Manual h25 30da en

MAST EXPLORER Rough Terrain Forklift Trucks
H25/30DA medium range operation and maintenance manual

Page 2 of 90
MANUFACTURER:
MECANO CONTINENTAL S.A.
Polígono Industrial Base 2,000
Calle Aragón C.P 30564
LORQUÍ, MURCIA, SPAIN
TELEPHONE: (+34) 902 200 300 / (+34) 968 672 892
FAX: (+34) 968 670 901
atencionalcliente@mecanocontinental.com
www.mecanocontinental.com
WHERE WE ARE LOCATED:
AUTHORISED DEALER:
(Authorised dealer stamp)
H25/30DA medium range operation and maintenance manual:

This manual has been written by staff at Mecano Continental S.A. It cannot be reproduced, saved or distributed to
third parties in any way.
Mecano Continental S.A. reserves the right to modify and improve its products at any time without prior notice in an
effort to constantly improve quality and this documentation may therefore be modified at any time.
Some drawings or photos have been used solely for illustrative purposes and may not correspond to the exact
model covered by this manual.
© Copyright 2011 MECANO CONTINENTAL S.A. All rights reserved.

Page 3 of 90

Page 4 of 90
INTRODUCTION These sections are in turn sub-divided into sequentially

numbered chapters and paragraphs to make it easier to
This manual has been written by staff at MECANO find information. The quickest way to find information is
CONTINENTAL S.A in order to provide all the to use the table of contents page.
necessary information for correct operation of the forklift
and to ensure correct and safe maintenance. Safety and If you have any trouble understanding this manual, or
troubleshooting sections are also included. parts of the manual, we recommend contacting the
Mecano Continental S.A. Technical Support department
or the After-Sales department.
WARNING
Read and understand this manual before starting,
operating and maintaining the forklift.
IMPORTANT
Due to continually improving our forklift models
This manual is divided into the following sections:
and in order to improve our products further, there
may be slight differences between your model and
A) GENERAL INFORMATION the model described in this manual.
B) OPERATION AND OPERATING In this case, contact the MECANO CONTINENTAL

S.A. Technical Support department for possible
INSTRUCTIONS clarifications or updates.
C) MAINTENANCE
D) SAFETY
E) TROUBLESHOOTING
F) APPENDICES
Section A: general information about the machine and

its main components. This section also includes data
plate information, serial number and main technical
characteristics.
Section B: primarily for machine operators. All the

different controls and switches are described in this
section.
Section C: specifically for maintenance manager and

mechanical maintenance staff. This section contains
information about the maintenance programme and
actions required during each maintenance period.
Section D: for staff responsible for forklift operation,

repair and maintenance and, in the case of companies
with a large fleet of vehicles, the safety manager.
Section E: its purpose is to diagnose and solve

possible breakdowns (mast, brakes, engine, bleeding of
brakes, etc.).
Section F: additional information such as hydraulic and

electrical drawings, load diagrams, recommended
torques, etc.

Page 5 of 90
SYMBOLS USED
While operating the forklift, the operator may find

WARNING
himself in situations that require him to consult the
considerations and clarifications given in this manual. Warns you of situations that endanger your safety
and the safety of others with risks of minor
In this manual, when such situations put the operator's accidents or injury, or that risk compromising the
safety and the safety of others at risk and affect the forklift's efficiency.
forklift's efficiency and its correct operation, specific
instructions displaying a SPECIAL SYMBOL to highlight
such situations are given to minimise risks.
There are five special (or safety) symbols used in the

manual and these are always accompanied by other
IMPORTANT
key words that classify the situations according to the
potential hazard. Makes you aware of important technical
information or practical advice that can help you
Each symbol is accompanied by text describing the operate the forklift more efficiently and safely.
likelihood of a situation, what to look out for and the
recommended method or behaviour to be adopted.
When necessary, this text includes prohibitions or
appropriate instructions to avoid risks.
In some cases the text may be accompanied by

ENVIRONMENTAL
illustrations. PROTECTION
The special (or safety) symbols are shown below in
order of importance:
Makes you aware of important environmental
protection information.
HAZARD
Warns you of situations that endanger your safety
and the safety of others with risks of serious harm
to personnel or the forklift, which may even result
in death.
ELECTRICAL
HAZARD
Warns you of situations that endanger your safety
and the safety of others with serious electrical
hazards, which may even result in death.

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TABLE OF CONTENTS
A) GENERAL INFORMATION
B) OPERATION AND OPERATING

INSTRUCTIONS
C) MAINTENANCE
D) SAFETY
E) TROUBLESHOOTING
F) APPENDICES

Page 7 of 90
CONTENTS:
SECTION A: GENERAL INFORMATION

A-1 CONVENTIONAL REFERENCES ........................................................................................................................ 12
A-1.1 Information on the forklift (instruction stickers).............................................................................................. 12
A-1.2 Forklift layout ................................................................................................................................................. 13
A-2 FORKLIFT INFORMATION .................................................................................................................................. 14
A-2.1 Manufacturer ................................................................................................................................................. 14
A-2.2 Model and type. Chassis number .................................................................................................................. 14
A-2.3 Permissible loads per model ......................................................................................................................... 15
A-2.4 Main measurements and specifications ........................................................................................................ 16
A-2.5 Engine specifications ..................................................................................................................................... 17
A-2.6 Fluid capacity................................................................................................................................................. 18
A-2.7 Wheels and brakes ........................................................................................................................................ 18
A-2.8 Other data of interest ..................................................................................................................................... 18
A-2.9 Forklift's residual capacity ............................................................................................................................. 19
A-3 PERMITTED USES .............................................................................................................................................. 19
A-4 IMPROPER USE .................................................................................................................................................. 19
SECTION B: OPERATION AND OPERATING INSTRUCTIONS

B-1 BEFORE CLIMBING INTO THE FORKLIFT ........................................................................................................ 22
B-2 CLIMBING INTO THE FORKLIFT ........................................................................................................................ 22
B-2.1 Entering the cabin ......................................................................................................................................... 22
B-2.2 Adjusting the seat .......................................................................................................................................... 23
B-2.3 Putting on the seat belt.................................................................................................................................. 23
B-2.4 Adjusting the steering wheel.......................................................................................................................... 23
B-2.5 Adjusting the rear-view mirrors ...................................................................................................................... 24
B-3 OPERATOR'S CONTROL PANEL ........................................................................................................................ 24
B-3.1 Key positions ................................................................................................................................................. 24
B-3.2 Instruments and controls ............................................................................................................................... 24
B-3.3 Joystick .......................................................................................................................................................... 26
B-3.4 Hydraulic oil level gauges.............................................................................................................................. 27
B-3.5 Lights panel and hour meter.......................................................................................................................... 27
B-4 ELECTRICAL SYSTEM ........................................................................................................................................ 28
B-5 STARTING ............................................................................................................................................................ 29
B-5.1 Starting using external power source ............................................................................................................ 29
B-5.2 Disconnecting the battery .............................................................................................................................. 29
B-5.3 Battery location .............................................................................................................................................. 30
B-5.4 Battery disposal ............................................................................................................................................. 30
B-6 TRANSPORTING THE FORKLIFT ....................................................................................................................... 30
B-6.1 Transporting and towing a broken-down forklift ............................................................................................ 30
B-6.2 Transporting by crane.................................................................................................................................... 30

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B-7 CLEANING AND WASHING THE FORKLIFT ...................................................................................................... 30

B-7.1 Disposal. End of service life .......................................................................................................................... 31
SECCIÓN C: MAINTENANCE
C-1 LUBRICANTS. HEALTH AND SAFETY STANDARDS ........................................................................................ 34
C-2 SCHEDULED MAINTENANCE ............................................................................................................................ 34
C-3 MAINTENANCE ON THE ENGINE ...................................................................................................................... 37
C-3.1 Main Perkins engine components ................................................................................................................. 37
C-3.2 Perkins engine identification ......................................................................................................................... 37
C-3.3 Main Kubota engine components .................................................................................................................. 38
C-3.4 Kubota engine identification .......................................................................................................................... 38
C-3.5 Inspection of the engine alternator ................................................................................................................ 38
C-3.6 Inspection of the alternator belt ..................................................................................................................... 39
C-3.7 Changing the coolant .................................................................................................................................... 39
C-3.7.1 Checking the coolant level ..................................................................................................................... 40
C-3.8 Replacing the air filter ................................................................................................................................... 40
C-3.8.1 Cleaning the air filter .............................................................................................................................. 41
C-3.9 Changing the engine lubricating oil ............................................................................................................... 42
C-3.10 Changing the engine oil filter....................................................................................................................... 42
C-3.11 Fuel injectors ............................................................................................................................................... 43
C-3.12 Priming the fuel system ............................................................................................................................... 43
C-3.13 Changing the fuel filter ................................................................................................................................ 44
C-4 HYDROSTATIC SYSTEM MAINTENANCE ......................................................................................................... 45
C-4.1 Maintaining the hydraulic oil filter .................................................................................................................. 45
C-4.2 Maintaining the hydrostatic pump ................................................................................................................. 45
C-4.3 Hydrostatic regulation and pressure measurement ...................................................................................... 47
C-5 ELECTRICAL SYSTEM MAINTENANCE ............................................................................................................ 47
C-5.1 Battery ........................................................................................................................................................... 47
C-5.2 Fuses and relays ........................................................................................................................................... 48
C-6 TRANSMISSION SYSTEM MAINTENANCE. GREASING THE FORKLIFT ....................................................... 49
C-7 FORKS ................................................................................................................................................................. 49
C-8 MAST MAINTENANCE ........................................................................................................................................ 49
C-9 TYRES .................................................................................................................................................................. 51
C-10 TIGHTENING OF WHEEL BOLTS ..................................................................................................................... 52
C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT FLUIDS .................................................................................. 53
C-12 MAINTENANCE PROGRAMME FOR THE PERKINS 400 D SERIES ENGINE ............................................... 54
C-13 MAINTENANCE PROGRAMME FOR THE KUBOTA ENGINE ......................................................................... 56

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SECTION D: SAFETY
D-1 GENERAL OBSERVATIONS ................................................................................................................................ 58
D-2 CONDITIONS TO BE MET BY OPERATORS...................................................................................................... 58
D-3 RESIDUAL RISKS ................................................................................................................................................ 58
D-4 NOISE EMISSIONS AND VIBRATIONS .............................................................................................................. 58
D-5 DESCRIPTION OF SAFETY DEVICES ............................................................................................................... 59
D-6 SAFETY RECOMMENDATIONS ......................................................................................................................... 60
D-7 RULES ON DRIVING THE FORKLIFT ................................................................................................................ 61
D-8 AT THE END OF THE DAY .................................................................................................................................. 62
D-9 GENERAL SAFETY MEASURES REGARDING THE ENGINE .......................................................................... 62
D-10 GENERAL SAFETY MEASURES REGARDING THE ELECTRICAL SYSTEM ................................................ 64
D-11 PERSONAL PROTECTION ................................................................................................................................ 64
SECTION E: TROUBLESHOOTING
E-1 MALFUNCTION AND FAULT FINDING................................................................................................................ 68
E-2 PROBLEMS - CAUSES - SOLUTIONS................................................................................................................ 68
E-2.1 Movements .................................................................................................................................................... 68
E-2.2 Electrics ......................................................................................................................................................... 69
E-2.3 Brakes ........................................................................................................................................................... 69
E-2.4 Mast ............................................................................................................................................................... 69
E-2.5 Engine ........................................................................................................................................................... 70
SECTION F: APPENDICES
F-1 HYDRAULIC DIAGRAM H25/30DA 2WD ............................................................................................................. 72
F-2 HYDRAULIC DIAGRAM H25/30DA 4WD ............................................................................................................. 73
F-3 TIGHTENING TORQUES ..................................................................................................................................... 74
F-4 LOAD DIAGRAMS ................................................................................................................................................ 76
F-5 MAINTENANCE REPORT TEMPLATES .............................................................................................................. 77

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Section A
GENERAL INFORMATION
CONTENTS
A-1 CONVENTIONAL REFERENCES
A-1.1 Information on the forklift (instruction stickers)
A-1.2 Forklift layout
A-2 FORKLIFT INFORMATION
A-2.1 Manufacturer
A-2.2 Model and type. Chassis number
A-2.3 Permissible loads per model
A-2.4 Main measurements and specifications
A-2.5 Engine specifications
A-2.6 Fluid capacity
A-2.7 Wheels and brakes
A-2.8 Other data of interest
A-2.9 Forklift's residual capacity
A-3 PERMITTED USES
A-4 IMPROPER USE

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A-1 CONVENTIONAL REFERENCES
A-1.1 Information on the forklift (instruction stickers)

There are several stickers on the forklifts that give safety and operating information. Carefully read the instruction
stickers before operating the forklift. The following photo shows the H25/30DA model:

Page 12 of 90
A-1.2 Forklift layout Main external components:

The following photo shows the layout of the forklift. This
is to ensure that any reference to the different parts of Number Description
the forklift (front, rear, etc.) in this manual is clear in 1 FORKS
order to avoid errors in terms of name and position. 2 MAST
3 STEERING COLUMN
TOP 4 MIRRORS
5 STEERING WHEEL
6 OVERHEAD GUARD
7 JOYSTICK
8 ROTATING BEACON
9 ENGINE
10 REAR COUNTERWEIGHT
REAR
11 REAR STEERING AXLE
12 FUEL TANK
RIGHT SIDE 13 FRONT AXLE
FRONT LEFT SIDE
BOTTOM
4 5 6
7
3 8
9
2
10
1
13
12 11

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A-2 FORKLIFT INFORMATION A-2.1 Manufacturer

The forklift truck manufacturer is MECANO
IMPORTANT CONTINENTAL, S.A. This company has developed

various models of Rough Terrain forklifts, such as the
H25/30DA medium range, with different load
capacities and specifications. Each forklift truck will be
Check that you have the right operation manual. If identified by a serial number recorded on the CE mark
you need further information or technical support, data plate attached to the forklift since Mecano
you must specify the model and type of forklift Continental S.A meets the requirements set out in
plus the chassis number. Directive 2006/42/EC on the approximation of the laws
of Member states relating to machinery.
Forklift information can be found on the data plate fitted
in the cabin, similar to the one shown below.
This data plate gives the following information:

• Make
• Model
• Load capacity
• Lift height
• Centre of gravity
• Weight
• Serial number
• Year of manufacture A-2.2 Model and type. Chassis number
• Engine power in HP/kW
To correctly identify the forklift model and type, Mecano
• CE mark Continental S.A has engraved a number on the front
• Tyre pressure right-hand side of the forklift chassis behind the mast,
as shown in the following photo:
The different available configurations of the MAST

EXPLORER H25/30 DA medium range are:
2WD (2 wheel drive):
H25DA and H30DA
4WD (4 wheel drive):
H25DA and H30DA

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A H25/30DA range rough terrain forklift truck can be

described as a self-propelled machine that has a mast
with a determined rated load capacity for lifting loads
using forks. Load capacities are given below according
HAZARD
to the mast model fitted:
The following diagrams are valid for a lift height of
3300, 4300 and 6000 mm (without additional
RATED CAPACITY OF THE MAST attachments fitted)
H25 DA (2500 kg) C
H30 DA (3000 kg)
Load diagrams for the H25/30DA models are shown
D
below. The load is given in kg on the vertical axis and
the distance from the centre of gravity (CG) to the
The MAST EXPLORER H25/30DA medium range carriage is given in mm along the horizontal axis, with
rough terrain forklift trucks have been designed to carry CG being 500 mm for the standard load.
and lift loads vertically. The forklift truck is a self-
contained vehicle suitable for carrying hanging loads Larger copies of these load diagrams are included in
and is designed for such use. the Appendices section (F) to make it easier to read the
data.
FORKLIFT INFORMATION: FOR H25DA MODEL

Mast height 3300 mm
To be able to understand the model's code we must Load Mast height 4300 mm
understand the following: Mast height 6000 mm
CG_Qe (mm)
FOR H30DA MODEL

Mast height 2400 mm
Load (kg) Mast height 3500 mm
Mast height 6000 mm
CG_Qe (mm)
For greater heights, the loss of capacity charts adhered

to the forklift truck will be used to ensure that the
A-2.3 Permissible loads per model operator uses the forklift truck safely.
The loss of capacity charts are similar to the one shown
The maximum permissible load of each forklift will vary below and are adhered to the forklift:
according to the forklift model and the mast fitted.

Page 15 of 90
FOR H25 DA MODELS (2WD and 4WD)
H1
H6
H7
M1
M2
X1 Y X2
L L2
L1
IMPORTANT FORKLIFT WEIGHTS

TOTAL UNLADEN WEIGHT (kg) 4750
The capacity loss charts shown here are for WEIGHT ON AXLES WITH LOAD (FRONT/REAR)
6450 / 800
(kg)
illustrative purposes only as only those charts that
apply to a specific model are adhered to that WEIGHT ON AXLES WITHOUT LOAD
2510 / 2240
(FRONT/REAR) (kg)
forklift according to each model's rated
specifications. MAXIMUM PERMISSIBLE WEIGHT (kg) 7250
MAIN MEASUREMENTS
TOTAL LENGTH (mm) L1 4275
IMPORTANT LENGTH TO FORK CARRIAGE (mm)

DISTANCE FROM LOAD TO FRONT AXLE
(mm)
L2
X1
3075
650
WHEEL BASE (mm) Y 1875

Any modification made to the forklift that may REAR OVERHANG (mm) X2 550
affect its load capacity invalidates the original
TOTAL WIDTH (mm) B 1575
diagram (attachments, fork positioners, etc.).
TOTAL HEIGHT WITHOUT MAST (mm) H6 2185
A-2.4 Main measurements and specifications 1270 /

FRONT/REAR TREAD (mm) (2WD) C1/C2
1220
The forklifts' main weights and measurements are given
1270 /
below. This information can be used by the operator for FRONT/REAR TREAD (mm) (4WD) C1/C2
1200
transporting the forklift.
TOTAL HEIGHT WITH MAST (mm) H1 2755
TOTAL HEIGHT WITH MAST EXTENDED
H4 6825
(mm)
IMPORTANT GROUND CLEARANCE, MINIMUM (2WD)

GROUND CLEARANCE, MINIMUM (4WD)
M1
M1
330
380
GROUND CLEARANCE, CENTRE OF WHEEL
M2 300
BASE (2WD)
The weights and measurements given below are
exclusively for the models indicated. GROUND CLEARANCE, CENTRE OF WHEEL
M2 310
BASE (4WD)
TURNING RADIUS (mm) (2WD) WA 3885
DRIVING SEAT HEIGHT (mm) H7 1215

Page 16 of 90
MAIN MEASUREMENTS
TOTAL HEIGHT WITH MAST (mm) H1 2755
W A
TOTAL HEIGHT WITH MAST EXTENDED
H4 6825
(mm)
GROUND CLEARANCE, MINIMUM (2WD) M1 330
GROUND CLEARANCE, MINIMUM (4WD) M1 380
C1
C2
B

M2 300
BASE (2WD)
M2 310
BASE (4WD)
PERMISSIBLE WEIGHTS
DRIVING SEAT HEIGHT (mm) H7 1215
SERVICE WEIGHT (kg) 4750
GVWR / GVW (kg) 7250
PERMISSIBLE WEIGHTS
GVWR / GVW, FRONT (kg) 7000
SERVICE WEIGHT (kg) 4990
GVWR / GVW, REAR (kg) 2400
GVWR / GVW (kg) 7990
GVWR / GVW, FRONT (kg) 7500
FOR H30 DA MODELS (2WD and 4WD) GVWR / GVW, REAR (kg) 2800
FOR H25/H30 DA MODELS (2WD and 4WD)
MAST
TYPE TRIPLEX
H1
H6
MAXIMUM HEIGHT (mm) 6000

H7
WEIGHT (kg) 1100

FORK LENGTH (L) (mm) 1200
M1
M2
TOTAL LIFT HEIGHT (H3) mm 6000

X1 Y X2 FREE LIFT (H2) mm 1985
L L2
L1 LOAD CENTRE OF GRAVITY (CG) mm 500
FORK CARRIAGE FEM III B
TILT FORWARD/BACKWARD º/º 10 / 12
FORKLIFT WEIGHTS
MAXIMUM LOAD LIFTING SPEED m/s 0.4
TOTAL UNLADEN WEIGHT (kg) 4990
MAXIMUM LOAD LOWERING SPEED m/s 0.5
WEIGHT ON AXLES WITH LOAD (FRONT/REAR)
7250 / 740
(kg)
A-2.5 Engine specifications
WEIGHT ON AXLES WITHOUT LOAD
2400 / 2590
(FRONT/REAR) (kg)
MAXIMUM PERMISSIBLE WEIGHT (kg) 7990
MAIN MEASUREMENTS
IMPORTANT
TOTAL LENGTH (mm) L1 4275
LENGTH TO FORK CARRIAGE (mm) L2 3075
Different engines can be fitted on each model in
the DA range (4WD and 2WD). The different
DISTANCE FROM LOAD TO FRONT AXLE
(mm)
X1 650 possibilities for your forklift are shown below.
WHEEL BASE (mm) Y 1875
PERKINS ENGINE FOR H25/H30 DA 2WD
REAR OVERHANG (mm) X2 550
MAKE / MODEL Perkins / 404D22
TOTAL WIDTH (mm) B 1575
NO. CYLINDERS / DISPLACEMENT 4 / 2216 cm3
TOTAL HEIGHT WITHOUT MAST (mm) H6 2185
ACTUAL OUTPUT HP / KW 51 / 38
1270 /
1220 RATED OUTPUT HP / KW 14.16 / 10.42
1270 /
1200

Page 17 of 90
KUBOTA ENGINE FOR H25/H30 DA 2WD OTHER DATA OF INTEREST

MAKE / MODEL KUBOTA / V2403M DRIVE OPERATING PRESSURE 420 bar
NO. CYLINDERS / DISPLACEMENT 4 / 2434 cm3 AUXILIARY PRESSURE / FLOW
200 bar / 78 l/min
ACTUAL OUTPUT HP / KW 48.9 / 36.5 CONNECTION
RATED OUTPUT HP / KW 14.99 / 10.42 BATTERY 12V 70Ah 570A
SOUND POWER LEVEL < 104 dBA

PERKINS ENGINE FOR H25/H30 DA 4WD HYDROSTATIC PUMP -
MAKE / MODEL Perkins / 404D22T
ACTUAL OUTPUT HP / KW 61 / 45.5
RATED OUTPUT HP / KW 14.16 / 10.42
KUBOTA ENGINE FOR H25/H30 DA 4WD

MAKE / MODEL KUBOTA / V2403MT
ACTUAL OUTPUT HP / KW 59 / 44
RATED OUTPUT HP / KW 14.99 / 11.02
A-2.6 Fluid capacity
FLUIDS
ENGINE OIL (l) 10.5
HYDRAULIC SYSTEM (l) 70
COOLING SYSTEM (l) 23
FUEL (l) 65
A-2.7 Wheels and brakes
WHEELS AND BRAKES

12-16.5 / 14 PR
FRONT WHEELS
11.5 / 80-15.3 / 14 PR
10-16.5 / 12PR
12-16.5 / 14 PR
REAR WHEELS
10.0/75-15.3 / 10PR
11.5 / 80-15.3 / 14 PR
SERVICE BRAKE HYDROSTATIC
2WD MECHANIC DISC
PARKING BRAKE NEGATIVE-ACTING
4WD
MULTIPLE-DISC
A-2.8 Other data of interest
OTHER DATA OF INTEREST

TRAVEL SPEED WITHOUT LOAD 24 km/h
TRAVEL SPEED WITH LOAD 20 km/h
RATED DRAWBAR PULL WITHOUT LOAD
2450/2250daN
4WD/2WD
GRADEABILITY WITHOUT LOAD 4WD/2WD 35/30 %
GRADEABILITY WITH LOAD 4WD/2WD 30/25 %
FORWARD/REVERSE GEAR SHIFT ELECTRIC
DRIVE TYPE HYDROSTATIC

Page 18 of 90
A-4 IMPROPER USE

A-2.9 Forklift's residual capacity
Using the MAST EXPLORER forklift trucks according to
To improve safety when operating the forklift trucks, it is operating criteria that do not comply with the
recommended that the following formula be used if instructions contained in this manual and that could be
loads with front dimensions greater than the standard dangerous for the operator or others is understood to be
considered by Mecano Continental S.A., generally 1000 improper use.
mm, are to be lifted (centre of gravity of 500mm):
X= (S×N) / L HAZARD
where:
Some of the most common and dangerous cases of
improper use are listed below:
X = residual capacity of the forklift with
bulky load
S = distance between the vertical axis of the front − Transporting people on the forks.
wheels and the rated load centre (500 mm)
N= forklift's rated capacity − Not following the operation and
L =distance between the vertical axis of the front wheels maintenance instructions given in this
and the centre of gravity of the load to be transported manual to the letter.
− Exceeding mast, height and load limits.
WARNING − Working on unstable pit/ditch edges.
− Travelling across slopes instead of up and

down them.
This formula is only valid in terms of lifting
capacity. The stability and risks presented by the − Working during heavy storms.
vehicle when moving depend on many other
factors that are not taken into account in the − Working in excessively steep conditions as
formula above. there is a risk of overturning.
− Using the equipment for jobs other than for

A-3 PERMITTED USES which it was designed.
The MAST EXPLORER forklift trucks have been
− Working in potentially explosive areas.
designed and manufactured to lift, move and carry
products. Any other use is not permitted and is therefore
− Working in enclosed or poorly ventilated
considered improper use. Strict compliance with the
areas.
operation, maintenance and repair conditions specified
by Mecano Continental S.A is an essential element of
permitted use.
The forklift must only be used and maintained by people

who are fully acquainted with its specifications and
safety procedures. It is also necessary to respect all
accident prevention standards, generally recognised
occupational health and safety standards and all traffic
standards.
WARNING
Any type of modification or change to the forklift,
except for modifications contemplated in this
manual for normal maintenance purposes, is
prohibited.

Page 19 of 90

Page 20 of 90
Section B
OPERATION AND OPERATING
INSTRUCTIONS
CONTENTS
B-1 BEFORE CLIMBING INTO THE FORKLIFT
B-2 CLIMBING INTO THE FORKLIFT
B-2.1 Entering the cabin
B-2.2 Adjusting the seat
B-2.3 Putting on the seat belt
B-2.4 Adjusting the steering wheel
B-2.5 Adjusting the rear-view mirrors
B-3 OPERATOR'S CONTROL PANEL
B-3.1 Key positions
B-3.2 Instruments and controls
B-3.3 Levers and switches
B-3.4 Hydraulic oil level gauges
B-3.5 Lights panel and hour meter
B-4 HYDRAULIC OPERATING SYSTEM
B-5 ELECTRICAL SYSTEM
B-6 STARTING
B-6.1 Starting using external power source
B-6.2 Disconnecting the battery
B-6.3 Battery location
B-6.4 Battery disposal
B-7 TRANSPORTING THE FORKLIFT
B-7.1 Transporting and towing a broken-down forklift
B-7.2 Transporting by crane
B-8 CLEANING AND WASHING THE FORKLIFT
B-8.1 Disposal. End of service life

Page 21 of 90
Model H25DA
B-1 BEFORE CLIMBING INTO THE FORKLIFT Tyres Pressure
and H30DA
12-16.5 / 14 PR
Front tyre 4.5 bar
WARNING 11.5 / 80-15.3 / 14 PR
10-16.5 / 12PR
4 bar
10.0/75-15.3 / 10PR
This section contains support material for the Rear tyre
operator that outlines how to operate the MAST 12-16.5 / 14 PR
4.5 bar
EXPLORER forklift truck. 11.5 / 80-15.3 / 14 PR
Once the operator has taken up his or her position

inside the operator's cabin and has completed the B-2 CLIMBING INTO THE FORKLIFT
preliminary adjustment operations, he or she must then
study and learn the position of all the controls and B-2.1 Entering the cabin
instruments inside the cabin.
Becoming well acquainted with their position is vital to

ensure correct usage during operation and fast, timely
intervention by the operator should sudden manoeuvres
WARNING
become necessary to protect the safety of the operator
and the forklift. Always make sure your hands and footwear are
dry and clean before climbing into the driving
seat.
IMPORTANT The forklift truck has been designed and manufactured

to be operated by an operator from the driving seat
located at the front of the forklift in compliance with the
Learn to operate the forklift and predict how it will operating instructions given in this manual. Use the
respond. Learn how to use the controls in an open, handhold on the side of the overhead guard to climb
safe space with no obstacles or people nearby. into the forklift.
Never jerk the controls; use them with caution
until you are sure what effect they have on the
forklift in order to reduce risks.
Inspection and cleaning:
-Clean the windows, lights and rear-view mirrors.

-Check the wheel nuts, articulated machine parts
(mast) and overall condition of the forklift.
-Check for oil, fuel or coolant leaks.
-Check the tyre pressure.
-Check for possible cracks in covers..
HAZARD
From the driving post, it is possible to activate all of the
A burst tyre could cause serious injuries and necessary elements, both of the drive system and for
accidents. Do not use the forklift with damaged, using the vertical load lifting system.
under-inflated or worn tyres.
The operator should check the position of the battery
cut-off device. When this is in the horizontal position,
To check tyre wear and pressure, see the following the battery will be connected to the forklift's electrical
table: circuits. In a vertical position, the battery will be
disconnected from the forklift's electrical circuit.

Page 22 of 90
B-2.2 Adjusting the seat

Careful seat adjustment ensures that the operator can
drive safely and comfortably. The seat has several
devices for adjusting the seat's distance from the
controls. For this purpose, the seat has a knob and
lever on the right-hand side. By using these devices,
the seat can be adjusted to the desired position.
WARNING
The operator should adjust the seat's distance in
order to be able to safely operate all of the B-2.4 Adjusting the steering wheel
forklift's instruments and controls. To adjust the steering wheel, use the adjusting handle
on the right-hand side of the steering wheel as follows:
-Turn the handle anti-clockwise to loosen.
-Adjust the tilt of the steering wheel.
-Tighten the handle.
HAZARD
Before driving, check that the steering wheel
adjusting handle is locked to prevent accidents.
B-2.3 Putting on the seat belt

WARNING
If you need to change the position of the handle,
IMPORTANT pull the handle out, turn it towards the operator
and release in the appropriate position.
The operator should fasten his or her seat belt

before operating the forklift in any way. The
overall condition and operation of the seat belt
should be checked periodically.
Sit correctly in the driving seat before doing the

following:
-The seat belts have retractors. To fasten the seat belts,

pull the tongue 1 and clip it into the buckle 2.
-To unfasten the seat belt, press the button 3 and

release the tongue from the buckle.
-Check that the seat belt is positioned across the waist

and not the stomach.
-Adjust the length of the seat belt at both ends, keeping

the buckle in the middle.

Page 23 of 90
B-2.5 Adjusting the rear-view mirrors -Adjust the seat so you can comfortably reach all
The forklift is fitted with two exterior rear-view mirrors control levers and fully depress the brake pedal with
attached to the overhead guard to the sides of the your back still against the back of the driving seat.
cabin.
-Adjust the rear-view mirrors so you have a good
view of the area behind the forklift while remaining
seated comfortably in the driving seat.
-Check that the parking brake is on.
B-3.1 Key positions

To start the forklift, put the ignition key in the lock and
turn to operate. The key can be in the following
positions:
-Position 1: Off: The forklift is not running.

-Position 2: Heat: Engine preheating. Hold for 5
seconds and repeat the operation if the engine does not
start or if the outside temperature is very low.
-Position 3: On: The on position (the beacon comes
on).
-Position 4: Start: Starter.
WARNING
Adjust the position of the rear-view mirrors by
rotating the mirror head by hand until you have a
clear view of the area behind the forklift.
B-3 OPERATOR'S CONTROL PANEL

BEFORE STARTING THE ENGINE
WARNING
To ensure the safety of the operator and others and
a long machine service life, do an all-round check
before starting the engine, as described below. HAZARD
-Remove all dirt from inside the cabin, particularly
from the area near the pedals and control levers. After starting the engine, if you climb down from
the driving seat, the engine will still be running
-Remove all oil, grease or mud from the pedals and and may create a hazard. DO NOT LEAVE THE
control levers. DRIVING SEAT WITHOUT FIRST TURNING OFF
THE ENGINE, LOWERING THE MAST AND
-Make sure your hands and footwear are clean and PUTTING THE PARKING BRAKE ON!
dry.
B-3.2 Instruments and controls
-Make sure the seat belt is secure. Below is a description of the main instruments and
controls of the H25/30 DA forklift:
-Check that the lights, gauges, indicators, emergency
lights and acoustic warning alarm are in correct working
order.

Page 24 of 90
Detailed description:
NUMBER DESCRIPTION
1 Steering column adjuster Indicators: move the lever to the right of the steering
2 Rear light switch wheel up (left) or down (right) according to the direction
of travel.
3 Gear stick
4 Parking brake Parking brake switch:

5 Indicators, headlights, horn Lift the guard and push to the left to activate.
6 Key switch
8
Accelerator pedal
Service brake pedal

HAZARD
9 Hour meter
This brake must be activated with the forklift
stationary to prevent accidents as it would lock on
suddenly.
Moving forward and reversing:
-If the parking brake is off:
1) Forward drive: push the forward-reverse lever

forward and step on the accelerator. The forklift will
move forward.
WARNING 2) Reverse: move the forward-reverse lever backward

and step on the accelerator. The acoustic warning
alarm will sound.
The 4WD models are designed with a twin
differential, front and rear, joined by a mechanical
transmission, with which the transmission cannot
be reduced to 2WD at any time.

Page 25 of 90
HAZARD
On putting the forklift into gear, the forklift can
move slowly even without stepping on the
accelerator.
3) If the parking brake is on, the forklift will start but will
not begin to move.
4) If the parking brake is off but the forklift is in gear, the

forklift will not start.
Horn: Located on the end of the light switch. To
5) The parking brake can be activated if the forklift is not sound the horn, simply press the button.
in gear (in neutral).
HAZARD
If the forklift is in gear and the button is pressed,
the brake does not work.
3 2 1
Light switch:
Pedals:
-Position 0: lights off
Position 1: side lights and lights panel
1) Service brake (left pedal) and emergency brake
on
pedal.
-Position 2: headlights on
-Button 3: windscreen wiper 2) Accelerator pedal (right pedal).
-Button 4: horn
3) Parking brake pedal. If the third pedal is fitted,
the steering column will not have the parking
brake button.
To travel downhill with a load, drive with the rear of the

forklift downhill while accelerating to control the
descent speed.
B-3.3 Joystick
The MAST EXPLORER H25/30 DA forklift trucks
include a joystick with four buttons on the top and a fifth
button on the side. The joystick also allows 4
movements as we will see below:

Page 26 of 90
-Button C: optional for 4th valve
-Button D: optional for 4th valve
-Button E: hydraulic brake
B-3.4 Hydraulic oil level gauges
The forklift has 2 gauges or indicators to warn the

operator as shown below:
1
2
Movements of the H25/30 DA joystick:
-Forward: tilts the mast forward
-Backward: tilts the mast backward
-Left: lifts the mast
-Right: lowers the mast 1) Hydraulic oil level window on the service tank
(mast and steering).
2) Hydraulic oil level window on the hydrostatic
transmission tank.
HAZARD
If the oil level is not high enough, the tank should
be topped up with the oil specified in the
maintenance section.
HAZARD
If the hydraulic oil temperature exceeds 100ºC,
contact the Mecano Continental S.A. after-sales
department or qualified staff to check.
B-3.5 Lights panel and hour meter

The MAST EXPLORER forklift trucks have an hour
meter that also shows other useful information for the
forklift operator as described below:
Movements of the H25/30 DA side-shifter:
-Button A: shifts the mast carriage to the left
-Button B: shifts the mast carriage to the right

Page 27 of 90
ELECTRICAL
HAZARD
Specifications of the electrical system are given below:
-The fuse box, which is shown in the photo above, is

located next to the engine at the front of the forklift's
engine compartment. To access the fuse box:
1) Lift the bonnet.

2) Open the fuse box cover.
NUMBER DESCRIPTION
-A numbered chart is attached to the fuse box cover to
1 Hour meter
indicate the position of each fuse or relay. The fuses
2 Side lights fitted in the forklifts are shown in the following table:
3 Air filter change
FUSE No. NAME AMPERAGE (A)
4 Transmission filter change
1 Rotating 15
5 Engine oil pressure beacon
2 Windscreen wiper 25
6 Battery charge
3 Hour meter 5
7 Preheating
4 Forward drive/reverse 10
8 Engine water temperature
5 Full-beam 15
headlight
9 Indicators 6 Dipped headlights 15
10 Headlights 7 Right rear light 7.5
11 Fuel level 8 Left rear light 7.5
9 Indicators 10
10 Horn 10
B-4 ELECTRICAL SYSTEM
11 Engine heater 30
Electric power is provided by a maintenance-free, DC 12 Battery level indicator 7.5
battery located on the lower, right-hand side of the
13 Gear stick 10
forklift in the engine compartment as follows: 12 volt, 70
Ah and 570 A. 14 Fuel level 15
15 Work light 15
To access the battery, lift the bonnet as shown in the 16 Negative brake 15
following photo:
17 Service brake 10
18 Forward drive 5
19 Reverse 5
20 Heating 25
21 General fuse (large) 50

Page 28 of 90
WARNING IMPORTANT
Only use fuses with the indicated amperage. The battery used for jump starting must have the
Failure to do so could lead to damage to or fire in same voltage (12V) and capacity as the battery
the printed circuit board. fitted in the forklift.
The electrical installation must comply with Royal To start the engine using an external battery, proceed as
Decree 1580/2006, transposing the 2004/108/EC explained below:
directive on Electromagnetic Compatibility, and the
-Disconnect the forklift battery using the cut-off device
UNE-EN 1175 regulation on safety of industrial trucks.
fitted.
-Connect the two batteries by first connecting the

B-5 STARTING
positive terminals (+) and then the negative terminals
using the clamps provided for this purpose.
B-5.1 Starting using external power source
HAZARD
When jump starting from another battery that is
not part of the forklift, avoid contact between the
cable clamps once connected to the battery to
prevent sparks.
HAZARD -Proceed to start the forklift's engine using the start

switch.
Batteries produce a flammable gas that could be
ignited by the sparks, causing the battery to -Disconnect the cables by first removing the negative
explode. Do not smoke when checking the cable (-) from the earthing point and then from the
electrolyte. auxiliary battery.
-Disconnect the positive cable (+) from the forklift's

battery and then from the auxiliary battery.
ELECTRICAL
HAZARD HAZARD
Keep the positive cable (+) from the battery away Only use a 12V, 70Ah and 570A battery as other
from any metal object, such as buckles, watch devices (battery chargers, etc.) could cause the
straps, etc., that could cause a short circuit battery to explode or damage the electrical
between the battery terminal and nearby metal, installation.
resulting in the risk of burns for the operator.
B-5.2 Disconnecting the battery

If any type of repair or maintenance work is required on
the forklift, particularly work involving welding, it is
necessary to turn off the battery cut-off device.

Page 29 of 90
B-5.3 Battery location

The MAST EXPLORER forklift truck battery is located
under the bonnet to the left of the engine. HAZARD
B-5.4 Battery disposal Only people with adequate experience using the
appropriate securing and lifting devices may load
the forklift for transportation.
ENVIRONMENTAL
PROTECTION IMPORTANT
The lead-acid batteries used cannot be disposed of
To lift the forklift, use loading devices and tackle
with regular industrial solid waste; instead they
must be collected, disposed of and/or recycled that have sufficient load capacity.
according to the laws of the country where the
forklift is located. Textile devices may be used to protect edges. Secure
the forklift using the eyebolt attached to the forklift's
rear counterbalance and the mast at the front.
B-6 TRANSPORTING THE FORKLIFT
B-7 CLEANING AND WASHING THE FORKLIFT
B-6.1 Transporting and towing a broken-down To clean the forklift correctly, follow these instructions:
forklift
If the forklift breaks down and needs to be transported, -Clean dirty areas affected by oil or grease using dry
take the following into account: solvents or volatile mineral alcohol.
-The load capacity (permissible load) of the transport -Before assembling new spare parts, remove all
vehicle must be greater than the weight of the forklift. protective material (anti-rust, grease, wax, etc.)
-If there are signs of rust on metal parts of the forklift,

-Keep a safe distance from edges, ramps, work
clean using sandpaper and cover with adequate
platforms, etc.
protection (anti-rust, varnish, oil, etc.).
-Completely lower the forks.
Exterior washing
-Put the parking brake on. Remove the key. Before washing, check that the engine is off and that
doors and windows are closed. Do not use fuel for
-Put 2 chocks in front of and behind front and rear cleaning; use only water or a steam jet. In cold climates,
wheels to prevent movement. dry locks after washing or moisten with antifreeze.
Before using the forklift, reset all pre-wash conditions.
-Secure with ropes and tighten.
Interior washing
Wash the interior of the forklift using water and a
WARNING sponge. Never use pressurised water. After washing,

dry with a clean cloth.
Engine washing
For the MAST EXPLORER H25/30DA model, the Wash the engine after applying water-proofing to the air
forklift may only be towed if the instructions given intake filter located on top of the engine bonnet as water
in the maintenance section of this manual are can get into the engine via the air filter.
complied with.
B-6.2 Transporting by crane

Loading by crane is only considered for the initial
transportation of the forklift when commissioned. If
frequent loading of the forklift by crane is required at
the work site, consult Mecano Continental S.A.

Page 30 of 90
B-7.1 Disposal. End of service life
ENVIRONMENTAL
PROTECTION
At the end of the forklift's service life, we
recommend not leaving the forklift discarded as
waste but rather to contract specialised companies
to dispose of the forklift in compliance with current
regulations.

Page 31 of 90

Page 32 of 90
Section C
MAINTENANCE
CONTENTS
C-1 LUBRICANTS. HEALTH AND SAFETY C-5 ELECTRICAL SYSTEM MAINTENANCE

STANDARDS
C-5.1 Battery
C-2 SCHEDULED MAINTENANCE
C-5.2 Fuses and relays
C-3 MAINTENANCE ON THE ENGINE
C-6 TRANSMISSION SYSTEM MAINTENANCE.
C-3.1 Main Perkins engine components GREASING THE FORKLIFT
C-3.2 Perkins engine identification C-7 FORKS
C-3.3 Main Kubota engine components C-8 MAST MAINTENANCE
C-3.4 Kubota engine identification C-9 TYRES
C-3.5 Inspection of the engine alternator C-10 TIGHTENING OF WHEEL BOLTS
C-3.6 Inspection of the alternator belt C-11 TECHNICAL SPECIFICATIONS OF

FORKLIFT FLUIDS
C-3.7 Changing the coolant
C-12 MAINTENANCE PROGRAMME FOR THE
C-3.7.1 Checking the coolant level PERKINS 400D SERIES ENGINE
C-3.8 Replacing the air filter C-13 MAINTENANCE PROGRAMME FOR THE
KUBOTA ENGINE
C-3.8.1 Cleaning the air filter
C-3.9 Changing the engine lubricating oil
C-3.10 Changing the engine oil filter
C-3.11 Fuel injectors
C-3.12 Priming the fuel system
C-3.13 Changing the fuel filter
C-4 HYDROSTATIC SYSTEM MAINTENANCE
C-4.1 Maintaining the hydraulic oil filter
C-4.2 Maintaining the hydrostatic pump
C-4.3 Hydrostatic regulation and pressure

measurement

Page 33 of 90
INTRODUCTION
Disposal
Regular, correct maintenance will give the operator a Disposing of new or used oil is highly contaminating for
forklift that is always safe and operational. For this the environment. Carefully store new oil and keep used
reason, after having worked in particularly adverse oil in special containers for subsequent disposal by
conditions (muddy, dusty terrain, heavy work, etc.), specific waste disposal centres.
washing, greasing and correct maintenance of the
forklift is recommended. Spillage
In the event of accidental oil spills, use sand or a
Always check that all forklift components are in good suitable granulate to soak up the oil. Scrape off the
working condition, there are no oil leaks and safety compound obtained and dispose of as chemical waste.
guards and devices are efficient. If this is not the case,
find and resolve the causes. Emergencies
-Eyes: If oil comes into contact with the eyes, rinse with
Mecano Continental S.A. recommends using copious amounts of running water. If irritation continues,
go to the nearest hospital.
ORIGINAL MAST EXPLORER SPARE PARTS to
ensure adequate operation of the forklift.
-Ingestion: If oil is ingested, do not induce vomiting. See
a doctor.
-Skin: In cases of excessive and prolonged contact with

the skin, wash with soap and water.
-Fire: In the event of fire, use CO2, dry powder or foam

Maintenance operations are scheduled according to the fire extinguishers. Do not use water.
number of service hours completed by the forklift. Keep
track of service hours to be able to correctly determine
maintenance intervals. For this purpose an hour meter C-2 SCHEDULED MAINTENANCE
is fitted on the steering column.
IMPORTANT
Incorrect maintenance or no maintenance at all
Non-compliance with the scheduled maintenance
may make the forklift dangerous for the operator
standards indicated in this manual automatically cancels
and others in the surrounding area.
the guarantee given by Mecano Continental S.A.
Make sure maintenance and lubrication are done
IMPORTANT regularly as indicated by Mecano Continental S.A. in

this manual in order to keep the forklift safe and
operational.
For engine maintenance, carefully follow the Make sure all faults detected during maintenance are
specific operation and maintenance manual immediately resolved prior to using the forklift again.
supplied by Mecano Continental S.A with the
forklift.
C-1 LUBRICANTS. HEALTH AND SAFETY

STANDARDS
Health
Prolonged contact of oils with the skin may cause
irritation. Therefore rubber gloves and goggles are
recommended. After handling oils, thoroughly wash your
hands with soap and water.
Storage
Always store oils in an enclosed place out of the reach
of children. Never leave lubricant containers open and
without a label indicating their contents to avoid
mistakes and accidents.

Page 34 of 90
After 250 service hours or monthly

WARNING Operations to be carried out in addition to others
mentioned above:
All operations marked by the following symbol Grease roller bearings, bushings and articulations
must be done by a specialised technician. Grease lifting chains and mast guides
Within the first 10 service hours Check for correct operation of the lifting cylinders
Check the engine oil and fuel levels Check the condition of the engine's air filter cartridge;
Check the hydraulic oil level in the tank replace if necessary
Check the wheel bolt tightening torque Check that the terminals are tightly fastened to the
battery posts
Check the torque of all screws/bolts
Check that the hydraulic tubes are not worn as a result
Check for possible oil leaks from the hydraulic of rubbing against the chassis or other mechanical
connections components
Check the coolant level in the radiator Check for wear to the rollers on the mast sections
Clean the engine radiator Check the battery fluid level
Check parking brake operation Inspect forks and mast
Check the cleanliness of the hydraulic tank breather Every 500 service hours
and check that it is not blocked
Operations to be carried out in addition to others
Check the tyre pressure mentioned above:
Within the first 50 service hours Visually check the amount of fumes from the exhaust
pipe
Change the engine oil for the first time
Check that the bolts attaching the engine to the silent
Change the hydrostatic pump's hydraulic oil filter
blocks are tight
Every 10 service hours or daily
Check that there is no excessive play between bolts
Check the engine oil level and bushings at all joints
Clean the air intake filter Change hydraulic oil filter
Clean the radiator, if necessary Check brake linings or disc brake pads
Check the hydraulic oil level in the tank Change engine oil filter, air filter and fuel filter
Check that the components of the mast sections are Change the engine oil
well greased to ensure that rollers slide along rails
Check for correct operation of the hydrostatic pump
Check for correct operation of the electrical lighting
Check mast bushings
installation
Grease mast support pins
Check for correct operation of the brake system and
parking brake Every 1000 service hours or every year
Check that the steering system is working properly Operations to be carried out in addition to others
mentioned above:
Check for correct operation of the service brake
Check the brake discs and parking brake
Every 50 service hours or weekly
Grease the wheel hubs and bearings
Operations to be carried out in addition to daily
operations: Change brake fluid
Check the alternator belt tension Change hydraulic oil
Check the tyre pressure Change coolant
Check the wheel bolt tightening torque After each repair affecting the hydraulic system
Check the friction of the air intake tube between the Change hydraulic filters
engine and the filter and check that it is in good
condition Change hydraulic oil

Page 35 of 90
WARNING WARNING
These service hours / intervals are Before working on the hydraulic lines or
recommendations when operating the components, make sure there is no pressure in the
forklift under normal conditions. system. To do this, after turning off the engine and
Depending on usage and work putting the parking brake on, move the distributor
environment, these intervals may be control levers (in the opposite direction to the
longer or shorter. operating direction) to release pressure from the
hydraulic circuit.
IMPORTANT
IMPORTANT
It is vital that these maintenance intervals be
followed in order to claim a repair under the The high-pressure lines may only be replaced by
guarantee. qualified staff. Any impurity in the closed circuit
rapidly deteriorates the transmission and
hydrostatic pump.
HAZARD
All maintenance work must be carried out with the
IMPORTANT
engine stopped, the parking brake on and the mast
resting on a flat surface on the ground. The qualified staff performing maintenance on the
hydraulic circuit must carefully clean the
surrounding areas before carrying out any
operation.
WARNING
Before any maintenance operation involving the ENVIRONMENTAL
lifting of a component, secure the component to
be lifted to keep it safe and steady prior to moving. PROTECTION
Used oils should be handled and disposed of in
WARNING compliance with national standards and

regulations. Make sure there are authorised
disposal sites.
Operations on the hydraulic system are strictly

prohibited unless carried out by authorised staff.
This forklift's hydraulic installation has high-
pressure connections and lines that could cause
serious personal injury if not disconnected prior
to carrying out maintenance on the system.

Page 36 of 90
C-3 MAINTENANCE ON THE ENGINE Number

13 Upper oil filler tube cap
C-3.1 Main Perkins engine components 14 Oil pan breather
15 Rear lifting eyebolt
16 Air intake elbow
17 Valve gear cover
18 Turbocharger
19 Water thermostat box
20 Starter motor solenoid
21 Electric starter motor
22 Alternator
23 Engine oil pan
24 Engine oil drain plug
25 Fan drive belt
26 Crankshaft pulley
27 Coolant temperature switch
28 Cooling fan
C-3.2 Perkins engine identification

All Perkins engines are identified by a serial number. This
number appears on the serial number data plate attached
to the left side of the engine block, near the rear of the
engine.
Number
1
2
3
Fuel shut-off solenoid
Fuel injector 1
Water pump
IMPORTANT
4 Lower oil filler tube cap
5 Accelerator lever To order spare parts, the Mecano Continental S.A.
6 Attachment control cover Technical Support Department staff may ask for the
7 Engine oil level gauge data plate number to determine which components
8 Engine oil cooler are included in the engine.
9 Engine oil filter
10 Injection pump
11 Transfer pump
12 Fuel filter
Number
1 Data plate
2 Temporary Parts List number
3 List number
4 Serial number
5 Type

Page 37 of 90
C-3.3 Main Kubota engine components C-3.4 Kubota engine identification
KUBOTA engines have a serial number on the right

side of the engine block. The Mecano Continental S.A.
Technical Support Department may be asked for this
serial number to identify their engine.
The following information should therefore be checked:
Type Serial No.

Engine
Number
Purchase date
1 Intake manifold Name of
2 Speed control lever dealer
3 Engine stop lever (To be completed by the purchaser)
4 Injection pump
5 Fuel pump
6 Cooling fan
7 Fan pulley
8
9
10
Oil filter cartridge
Water drain tap
Oil filler plug
IMPORTANT
11 Exhaust manifold
12 Alternator
To order spare parts, the Mecano Continental S.A.
13 Starter motor Technical Support Department staff may ask for the
14 Dipstick data plate number to determine which components
15 Oil pressure switch are included in the engine.
16 Flywheel
17 Oil drain plug
C-3.5 Inspection of the engine alternator
18 Oil pan
19 Eyebolt Inspect the alternator to check that there are no loose
connections or that the battery is properly charged. To
check that the battery is properly charged, start the
forklift and turn the battery cut-off device. If the
alternator is working correctly, the forklift should not
stop.
19
15
16
ALTERNATOR

Page 38 of 90
MAINTENANCE INTERVAL
Check alternator
every 500 hours
Inspect the ammeter (if fitted) while the engine is

running to ensure proper battery and electrical system
performance. Make repairs as required. Check the
alternator and the battery charger for correct operation.
WARNING Adjust the belt as indicated below

If the batteries are properly charged, the ammeter -Loosen the pivot bolt of the alternator and the adjusting
reading should be 0 A bolt. Move the alternator to increase or reduce the belt
tension.
C-3.6 Inspection of the alternator belt
-Tighten the pivot bolt of the alternator and the adjusting
The belt will be inspected and replaced with the engine
bolt to 22 N·m.
stopped. Check that the belt tension is correct. To
properly check the belt tension, use a Burroughs gauge.
Check the belt tension C-3.7 Changing the coolant

every 50 service hours or weekly To change the coolant, make sure the vehicle is on level
ground, the cooling circuit is not pressurised and the
temperature is adequate. Then follow the instructions
below:
Instructions for replacing the belt:
To replace the alternator belt or check belt tension, -Remove the cooling system filler cap.
follow the instructions given below:
-Remove the drain plug from the side of the engine
-Fit the gauge as indicated in the following diagram at block to drain the engine. Make sure the drain hole is
the centre of the longest free length and check the not blocked.
tension. The correct tension is 535 N. If the belt tension
is below 250 N, adjust the belt to 535 N. -Open the radiator drain tap or remove the drain plug at
the bottom of the radiator to drain the radiator. If the
radiator does not have a tap or a drain plug, disconnect
the hose at the bottom of the radiator.

Page 39 of 90
-If the system is dirty or contains stagnant water, flush 3) Clean the cooling system filler cap and check its
the cooling system with clean water. condition. Replace the cap if the gaskets are damaged.
Refit the filler cap.
-Close the radiator drain tap. Connect the radiator hose
if this was removed. 4) Inspect the cooling system for leaks.
MAINTENANCE INTERVAL Filling and checking the level of the expansion tank:
The forklift has an expansion tank fitted in the cooling
Change coolant circuit as shown below:
every 2000 service hours or 2 years
HAZARD
Do not drain the coolant while the engine is still
hot and the system is under pressure because
dangerous hot coolant could be discharged.
-Fill the system with an approved antifreeze mixture.

The maximum fill rate for filling the system is 1 litre per
minute. Fill until water comes out of the engine drain or
bleed plug free of air bubbles. Tighten the screw with
the corresponding torque. Fit the filler cap.
-Clean up any remaining coolant. Check the engine for WARNING

coolant leaks.
To correctly fill the cooling system, make sure the
tank level is filled to within 1/3 of its maximum
WARNING capacity.
After running the engine, the coolant level may

vary. Check the level again after running the
engine for a few hours.
IMPORTANT
It is important to fill the expansion tank with the
C-3.7.1 Checking the coolant level
engine cold.
Check the coolant level only when the engine is stopped
and cool.
C-3.8 Replacing the air filter
1) Slowly remove the cooling system filler cap to relieve
the pressure.
2) Fill the coolant level to within 13 mm of the bottom of

the filler pipe. If the engine has a sight gauge, fill the Air filter elements prevent particles from entering the
coolant to the proper level on the sight gauge. engine's air intake.

Page 40 of 90
Dust entering the engine causes damage to 4) Remove the tape from the air inlet. Install the
components and premature wear. Never run the engine secondary element. Install a new or clean primary
without fitting an air filter. element.
Never run the engine with a damaged air filter. Do not 5) Install the air filter cover every time the dirty air filter
use air filter elements with damaged pleats, gaskets or elements are replaced with clean elements or proceed
seals. to clean.
The air filter is on the engine. To clean or replace the air Before installing the new filters, carefully check that
filter, release the 3 fasteners on the cover and remove there are no tears and/or holes in the filter material. The
the filter. pipes to the engine should also be checked.
Also inspect the gasket or the seal of the air filter

element for damage.
IMPORTANT
Keep an adequate supply of ORIGINAL MAST
EXPLORER air filter elements in stock as spare
parts for your forklift.
C-3.8.1 Cleaning the air filter
Clean the filter daily or every 8 hours The primary element must be replaced at least once a
Change every year or every 1000 service hours year. This replacement should be performed regardless
of the number of cleanings. Instructions for cleaning the
air filter are given below.
The filter must be replaced at least once a year. The

secondary element is not washable. Also:
-Check the pre-filter (if fitted) and the dirt cup daily for
IMPORTANT
accumulation of dust or dirt. Remove the dust and dirt
as required. Visually inspect the filter before cleaning for
damage to the gasket and the outer cover. Discard
any damaged air filter elements.
WARNING There are two common methods for cleaning primary air
filter elements:
Depending on the operating conditions (dust, dirt Compressed air
and particles), more frequent maintenance of the Compressed air can be used to clean filters that have
air filter element may be required. not been cleaned more than two times. Compressed air
will not remove deposits of carbon and oil. Use filtered,
-This replacement should be performed regardless of dry air with a maximum pressure of 207 kPa (2.07 bar).
the number of cleanings.
When the primary element is cleaned, always begin
Follow the instructions given below to change the with the clean side (inside) in order to force dirt particles
air filter: toward the dirty side (outside). Aim the hose so that the
air flows inside the element along the filter in order not
1) Release the 3 fasteners and remove the cover. to damage the paper pleats. Do not aim jets of air
Remove the air filter. directly at the primary air filter element.
Dirt could be forced into the pleats.
2) Cover the air inlet with tape in order to keep dirt out.
3) Clean the inside of the air filter cover and body with a
clean, dry cloth.

Page 41 of 90
Change the engine lubricating oil

every 500 service hours
IMPORTANT
Vacuum cleaning
Vacuum cleaning is a good method for cleaning primary Drain the oil when the oil is warm and the
filter elements that require daily cleaning because of a contaminants are suspended and not settled in the
dry, dusty environment. Cleaning with compressed air is oil pan.
recommended prior to vacuum cleaning. Vacuum
cleaning will not remove deposits of carbon and oil. Use one of the following methods to drain the oil from
the engine oil pan:
C-3.9 Changing the engine lubricating oil
-If the engine is equipped with a drain valve, turn the
valve knob to the left to drain the oil. After draining the
HAZARD oil, turn the drain valve knob to the right to close the
valve.
-If the engine is not equipped with a drain valve, remove

Hot oil and hot engine components can cause the oil drain plug (1) to allow the oil to drain. If the
personal injury. Do not allow hot oil or hot engine is equipped with a shallow oil pan, remove the
components to touch the skin. bottom oil drain plugs from the ends of the oil pan.
-After draining the oil, the oil drain plugs must be

cleaned and refitted. It is necessary to replace the
IMPORTANT gasket on the drain plug to prevent oil leaks.
C-3.10 Changing the engine oil filter

Do not drain the oil when the engine is cold. As the
oil cools, suspended waste particles settle on the Follow the recommendations given below to replace the
bottom of the oil pan. The waste particles are not filter properly:
removed on draining the cold oil.
1) Remove the oil filter using a suitable tool.
Drain the oil pan with the engine stopped and the oil 2) Clean the sealing surface of the oil filter. Make sure
warm. This draining method allows the waste particles the union on the oil filter head is secure.
suspended in the oil to be drained properly. Failure to
follow this recommended procedure will cause the 3) Apply clean engine oil to the oil filter seal. Do not fill
waste particles to be recirculated through the engine the oil filters before installing them as this oil would not
lubrication system with the new oil. The oil pan drain be filtered and could be contaminated.
plug is shown below.
DRAIN
PLUG
4) Install the oil filter.

Page 42 of 90
The fuel injectors should only be renewed if a fault
IMPORTANT occurs or if a specialised injection system technician

orders their renewal.
Some of the problems that may indicate that new fuel

Tighten the oil filter by hand (do not use tools) injectors are needed are listed below:
according to the instructions given on the oil filter.
Do not over-tighten. -The engine does not start or it is difficult to start.
-It does not have enough power.
MAINTENANCE INTERVAL -The engine misfires or runs erratically.
Change engine oil filters -High fuel consumption.

-Black exhaust smoke.
-The engine knocks or there is vibration in the engine.
ENVIRONMENTAL -Excessive engine temperature.
PROTECTION C-3.12 Priming the fuel system

If air enters the fuel system, the air must be purged from
the fuel system before starting the engine. Air can enter
Used filter waste should be handled by companies the fuel system when the following conditions occur:
authorised for this purpose according to the
country where the forklift is located. -The fuel tank is empty or partially drained.
-The low-pressure fuel lines are disconnected or break.

To fill the engine with oil:
-There is a leak in the low-pressure fuel system.
1) Remove the engine oil filler cap.
-The fuel filter is replaced.
2) Start the engine and run at “low idle” for two minutes.
Perform this procedure in order to ensure that the
-A new injection pump has been installed.
lubrication system has oil and the oil filters are filled.
Inspect the filters for leaks.
Use the following procedure to purge air from the
fuel system:
3) Stop the engine and allow the oil to drain back into
the oil pan for a minimum of 5 minutes.
-Check that there are no leaks in the lines and that
these are not in bad condition.
4) Keep the oil level between the "ADD" and "FULL"
marks on the engine oil dipstick.
-Loosen the fuel filter screw.
C-3.11 Fuel injectors -Use a hand pump until clean, bubble-free fuel flows
from the screw.
HAZARD -Loosen the nuts on the high-pressure fuel lines on all

fuel injectors.
-Turn the key switch to the on position.

Fuel spilled onto hot surfaces or electrical
components can cause a fire.
Perkins recommends regularly maintaining the fuel

injectors.
The fuel injectors should not be cleaned as cleaning

with incorrect tools can damage the nozzles. Only
specialised staff must clean the injectors.

Page 43 of 90
HAZARD
The fuel injection pump, battery and starter motor
can be damaged if the starter motor is used
excessively to bleed or purge air from the fuel
system.
Proceed to start for approximately 10 seconds. Repeat

this operation until clean fuel flows from the injector
screws.
-Loosen the flare nuts on the high-pressure fuel lines on

all fuel injectors. Replace the primary filter of the fuel system as follows:
-Observe the flare nut connection. Run the starter motor -Loosen the central filter screw.
and start the engine until fuel no longer contains air.
-Hold the bottom of the filter in one hand to prevent it
-Tighten the flare nuts to a tightening torque of 30 N·m. from falling. Remove the central filter screw and remove
the filter and the bowl together.
-The engine is ready for starting.
-Dispose of the fuel filter using suitable containers for
recycling.
IMPORTANT -Proceed to clean the bowl.
-Carefully fit new seals on both the bowl and the filter.
Let the engine idle for at least five minutes
immediately after air has been purged from the fuel
-Place the filter onto the bowl in the original position and
system.
assemble with the fuel filter support.
C-3.13 Changing the fuel filter -Refit the central fuel filter screw. Adjust by hand and
The fuel filter is located on the left side of the engine. apply the appropriate torque.
Before replacing the filter, take the following safety -Proceed to bleed the fuel filter in accordance with the
precautions: previous section.
-Fuel leaked or spilled onto hot surfaces or electrical

components can cause a fire. To prevent possible
accidents, turn the start switch to the off position when
preparing to change fuel filters or water separator
WARNING
elements.
The seals must be properly seated to prevent fuel
-Clean up fuel spills and the area around the fuel leaks or to prevent air entering.
system component to be disconnected immediately. Do
not allow dirt to enter the fuel system.
-Place a tray under the fuel filter to catch any fuel that
might spill. Change fuel filter

Page 44 of 90
C-4 HYDROSTATIC SYSTEM MAINTENANCE Under normal operating conditions, the hydraulic oil
filters should be replaced:
Regular maintenance operations for the forklift's
hydraulic installation include:
a) Checking and filling the hydraulic oil level as
necessary Change hydrostatic oil filter
b) Cleaning and maintaining the radiating surfaces after the first 50 hours
c) Changing the hydrostatic filters. every 500 hours
d) Changing the hydraulic oil.
During maintenance cycles, avoid contaminating the
Extraordinary maintenance operations are usually intake circuit whenever the filter cartridge is changed.
necessary as a result of forklift component malfunction. Use the hydraulic oil recommended by Mecano
Continental S.A that contains additives, according to
Extraordinary maintenance also includes:
viscosity grade ISO VG 46. Also always use original
MAST EXPLORER hydraulic filters.
-Adjusting and regulating the pump during the initial
start-up.
C-4.2 Maintaining the hydrostatic pump
-Disassembling and reassembling the pump and the It is very important that all parts and components of the
engine, or parts thereof. hydraulic installation are cleaned properly. This should
be done before starting the forklift or after changing any
The following actions are recommended: oil or mechanical elements.
-Carrying out all operations in a clean, dust-free It is necessary for the main connection operations to be
environment so that no foreign particles enter the carried out in a clean, dust-free environment with any
components. type of dirt that could enter the circuit being immediately
removed.
-Covering all pressure inlets with plastic plugs as soon
as the hydraulic lines are disconnected. To guarantee that the operating temperature of the
hydraulic system remains within the permissible limits,
-Replacing the seals every time the components are the condition and cleanliness of the oil-air heat
opened. We therefore recommend having several seal exchanger installed on the forklift must be checked.
kits to hand before working on the components.
WARNING
The maintenance intervals for filter and oil
changes stated in this manual must be complied
with in order for the guarantee to remain valid.
C-4.1 Maintaining the hydraulic oil filter

The frequency of filter maintenance and replacement
depends on the pump's rotation rate, the type of fluid After changing any mechanical element or oil, follow the
used, the pump's starting and operating temperatures instructions given below:
and accidental or systematic contamination in the
forklift. Before starting the forklift
-Check the cleanliness of all the parts of the installation
WARNING that come into contact with the circuit's hydraulic fluid
(tank, tubes, heat exchangers, filters, etc.).
-Make sure nothing is blocking the pump's normal intake

It is very important to change the hydraulic oil filter and check for loose connections that could cause air to
after the first 50 hours of operation. If it is not enter the tubes, kinked or restricted lines, etc.
changed, the supplier's guarantee will be lost in
the event of any breakdown.

Page 45 of 90
-Install the pressure gauges on the high-pressure circuit

line and the low-pressure pump line. The pump has
three 1/4" quick-connect terminals for pressure gauges,
two for high pressure (400 bar) and one for the supply
IMPORTANT
pressure (10-30 bar).
Make sure the pump is set to the zero
Filling the hydraulic tank displacement position (the gear stick must be in
the neutral position, i.e. not in either forward or
reverse).
IMPORTANT Correct operation of the loading pump is indicated by

the pressure gauge installed in the pump's supply circuit
(minimum pressure port), which indicates a minimum
Before filling the tank, check that it is clean and pressure of a few bar (10-25 bar).
with no signs of residue, particles, rust, etc.
inside. The following operations must be performed:
-Run the pump in both directions and make sure the

direction of rotation of the driven parts is correct.
IMPORTANT -Run the transmission until you are sure that all air has
been eliminated and there is no mixture of air and oil.
This usually takes a few minutes.
Use a 10-micron filter when filling the hydraulic
fluid to prevent foreign bodies from entering the -Increase the rotation speed and check that the
installation. pressure in the loading circuit reaches 18-20 bar and
that the depression on the intake line pressure gauge
does not exceed values of 0.5 bar with cold oil and 0.2
Even new oil may contain impurities. Also fill the tank
bar with hot oil.
and all other large-capacity components with fluid
(filters, heat exchangers).
-Gradually increase the load, monitoring the maximum
operating pressure on the high-pressure gauge.
Fill the hydraulic pump and motor with oil via one of the
drain ports and make sure the casing is at least 50% -During the starting phase, check the hydraulic fluid
full. level in the tank and, if necessary, fill to the appropriate
level.
HAZARD Checking the hydrostatic pump performance
To check the pump's performance, install one pressure

gauge (up to 60 bar) at the supply pressure intake and
Do not run the engine and the hydraulic pump
another (up to 600 bar) at the high-pressure intake.
before filling. The components may be seriously
damaged.
On starting the forklift

The vehicle must be started and all of the air present in
the hydraulic circuit eliminated before said circuit is
used to lift heavy loads.
To do this, with the emergency stop connected (the

forklift will not be able to start), keep the engine turning
over with only the starter motor (at less than 500 rpm)
until the entire circuit has filled with oil (this operation
tends to require two or three start phases lasting some
5 seconds each).
Always pay maximum attention to moving parts and

comply with all current safety standards.

Page 46 of 90
C-5 ELECTRICAL SYSTEM MAINTENANCE
HAZARD
Carry out this test in the shortest time possible to HAZARD
avoid overheating the pump and the installation.
All maintenance work on the electrical system
For closed circuit pumps, make sure the external must be carried out with the engine off, the parking
maximum pressure relief valve is correctly attached to brake on and with all working parts resting on the
the pump and that it properly protects the pump. Follow ground.
the procedure outlined below:
-Cover the high-pressure openings with plugs and seals C-5.1 Battery
capable of withstanding at least double the maximum The battery fitted on this forklift truck does not need
pressure of the pump. maintenance. Check:
-Turn the pump at 1200 rpm with zero displacement; -That all cable terminals are securely attached to the
with the oil at around 50ºC, check that the supply battery posts. To tighten the terminals, always use a
pressure is around 18-20 bar. spanner, not pliers.
-Slightly increase the pump displacement; check that -Protect the posts by coating them with pure vaseline or
the supply pressure does not suddenly drop and the battery terminal protector spray.
operating pressure is the same as the rating pressure of
the maximum pressure relief valves. -If the forklift is not going to be used for a long period of
time, remove the battery and store in a dry place.
-If the supply pressure suddenly drops and the pump
does not open the maximum pressure relief valves, the -Wear safety goggles and gloves and move the battery
wear and internal play of the components have probably carefully to avoid electrolyte leaks. Also:
reached such a level that the component needs
overhauling or replacing. -Keep all metal objects (watches, rings, chains) away
from the battery terminals as they could cause a short
circuit resulting in burns.
C-4.3 Hydrostatic regulation and pressure -Before connecting or disconnecting the battery, turn off
measurement all switches in the cabin.
-To disconnect the battery, first disconnect the negative
HAZARD terminal (-) from the earthing point.
-To connect the battery, first connect the positive

terminal (+).
Any modification to the hydrostatic pump must be
communicated to and authorised by the Mecano -Recharge the battery away from the forklift in a well-
Continental, S.A. Technical Support Department. ventilated area.
-Never approach with objects that could produce sparks

or open flames or cigarettes.
HAZARD -Avoid placing metal objects on top of the battery. This

could cause dangerous short circuits, especially during
recharging.
The hydrostatic pumps must not be regulated or -Given that the electrolyte is highly corrosive, avoid any
adjusted on site. Contact the Mecano Continental contact with the forklift chassis or with electrical or
S.A. Technical Support Department. electronic components. If this does occur, contact an
authorised support centre.

Page 47 of 90
ELECTRICAL
HAZARD
There is a risk of the battery exploding or short
circuiting. An explosive mixture of hydrogen gas
forms when recharging the battery.
HAZARD
The battery electrolyte contains caustic sulphuric
acid. If it contacts the skin, immediately wash off
with soap and plenty of water. If the acid contacts
the eyes or other sensitive body parts, flush with
abundant water and see a doctor.
IMPORTANT
ENVIRONMENTAL Do not use fuses with a higher amperage than
PROTECTION indicated as this may damage the electrical
installation.
Properly process the used battery as waste to FUSE No. NAME AMPERAGE (A)
protect the environment. 1 Rotating 15
beacon
2 Windscreen wiper 25
3 Hour meter 5
C-5.2 Fuses and relays
4 Forward drive/reverse 10
The electrical installation is protected by fuses installed
5 Full-beam 15
at the back of the cabin. Before replacing a blown fuse headlights
with another of the same amperage, find and correct 6 Dipped headlights 15
whatever caused the fuse to blow otherwise the 7 Right rear light 7.5
problem will continue. 8 Left rear light 7.5
9 Indicators 10
The fuse box that is located under the bonnet to the left
of the engine is shown below: 10 Horn 10
11 Engine heater 30
12 Battery charge indicator 7.5
13 Gear stick 10
14 Fuel level 15
15 Work light 15
16 Negative brake 15
17 Service brake 10
18 Forward drive 5
19 Reverse 5
20 Heating 25
21 General fuse (large) 50

Page 48 of 90
C-6 TRANSMISSION SYSTEM MAINTENANCE. C-7 FORKS

GREASING THE FORKLIFT
Check the following critical points
Grease axles, mast and mast pins every 30 days or 200 service hours
every 30 days or 200 service hours
The rear axle, mast, tilt cylinder linkage, mast pins and Visually inspect the forks, paying particular attention to
other elements requiring lubrication must be greased as points 1, 2 and 7 shown in the following diagram. If
shown in the following figures using adequate amounts there is a fault, replace with an original spare part.
of grease.
Greasing the rear axle: the axle has two grease points
per wheel as shown in the following diagram:
Rear axle grease points:
WARNING
All hinges, fork heads and other articulations must
be lubricated prior to use as required.
C-8 MAST MAINTENANCE

The runner blocks and rollers installed on the mast
guides must be greased.
WARNING The mast rails should also have liquid grease so that
the runners produce minimum friction and wear when
sliding.
The rear axle has 2 grease points per wheel. All grease points on the masts are broken down into the
areas shown below (A, B C and D).
Grease the grease points

every 30 days of operation

Page 49 of 90
WARNING Area A
There may be slight differences between the

photos shown below and your specific mast
depending on whether your forklift has a duplex or
triplex mast.
Details on each area are given below:
Points 2, 4 and 6 are in the same position on the other

side (mirror-image).
Area B (This area is for the triplex mast model only):
Points 2 and 4 are shown on the following photo:

Page 50 of 90
Area C Checking the mast chains
Points 1, 2, 3 and 4 MAINTENANCE INTERVAL
Check mast chains

every 30 days
Pay special attention to points 1 to 7. If there is a fault,

replace with an original spare part.
Point 4 is on the lower face.
Area D
Grease the chains

every 30 days or 200 service hours
We must also consider the two grease points on the tilt

cylinder linkage and the mast pins as shown below:
IMPORTANT
The lifting chains are safety elements. Chemical
cleaning products, acids and bleach must not be
used as they may damage the chains. Apply spray
grease recommended for this purpose.
C-9 TYRES
The air pressure used has a direct effect on the tyre's
service life. The tyre pressure must be checked every
100 service hours when the forklift is unloaded. Check
the tyre pressure according to the following table:
Check the pressure


Page 51 of 90
Model H25DA -Never cut or solder a rim if the tyre contains

Tyres Pressure pressurised air.
and H30DA
12-16.5 / 14 PR
Front tyre 4.5 bar -Never assemble rim pieces of different sizes and never
11.5 / 80-15.3 / 14 PR
use damaged or faulty pieces. See the service manual
10-16.5 / 12PR for authorised tyre and rim sizes. Do not fit tyres with a
4 bar
10.0/75-15.3 / 10PR different tread.
Rear tyre
12-16.5 / 14 PR -Remove the air before removing foreign bodies from
4.5 bar
11.5 / 80-15.3 / 14 PR the tyre.
-Put the valve dust caps back on after checking or filling

If the tyre pressure is wrong, correct as soon as
the tyres.
possible as operating a forklift truck with low tyre
pressure will have the following effect on the tyres:
-For special operations, for example on sandy terrain,
the air pressure can be modified after consulting the
-Excessive flexing.
after-sales department or the tyre manufacturer.
-Overheating.
-Excessive strain on fabric.
-Bulging of sidewalls. C-10 TIGHTENING OF WHEEL BOLTS
This results in damaged sidewalls and stretched MAINTENANCE INTERVAL

individual strands of fabric.
Check bolt torque
Tighten all wheel bolts daily during the first week of

operation.
IMPORTANT
The tightening torque is 270 N·m for the front
differential, 270 N·m for the rear differential on the
4WD model and 300 N·m for the rear axle on the
2WD model.
IMPORTANT Wheel nuts must also be tightened daily after each

wheel change during the first week of operation.
A high pressure is dangerous as it transmits

excessive tensile strain to the fabric and the tyre is
therefore susceptible to punctures and cuts.
Take the following precautions when servicing the tyres:
-Always stand to the side of the tyre so you are shielded

by the vehicle to protect yourself against possible
explosions.
-On filling a tyre on a split-rim wheel, check exactly if the
loose ring pieces are in the right position as a ring flying
off the rim may cause fatal injuries.
-Use a safety nozzle (that you do not have to hold APPLY TORQUE IN A CRISS-
manually) with a hose that is long enough for you to
CROSS PATTERN
stand outside the danger zone when filling the tyre.

Page 52 of 90
C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT Specification Method Typical values

FLUIDS
Pour point (ºC) ASTM D-97 -39
The following table shows the fluids used in the forklift:
Demulsibility 40/40/0 (min) ASTM D-1401 10
LIST OF LUBRICANTS USED

Specification Typical values
LUBRICANTS TYPE Colour Amber
Engine oil ISO 10W-40 Physical state Liquid at ambient temperature
Odour Characteristic mineral oil

Hydraulic oil ISO VG 46
Vapour pressure <0.1 Pa at 20ºC
Chains Chain spray
Initial boiling point 280ºC
Extreme-pressure adhesive
Mast
grease Water solubility Negligible
Fuel Diesel Upper flammable limit 10% (v/v)
Differential carrier oil SAE 75W-80, API GL-4 Lower flammable limit 1% (v/v)
Auto-ignition temperature >320ºC

Differential oil SAE 75W-80, API GL-4
Brake fluid LHM Super mineral oil BRAKE FLUID

Lithium soap-based grease
Grease points
(DIN 51825-KPF2 N-20 The brake fluid is a green, special, mineral oil-based
Penetration grade 2, lithium fluid that is to be used to initially fill and successively
soap)
refill the combined brake-suspension circuits.
HYDRAULIC OIL PROPERTIES This fluid offers notable lubricating power, which favours
optimum performance of the mechanical parts present
The hydraulic oil used in our forklift trucks allows high- in the hydraulic circuits.
pressure operation without hardly any variation in
viscosity as temperature changes. Thanks to a suitably It is also characterised by an extremely low freezing
high viscosity index, the oil maintains a suitable point and a very high viscosity index and can therefore
viscosity throughout the forklift's entire operating be used without drawbacks over a wide temperature
temperature range. range.
This oil complies with the following standards: Specification Typical values
Density at 15ºC (kg/l) 0.835

ISO/DIS 6743 Part 4 Category HV
Kinematic viscosity -
DIN 51524 Part 2 and 3 Category HLP/HLPV
-40ºC (cP) 1100
AFNOR NF E 48602 Category HV
40ºC (cSt) 18.2
AFNOR NF E 60 200 Category HV
100ºC (cSt) 6.2
Specification Method Typical values Viscosity index >300
ISO grade --- 46 Colour green
Density at 15ºC (g/ml) ASTM D-4052 0.870 Flash point (OC) 125ºC
Pour point -60ºC
Kinematic viscosity (cSt) ASTM D 115

ANTIFREEZE
4.6 Antifreeze is usually made of three elements: water,

40ºC
additives and glycol. We recommend using an
antifreeze with a minimum concentration of 50% in
100ºC 8.6
engine cooling systems.
Viscosity index ASTM D-2270 150
Flash point (ºC) ASTM D-93 202

Page 53 of 90
IMPORTANT
Do not use the following types of water in cooling
systems: Hard water, soft water that has been
softened with salt and seawater.
Many engine failures are a result of the cooling system.

The condition of the coolant is also important for it to do
its job properly.
Never work on an engine without a thermostat in the

cooling system. Thermostats help keep the engine
coolant at the right operating temperature.
The coolant's glycol content helps protect against

boiling over, freezing and water pump cavitation. A 1:1
mixture of water and glycol is used.

PERKINS 400 D SERIES ENGINE
WARNING
Before performing any maintenance work or
procedure, make sure you have read and
understood all the safety information, warnings
and instructions.
The following programmes must be performed

according to the interval that comes first:
PERKINS maintenance programme

A - When required
B - Daily or every 8 service hours
C - Every 50 service hours
D - Every 250 service hours or 6 months
E - Every 500 service hours or 12 months
F - Every 1000 service hours
G - Every 2000 service hours
H - Every 3000 hours
KEY FOR FOLLOWING TABLE
The preventive maintenance intervals are indicated for

normal operating conditions. When engine performance
must be adjusted to local standards, it may be
necessary to adapt the maintenance intervals and
procedures to guarantee correct engine performance.
As part of good preventive maintenance, look for leaks

or loose fasteners during each check.

Page 54 of 90
A B C D E F G H PERKINS 400D SERIES ENGINE
X Replace the battery
X Disconnect the battery or battery cable
X Check the battery electrolyte level
X Inspect and clean the engine's earthing connection
X Inspect the safety and wear of the electrical cables
X Clean the engine
X Inspect the engine
X Inspect the alternator
X Inspect the engine supports
X Inspect the starter motor
X Inspect the turbocharger (Model with turbo)
X Inspect the water pump
X Inspect the oil pan breather
X Check and correct leaks and damage to the engine
X Prime the fuel system
X Drain water from the fuel system separator
X Replace the fuel filter cartridge
X Check the injector performance
X Replace the injectors
X Check the engine oil level
X Change the engine oil (fill slowly, making sure the right amount is used)
X Change the engine oil filter
X Clean the primary air filter and empty the air filter's dust collector when the engine is
operating in extremely dusty environments
X Clean the air filter and empty the air filter's dust collector when the engine is operating
under normal conditions
X Replace the primary air filter
X Inspect the air filter service indicator
X Check the coolant level
X Change the coolant
X Check the coolant concentration
X Check the tension and state of the alternator belt
X Check all flexible pipes and connections
X Replace the engine breather
X Check the alternator and starter motor
X Inspect the safety and wear of the electrical cables
X Check and correct leaks and damage to the engine
X Replace hoses and clamps
X Clean the radiator

Page 55 of 90
SERVICE INTERVAL
Check the fuel lines and clamps Every 50 hours
KUBOTA ENGINE
After the first
During running-in Change the engine oil (depending on oil pan) 50 hours of
When running in the engine, do the following: operation
Clean the air filter element

-Change the engine oil and oil filter cartridge after the
first 50 hours of operation. Clean the fuel filter Every 100
Check the battery electrolyte level hours
-If the ambient temperature is low, only use the forklift
after completely warming the engine. Check the fan belt tension
Check the radiator hoses and clamps

Daily check
Change the oil filter if the engine has a Every 200
To avoid problems, it is important to thoroughly know standard oil pan hours
the engine's conditions. Check them before starting
the engine. Check the intake air pipe
Every 400
Change the fuel filter cartridge
hours
Dispose of the fuel tank sediment
Clean the radiator water jacket (inside the Every 500

radiator) hours
Change the fan belt
Every 1 or 2
Recharge the battery
months
Change the air filter element Every year
Every 800
Check the valve gear
hours
Check the fuel injection nozzle injection Every 1500

pressure hours
Check the turbocharger Every 3000

Check the injection pump hours
Change the radiator coolant
Change the battery

MAINTENANCE INTERVALS:
Change the radiator hoses and clamps Every 2 years
Ensure that the following points are completed to Change the fuel lines and clamps
guarantee adequate maintenance. The oil change
Change the intake air pipe
intervals shown in the table below are for API
category CF, CE and CD oils when low-sulfur fuels
are used.
IMPORTANT
If CF-4 or CG-4 oil is used with high-sulfur fuel,
change the oil at shorter intervals then those
recommended in the table below according to the
operating condition.

Page 56 of 90
Section D
SAFETY
CONTENTS
D-1 GENERAL OBSERVATIONS
D-2 CONDITIONS TO BE MET BY OPERATORS
D-3 RESIDUAL RISKS
D-4 NOISE EMISSIONS AND VIBRATIONS
D-5 DESCRIPTION OF SAFETY DEVICES
D-6 SAFETY RECOMMENDATIONS
D-7 RULES ON DRIVING THE FORKLIFT
D-8 AT THE END OF THE DAY
D-9 GENERAL SAFETY MEASURES REGARDING THE ENGINE
D-10 GENERAL SAFETY MEASURES REGARDING THE ELECTRICAL SYSTEM
D-11 PERSONAL PROTECTION

Page 57 of 90
D-3 RESIDUAL RISKS

D-1 GENERAL OBSERVATIONS
Although Mecano Continental S.A has made every
This forklift has been designed in accordance with the possible effort to ensure this forklift's safety by way of its
provisions of section 1.1.2 “Principles of safety design and manufacture, it considers that residual risks
integration” of point 1 “Essential health and safety may occur as a result of the operator's actions during
requirements” of annex I of Directive 2006/42/EC on the operation.
approximation of the laws of Member states relating to
machinery. Some examples are given below:
Most accidents involving forklifts and their maintenance -Risks due to working or driving too fast for the loading
or repair are the result of not complying with the most conditions or the area of operation.
basic safety precautions.
-Risks due to using incorrect methods for checking or
It is therefore necessary to always be aware of potential replacing a hydraulic valve (residual pressure not
risks that could arise as a result of operating the forklifts, discharged – uncontrolled movements).
paying constant attention to the effects that each action
performed could have. -Risks due to using incorrect methods for disassembling
parts, such as cylinders without having secured moving
parts correctly (risk of the moving part accidentally
IMPORTANT falling).
-Risks due to the forklift accidentally overturning without

the operator using the seat belt.
Being aware of potentially dangerous situations
could prevent an accident. D-4 NOISE EMISSIONS AND VIBRATIONS
All MAST EXPLORER forklifts have a guaranteed
D-2 CONDITIONS TO BE MET BY OPERATORS sound power level according to Directive 2000/14/EC
The person that usually operates the forklift must meet of the European Parliament and of the Council on the
the following conditions: approximation of the laws of the Member States
relating to the noise emission in the environment by
Medical: equipment for use outdoors.
Before operating the forklift and during operation, the
operator must not consume alcoholic beverages, drugs In accordance with the provisions of EN 12053 and
or other substances that could impair his or her EN-ISO 4871, the sound pressure level reaching the
psychological and physical condition and consequently driving seat, for a complete operational cycle, does not
the ability to drive the forklift. exceed the 80 dB limit established by applicable
legislation.
Physical:
The operator must have good eyesight, good hearing,
good coordination and the ability to safely perform the
functions needed to operate the forklift as specified in
this manual.
WARNING
Mental: Noise measurements have been taken under the
The ability to understand and apply established safety following operating conditions: idling, lifting and
standards, rules and precautions. The operator must be movement.
alert and use good judgement for his or her own safety
and that of others and must make every effort to do the
work correctly and responsibly. The vibration level to which the operator's body is
exposed has been measured using representative and
Training: technically comparable forklifts as indicated in EN
The operator must have carefully read and studied this 14253:2004, Royal Decree 1311/2005 and Royal
manual, the attached charts and diagrams and the Decree 1311/2005 Technical Guidelines in order to
warning and hazard stickers. He or she must be minimise risks for the operator.
specialised and competent in all aspects regarding
operation and use of the forklift. These measurements have been taken by an
authorised control body with the forklift in motion and
values not exceeding 0.74 have been obtained.

Page 58 of 90
IMPORTANT
Any arbitrary modification to the forklift causes
the sound power values to vary.
D-5 DESCRIPTION OF SAFETY DEVICES

All MAST EXPLORER forklifts have all of the means
necessary to guarantee their safe use.
In designing these forklifts, all possible risks have been

taken into account. As such, covers and guards have
been fitted to protect the operator from any hazards that
may be encountered during operation of the forklift,
such as becoming trapped in the engines and/or moving
parts of the transmission, electrical system, etc.
WARNING
If the emergency stop button is pushed, the engine
will not start.
Safety cabin: this robust element protects the driver in

the event of the load falling off the forks or the forklift
overturning.
Fork carriage: this is a rigid element located on the

front of the mast which moves along with the load
HAZARD platform. It increases the support surface of the loads,
preventing them from falling on top of the operator.
Bonnet: protects the engine from any unauthorised

If the safety covers and guards are removed
handling.
(which is only authorised during maintenance),
they should be refitted as soon as the repair is
Chassis: the forklift is totally protected to prevent any
completed.
contact with the electrical circuits, tyres, etc.
The forklift has an emergency stop button located next Signalling beacon: light indicating that the forklift is
to the mast control levers and the corresponding risk running. It is located on top of the rear of the cabin.
indicator diagrams.
Emergency stop: the emergency stop is located on the

right-hand side of the driver, next to the mast control
levers. It automatically brings the engine to a halt in the
event of an emergency or problem. On those vehicles
fitted with a negative brake, this will come on when the
emergency stop button is pushed.
Acoustic warning alarm: when the forklift is moving in

reverse, an audible signal is activated.
Seat belt: located on the seat and worn by the operator.

Page 59 of 90
HAZARD
Wearing the seat belt is compulsory to prevent
injury in the event of an accident.
Key: locking device that prevents any unauthorised

persons from using the vehicle.
D-6 SAFETY RECOMMENDATIONS

The driver of any motorised industrial forklift must be at
least 18 years of age and be expressly assigned by the -Do not, under any circumstances, increase the
company. weight of the counterweight by adding additional
loads, especially not by having people climb onto the
vehicle. If the load capacity of the forklift is never
IMPORTANT exceeded, resorting to such tricks will never be
necessary.
-Do not use two forklifts simultaneously to move

Make sure that new operators are trained,
heavy or very large loads as this is a dangerous
monitored and assisted by expert staff who are
operation that requires very special precautions. This
qualified to operate forklifts.
should only be attempted in exceptional circumstances
and under the supervision of the head maintenance
Nobody who fails to meet these requirements should be technician.
allowed to drive an industrial forklift truck.
-To lift a load safely, fully insert the forks
underneath the load, lift the load slightly and
IMPORTANT immediately tilt the mast backwards.
-Before driving, check that the load is balanced and

secure on its support. Whenever the forklift is laden,
The driver must be aware that, in addition to those
keep the forks lowered and with the load tilted back
accidents that he or she may suffer, the equipment
towards the driver. This will ensure greater stability.
that they are operating can cause injury to other
people if all of the safety rules are not carefully
followed.
It is not the forklift truck in itself that is dangerous but

rather the way in which it is used. On using this type of
equipment, hazards similar to those present when
driving other vehicles may occur: bumps, impacts,
turning over, trapped limbs, etc.
Some safety considerations that must be followed are

listed below:
-Never exceed the forklift's load capacity. Failure to -Before undertaking any manoeuvre, check that there
follow this rule may cause the vehicle to overturn, is nobody in the immediate vicinity of the forklift,
risking injury to both the driver and to his or her especially when reversing.
colleagues. See load diagrams on the forklift for this
purpose.

Page 60 of 90
-When raising or lowering the forks, the driver must

make sure his or her hands or feet, or those of any
colleague, cannot become trapped.
-Do not point the forks towards people working

IMPORTANT
close to walls or boxes.
If the size of the load prevents good forward
-Nobody should stand or walk under the raised visibility, the driver should proceed in reverse.
forks, even when the vehicle is unladen.
-Drive slowly over any wet, slippery or uneven terrain.
-Brake progressively, not sharply.
-Respect the signs and driving rules established by the

company.
-Only follow the set routes.
-The forklift truck must not be used to carry passengers.

The driver will be held responsible for any
consequences resulting from failing to obey this rule.
-Do not drive with the load in the raised position since
-Never leave the forklift with a raised load. doing so would greatly decrease the stability of the
vehicle. The load should always be carried in the lowest
possible position.
D-7 RULES ON DRIVING THE FORKLIFT
-Do not allow yourself to become distracted from the
task of driving.
-Look in the direction in which the vehicle is moving,

maintaining good visibility at all times.
-Drive at a reasonable speed.
-Avoid accelerating, changing direction or stopping

suddenly.
-Take all turns at a low speed, using the horn to warn

anyone nearby.
-Indicate each manoeuvre that is to be carried out with -With platform forklifts, the vehicle should be driven with
sufficient advance warning. the load in front. The driver would then not be crushed
in the event of a fall.
-Use the horn when approaching bridges, crossroads,
pedestrians, animals, etc.

Page 61 of 90
-When driving with the vehicle unladen, the forks should -If during the course of a job it is necessary to stop,
be kept at around 15 cm from the ground. unless said stop is for a very short period of time, the
engine should always be turned off.
-Take special care with the loads when passing
underneath bridges or through doorways. D-8 AT THE END OF THE DAY
-At the end of the working day, the forklift should be
-If it is necessary to drive on slopes, proceed forwards
parked in the place specifically set aside for this
when going up and in reverse when going down. Do not
purpose, where it will be protected from the elements.
turn on a slope.
-When parking the forklift, the engine will be switched
off, the parking brake applied, the battery disconnected
and the key removed from the ignition.
-The forks should be left in the lowest possible position

resting on the ground.
-The forklift should always be parked on level ground. If

for any exceptional reason it is necessary to leave it
parked on a slope, the wheels must be carefully blocked
using wedges and the parking brake applied.
-The driver must not make any repairs or adjustments to

the forklift. Any anomaly observed during work, no
-Stacks of material should be placed tidily and safely. If matter how small, must be duly reported to a senior
stacking reels, remember that they can roll around. Pay member of staff.
attention to where they are left and make sure they are
secured using wedges. -The operator must never stand between the mast and
the overhead guard of the forklift. If it is necessary to do
-Do not use the forklift to push other vehicles. If it is so, lock all controls to prevent any unexpected
necessary to tow another vehicle, this must be done movement of the mast.
using a rigid bar at a very low speed.
-Make sure that the combined weight of the forklift and

the transported goods do not exceed the maximum
capacity for the terrain.
-Before driving onto walkways, platforms, gangways,

etc., make sure that they can bear the weight of the
vehicle.
-When driving behind another vehicle, maintain a

distance equal to approximately three times the length
of the forklift. This will help prevent accidents in the
event that the other vehicle needs to brake suddenly.
-When passing through narrow passages, the driver

must take care that his or her head, arms and legs do
not stick out past the width of the vehicle. D-9 GENERAL SAFETY MEASURES REGARDING
THE ENGINE
-When tilting the forks or the backplate forwards, the This section indicates the basic safety precautions that
stability of the vehicle is reduced. When it is necessary must be followed. Read and make sure you fully
to put down a load using these mechanisms, do not lift it understand the basic precautions that appear in this
any higher than necessary and, when lowering, do so section before operating, lubricating, carrying out
slowly. maintenance on or repairing this product.
-Tin and sheet metal bundles can break and shoot out The operator in charge of engine maintenance must
at nearby co-workers. Avoid accelerating or braking observe the following safety recommendations:
sharply, as well as turning at speed.

Page 62 of 90
-Make sure that all warning stickers are clearly legible. them. Wear protective goggles to prevent possible eye
Clean or replace any stickers that cannot easily be read injuries caused by flying objects.
or that have illustrations that cannot be seen.
-Clean up any spilled fuel.
-Do not wear any clothing or jewellery that could
become trapped in or wrapped around the controls or -Any materials that have been splashed with fuel should
any parts of the engine. be set aside at a safe distance.
-Make sure that all guards and covers are correctly -While running, the engine cannot be cleaned or
fitted on the engine. adjusted, and neither lubricant nor fuel can be added.
-Keep the engine free from foreign materials. Remove -Do not make any kind of adjustment without first
any rubbish, oil, tools and other items from the learning how to do so correctly.
walkways and from the steps.
-Make sure that the engine is not started in any location
-Never store maintenance fluids in glass containers. where doing so could lead to a high concentration of
Drain all liquids into a suitable container. toxic emissions.
-Do not disassemble any component or part of the -Keep other people at a safe distance whilst either the
hydraulic system without having first released the engine or any auxiliary equipment is running.
pressure from the system. Failure to do so could result
in injury. -Keep loose clothing and long hair away from moving
parts.
-Do not touch any part of the engine whilst it is running.
Allow the engine to cool before carrying out any -Keep away from moving parts when the engine is
maintenance work on it. running.
-The electrolyte is an acid and may cause personal

injury. Do not allow the electrolyte to come into contact
with skin or eyes. Always wear protective goggles when
servicing the batteries. Wash your hands after touching
IMPORTANT
the batteries or the connectors. The use of gloves is
recommended. Some moving parts are not visible when the engine
is running.
-Do not start the engine if any of the safety guards have
been removed.
-Do not remove the filler cap or any component of the

cooling system whilst the engine is hot and the coolant
is under pressure. Doing so could cause dangerous hot
coolant to overflow.
-Do not smoke whilst filling the fuel tank.
-Do not allow any sparks or naked flames in the vicinity
-Do not carry out any welding on pipes or tanks that of the batteries (especially during the battery recharging
contain flammable liquids. process). The gases given off by the electrolyte are
highly flammable. The battery fluid is harmful to the skin
and especially to the eyes.
-There should only be one person at the engine

controls.
-Make sure that the engine is only controlled from the

control panel or from the operator's seat.
-If the pressurised fuel comes into contact with anyone's

-Do not bend pressurised pipes. Do not hit pressurised skin, seek medical attention immediately.
pipes. Do not install pipes that are bent or damaged.
-Do not place any objects near the moving fan blades.
The fan blades will launch or cut any objects that touch

Page 63 of 90
-Fuel and oil (especially used oil) can be harmful to -Stop the engine before working on the electrical
some people's skin. Wear protective gloves or use a system.
special protective solution for the skin. -All wires and plugs should be marked up before being
disconnected and must be protected against making
contact with metal parts, by fitting them with protective
HAZARD caps or taping them with insulation tape, for example.
-Any defects in the electrical installation (broken

insulation, for example) must be repaired immediately.
Before working on pressurised lines (hydraulic oil,
compressed air) and/or disconnecting hydraulic -The battery's negative (-) cable must always be
elements, make sure the line is not pressurised disconnected before starting any cleaning operation. It
and no longer contains hot fluid. is not enough to simply turn off the battery's cut-off
switch.
-If it is necessary to clean the interior of the cabin with

water or water-soluble detergents, it is important to take
special care not to damage the electronics system. Use
only authorised solvents. Avoid breathing in the fumes
from any thinners used.
-Do not wear clothing that has been stained with -After the cleaning operation, make sure all electrical
lubricant. Do not put materials that have been stained components are completely dry before reconnecting the
with oil in your pockets. battery.
-Dispose of used lubricant in accordance with local -The electrical conductors must be protected against
environmental pollution regulations. wear and should be checked regularly for damage;
change as required.
-The material used to make some of the engine
components (some of the seals, for example) can be -Unprotected electrical conductors should not be
extremely dangerous if burned. Never allow this burnt allowed to rest on pipes containing oil or brake fluid.
material to come into contact with skin or eyes.
-Make sure that the transmission control lever is in the D-11 PERSONAL PROTECTION
neutral position before starting the engine.
All forklift truck drivers must be provided with the
-Take extreme care when carrying out emergency following personal protective equipment:
repairs in adverse conditions.
Protective helmet, compulsory when the operator's
-Do not allow compressed air to come into contact with cabin does not feature an overhead guard. In any case,
skin. If compressed air breaks the surface of your skin, it is essential that all drivers have a helmet for use
seek immediate medical attention. outside the forklift.
Non-slip safety boots, with reinforced toecap.
WARNING Safety gloves. Although not necessary for driving, they

should be available for use in any possible emergency
and for handling materials.
Do not clean the engine whilst it is running. If cold
cleaning fluids are applied to a hot engine, some Work clothes. Forklift truck drivers should not wear any
engine components can become damaged. loose clothing that could get trapped in or around the
moving parts of the vehicle.
Ear protectors. When the noise level exceeds the

D-10 GENERAL SAFETY MEASURES REGARDING
THE ELECTRICAL SYSTEM established safety margin and in any case when it is
above 80 dB (A), the use of earphones or earplugs will
-Work on the electrical system should only be carried be compulsory.
out by specialised personnel with suitable work and
verification methods.

Page 64 of 90
The forklift is not designed for working with hazardous

materials such as explosives, toxic, flammable or
harmful substances, nor for working in explosive
environments or in bad weather. It is therefore
prohibited to use the vehicle in environments containing
flammable or explosive materials.
IMPORTANT
The service life of the forklift is estimated at 6
years, after which time the vehicle should either be
decommissioned or MECANO CONTINENTAL, S.A.
should be asked to carry out a thorough
inspection.
IMPORTANT
MECANO CONTINENTAL, S.A. will not be held
responsible for improper use of the forklift,
whatever the circumstances.

Page 65 of 90

Page 66 of 90
Section E
TROUBLESHOOTING
CONTENTS
E-1 MALFUNCTION AND FAULT FINDING
E-2 PROBLEMS - CAUSES - SOLUTIONS
E-2.1 Movements
E-2.2 Electrics
E-2.3 Brakes
E-2.4 Mast
E-2.5 Engine

Page 67 of 90
E-1 MALFUNCTION AND FAULT FINDING

This chapter gives the operator guidelines on the most typical fault repairs but also gives a clear indication of
maintenance work that may only be carried out by specialised technicians as a result of the responsibility resulting
from such repairs. If in doubt, do not undertake any work on the forklift without first talking to a specialised
technician.
HAZARD
All maintenance, troubleshooting or repair work must be carried out with the engine turned off, the mast
lowered or resting on the ground, the parking brake on and with the key removed from the steering
column.
E-2 PROBLEMS - CAUSES - SOLUTIONS
E-2.1 Movements
PROBLEM CAUSE SOLUTION

-blown fuse
The forklift runs OK in one direction -change fuse
-gear stick not sending signal to
but does nut run properly in the other -change electro-valve
change direction
direction -check hydraulic circuit pressures
-electro-valve not working
-engine coupling to the hydrostatic
pump broken
The forklift will not go in either -check engine coupling
-negative parking brake on
direction but the engine will start -take off parking brake
-driver not in seat
-fuses, gear stick
The forklift will not go in either
-check nylon flywheel coupling
direction and will not rotate or pick up -engine coupling defect
between engine and pump
loads
-wait until the working temperature is
reached
The forklift moves without touching -the forklift is cold -adjust engine revolutions to 900 to
the accelerator -engine unbalance 950 rpm
-adjust hydrostatic pump starting
point
The forklift has no power -hydrostatic pump filter blocked -change filter
-change oil
The forklift is losing power when hot -degraded oil -check fuses
-check operating pressures
-check gear stick
-electro-valve error
The forklift won't go into 2nd gear -check electro-valve
-insufficient pressure
-check minimum pump pressure
Swap the gear pump outlets to check operation. If the forklift then turns, the
The forklift won't turn problem is the gear pump and if it still does not turn, change the steering
unit.
-priority vale not regulated -change pump
The steering is stiff
-pump is damaged -regulate valve

Page 68 of 90
E-2.2 Electrics

-blown fuse, short circuit in wire,
The hour meter is not working Check fuses and alternator charge
alternator
The indicators, headlights and horn -no power reaching them -check fuses, connections or horn
are not working -poor connections -if there is power, replace bulbs
E-2.3 Brakes

-fill tank
-no brake fluid in the tank
The brakes don't work and the pedal -bleed circuit to expel air
-no pressure to the pump
goes to the floor -change seals
-change pump
E-2.4 Mast

-check thermostat and thermostat
-oil temperature above 90ºC
fuse to see if fan comes on
The load isn't lifted -distributor not regulated
-regulate distributor
-gear pump
-check gear pump
-inadequate temperature
-regulate distributor
The engine stalls on touching the -low idle
-wait for temperature to rise
mast -distributor not regulated
-adjust starting point
-gear pump
-the levers are not working -change levers
The mast does not go up or tilt
-no pressure to distributor -change gear pump
-check lever
-no current reaching electro-valve
The 4th valve is not working -change distributor
-change gear pump
-resolve hydraulic leaks
-leaks in distributor or lines -raise cylinders, close valve and wait
The load is automatically lowered
-faulty lifting cylinder to see if it drops; if it does, cylinders
faulty

Page 69 of 90
E-2.5 Engine

-check battery
-check battery cut-off device
-engine not turning over -check starter motor
-no fuel reaching the pump -emergency stop on
The engine doesn't start
-no fuel reaching the injectors -check fuses
-heaters -key cylinder
-no fuel
-heaters not receiving 12V
-check circuit
-air getting into circuit
-add fuel
-low fuel level
-replace fuel filter
The engine starts with difficulty -fuel filter blocked
-change hoses
-pump error
-change water separator (first hot-
-injectors
wire to check)
-check air filters
-check turbocharger
The engine has no power
-check valve setting
-check fuel filter
-adjust oil level
Oil is coming out of the exhaust -oil level too high
-check turbocharger
-check oil level
-poor fuel quality
Too much smoke is coming out of the -check air filters
-oil level too high
exhaust -check fuel quality
-fuel pump damaged
-check pump
-check fuel level
-check for leaks in lines
The engine cuts out after starting -check filters
-check water separator
-clean turbocharger

Page 70 of 90
Section F
APPENDICES
CONTENTS
F-1 HYDRAULIC DIAGRAM H25/30DA 2WD
F-3 TIGHTENING TORQUES
F-4 LOAD DIAGRAMS
F-5 MAINTENANCE REPORT TEMPLATES

Page 71 of 90

Page 72 of 90

Page 73 of 90
F-3 TIGHTENING TORQUES

Whenever possible, apply the tightening torque by holding the head of the screw firm and turning the nut. To apply
the right torque (Nm) when tightening the screws, you must first know the following data:
• Screw diameter in mm (metric) or inches (Whitworth)

• Pitch (standard, distance between two consecutive thread crests)
• Quality or grade (class, referring to the strength of the material)
With these values and the help of the following tables, you can find the right torque in Nm:
ZINC-PLATED METRIC SCREWS

Property class Property class Property class Property class
D P 8.8 9.8 10.9 12.9
(mm (mm
) ) Torqu Ten- Torqu Ten- Torqu Ten- Torqu Ten-
e (Nm) sion (N) e (Nm) sion (N) e (Nm) sion (N) e (Nm) sion (N)
4 0.70 2.2 3985 2.5 4484 3.2 5853 3.8 6849
5 0.80 4.3 6514 4.9 7335 6.3 9568 7.4 11196
6 1.00 7.5 9195 8.5 10336 11.0 13506 12.9 15805
8 1.25 18 16863 20 18968 26 24768 31 28984
10 1.50 36 26838 41 30197 52 39418 61 46128
12 1.75 62 39119 70 44022 91 57457 106 67236
14 2.00 99 53707 11 60251 145 78882 170 92309
16 2.00 153 73808 173 83165 225 108406 263 126858
18 2.50 220 92440 - - 313 131897 366 154348
20 2.50 311 119003 - - 440 169385 515 198216
22 2.50 424 148374 - - 602 211534 704 247540
24 3.00 534 171437 - - 758 243914 887 285432

Page 74 of 90
ZINC-PLATED WHITWORTH SCREWS

Grade 2 Grade 5 Grade 8
Measurement
Torque (Nm) Torque (Nm) Torque (Nm)
5/16 10 - 14 16 - 22 24 - 33
3/8 19 - 26 29 - 41 43 - 60
12/125 4-6 7 - 10 11 - 15
14/150 27 - 37 41 - 57 61 - 85
WARNING
IMPORTANT NOTES:
• Never exceed the specified tension value and never continue tightening after the torque spanner reaches
the given torque.
• Torque spanners are precision tools that require special care and treatment.

Page 75 of 90
F-4 LOAD DIAGRAMS

Load diagrams for the MAST EXPLORER rough terrain forklift truck models H25/30DA are shown below. These
forklifts can operate for different centres of gravity from the load to the mast carriage (CG_Qe in mm) and different
loads (kg).
Qm
CDG_QM
QM
Qi
Qe
Y_Qe
+Y
+X
CDG_Qi CDG_Qm
CDG_Qe Xi X1 Xe
FOR H25DA MODEL:
Mast height 3300 mm

Mast height 4300 mm
CG_Qe (mm)

Page 76 of 90
FOR H30DA MODEL:
Mast height 3300 mm

Mast height 4300 mm
CG_Qe (mm)
F-5 MAINTENANCE REPORT TEMPLATES

Page 77 of 90
50-HOUR MAINTENANCE REPORT

Forklift ID Number:
X Mechanic X Mechanic
Chassis check Brake system
Cracks or splits Pads, drums or calipers
Bumps Seal
Overhead guard Hydraulic installation
Seat Valve block seal
Seat belt Cylinder and tube seal
Data plates Tight connections
Noise Oil level
Clearances Filters
Bearings Articulations and levers
Greases and seal Engine
Transmission Check filters, oil, diesel
Oil level Radiator
Pump Belts
Motor Starter motor
Seal Exhaust pipe and exhaust emission
Wheels and bearings Mast, carriage and forks
Punctures and deformities Clearances
Check wear Rollers and chain
Travel controls Cylinder seal
Accelerator and brakes Wear
Gear stick Greasing
Electrical system Tilt cylinders and accessories
Electrical panel check Cylinder linkage, pins, locks
Wiring condition Runner wear
Safety system Seal
Lights, beacon Tight connections
Horn and acoustic warning alarm Battery
Fuse box Cell condition
Cleanliness and watertightness Jumpers, dirt, cover condition
Steering system Water and electrolyte level
Clearances Check alternator charge
Greasing Others
Seal Check fluids and components
DATE, SIGNATURE AND STAMP

Page 78 of 90
200 AND 500-HOUR MAINTENANCE REPORT

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 79 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 80 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 81 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 82 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 83 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 84 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 85 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 86 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 87 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 88 of 90

Forklift ID Number:
Bumps Seal
Noise Oil level
Clearances Filters
Oil level Radiator
Pump Belts
Motor Starter motor
Gear stick Greasing
Safety system Seal
Greasing Others

Page 89 of 90

Page 90 of 90

Manual h25 30da en

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Manual h25 30da en

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MAST EXPLORER Rough Terrain Forklift Trucks

H25/30DA medium range operation and maintenance manual

WHERE WE ARE LOCATED:

(Authorised dealer stamp)

H25/30DA medium range operation and maintenance manual:

© Copyright 2011 MECANO CONTINENTAL S.A. All rights reserved.

H25/30DA medium range operation and maintenance manual

H25/30DA medium range operation and maintenance manual

INTRODUCTION These sections are in turn sub-divided into sequentially

B) OPERATION AND OPERATING In this case, contact the MECANO CONTINENTAL

Section A: general information about the machine and

Section B: primarily for machine operators. All the

Section C: specifically for maintenance manager and

Section D: for staff responsible for forklift operation,

Section E: its purpose is to diagnose and solve

Section F: additional information such as hydraulic and

H25/30DA medium range operation and maintenance manual

While operating the forklift, the operator may find

There are five special (or safety) symbols used in the

In some cases the text may be accompanied by

H25/30DA medium range operation and maintenance manual

B) OPERATION AND OPERATING

H25/30DA medium range operation and maintenance manual

SECTION A: GENERAL INFORMATION

SECTION B: OPERATION AND OPERATING INSTRUCTIONS

H25/30DA medium range operation and maintenance manual

B-7 CLEANING AND WASHING THE FORKLIFT ...................................................................................................... 30

H25/30DA medium range operation and maintenance manual

H25/30DA medium range operation and maintenance manual

A-1 CONVENTIONAL REFERENCES

A-1.1 Information on the forklift (instruction stickers)

A-1.2 Forklift layout

A-2 FORKLIFT INFORMATION

A-2.2 Model and type. Chassis number

A-2.3 Permissible loads per model

A-2.4 Main measurements and specifications

A-2.5 Engine specifications

A-2.6 Fluid capacity

A-2.7 Wheels and brakes

A-2.8 Other data of interest

A-2.9 Forklift's residual capacity

A-3 PERMITTED USES

A-4 IMPROPER USE

H25/30DA medium range operation and maintenance manual

A-1 CONVENTIONAL REFERENCES

A-1.1 Information on the forklift (instruction stickers)

H25/30DA medium range operation and maintenance manual

A-1.2 Forklift layout Main external components:

RIGHT SIDE 13 FRONT AXLE

FRONT LEFT SIDE

H25/30DA medium range operation and maintenance manual

A-2 FORKLIFT INFORMATION A-2.1 Manufacturer

IMPORTANT CONTINENTAL, S.A. This company has developed

This data plate gives the following information:

The different available configurations of the MAST

2WD (2 wheel drive):

H25DA and H30DA

4WD (4 wheel drive):

H25DA and H30DA

H25/30DA medium range operation and maintenance manual

A H25/30DA range rough terrain forklift truck can be

FORKLIFT INFORMATION: FOR H25DA MODEL