F12-F16-F18

Chapter 7 - LUBRICATION

LUBRICATION
To facilitate the tasks of the user, following
pages contain the maintenance steps to be
performed and the lubricants that are necessary
to always achieve best performances from your
lift truck.

This chapter contains information about :

- Fuel, fluids and lubricant chart

- Maintenance schedules

- Lubricating points

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Chapter 7 - LUBRICATION

FUEL, FLUIDS AND LUBRICANTS CHART

DESCRIPTION CAPACITY SPECIFICATIONS SAE

liters kg (1) NUMBER
Fuel tank 235 / Gasoil
(2)
Engine coolant 50  55 / -35°C +35°C
50/50
Antifreeze/Water
(3)
Engine oil (with filter(s)) :
MIL-L-2104 E
 PERKINS 1106C-E60TA 15,5 14 MIL-L-46152 E 15W/40
API CG-4/SG
 CUMMINS “QSB 5.9” 16,5 15 Acea E3-96 (4)
(4)
Transmission oil : Caterpillar TO-4
Allison C-4
 Z.F. "3WG 161" or "3WG 131" 32 29 John Deere J20C, D 15W/40
MIL-PRF-2104G
(5) (5)
Drive axle oil :

 KESSLER
- Differential gear 48 43
- Wheel gears 2,5x2 2,2x2 MIL-L-2105 D 80W/90
API GL-5
 MERITOR (6)
- Differential gear
- Wheel gears

Hydraulic oil (tank) :

MIL-L-2104 E
- Lifting, Brakes, Steering ; MIL-L-46152 C
- Attachments (forks, spreader, etc.); 280 252 API CD/SF
Acea E1-96
mixed with additive 10W/20
"LUBRIZOL" type
6270 or 9990A with a
ratio of 5%
* Oil quantity 1st filling 350 315
(7)
Conditioner compressor oil 0,03 0,028 PAG SP10 (8)
Air conditioner / 1 Biogas R134 (8)
Lubricating grease / / EP/NLGI-2 (9)

NOTE: - ( 1 - 9 ) see next pages.

- The quantities shown are indicative, in any case checks the relevant levels.

- The SAE grades in above chart are values recommended by the manufacturers to optimise
the function of the various components or systems (In any case, see following Notes).

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Chapter 7 - LUBRICATION

FUEL, FLUIDS AND LUBRICANTS (continuation)

NOTE:

(1) Before using, always carefully read and completely understand the oil specifications and ask the
product manufacturers or dealers for accurate use and mixing (if applicable) instructions and
replacement intervals basing on the different operating conditions, especially in case of use of
different lubricants, as instructed in our chart.

(2) DIN51601, ASTM D975, BS28689, W-F-800C. Cetane number higher than 45.
Sulphur content: max 0,05% (0,3% stable).
With ambient temperatures under 0°C, use winter fuels.
With temperatures lower than -20°C use dewaxed "ARCTIC" fuel.

(3) To protect the system against corrosion, add the antifreeze product "AGIP ANTIFREEZE EXTRA"
(freezing point -35°C) to the coolant with a ratio of 50% the whole year long (also in summer).
Using other antifreeze products, observe the manufacturer’s instructions.

(4) For the proper function of the engine, the SAE oil
viscosity must correspond to the indicated values
in relation with the outdoor temperature.
If the vehicle is used less, as indicated here, the
engine oil must be changed in any case at
least once a year.
In case of use of fuels containing more than 0,5%
sulphur, halve the number of kilometres to be
covered for the engine oil change.

NOTE :
The replacements intervals of engine oil and filter may be considerably lengthened using specific
oils, i.e. long-drain multigrade oils designed and produced to meet the requirements of heavy-duty
diesel and turbo-diesel engines, and at the same time of the user.
Oil and filter replacement intervals may vary between 100 and 1000 operating hours, depending on
the quality of the lubricant and on the sulphur content in the fuel.

CAUTION: Anyway, the replacement intervals cannot exceed 12 months.

CAUTION: In any case, refer to the lubrication specifications in the original manuals
of the installed engine; not all engine manufacturers recommend
extending the maintenance intervals.

CAUTION: If the user wants to operate with particularly long intervals in comparison
to those indicated in this manual, the condition of the lubrication oil must
be checked regularly by its manufacturer by means of analyses of oil
samples of each engine.

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Chapter 7 - LUBRICATION

FUEL, FLUIDS AND LUBRICANTS (continuation)

NOTE:
(5) Perform the 1st filling of the transmission with oil "AGIP ROTRA CT SAE 30" meeting following
specifications:
* ALLISON C-4, * CATERPILLAR TO-4, * DANA,
* EATON, * ZF TE-ML01,03, * KOMATSU, * KOMATSU DRESSER.
The oil gradation SAE 30 "AGIP ROTRA CT" is suitable for a temperature range between -15°C and
+35°C; while the oil gradation SAE 50 is suitable for higher temperatures between -5°C and +50°C.
For temperatures lower than -15°C and up to -35°C, use "Arctic" lubricants, as stated in the standard
MIL-L-46167B SAE 0W/20.

IMPORTANT INFORMATION:
- DO NOT use following lubricants: DEXRON (II – III), engine oil and oils GL-5.
- We recommend using only lubricants approved by the specifications “C4 and CAT TO-4”.

CAUTION: Under extreme climatic conditions, the maintenance intervals must be

halved.

(6) For temperatures lower than -10°C use oils with gradation SAE 75W/85.

(7) Perform the 1st filling of the hydraulic system with the additived oil "AGIP ROTRA JD/F SAE 80W"
meeting following specifications:
* ALLISON C-4 , * API GL-4 , * CAT TO-2 , * FORD M2C 134-D ,
* J.1.CASE MS1206 , * JOHN DEER J20C , * MASSEY FERGUSON .

For temperatures between 0°C and -10°C use oils VG22 mixed with the additive "LUBRIZOL" type
6270 or 9990A with a ratio of 3% - 6%.
For temperatures between 0°C and -20°C use oils VG10 mixed with the additive "LUBRIZOL" type
6270 or 9990A with a ratio of 3% - 6%.

NOTE: At a temperature of -15°C, a hydraulic oil pre-heater is necessary.

CAUTION: Under extreme climatic conditions, the maintenance intervals must be

halved.
NOTE: The quantity shown in the chart is the TOTAL capacity of the system.
Watch the check window of the tank during the filling of the system.

(8) For the change, contact an authorised “DIAVIA” workshop.

(9) Use an anti-rust, lithium based grease with EP features, containing molybdenum disulphide and with
high viscosity base oil.

For temperatures between 0°C and -10°C use grease with consistency NLGI- 0.

For temperatures between 0°C and -30°C use grease "AGIP ROCOL"
Consistency as per Sapphire standard NLGI-000.

For temperatures between 0°C and -50°C use grease "AGIP ROCOL"
Sapphire standard Low-Temp2.

WARNING: We remind that collection and disposal of waste lubricants is ruled by law.
Take all residual quantities to authorised waste materials collectors.
It is strictly forbidden to discharge them in indiscriminate dumps, in
watercourses or in drains.

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Chapter 7 - LUBRICATION

MAINTENANCE SCHEDULES
A badly maintained truck is dangerous both for the driver and bystanders.
Verify that maintenance and lubrication are performed in compliance with following intervals, to keep the
vehicle in efficient and safe working conditions.

WARNING : Only qualified and trained technicians must perform maintenance steps.
Before performing any service step, make sure that the vehicle is in maximum
safety conditions.
Park the vehicle on a level and compact ground, apply the parking brake and
switch-off the engine (if not diversely instructed).
In any case, refer to the section “SAFETY” in this manual.

NOTE:
 Service and maintenance intervals are based on the operating hours of the vehicle.
 Check the hour counter (that must be always functioning) to state the service intervals.
 Do not use the vehicle if it has to be maintained.
 Make sure that all defects detected during maintenance are immediately corrected.
 Concerning the possible attachments of the vehicle, refer to the separate enclosures.
 Refer in any case to the original documents of the manufacturer of the installed engine and
transmission (enclosed with the vehicle).

First maintenance steps

SERVICING STEPS

I = Inspect C = clean G = grease A = adjust R = replace

Interval Description I C G A R
After the first Engine oil R
100 operating Engine oil filter R
hours Transmission oil R
Transmission oil filters R
Driving axle oil R
Hydraulic oil filters R

After the first Timing system I A

250 working Injectors I
hours Tightening of propeller shaft bolts I A
Tightening of counterweights bolts I A
Tightening of towing hook bolts I A
Visual inspection and tightening of vehicle I A
components (axle, mast, cab and supporting
structure, ladders, mudguards, etc.)

After the first Hydraulic oil R

500 working
hours

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Chapter 7 - LUBRICATION

MAINTENANCE SCHEDULES (continuation)

SERVICING STEPS
I = Inspect C = clean G = grease A = adjust R = replace

Interval Description I C G A R
Daily Engine oil level I A
Engine oil pressure I
Engine fan I
Air cleaner clogging gauge I
Fuel level I A
Water/fuel separator [fuel pre-filter] (*) I C
Coolant level I A
Window washer level I A
Hydraulic oil level I A
Grease level in the pump reservoir (*) I C A
[automatic centralised lubrication system]
Windows, rear view mirrors, headlights and I C
working lights
Indicator lights, Instruments and screen (*) I C
Parking brake I

Weekly Transmission oil level I A

Coolant reservoir I C A
Radiator I C
Brake fluid cooling spiral I C
Oil level "Inching and Brake" pedal system I A
Batteries I C
Air conditioner drive belt (*) I C A
Air-conditioner condenser (*) I C
Body I C
- Tightening of screws and bolts I A

Every 100 Fuel filter cup (*) C

working hours Propeller shaft I C G
Driving axle oil levels (differential/wheel gears) I A
Air vent driving axle I C
Air vent parking brake cylinder I C
Steering axle (bolts, links and cylinder) I C G A
Tyre pressure (on cold tyres) I A
Wheel nuts tightening I A
Lifting cylinders and fastening bolts I C
Tilting cylinders and fastening bolts I C G
Mast (guides, bolts, rollers, pulleys, sliding shoes) I C G
Mast proximity switches I C A
Mast fastening to the chassis I G
Mast chains I C G
Fork carriage (*) (rollers, guides, bolts cylinders) I C G
Fork supports (*) (rollers, guides, bolts) I C G
Sensors [all] I C A
Lubrication of all lubrication points of the vehicle C G

(*) = if fitted

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Chapter 7 - LUBRICATION

MAINTENANCE SCHEDULES (continuation)

SERVICING STEPS

I = Inspect C = clean G = grease A = adjust R = replace

Interval Description I C G A R
Every 500 Engine oil R
working hours Engine oil filter R
Oil cleaner (*) C
Slack of all drive belts I A
Fuel filter R
Water/fuel separator [fuel pre-filter] (*) R
Gauze strainer of the fuel lift pump C
Fuel tank I C
Coolant filter (*) R
Water pump I
Water hoses and lines I
Engine vent closed system (*) I C
Engine lines and fittings I
Engine electric cables and connections I
Hydraulic oil filter R
Brake fluid filter (feeding line) R
Brake fluid filter (return line) R
Tightening of propeller shaft bolts I A
Tightening anchor bolts driving axle/chassis I A
Axle: clearances of bolts/pivots/links and structure I
Tightening of ring nuts of the wheel hub bearings I A
Wheel hubs I G
Pressurised cap of the oil tank I C
Lifting structure (mast, etc.) :
- Welds, guides, cylinders I
- Pulleys, sliding shoes, bolts, sleeves, rollers I
- Tightening of bolts I A
- Chains and tightening of chain tensioners I A
Fork carriage and holders (*) :
- Welds, Guides, Rollers, Bolts, Cylinders I
Cab :
- Supports, structure, tilting cylinders(*) I
- Tightening of bolts I A
Towing hook (as well as tightening of bolts) I C G A
Counterweights (as well as tightening of bolts) I A

Every 1000 Timing system I A

working hours Injectors I C
and Turbocharger and intake line I
in any case Transmission oil R
yearly Transmission oil filter (cartridge) R
Exhaust lines I A
Mast chains (slack and wear) I

Continuation on next page 

(*) = if fitted

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Chapter 7 - LUBRICATION

MAINTENANCE SCHEDULES (continuation)

SERVICING STEPS

I = Inspect C = clean G = grease A = adjust R = replace

Interval Description I C G A R
Every 1000 Air cleaner ( ) C R
working hours I C R
Fine-mesh cartridge of the air cleaner ( ) (*)
and R
Drive axle oil (differential and wheel gears)
in any case
Steering axle bearings I C A
yearly
Air conditioner gas (*) I
Air conditioner compressor oil (*) I

Every 2000 Mast sliding shoes I R

working hours AC Generator I C A
Starter motor I C A
Coolant R
Catalytic converter (*) I C
Pipes and hoses of all systems I

Every 3000 Fuel tank I C

working hours Hydraulic oil R

Every 6000 Hydraulic cylinders:

working hours - overhauling I C
- gaskets R

(*) = if fitted

( ) CAUTION : This value is indicative and greatly depends on the presence of suspended dust .
When the warning light of the air cleaner in the cab (in case of an electric clogging
gauge) comes on, or when the clogging indicator on the air cleaner shows its "red" part,
immediately clean the filter, bearing in mind that it should not be cleaned for more than 6
times, then it must be replaced (see the relevant section of the chapter “MAINTENANCE”).
Filter life cycle can range from 200 operating hours (in a desert or on very dusty yards), up to
max. 1500 operating hours (on paved yards).

CAUTION : In any case, refer to the relevant section of the chapter "MAINTENANCE”.

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Chapter 7 - LUBRICATION

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Chapter 7 - LUBRICATION

LUBRICATION POINTS OF A LIFT TRUCK WITH FORKS

13

8
10 12

14 29
22

24

22 11 6 15 7 7a

The lift truck and the arrangement of the various components shown
are referred to the "STANDARD" version; Different arrangements,
than shown, are due to customised versions.

19 9 5 3 19 2 1 7

23

21 7a

9 17 18 4 16 15 20 7

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Chapter 7 - LUBRICATION

LUBRICATION POINTS OF A LIFT TRUCK WITH FORKS (continuation)

Maintenance steps

I = Inspect L = Lubricate R = Replace

Intervals (working hours)

Pos. Description Daily Weekly
100 500 1000 2000 3000
1 Engine oil I R
2 Engine oil filters R
3 Transmission oil I R
4 Transmission oil filter R
5 Propeller shaft I/L
6 Drive axle, differential and
I R
wheel gears oil
7 Steering bearings and bolts I/L
7a Steering axle (bolts, links and
I/L
cylinder)
8 Mast guides I/L
9 Mast rollers and bearings I/L
10 Mast bolts/pulleys I/L
11 Fastening mast/chassis (bolts) I/L
12 Tilting cylinder bolts I/L
13 Mast sliding shoes I/L I/R
14 Chains I/L
15 Hydraulic oil I R
16 Hydraulic oil filter S
17 Brake fluid filter (feeding line) S
18 Brake fluid filter (return line) S
19 El. pumps of the automatic
I
greasing system (if fitted)
20 Conditioner compressor oil
I
(if fitted)
21 Fork carriage bolts, rollers,
I/L
and sliding shoes
22 Fork supports bolts, rollers
I/L
and sliding shoes
23 Fork carriage guides I/L
24 Fork cylinder supports I/L
25
26
27
28
29 Oil level "Inching and Brake"
I
pedal system
30

CAUTION : - These intervals depend on the type of lubricant used and on the operating
conditions.
For longer intervals, the type of oil to be used must be checked by the
manufacturer or dealer of the product.

- In any case, refer to the relevant sections of the chapter "MAINTENANCE".

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Chapter 7 - LUBRICATION

LUBRICATION POINTS OF A LIFT TRUCK WITH SPREADER

13
10

14

8
23 12

29
25
1
16
22

24 11 6 15 7 7a
The lift truck and the arrangement of the various components shown are referred to the
"STANDARD" version; Different arrangements, than shown, are due to customised versions.
.

23
9 5 3 19 2 1 7

24

8
22
19 7a
22
8

24

9 17 18 4 20 7
23

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Chapter 7 - LUBRICATION

LUBRICATION POINTS OF A LIFT TRUCK WITH SPREADER (continuation)

Maintenance steps

I = Inspect L = Lubricate R = Replace

Intervals (working hours)

Pos. Description Daily Weekly
100 500 1000 2000 3000
1 Engine oil I R
2 Engine oil filters R
3 Transmission oil I R
4 Transmission oil filter R
5 Propeller shaft I/L
6 Drive axle, differential and
I R
wheel gears oil
7 Steering bearings and bolts I/L
7a Steering axle (bolts, links and
I/L
cylinder)
8 Mast guides I/L
9 Mast rollers and bearings I/L
10 Mast bolts/pulleys I/L
11 Fastening mast/chassis (bolts) I/L
12 Tilting cylinder bolts I/L
13 Mast sliding shoes I/L I/R
14 Chains I/L
15 Hydraulic oil I R
16 Hydraulic oil filter S
17 Brake fluid filter (feeding line) S
18 Brake fluid filter (return line) S
19 El. pumps of the automatic
I
greasing system (if fitted)
20 Conditioner compressor oil
I
(if fitted)
21
22 Spreader plate rollers and
I/L
sliding shoes
23 Spreader sliding shoes I/L
24 Spreader bolts and cylinder
I/L
supports
25 Twistlocks spreader I/L
26
27
28
29 Oil level "Inching and Brake"
I
pedal system
30

CAUTION : - These intervals depend on the type of lubricant used and on the operating
conditions.
For longer intervals, the type of oil to be used must be checked by the
manufacturer or dealer of the product.

- In any case, refer to the relevant sections of the chapter "MAINTENANCE".

Page 7.13