service hours or 12 Months - 1
Check the Brake-, Cooling-, Electrical-, Hydraulic-, Exhaust & Driving System,
Engine, Front Axle, Rear Axle & Steering System.
(check service manual for details)

Every 3000 (9000) Service hours

Check the Exhaust System.
Replace Diesel Partical Filter with cleaned filter by autorised cleaning company
and replace by a new one every 9000 hours.
(check service manual for details)

Every 2 Years
Check the Cooling- & Exhaust System.
(check service manual for details)

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 Maintenance & Inspection

Periodic replacement parts

Ref.No. Parts to be changed Interval

1 *Hose and Rubber Parts of Brake Master Cylinder 2000 service hours or 1 year, whichever comes first
2 *Rubber Parts of Brake Wheel Cylinders 2000 service hours or 1 year, whichever comes first
3 *Vaporizer Rubber Parts for LP-Gas 6000 service hours or 30 months, whichever comes first
4 *High Pressure Hoses of Hydraulic System 2000 to 4000 service hours or 1 to 2 years, whichever comes first
5 *Hose and Rubber Parts of Power Steering Cylinder 4000 service hours or 2 years, whichever comes first
6 *Lift Chains 4000 to 8000 service hours or 2 to 4 years, whichever comes first
7 *Fuel Hoses and Clamp 4000 to 8000 service hours or 2 to 4 years, whichever comes first
8 EGR Cooling Hose and Clamp 4000 to 8000 service hours or 2 to 4 years, whichever comes first
9 Breather Hose and Clamp 4000 to 8000 service hours or 2 to 4 years, whichever comes first
10 Engine Oil Filter Element 500 service hours or 3 months, whichever comes first
11 Fuel Filter Element (Diesel Model) 500 service hours or 3 months, whichever comes first
12 Hydraulic Tank Return Filter 1000 service hours or 6 months, whichever comes first
13 Air Cleaner Element 1000 service hours or 6 months, whichever comes first
14 Engine Coolant 2000 to 4000 service hours or 1 to 2 years, whichever comes first
15 *DPF, Exhaust Throttle Valve (Diesel Model) 3000 Service hours
16 *DPF Differential Pressure Hose (Diesel Model) 2 years
17 *DPF 9000 Service hours (2 x 3000 Service hours cleaned/REMAN)

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 Maintenance & Inspection
Automatic Adjuster

• With the clearance A between the lining and

drum being set to specification, pull the cable
with attached spring using a finger as shown.
The lever should turn the adjusting screw
wheel by one notch and, when the cable is
released, return to the original position.

• If the lever fails, or turning the adjusting screw

wheel is slow, check that adjuster screw is
turned 2.5 mm outwards and the position of the
lever relative to the toothed wheel. The lever's
actuating tip should touch the toothed wheel at
approximately 7 to 9 mm (0.28 to 0.35 in.) below
the center line of the screw. If the lever contact is
out of range, the lever will not correctly engage
with the toothed wheel, and the lever will either
fail or the wheel will turn slowly.

7
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 Maintenance & Inspection
Brake Adjustment

Automatic adjusting might take many times pressing of the brake pedal
before the brake starts to apply.
1 (one) tooth makes

0.026mm (diameter)

Only for releasing the brakes

Items 2 - 3 ton
Drum inside diameter 310mm (12.2 in.)
Drum-to-lining clearance A 0.1 to 0.35 mm (0.004 to 0.014 in.)

NOTE: Only use this sequence when brake shoes or other components
have been replaced, if the drum to lining clearance is incorrect the
auto adjuster system won’t work properly, and neither will the brakes.

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 Maintenance & Inspection
Brake Lines bleeding

1. Install rubber tube on wheel brake cylinder

2. Ensure brake fluid at correct level.
bleeding screw.
Fill up if necessary
Put the other end of the tube in a
container

4.Keep brake pedal depressed during step 4.

Loosen bleeding screw to bleed the brake fluid.
Tighten bleeding screw while the brake fluid is still flowing. 3. Depress and release brake pedal a few
Repeat step 2 until there are no more air bubbles during the bleeding times and then hold at depressed.

After sequence is completed and bleeding screw has been tightened

release the brake pedal and check the pedal feeling and brake Use only DOT3 or DOT4 brake fluid
performance.
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 Maintenance & Inspection
Check and clean radiator fin

・ NOTE: If due to application the

radiator fins are contaminated with
seeds Etc., don’t clean with
compressed air because this will open
・ the seed shells and clog the core even
more.

Co
ol ing
air
Radiator
Cooling water Fan

Tube

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 Maintenance & Inspection
Engine oil level check

▪ Park the truck on a level, solid surface and check the oil level.

Engine oil specification

Oil dipstick Engine type Specified Engine oil
D04EG API Service classification
Diesel Engine CF, min. ACEA: E9

1. Correct level range (Low – High) 2. Oil change level

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 Maintenance & Inspection
Engine oil warning

• Engine oil warning icon indicates the engine oil and filters must be
replaced and resetting of engine oil replacement time performed.
• To maintain the engine performance, use specified fuel and engine oil,
and replace the engine oil and filters every 500 service hours or three
months, whichever comes first.
• Reset the engine oil replacement time with the meter panel, after replacing
the engine oil and filters.
• For reset procedure, see OMM.
Engine oil warning icon

** Engine oil: API Class CF-4

ACEA:E9
– SAE5W-30 / SAE10W-30

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 Maintenance & Inspection
Rear Axle Support

▪ Lubricate the front and back mounting bushes.

Tightening torque: 247.4 – 334.8 Nm Greasing Autolex A Grease

Clearance, A 0.8 mm or less (equal) Service Limit Damaged or Worn

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 Maintenance & Inspection
Wheel Hub
Turn the wheel hub back and forth 2 to 3 times making sure, that the rotational
driving force or starting tangential force is within the range shown below.
If it is out of the range, adjust it.
When reusing bearings, the lower values of the tolerances should be used.

NOTE: Changing the lock

plate face position inside
or outside changes the
hole positions.

Item 2 - 3 ton class

Tangential force of hub bolt 5.6 to 56 N
(increment from when pre- 2P (0.57 to 5.7 kgf)
load is zero)
[12.35 to 123.5 lbf]
6.3 to 63 N
4P (0.64 to 6.4 kgf)
[13.89 to 138.9 lbf]
Starting torque of hub rotation 0.5 to 5.0 N
(increment from when pre-load is zero) (0.051 to 0.510 kgf ・m)
[0.369 to 3.688 lbf ・ft]

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 Maintenance & Inspection
Wheel Hub - Greasing

Lubricating
Bearings, put some 1
grease on your hand
2
and "scrape" it into
the bearing with 3
your fingers and 4
hand palm. This 5
should be done at 6
both inner and outer 7
bearings. Install 8
inner bearing and
seal in housing and 9
1
place on the spindle, 0
fill the hub with
grease apply outer
bearing and locknut. Greasing Autolex A or equivalent
When rotating the
hub, grease should Service Limit Loose cup and cone bearing
spill out a little.

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 Maintenance & Inspection
Tie rod pins
▪ Lubricate Tie rod pins (2 x LH & 2 x RH).
▪ The pins installed in rear axle center have spherical bushes, so greasing is more important.

Grease nipple < Advice>

Especially in dusty applications, check
bush condition more frequently.

Grease nipple

Grease nipple

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 Maintenance & Inspection
Check transmission oil
▪ Measure oil level with the dipstick.
▪ Warm up the engine and the transmission before measuring.
▪ Measure the oil level between 3 and 5 minutes after turning the engine OFF.

< Advice> Checking points: Level, Color, Smell, Viscosity of oil

Dipstick

e l
l ev Item Recommendation
ct
re Hydraulic oil ISO VG32
or
C

Item Recommendation
Power shift transmission oil Dexron®III

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 Maintenance & Inspection
Oil Pressure measurement
▪ Start the engine, place the direction lever in the neutral position
and measure the Main oil pressure, Torque converter inlet
pressure, and Lubrication oil pressure.
▪ Measure the Clutch oil pressure with the direction lever placed in
the Forward position then measure it again with the lever in the
Reverse position.

Item Truck type ( 1-3 ton class )

Main pressure Forward: 1.25 ± 0.03 MPa (12.75 ± 0.31 kgf/cm 2)
Engine at 1600 ± 100 min-1 [181.3 ± 4.4 psi]
Clutch pressure Forward: 1.21 ± 0.03 MPa (12.34 ± 0.31 kgf/cm 2)
Engine at 1600 ± 100 min-1 [175.5 ± 4.4 psi]
Reverse: 1.18 ± 0.03 MPa (12.03 ± 0.31 kgf/cm 2)
[171.2 ± 4.4 psi]
Torque converter inlet pressure Forward: 0.39 ± 0.02 MPa (3.98 ± 0.20 kgf/cm 2)
Engine at 1600 ± 100 min-1 [56.6 ± 2.9 psi]
Lubrication oil pressure Forward: 0.05 ± 0.02 MPa (0.51 ± 0.20 kgf/cm 2)
Engine at 1600 ± 100 min-1 [7.3 ± 2.9 psi] Oil gauges & connector part numbers
Travel time for 10 m starting 5 seconds, maxmum are available in the service manual
acceleration (no load) sec.
Stall speed in theort D04EG: 2100 ± 100 min-1

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 Maintenance & Inspection
Check hydraulic oil level
▪ Check for hydraulic oil contamination and check the oil level.
1. Operate the truck for a few minutes to warm the oil. < Advise > The hydraulic oil should
2. Lower the forks until the forks touch the floor. be a “N” level.
3. Tilt the mast back.

Cor
re c t le
vel

Hydraulic oil filer Hydraulic oil level gauge

< Advice> Checking points:

Level, Color, Smell, Viscosity of oil

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 Maintenance & Inspection
1. Recommended Fuels and Oils
The diesel fuel specification is EN590

-4

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 Maintenance & Inspection
Coolant information

• The manufacturer recommends the use distilled water or deionized

water to reduce the potential and severity of chemical insolubility.

• The manufacturer recommends that the coolant mix contain 50%

commercially available long-life antifreeze, or equivalent, and
acceptable water to maintain an adequate water pump cavitation
temperature for efficient water pump performance.

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 Maintenance & Inspection
Lubrication chart

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 Maintenance & Inspection

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