Manual h35 40da en

MAST EXPLORER Rough Terrain Forklift Trucks
H35/40DA high-end range operation and maintenance manual

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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)
H35/40DA high-end 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.

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INTRODUCTION Section F: additional information such as hydraulic and

electrical drawings, load diagrams, recommended
This manual has been written by staff at MECANO torques, etc.
CONTINENTAL S.A in order to provide all the
necessary information for correct operation of the forklift These sections are in turn sub-divided into sequentially
and to ensure correct and safe maintenance. Safety and numbered chapters and paragraphs to make it easier to
troubleshooting sections are also included. find information. The quickest way to find information is
to use the table of contents page.
WARNING If you have any trouble understanding this manual, or

parts of the manual, we recommend contacting the
Mecano Continental S.A. Technical Support department
or the After-Sales department.
Read and understand this manual before starting,
operating and maintaining the forklift.
This manual is divided into the following sections:

IMPORTANT
A) GENERAL INFORMATION
Due to continually improving our forklift models
B) OPERATION AND OPERATING and in order to improve our products further, there
may be slight differences between your model and
INSTRUCTIONS the model described in this manual.
C) MAINTENANCE In this case, contact the MECANO CONTINENTAL

S.A. Technical Support department for possible
D) SAFETY clarifications or updates.
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.).

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SYMBOLS USED
While operating the forklift, the operator may find

himself in situations that require him to consult the
WARNING
considerations and clarifications given in this manual.
Warns you of situations that endanger your safety
In this manual, when such situations put the operator's and the safety of others with risks of minor
safety and the safety of others at risk and affect the accidents or injury, or that risk compromising the
forklift's efficiency and its correct operation, specific forklift's efficiency.
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
key words that classify the situations according to the
IMPORTANT
potential hazard.
Makes you aware of important technical
Each symbol is accompanied by text describing the information or practical advice that can help you
likelihood of a situation, what to look out for and the operate the forklift more efficiently and safely.
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

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

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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 ..................................................................................................................................... 18
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 ............................................................................................................................. 18
A-3 PERMITTED USES .............................................................................................................................................. 18
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 .......................................................................................................................................... 22
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 ............................................................................................................................... 25
B-3.3 Joystick .......................................................................................................................................................... 26
B-3.4 Hydraulic oil level .......................................................................................................................................... 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 .............................................................................................................................................. 29
B-5.4 Battery disposal ............................................................................................................................................. 30
B-6 TRANSPORTING THE FORKLIFT ....................................................................................................................... 30
B-6.1 Transporting and towing the 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 .......................................................................................................................... 30
SECCIÓN C: MAINTENANCE
C-1 LUBRICANTS. HEALTH AND SAFETY STANDARDS ........................................................................................ 32
C-2 SCHEDULED MAINTENANCE ............................................................................................................................ 32
C-3 MAINTENANCE ON THE ENGINE ...................................................................................................................... 35
C-3.1 Main Perkins engine components ................................................................................................................. 35
C-3.2 Perkins engine identification ......................................................................................................................... 35
C-3.3 Inspection of the engine alternator ................................................................................................................ 36
C-3.4 Changing the alternator belt .......................................................................................................................... 36
C-3.5 Changing the coolant .................................................................................................................................... 37
C-3.5.1 Checking the coolant level ..................................................................................................................... 38
C-3.6 Replacing the air filter ................................................................................................................................... 38
C-3.6.1 Cleaning the air filter .............................................................................................................................. 39
C-3.7 Changing the lubricating oil ........................................................................................................................... 40
C-3.8 Changing the oil filter .................................................................................................................................... 40
C-3.9 Fuel injectors ................................................................................................................................................. 41
C-3.10 Fuel system. Prime ..................................................................................................................................... 42
C-3.11 Fuel filter. Change ....................................................................................................................................... 42
C-3.12 Fuel filter. Drain ........................................................................................................................................... 43
C-4 HYDROSTATIC SYSTEM MAINTENANCE ......................................................................................................... 43
C-4.1 Maintaining the hydraulic oil filter .................................................................................................................. 43
C-4.2 Maintaining the hydrostatic pump ................................................................................................................. 43
C-4.3 Hydrostatic regulation and pressure measurement ...................................................................................... 45
C-5 ELECTRICAL SYSTEM MAINTENANCE ............................................................................................................ 45
C-5.1 Battery ........................................................................................................................................................... 45
C-5.2 Fuses and relays ........................................................................................................................................... 46
C-6 TRANSMISSION SYSTEM MAINTENANCE. GREASING THE FORKLIFT ....................................................... 46
C-7 FORKS ................................................................................................................................................................. 47
C-8 MAST MAINTENANCE ........................................................................................................................................ 47
C-9 TYRES .................................................................................................................................................................. 49
C-10 TIGHTENING OF WHEEL BOLTS ..................................................................................................................... 50
C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT FLUIDS .................................................................................. 50
C-12 MAINTENANCE PROGRAMME FOR THE PERKINS 800 D SERIES ENGINE ............................................... 51

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SECTION D: SAFETY
D-1 GENERAL OBSERVATIONS ................................................................................................................................ 54
D-2 CONDITIONS TO BE MET BY OPERATORS...................................................................................................... 54
D-3 RESIDUAL RISKS ................................................................................................................................................ 54
D-4 NOISE EMISSIONS AND VIBRATIONS .............................................................................................................. 54
D-5 DESCRIPTION OF SAFETY DEVICES. .............................................................................................................. 55
D-6 SAFETY RECOMMENDATIONS ......................................................................................................................... 56
D-7 RULES ON DRIVING THE FORKLIFT ................................................................................................................ 57
D-8 AT THE END OF THE DAY .................................................................................................................................. 58
D-9 GENERAL SAFETY MEASURES REGARDING THE ENGINE .......................................................................... 58
D-10 GENERAL SAFETY MEASURES REGARDING THE ELECTRICAL SYSTEM ................................................ 60
D-11 PERSONAL PROTECTION ................................................................................................................................ 60
SECTION E: TROUBLESHOOTING
E-1 MALFUNCTION AND FAULT FINDING................................................................................................................ 64
E-2 PROBLEMS - CAUSES - SOLUTIONS................................................................................................................ 64
E-2.1 Movements .................................................................................................................................................... 64
E-2.2 Electrics ......................................................................................................................................................... 65
E-2.3 Brakes ........................................................................................................................................................... 65
E-2.4 Mast ............................................................................................................................................................... 65
E-2.5 Engine ........................................................................................................................................................... 66
SECTION F: APPENDICES
F-1 HYDRAULIC DIAGRAM H35/40DA (2WD and 4WD) .......................................................................................... 68
F-2 TIGHTENING TORQUES ..................................................................................................................................... 69
F-3 LOAD DIAGRAMS ................................................................................................................................................ 71
F-4 MAINTENANCE REPORT TEMPLATES .............................................................................................................. 72

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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 H35/40DA model:

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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
H35/40DA high-end 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 H35/40 DA medium range are:
2WD (2 wheel drive):
H35DA and H40DA
4WD (4 wheel drive):
H35DA and H40DA

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A H35/40DA high-end range rough terrain forklift truck A-2.3 Permissible loads per model
can be described as a self-propelled machine that has The maximum permissible load of each forklift will vary
a mast with a determined rated load capacity for lifting according to the forklift model and the mast fitted.
loads using forks. Load capacities are given below
according to the mast model fitted:
RATED CAPACITY OF THE MAST HAZARD

H35 DA (3500 kg) F
The following diagrams are valid for a lift height of
H40 DA (4000 kg) G
3300, 4300 and 6000 mm (without additional
attachments fitted)
The MAST EXPLORER H35/40DA high-end range
rough terrain forklift trucks have been designed to carry Load diagrams for the H35/40DA models are shown
and lift loads vertically. The forklift truck is a self- below. The load is given in kg on the vertical axis and
contained vehicle suitable for carrying hanging loads the distance from the centre of gravity (CG) to the
and is designed for such use. carriage is given in mm along the horizontal axis, with
CG being 500 mm for the standard load.
Larger copies of these load diagrams are included in

FORKLIFT INFORMATION: the Appendices section (F) to make it easier to read the
data.
To be able to understand the model's code we must
understand the following:
FOR H35DA MODEL:
Mast height 3300 mm

Mast height 4300 mm
Load Mast height 6000 mm
CG_Qe (mm)
FOR H40DA MODEL:
Mast height 2400 mm

Mast height 3500 mm
Load (kg) Mast height 6000 mm
CG_Qe (mm)

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For greater heights, the loss of capacity charts adhered

to the forklift truck will be used to ensure that the FOR H35DA MODELS (2WD and 4WD):
operator uses the forklift truck safely.
The loss of capacity charts are similar to the one shown

below and are adhered to the forklift:
H1
H6
H7
M1
M2
X1 Y X2
L L2
L1
FORKLIFT WEIGHTS
TOTAL UNLADEN WEIGHT (kg) 5820
WEIGHT ON AXLES WITH LOAD (FRONT/REAR)
8540 / 780
(kg)
WEIGHT ON AXLES WITHOUT LOAD
2770 / 3050
(FRONT/REAR) (kg)
IMPORTANT MAXIMUM PERMISSIBLE WEIGHT (kg) 9320
The capacity loss charts shown here are for MAIN MEASUREMENTS
illustrative purposes only as only those charts that TOTAL LENGTH (mm) L1 4565
apply to a specific model are adhered to that LENGTH TO FORK CARRIAGE (mm) L2 3365
forklift according to each model's rated
DISTANCE FROM LOAD TO FRONT AXLE
specifications. (mm)
X1 670
WHEEL BASE (mm) Y 2045

REAR OVERHANG (mm) X2 650
TOTAL WIDTH (mm) B 1790
IMPORTANT TOTAL HEIGHT WITHOUT MAST (mm)

FRONT/REAR TREAD (mm) (2WD)
H6 2220
C1/C2 1435/1400
1435 /
Any modification made to the forklift that may FRONT/REAR TREAD (mm) (4WD) C1/C2
1435
affect its load capacity invalidates the original TOTAL HEIGHT WITH MAST (mm) H1 2900
diagram (attachments, fork positioners, etc.).
TOTAL HEIGHT WITH MAST EXTENDED
H4 6912
(mm)
A-2.4 Main measurements and specifications GROUND CLEARANCE, MINIMUM
M1 400 / 410
The forklifts' main weights and measurements are given 2WD / 4WD
below. This information can be used by the operator for GROUND CLEARANCE, CENTRE OF WHEEL
transporting the forklift. BASE M2 310 / 320
2WD / 4WD
TURNING RADIUS (mm) (2WD) WA 3300
IMPORTANT TURNING RADIUS (mm) (4WD)

DRIVING SEAT HEIGHT (mm)
WA
H7
4630
1240
The weights and measurements given below are

exclusively for the models indicated.

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MAIN MEASUREMENTS
TOTAL HEIGHT WITH MAST EXTENDED
H4 6912
(mm)
W A
GROUND CLEARANCE, MINIMUM
M1 400 / 410
2WD / 4WD
GROUND CLEARANCE, CENTRE OF WHEEL
BASE M2 310 / 320
C1
C2
B
2WD / 4WD
DRIVING SEAT HEIGHT (mm) H7 1240
PERMISSIBLE WEIGHTS
SERVICE WEIGHT (kg) 5820
GVWR / GVW (kg) 9320
W A
GVWR / GVW, FRONT (kg) 9400
GVWR / GVW, REAR (kg) 3400
FOR H40DA MODELS (2WD and 4WD)
C1
C2
B
H1
H6
PERMISSIBLE WEIGHTS
H7
SERVICE WEIGHT (kg) 6240

GVWR / GVW (kg) 10,240
M1
M2
GVWR / GVW, FRONT (kg) 10,300

X1 Y X2
GVWR / GVW, REAR (kg) 3500
L L2
L1
FOR H35/H40DA MODELS (2WD and 4WD)

FORKLIFT WEIGHTS
TOTAL UNLADEN WEIGHT (kg) 6240 MAST
WEIGHT ON AXLES WITH LOAD (FRONT/REAR) TYPE TRIPLEX
9380 / 860
(kg)
MAXIMUM HEIGHT (mm) 6000
WEIGHT ON AXLES WITHOUT LOAD
3040 / 3200 WEIGHT (kg) 1300
(FRONT/REAR) (kg)
MAXIMUM PERMISSIBLE WEIGHT (kg) 10,240 FORK LENGTH (L) (mm) 1200
TOTAL LIFT HEIGHT (H3) mm 6000
MAIN MEASUREMENTS FREE LIFT (H2) mm 2039
TOTAL LENGTH (mm) L1 4565 LOAD CENTRE OF GRAVITY (CG) mm 500
LENGTH TO FORK CARRIAGE (mm) L2 3365 FORK CARRIAGE FEM III B
DISTANCE FROM LOAD TO FRONT AXLE TILT FORWARD/BACKWARD º/º 10 / 12
X1 670
(mm)
MAXIMUM LOAD LIFTING SPEED m/s 0.4
WHEEL BASE (mm) Y 2045
MAXIMUM LOAD LOWERING SPEED m/s 0.5
REAR OVERHANG (mm) X2 650
TOTAL WIDTH (mm) B 1790
TOTAL HEIGHT WITHOUT MAST (mm) H6 2220
1435 /
FRONT/REAR TREAD (mm) (2WD) C1/C2
1400
1435 /
FRONT/REAR TREAD (mm) (4WD) C1/C2
1435
TOTAL HEIGHT WITH MAST (mm) H1 2900

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A-2.5 Engine specifications A-2.9 Forklift's residual capacity

To improve safety when operating the forklift trucks, it is
PERKINS ENGINE FOR H35/40DA 2WD recommended that the following formula be used if
MAKE / MODEL Perkins / 804D33 loads with front dimensions greater than the standard
considered by Mecano Continental S.A., generally 1000
NO. CYLINDERS / DISPLACEMENT 4 / 3331
mm, are to be lifted (centre of gravity of 500mm):
ACTUAL OUTPUT HP / KW 63 / 43
RATED OUTPUT HP / KW 18.09 / 13.3 X= (S×N) / L
PERKINS ENGINE FOR H35/40DA 4WD where:

MAKE / MODEL Perkins / 804D33T
NO. CYLINDERS / DISPLACEMENT 4 / 3331 X = residual capacity of the forklift with
bulky load
ACTUAL OUTPUT HP / KW 81.1 / 62
S = distance between the vertical axis of the front
RATED OUTPUT HP / KW 18.09 / 13.3 wheels and the rated load centre (500 mm)
N= forklift's rated capacity
A-2.6 Fluid capacity L =distance between the vertical axis of the front wheels
and the centre of gravity of the load to be transported
FLUID CAPACITIES
ENGINE OIL (l)
HYDRAULIC SYSTEM (l)
11
70 WARNING
COOLING SYSTEM (l) 25
FUEL (l) 65 This formula is only valid in terms of lifting

capacity. The stability and risks presented by the
A-2.7 Wheels and brakes vehicle when moving depend on many other
factors that are not taken into account in the
formula above.
WHEELS AND BRAKES
FRONT WHEELS 400/60- 15.5 / 14PR
A-3 PERMITTED USES
REAR WHEELS 400/60- 15.5 / 14PR
The MAST EXPLORER forklift trucks have been
SERVICE BRAKE HYDRAULIC
designed and manufactured to lift, move and carry
NEGATIVE-ACTING products. Any other use is not permitted and is therefore
PARKING BRAKE
MULTIPLE-DISC considered improper use. Strict compliance with the
operation, maintenance and repair conditions specified
A-2.8 Other data of interest by Mecano Continental S.A is an essential element of
permitted use.
OTHER DATA OF INTEREST
The forklift must only be used and maintained by people
TRAVEL SPEED WITHOUT LOAD 24 km/h who are fully acquainted with its specifications and
TRAVEL SPEED WITH LOAD 20 km/h safety procedures. It is also necessary to respect all
RATED DRAWBAR PULL WITHOUT LOAD accident prevention standards, generally recognised
2650/ 2500 daN occupational health and safety standards and all traffic
4WD/2WD
standards.
GRADEABILITY WITHOUT LOAD 4WD/2WD 35 / 30 %
GRADEABILITY WITH LOAD 4WD/2WD 30 / 25 %
FORWARD/REVERSE GEAR SHIFT
DRIVE TYPE
ELECTRIC
HYDROSTATIC
WARNING
DRIVE OPERATING PRESSURE 420 bar
Any type of modification or change to the forklift,
AUXILIARY PRESSURE / FLOW
200 bar / 78 l/min
except for modifications contemplated in this
CONNECTION manual for normal maintenance purposes, is
BATTERY 12V 70Ah 570A prohibited.
NOISE LEVEL 104 dB (A)
HYDROSTATIC PUMP LINDE HPV55

Page 18 of 85
A-4 IMPROPER USE

Using the MAST EXPLORER forklift trucks according to
operating criteria that do not comply with the
instructions contained in this manual and that could be
dangerous for the operator or others is understood to be
improper use.
HAZARD
Some of the most common and dangerous cases of
improper use are listed below:
− Transporting people on the forks.
− Not following the operation and

maintenance instructions given in this
manual to the letter.
− Exceeding mast, height and load limits.
− Working on unstable pit/ditch edges.
− Travelling across slopes instead of up and

down them.
− Working during heavy storms.
− Working in excessively steep conditions as

there is a risk of overturning.
− Using the equipment for jobs other than for

which it was designed.
− Working in potentially explosive areas.
− Working in enclosed or poorly ventilated

areas.

Page 19 of 85

Page 20 of 85
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 Joystick
B-3.4 Hydraulic oil level
B-3.5 Lights panel and hour meter
B-4 ELECTRICAL SYSTEM
B-5 STARTING
B-5.1 Starting using external power source
B-5.2 Disconnecting the battery
B-5.3 Battery location
B-5.4 Battery disposal
B-6 TRANSPORTING THE FORKLIFT
B-6.1 Transporting and towing a broken-down forklift
B-6.2 Transporting by crane
B-7 CLEANING AND WASHING THE FORKLIFT
B-7.1 Disposal. End of service life

Page 21 of 85
B-1 BEFORE CLIMBING INTO THE FORKLIFT

B-2 CLIMBING INTO THE FORKLIFT
WARNING B-2.1 Entering the cabin
This section contains support material for the

operator that outlines how to operate the MAST
EXPLORER forklift truck.
WARNING
Always make sure your hands and footwear are
Once the operator has taken up his or her position
dry and clean before climbing into the driving
inside the operator's cabin and has completed the
preliminary adjustment operations, he or she must then seat.
study and learn the position of all the controls and
instruments inside the cabin. The forklift truck has been designed and manufactured
to be operated by an operator from the driving seat
Becoming well acquainted with their position is vital to located at the front of the forklift in compliance with the
ensure correct usage during operation and fast, timely operating instructions given in this manual. Use the
intervention by the operator should sudden manoeuvres handhold on the side of the overhead guard to climb
become necessary to protect the safety of the operator into the forklift.
and the forklift.
IMPORTANT
Learn to operate the forklift and predict how it will
respond. Learn how to use the controls in an open,
safe space with no obstacles or people nearby.
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.
From the driving post, it is possible to activate all of the
-Check the tyre pressure.
necessary elements, both of the drive system and for
-Check for possible cracks in covers.
using the vertical load lifting system.
The operator should check the position of the battery

HAZARD cut-off device. In a horizontal position, the battery will be
connected to the forklift's electrical circuits and in a
vertical position, the battery will be disconnected from
A burst tyre could cause serious injuries and the forklift's electrical circuit.
accidents. Do not use the forklift with damaged,
under-inflated or worn tyres. B-2.2 Adjusting the seat
Careful seat adjustment ensures that the operator can
To check tyre wear and pressure, see the following
drive safely and comfortably. The seat has several
table:
devices for adjusting the seat's distance from the
controls. For this purpose, the seat has a knob and
Pressur lever on the right-hand side. By using these devices,
H35/40DA Model Tyres
e
the seat can be adjusted to the desired position.
Front tyre 400/60- 15.5 / 14PR 4 bar
Rear tyre 400/60- 15.5 / 14PR 4 bar

Page 22 of 85
WARNING
The operator should adjust the seat's distance in
order to be able to safely operate all of the
forklift's instruments and controls.
B-2.4 Adjusting the steering wheel

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.
B-2.3 Putting on the seat belt

HAZARD
Before driving, check that the steering wheel
adjusting handle is locked to prevent accidents.
IMPORTANT
The operator should fasten his or her seat belt
before operating the forklift in any way. The
WARNING
overall condition and operation of the seat belt
should be checked periodically. If you need to change the position of the handle,
pull the handle out, turn it towards the operator
Sit correctly in the driving seat before doing the and release in the appropriate position.
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 85
B-2.5 Adjusting the rear-view mirrors -Adjust the seat so you can comfortably reach all
The forklift cabin is fitted with two exterior rear-view control levers and fully depress the brake pedal with
mirrors attached to the overhead guard. your back still against the back of the driving seat.
-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.
-Remove all dirt from inside the cabin, particularly

from the area near the pedals and control levers.
-Remove all oil, grease or mud from the pedals and

control levers.
HAZARD
-Make sure your hands and footwear are clean and After starting the engine, if you climb down from
dry. the driving seat, the engine will still be running.
DO NOT LEAVE THE DRIVING SEAT WITHOUT
-Make sure the seat belt is secure. FIRST TURNING OFF THE ENGINE, LOWERING
THE MAST AND PUTTING THE PARKING BRAKE
-Check that the lights, gauges, indicators, emergency ON!
lights and acoustic warning alarm are in correct working
order.

Page 24 of 85
B-3.2 Instruments and controls

Below is a description of the main instruments and
controls of the H35/40DA forklift:
Detailed description:
Indicators: move the lever to the right of the steering

wheel up (left) or down (right) according to the direction
of travel.
Parking brake switch:

NUMBER DESCRIPTION Lift the guard and push to the left to activate. If the
forklift has a third pedal, the parking brake switch will
1 Steering column adjuster
not be fitted.
2 Rear light switch
3 Gear stick
5
Parking brake
Indicators, headlights, horn

HAZARD
6 Key switch
This brake must be activated with the forklift
7 Accelerator pedal stationary to prevent accidents.
8 Service brake pedal
9 Hour meter 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
The 4WD models are designed with a twin and step on the accelerator. The acoustic warning
differential, front and rear, joined by a mechanical alarm will sound.
transmission, with which the transmission cannot
be reduced to 2WD at any time. Gear shift:
Both the 2WD and 4WD high-end H70/80DA forklifts
have 2 gears. To change gear:

Page 25 of 85
1) Turn the gear stick lever clockwise to select 1st

gear (I).
2) Turn the gear stick lever anti-clockwise to select
2nd gear (II).
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 Horn: located on the end of the light switch. To sound
not begin to move. the horn, simply press the button.
4) If the parking brake is off but the forklift is in gear, the

forklift will not start.
5) The parking brake can be activated if the forklift is not

in gear (in neutral).
HAZARD
If the forklift is in gear and the button is pressed, 2 1
the brake does not work.
Pedals:
Light switch:
1) Accelerator pedal (right pedal).
-Position 0: lights off
Position 1: side lights and lights panel
2) Service brake pedal.
on
-Position 2: headlights on To drive down slopes whilst the forklift is laden, the
-Button 3: windscreen wiper forklift must come down backwards (in reverse) whilst
-Button 4: horn the accelerator is used to control the speed of descent.
B-3.3 Joystick
The MAST EXPLORER H35/40 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 85
Movements of the H35/40DA side-shifter:
-Button A: shifts the mast carriage to the left
-Button B: shifts the mast carriage to the right
-Button C: optional for 4th valve
-Button D: optional for 4th valve
-Button E: hydraulic brake
B-3.4 Hydraulic oil level

The forklift has 2 gauges or indicators to warn the
operator as shown below:
Movements of the H35/40DA joystick:
-Forward: tilts the mast forward

1
-Backward: tilts the mast backward 2
-Left: lifts the mast
-Right: lowers the mast
WARNING
1) Hydraulic oil level window on the service tank
(mast and steering).
Before moving the forks, make sure nobody is
2) Hydraulic oil level window on the hydrostatic
within the forklift's operating radius
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:

Page 27 of 85
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.
-A numbered chart is attached to the fuse box cover to

indicate the position of each fuse or relay. The fuses
fitted in the forklifts are shown in the following table:
NUMBER DESCRIPTION FUSE No. NAME AMPERAGE (A)

1 Hour meter 1 Rotating 15
beacon
2 Side lights 2 Windscreen wiper 25
3 Air filter change 3 Hour meter 5
4 Forward drive/reverse 10
4 Transmission filter change
5 Full-beam headlights 15
5 Engine oil pressure
6 Dipped headlights 15
6 Battery charge
7 Right rear light 7.5
7 Preheating
8 Left rear light 7.5
8 Engine water temperature
9 Indicators 10
9 Indicators 10 Horn 10
10 Headlights 11 Engine heater 30
11 Fuel level 12 Battery level indicator 7.5
13 Gear stick 10
14 Fuel level 15
B-4 ELECTRICAL SYSTEM
15 Work light 15
Electric power is provided by a maintenance-free, DC 16 Negative brake 15
battery located beneath the foot rest on the left-hand
17 Service brake 10
side as follows: 12 volt, 70 Ah and 570 A.
18 Forward drive 5
To access the battery, lift the foot rest cover in the cabin. 19 Reverse 5
20 Heating 25
ELECTRICAL 21 General fuse (large) 50
HAZARD

Page 28 of 85
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 fuse box is accessed by lifting the bonnet located To start the engine using an external battery, proceed as
at the rear of the forklift. It should be accessed in explained below:
accordance with the instructions given in the
maintenance section of this manual. -Disconnect the forklift battery using the cut-off device
fitted.
The electrical installation must comply with Royal
-Connect the two batteries by first connecting the
Decree 1580/2006, transposing the 2004/108/EC
positive terminals (+) and then the negative terminals
directive on Electromagnetic Compatibility, and the
using the clamps provided for this purpose.
UNE-EN 1175 regulation on safety of industrial trucks.
B-5 STARTING
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.
-Proceed to start the forklift's engine using the start
switch.
HAZARD -Disconnect the cables by first removing the negative

cable (-) from the earthing point and then from the
auxiliary battery.
Batteries produce a flammable gas that could be -Disconnect the positive cable (+) from the forklift's
ignited by the sparks, causing the battery to battery and then from the auxiliary battery.
explode. Do not smoke when checking the
electrolyte.
HAZARD
ELECTRICAL Only use a 12V battery as other devices (battery
HAZARD chargers, etc.) could cause the battery to explode
or damage the electrical installation.
Keep the positive cable (+) from the battery away B-5.2 Disconnecting the battery
from any metal object, such as buckles, watch If any type of repair or maintenance work is required on
straps, etc., that could cause a short circuit the forklift, particularly work involving welding, it is
between the battery terminal and nearby metal, necessary to turn off the battery cut-off device.
resulting in the risk of burns for the operator.
B-5.3 Battery location
The MAST EXPLORER forklift truck battery is located
beneath the foot rest, inside the cabin.

Page 29 of 85
B-5.4 Battery disposal
IMPORTANT
ENVIRONMENTAL
To lift the forklift, use loading devices and tackle
PROTECTION that have sufficient load capacity.
Textile devices may be used to protect edges. Secure

The lead-acid batteries used cannot be disposed of the forklift using the eyebolt attached to the forklift's
with regular industrial solid waste; instead they rear counterbalance and the mast at the front.
must be collected, disposed of and/or recycled
according to the laws of the country where the B-7 CLEANING AND WASHING THE FORKLIFT
forklift is located.
To clean the forklift correctly, follow these instructions:
B-6 TRANSPORTING THE FORKLIFT -Clean dirty areas affected by oil or grease using dry
solvents or volatile mineral alcohol.
B-6.1 Transporting and towing the broken-down
forklift -Before assembling new spare parts, remove all
If the forklift breaks down and needs to be transported, protective material (anti-rust, grease, wax, etc.)
take the following into account:
-If there are signs of rust on metal parts of the forklift,
-The load capacity (permissible load) of the transport clean using sandpaper and cover with adequate
vehicle must be greater than the weight of the forklift. protection (anti-rust, varnish, oil, etc.).
-Keep a safe distance from edges, ramps, work Exterior washing

platforms, etc. Before washing, check that the engine is off and that
doors and windows are closed. Do not use fuel for
-Completely lower the forks cleaning; use only water or a steam jet. In cold climates,
dry locks after washing or moisten with antifreeze.
-Put the parking brake on. Remove the key Before using the forklift, reset all pre-wash conditions.
-Put 2 chocks in front of and behind front and rear Interior washing
Wash the interior of the forklift using water and a
wheels to prevent movement
sponge. Never use pressurised water. After washing,
dry with a clean cloth.
-Secure with ropes and tighten.
Engine washing
Wash the engine after applying water-proofing to the air
WARNING intake filter located on top of the engine bonnet as water
can get into the engine via the air filter.
B-7.1 Disposal. End of service life

For the MAST EXPLORER model, the forklift may
only be towed if the instructions given in the
maintenance section of this manual are complied
with. ENVIRONMENTAL
B-6.2 Transporting by crane PROTECTION
Loading by crane is only considered for the initial
transportation of the forklift when commissioned. If
At the end of the forklift's service life, we
frequent loading of the forklift by crane is required at
recommend not leaving the forklift discarded as
the work site, consult Mecano Continental S.A.
waste but rather to contract specialised companies
to dispose of the forklift in compliance with current
regulations.
HAZARD
Only people with adequate experience using the
appropriate securing and lifting devices may load
the forklift for transportation.

Page 30 of 85
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-3.1 Main Perkins engine components C-6 TRANSMISSION SYSTEM MAINTENANCE.

GREASING THE FORKLIFT
C-3.2 Perkins engine identification
C-7 FORKS
C-3.3 Inspection of the engine alternator
C-8 MAST MAINTENANCE
C-3.4 Changing the alternator belt
C-9 TYRES
C-3.5 Changing the coolant
C-10 TIGHTENING OF WHEEL BOLTS
C-3.5.1 Checking the coolant level
C-11 TECHNICAL SPECIFICATIONS OF FLUIDS
C-3.6 Changing the air filter
C-12 MAINTENANCE PROGRAMME FOR THE
C-3.6.1 Cleaning the air filter PERKINS 800D SERIES ENGINE
C-3.7 Changing the lubricating oil
C-3.7.1 Filling the engine oil
C-3.8 Changing the oil filter
C-3.9 Fuel injectors
C-3.10 Fuel system. Prime
C-3.11 Fuel filter. Change
C-3.12 Fuel filter. Drain
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 31 of 85
INTRODUCTION Storage
Always store oils in an enclosed place out of the
Regular, correct maintenance will give the operator a reach of children. Never leave lubricant containers
forklift that is always safe and operational. For this open and without a label indicating their contents to
reason, after having worked in particularly adverse avoid mistakes and accidents.
conditions (muddy, dusty terrain, heavy work, etc.),
washing, greasing and correct maintenance of the Disposal
forklift is recommended. Disposing of new or used oil is highly contaminating
for the environment. Carefully store new oil and keep
Always check that all forklift components are in good used oil in special containers for subsequent disposal
working condition, there are no oil leaks and safety by specific waste disposal centres.
guards and devices are efficient. If this is not the
case, find and resolve the causes. Spillage
In the event of accidental oil spills, use sand or a
Mecano Continental S.A. recommends using suitable granulate to soak up the oil. Scrape off the
compound obtained and dispose of as chemical
ORIGINAL MAST EXPLORER SPARE PARTS to
waste.
ensure adequate operation of the forklift.
Emergencies
-Eyes: If oil comes into contact with the eyes, rinse
with copious amounts of running water. If irritation
continues, go to the nearest hospital.
-Ingestion: If oil is ingested, do not induce vomiting.

Maintenance operations are scheduled according to See a doctor.
the number of service hours completed by the forklift.
Keep track of service hours to be able to correctly -Skin: In cases of excessive and prolonged contact
determine maintenance intervals. For this purpose an with the skin, wash with soap and water.
hour meter is fitted on the steering column.
-Fire: In the event of fire, use CO2, dry powder or
foam fire extinguishers. Do not use water.
C-2 SCHEDULED MAINTENANCE
Non-compliance with the scheduled maintenance

standards indicated in this manual automatically
cancels the guarantee given by Mecano Continental
S.A.
IMPORTANT
Incorrect maintenance or no maintenance at all
IMPORTANT may make the forklift dangerous for the operator
and others in the surrounding area.
For engine maintenance, carefully follow the Make sure maintenance and lubrication are done
specific operation and maintenance manual regularly as indicated by Mecano Continental S.A. in
supplied by Mecano Continental S.A with the this manual in order to keep the forklift safe and
forklift. operational.
C-1 LUBRICANTS. HEALTH AND SAFETY Make sure all faults detected during maintenance are
STANDARDS immediately resolved prior to using the forklift again.
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.

Page 32 of 85
Check the friction of the air intake tube between the

WARNING engine and the filter and check that it is in good
condition
After 250 service hours or monthly
All operations marked by the following symbol
must be done by a specialised technician. Operations to be carried out in addition to others
mentioned above:
Grease roller bearings, bushings and articulations
Within the first 10 service hours
Grease lifting chains and mast guides
Check the engine oil and fuel levels
Check for correct operation of the lifting cylinders
Check the hydraulic oil level in the tank
Check the condition of the engine's air filter cartridge;
Check the wheel bolt tightening torque
replace if necessary
Check the torque of all screws/bolts
Check that the terminals are tightly fastened to the
Check for possible oil leaks from the hydraulic battery posts
connections
Check that the hydraulic tubes are not
Check the coolant level in the radiator worn as a result of rubbing against the chassis or other
mechanical components
Clean the engine radiator
Check for wear to the rollerson the mast sections
Check parking brake operation
Check the battery fluid level
Check the cleanliness of the hydraulic tank breather
and check that it is not blocked Inspect forks and mast
Check the tyre pressure Every 500 service hours
Within the first 50 service hours Operations to be carried out in addition to others
mentioned above
Change the engine oil for the first time
Visually check the amount of fumes from the
Change the hydrostatic pump's hydraulic oil filter exhaust pipe
Every 10 service hours or daily Check that the bolts attaching the engine to the silent
Check the engine oil level blocks are tight
Clean the air intake filter Check that there is no excessive play between
bolts and bushings at all joints
Clean the radiator, if necessary
Change hydraulic oil filter
Check the hydraulic oil level in the tank
Check brake linings or disc brake pads
Check that the components of the mast
sections are well greased to ensure that rollers slide Change engine oil filter, air filter and fuel filter
along rails Change the engine oil
Check for correct operation of the electrical Check for correct operation of the hydrostatic pump
lighting installation
Check mast bushings
Check for correct operation of the brake
system and parking brake Grease mast support pins
Check that the steering system is working properly Every 1000 service hours or every year
Check for correct operation of the service brake Operations to be carried out in addition to others
mentioned above
Every 50 service hours or weekly
Check the brake discs and parking brake
Operations to be carried out in addition to daily
operations Grease the wheel hubs and bearings
Check the alternator belt tension Change brake fluid
Check the tyre pressure Change hydraulic oil
Check the wheel bolt tightening torque Change coolant
Check front differential carrier oil level

Page 33 of 85
Check front differential assembly oil level

Check rear differential assembly oil level WARNING
After each repair affecting the hydraulic system
Change hydraulic filters Before working on the hydraulic lines or
components, make sure there is no pressure in the
Change hydraulic oil system. To do this, after turning off the engine and
putting the parking brake on, move the distributor
control levers (in the opposite direction to the
operating direction) to release pressure from the
WARNING hydraulic circuit.
These service hours / intervals are

recommendations when operating the
IMPORTANT
forklift under normal conditions.
Depending on usage and work The high-pressure lines may only be replaced by
environment, these intervals may be qualified staff. Any impurity in the closed circuit
longer or shorter. rapidly deteriorates the transmission and
hydrostatic pump.
IMPORTANT IMPORTANT
It is vital that these maintenance intervals be
followed in order to claim a repair under the The qualified staff performing maintenance on the
guarantee. hydraulic circuit must carefully clean the
surrounding areas before carrying out any
operation.
HAZARD
ENVIRONMENTAL
All maintenance work must be carried out with the
engine stopped, the parking brake on and the mast PROTECTION
resting on a flat surface on the ground.
Used oils should be handled and disposed of in

compliance with national standards and
WARNING regulations. Make sure there are authorised

disposal sites.
Before any maintenance operation involving the

lifting of a component, secure the component to
be lifted to keep it safe and steady prior to moving.
WARNING
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 34 of 85
C-3 MAINTENANCE ON THE ENGINE
C-3.1 Main Perkins engine components
Number
1 Glow plug
2 Intake manifold
3 Fuel injector
4 Oil pan breather
5 Water drain plug or drain valve
6 Oil level gauge
7 Injection pump
8 Oil filter
9 Pressure relief valve
10 Oil drain plug
11 Oil filter
12 V-belt
13 Oil cooler
14 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 right side of the engine block, near the
rear of the engine.
Number
15
16
17
Turbocharger
Front lifting eye
Coolant switch
IMPORTANT
18 Alternator
19 Starter motor To order spare parts, Mecano Continental S.A may
20 Oil pan need the data plate number to determine which
21 Flywheel housing components are included in the engine.
22 Flywheel
23 Exhaust manifold
24 Rear lifting eye
25 Upper oil filler pipe

Page 35 of 85
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.
Number
1 Data plate
Check the alternator and the battery charger for
2 Temporary Parts List number correct operation.
3 List number
4 Serial number When the engine is not run for long periods of time or
5 Type if the engine is only run for short periods, the
batteries may not fully charge. A battery with a low
charge freezes more easily than a battery with a full
charge.
WARNING
If the batteries are properly charged, the ammeter
reading should be very near zero. (0 A)
C-3.4 Changing the alternator belt

The belt will be inspected and replaced with the
engine stopped. Check that the belt tension is correct.
To properly check the belt tension, use a Burroughs
gauge.
C-3.3 Inspection of the engine alternator

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.
Check the belt tension

every 50 service hours or weekly
Inspecting the belt:

To optimise engine performance, inspect the belts for
wear or cracks. Replace worn or damaged belts.
If the belts are too loose, vibration causes unnecessary

ALTERNATOR wear to both the belts and pulleys. Loose belts may slip
enough to cause overheating.

Page 36 of 85
To check belt tension, apply a 45 N (10 lb ft) force to

the mid point between the pulleys. A properly adjusted
belt will flex 10 mm (0.39 inch).
Adjusting the belt:
-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.
-If the system is dirty or contains stagnant water, flush

the cooling system with clean water.
-Close the radiator drain tap. Connect the radiator

hose if this was removed.
Number
1 Assembly bolts Change coolant
2 Support every 2000 service hours or 2 years
3 Belt
4 Alternator
-Loosen the assembly bolts (1).
-Move the alternator (4) to increase or reduce the belt

HAZARD
tension. To check belt tension, apply a 45 N (10 lb ft)
force to the mid point between the pulleys. A properly Do not drain the coolant while the engine is still
adjusted belt will flex 10 mm (0.39 inch). hot and the system is under pressure because
dangerous hot coolant could be discharged.
-Tighten the assembly bolts (1).
Replacing the belt:

When fitting a new belt, check the belt tension after 20 -Fill the system with an approved antifreeze mixture.
The maximum fill rate for filling the system is 1 litre
hours of engine operation.
per minute. Fill until water comes out of the engine
drain or bleed plug free of air bubbles. Tighten the
C-3.5 Changing the coolant
screw with the corresponding torque. Fit the filler cap.
To change the coolant, make sure the vehicle is on
level ground, the cooling circuit is not pressurised and -Clean up any remaining coolant. Check the engine
the temperature is adequate. Then follow the for coolant leaks.
instructions below:
-Remove the cooling system filler cap.
-Remove the drain plug (1) from the side of the engine
WARNING
block to drain the engine. Make sure the drain hole is
not blocked. After running the engine, the coolant level may
vary. Check the level again after running the
engine for a few hours.

Page 37 of 85
C-3.5.1 Checking the coolant level

Check the coolant level only when the engine is
stopped and cool. IMPORTANT
1) Slowly remove the cooling system filler cap to
It is important to fill the expansion tank with the
relieve the pressure.
engine cold.
C-3.6 Replacing the air filter

Air filter elements prevent particles from entering the
engine's air intake.
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 coolant to the proper level on the sight gauge.
AIR
3) Clean the cooling system filler cap and check its FILTER
condition. Replace the cap if the gaskets are
damaged. Refit the filler cap. Dust entering the engine causes damage to
components and premature wear. Never run the
4) Inspect the cooling system for leaks. engine without fitting an air filter.
Filling and checking the level of the expansion Never run the engine with a damaged air filter. Do not
tank: use air filter elements with damaged pleats, gaskets
The forklift has an expansion tank fitted in the cooling or seals.
circuit as shown below:
The air filter is on the engine. To clean or replace the

air filter, release the 3 fasteners on the cover and
remove the filter.
WARNING Clean the filter daily or every 8 hours

Change every year or every 1000 service hours
To correctly fill the cooling system, make sure the

tank level is filled to within 1/3 of its maximum
capacity. 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
accumulation of dust or dirt. Remove the dust and dirt
as required.

Page 38 of 85
C-3.6.1 Cleaning the air filter
WARNING The primary element must be replaced at least once a

year. This replacement should be performed
regardless of the number of cleanings. Instructions for
cleaning the air filter are given below.
Depending on the operating conditions (dust, dirt
and particles), more frequent maintenance of the
air filter element may be required.
-This replacement should be performed regardless of

IMPORTANT
the number of cleanings.
Visually inspect the filter before cleaning for
damage to the gasket and the outer cover. Discard
Follow the instructions given below to change the any damaged air filter elements.
air filter:
1) Release the 3 fasteners and remove the cover.

Remove the air filter. There are two common methods for cleaning primary
air filter elements:
2) Cover the air inlet with tape in order to keep dirt
out. Compressed air
Compressed air can be used to clean filters that have
3) Clean the inside of the air filter cover and body with not been cleaned more than two times. Compressed
a clean, dry cloth. air will not remove deposits of carbon and oil. Use
filtered, dry air with a maximum pressure of 207 kPa
4) Remove the tape from the air inlet. Install the (2.07 bar).
secondary element. Install a new or clean primary
element. When the primary element is cleaned, always begin
with the clean side (inside) in order to force dirt
5) Install the air filter cover every time the dirty air filter particles toward the dirty side (outside). Aim the hose
elements are replaced with clean elements or proceed so that the air flows inside the element along the filter
to clean. in order not to damage the paper pleats. Do not aim
jets of air directly at the primary air filter element.
Before installing the new filters, carefully check that
there are no tears and/or holes in the filter material. Dirt could be forced into the pleats.
The 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.
Vacuum cleaning
Vacuum cleaning is a good method for cleaning
primary filter elements that require daily cleaning
because of a dry, dusty environment. Cleaning with
compressed air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits of
carbon and oil.

Page 39 of 85
DRAIN
PLUG
IMPORTANT
C-3.7 Changing the lubricating oil Drain the oil when the oil is warm and the
contaminants are suspended and not settled in the
oil pan.
HAZARD Use one of the following methods to drain the oil from
the engine oil pan:
-If the engine is equipped with a drain valve, turn the

Hot oil and hot engine components can cause valve knob to the left to drain the oil. After draining the
personal injury. Do not allow hot oil or hot oil, turn the drain valve knob to the right to close the
components to touch the skin. valve.
-If the engine is not equipped with a drain valve,

remove the oil drain plug (1) to allow the oil to drain. If
IMPORTANT the engine is equipped with a shallow oil pan, remove
the bottom oil drain plugs from the ends of the oil pan.
-After draining the oil, the oil drain plugs must be

Do not drain the oil when the engine is cold. As the
cleaned and refitted. It is necessary to replace the
oil cools, suspended waste particles settle on the
gasket on the drain plug to prevent oil leaks.
bottom of the oil pan. The waste particles are not
removed on draining the cold oil.
C-3.8 Changing the oil filter
Follow the recommendations given below to replace
Drain the oil pan with the engine stopped and the oil the filter properly:
warm. This draining method allows the waste particles
suspended in the oil to be drained properly. Failure to Follow the recommendations given below to replace
follow this recommended procedure will cause the the filter properly:
waste particles to be recirculated through the engine
lubrication system with the new oil. The oil pan drain 1) Remove the oil filter using a suitable tool.
plug is shown below.
2) Clean the sealing surface of the oil filter. Make sure
MAINTENANCE INTERVAL the union on the oil filter head is secure.
Change the engine lubricating oil 3) Apply clean engine oil to the oil filter seal. Do not fill
every 500 service hours the oil filters before installing them as this oil would
not be filtered and could be contaminated
4) Install the oil filter.

Page 40 of 85
4) Keep the oil level between the "ADD" and "FULL"

marks on the engine oil dipstick.
C-3.9 Fuel injectors
HAZARD
Fuel spilled onto hot surfaces or electrical
components can cause a fire.
IMPORTANT Perkins recommends regularly maintaining the fuel

injectors.
Tighten the oil filter by hand (do not use tools)
according to the instructions given on the oil filter. The fuel injectors should not be cleaned as cleaning
Do not over-tighten. with incorrect tools can damage the nozzles. Only
specialised staff must clean the injectors.
Change engine oil filters

every 500 service hours
ENVIRONMENTAL The fuel injectors should only be renewed if a fault

occurs or if a specialised injection system technician
PROTECTION orders their renewal.
Some of the problems that may indicate that new fuel

injectors are needed are listed below:
Used filter waste should be handled by companies
authorised for this purpose according to the -The engine does not start or it is difficult to start.
country where the forklift is located.
-It does not have enough power.
To fill the engine with oil -The engine misfires or runs erratically.
1) Remove the engine oil filler cap. -High fuel consumption.
2) Start the engine and run at “low idle” for two -Black exhaust smoke.
minutes. Perform this procedure in order to ensure
that the lubrication system has oil and the oil filters -The engine knocks or there is vibration in the engine.
are filled. Inspect the filters for leaks.
-Excessive engine temperature.
3) Stop the engine and allow the oil to drain back into
the oil pan for a minimum of 5 minutes.

Page 41 of 85
C-3.10 Fuel system. Prime

If air gets into the fuel system, bleed the air before
starting the engine. Air can get into the fuel system
under the following conditions: HAZARD
-The fuel tank is empty or partially drained.
The fuel injection pump, battery and starter motor
can be damaged if the starter motor is used
-The low-pressure fuel lines are disconnected or
excessively to bleed or purge air from the fuel
break.
system.
-There is a leak in the low-pressure fuel system.
Loosen the nuts (1) on the high-pressure fuel lines on
-The fuel filter is replaced. all fuel injectors.
-A new injection pump has been installed. Operate the starter motor and turn the engine.
Observe the adjusted connections.
When fuel, free of air, flows from the connection,

tighten the connections.
Tighten the nuts to a torque of 29 N.m (21 lb-ft).
C-3.11 Fuel filter. Change
HAZARD
Fuel spilled onto hot surfaces or electrical
components can cause a fire.
Use the following procedure to purge air from the
fuel system:
Number
1 Electric fuel priming pump
-Open the bleed screw (1). Turn the ignition key to the 2 Fuel filter base
ON position until fuel, free of air, flows from the 3 Quick-disconnect switch
connection. Turn the ignition key to the OFF position. 4 Fuel filter
5 Sediment box
6 Fuel filter drain valve
-Tighten the bleed screw to 7 N.m (61 lb-in).
-Turn the ignition key to the ON position. Leave the

ignition key in the ON position for 1 minute.
-Turn the ignition key to the OFF position.

Page 42 of 85
1) Close the fuel supply valve. The following actions are recommended:
2) Thoroughly clean the outside of the fuel filter
assembly. Open the valve (6) and drain the oil -Carrying out all operations in a clean, dust-free
into a suitable container. environment so that no foreign particles enter the
3) Remove the sediment bowl (5). components.
4) Hold the fuel filter (4) and turn the quick-
disconnect switch (3). The used element must -Covering all pressure inlets with plastic plugs as soon
be removed and discarded. as the hydraulic lines are disconnected.
5) Make sure the fuel filter base is clean.
6) Hold the fuel filter in position. Install the -Replacing the seals every time the components are
retaining ring (3). Screw the fuel ring onto the opened. We therefore recommend having several seal
fuel filter base. kits to hand before working on the components.
7) Thoroughly clean the sediment bowl (5).
Inspect the ring seals. Fit the sediment bowl
onto the new element.
8) Prime the fuel system.
WARNING
C-3.12 Fuel filter. Drain The maintenance intervals for filter and oil
1) Open the drain valve (6) and drain the fluid changes stated in this manual must be complied
into a suitable container. with in order for the guarantee to remain valid.
2) Close the drain valve (6). Dispose of the fluid
in a safe place.
C-4.1 Maintaining the hydraulic oil filter
The frequency of filter maintenance and replacement
WARNING depends on the pump's rotation rate, the type of fluid

used, the pump's starting and operating temperatures
and accidental or systematic contamination in the
forklift.
The seals must be properly seated to prevent fuel
leaks or to prevent air entering.
WARNING
Change fuel filter It is very important to change the hydraulic oil filter
every 500 service hours after the first 50 hours of operation. If it is not
changed, the supplier's guarantee will be lost in
the event of any breakdown.
C-4 HYDROSTATIC SYSTEM MAINTENANCE
Under normal operating conditions, the hydraulic oil
Regular maintenance operations for the forklift's
filters should be replaced:
hydraulic installation include:
a) Checking and filling the hydraulic oil level as MAINTENANCE INTERVAL

necessary
b) Cleaning and maintaining the radiating surfaces Change hydrostatic oil filter
c) Changing the hydrostatic filters after the first 50 hours
d) Changing the hydraulic oil. every 500 hours
Extraordinary maintenance operations are usually During maintenance cycles, avoid contaminating the
necessary as a result of forklift component intake circuit whenever the filter cartridge is changed.
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
engine, or parts thereof. the hydraulic installation are cleaned properly. This
should be done before starting the forklift or after
changing any oil or mechanical elements.

Page 43 of 85
It is necessary for the main connection operations to

be carried out in a clean, dust-free environment with
any type of dirt that could enter the circuit being
immediately removed.
IMPORTANT
To guarantee that the operating temperature of the Use a 10-micron filter when filling the hydraulic
hydraulic system remains within the permissible limits, fluid to prevent foreign bodies from entering the
the condition and cleanliness of the oil-air heat installation.
exchanger installed on the forklift must be checked.
Even new oil may contain impurities. Also fill the tank
and all other large-capacity components with fluid
(filters, heat exchangers).
Fill the hydraulic pump and motor with oil via one of
the drain ports and make sure the casing is at least
50% full.
HAZARD
Do not run the engine and the hydraulic pump
before filling. The components may be seriously
After changing any mechanical element or oil, follow damaged.
the instructions given below:
Before starting the forklift On starting the forklift

The vehicle must be started and all of the air present
-Check the cleanliness of all the parts of the in the hydraulic circuit eliminated before said circuit is
installation that come into contact with the circuit's used to lift heavy loads.
hydraulic fluid (tank, tubes, heat exchangers, filters,
etc.). To do this, with the emergency stop connected (the
forklift will not be able to start), keep the engine
-Make sure nothing is blocking the pump's normal turning over with only the starter motor (at less than
intake and check for loose connections that could 500 rpm) until the entire circuit has filled with oil (this
cause air to enter the tubes, kinked or restricted lines, operation tends to require two or three start phases
etc. lasting some 5 seconds each).
-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
IMPORTANT
the supply 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
Before filling the tank, check that it is clean and
minimum 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.
-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.

Page 44 of 85
-Increase the rotation speed and check that the -Wear safety goggles and gloves and move the
pressure in the loading circuit reaches 18-20 bar and battery carefully to avoid electrolyte leaks. Also:
that the depression on the intake line pressure gauge -Keep all metal objects (watches, rings, chains) away
does not exceed values of 0.5 bar with cold oil and from the battery terminals as they could cause a short
0.2 bar with hot oil. circuit resulting in burns.
-Gradually increase the load, monitoring the maximum -Before connecting or disconnecting the battery, turn
operating pressure on the high-pressure gauge. off all switches in the cabin.
-During the starting phase, check the hydraulic fluid -To disconnect the battery, first disconnect the
level in the tank and, if necessary, fill to the negative terminal (-) from the earthing point.
appropriate level.
-To connect the battery, first connect the positive
C-4.3 Hydrostatic regulation and pressure terminal (+).
measurement
-Recharge the battery away from the forklift in a well-
ventilated area.
HAZARD -Never approach with objects that could produce

sparks or open flames or cigarettes.
Any modification to the hydrostatic pump must be -Avoid placing metal objects on top of the battery. This
communicated to and authorised by the Mecano could cause dangerous short circuits, especially
Continental, S.A. Technical Support Department. during recharging.
-Given that the electrolyte is highly corrosive, avoid

any contact with the forklift chassis or with electrical or
HAZARD electronic components. If this does occur, contact an
authorised support centre.
The hydrostatic pumps must not be regulated or

adjusted on site. Contact the Mecano Continental ELECTRICAL
S.A. Technical Support Department.
HAZARD
C-5 ELECTRICAL SYSTEM MAINTENANCE
There is a risk of the battery exploding or short
circuiting. An explosive mixture of hydrogen gas
HAZARD forms when recharging the battery.
All maintenance work on the electrical system

must be carried out with the engine off, the parking
brake on and with all working parts resting on the
HAZARD
ground.
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
C-5.1 Battery the eyes or other sensitive body parts, flush with
The battery fitted on this forklift truck does not need abundant water and see a doctor.
maintenance. Check:
-That all cable terminals are securely attached to the

battery posts. To tighten the terminals, always use a ENVIRONMENTAL
spanner, not pliers.
-Protect the posts by coating them with pure vaseline

PROTECTION
or battery terminal protector spray.
-If the forklift is not going to be used for a long period Properly process the used battery as waste to
of time, remove the battery and store in a dry place. protect the environment.

Page 45 of 85
C-5.2 Fuses and relays FUSE No. NAME AMPERAGE (A)

The electrical installation is protected by fuses 15 Work light 15
installed at the back of the cabin. Before replacing a
16 Negative brake 15
blown fuse with another of the same amperage, find
and correct whatever caused the fuse to blow 17 Service brake 10
otherwise the problem will continue. 18 Forward drive 5
19 Reverse 5
The fuse box that is located under the bonnet to the
20 Heating 25
right of the engine is shown below:
21 General fuse (large) 50
C-6 TRANSMISSION SYSTEM MAINTENANCE.

GREASING THE FORKLIFT
Grease axles, mast and mast pins

every 30 days or 200 service hours
The rear axle, mast, tilt cylinder linkage, mast pins

and other elements requiring lubrication must be
greased as shown in the following figures using
adequate amounts of grease.
Greasing the rear axle: the axle has two grease

points per wheel as shown in the following diagram:
IMPORTANT
Do not use fuses with a higher amperage than
indicated as this may damage the electrical
installation.
FUSE No. NAME AMPERAGE (A)
1 Rotating 15 Rear axle grease points:

beacon
2 Windscreen wiper 25
3 Hour meter 5
4 Forward drive/reverse 10
5 Full-beam headlights 15
6 Dipped headlights 15
7 Right rear light 7.5
8 Left rear light 7.5
9 Indicators 10
10 Horn 10
11 Engine heater 30
12 Battery charge indicator 7.5
13 Gear stick 10
14 Fuel level 15

Page 46 of 85
C-8 MAST MAINTENANCE
WARNING The runner blocks and rollers installed on the mast

guides must be greased.
The rear axle has 2 grease points per wheel. The mast rails should also have liquid grease so that
the runners produce minimum friction and wear when
sliding.
All grease points on the masts are broken down into
Grease the grease points the areas shown below (A, B C and D).
every 30 days of operation
WARNING
C-7 FORKS
There may be slight differences between the
photos shown below and your specific mast
depending on whether your forklift has a duplex or
Check the following critical points triplex mast.
Details on each area are given below:
Visually inspect the forks, paying particular attention

to points 1, 2 and 7 shown in the following diagram. If
there is a fault, replace with an original spare part.
WARNING
All hinges, fork heads and other articulations must
be lubricated prior to use as required.

Page 47 of 85
Area A
Area C
Points 1, 2, 3 and 4
Point 4 is on the lower face.
Area D
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):

We must also consider the two grease points on the
Points 2 and 4 are shown on the following photo: tilt cylinder linkage and the mast pins as shown below:

Page 48 of 85
Checking the mast chains MAINTENANCE INTERVAL
MAINTENANCE INTERVAL Check the pressure

every 100 service hours
Check mast chains
every 30 days
Pressur
H35/40DA Model Tyres
Pay special attention to points 1 to 7. If there is a fault, e
replace with an original spare part. Front tyre 400/60- 15.5 / 14PR 4 bar
Rear tyre 400/60- 15.5 / 14PR 4 bar
If the tyre pressure is wrong, correct as soon as

possible as operating a forklift truck with low tyre
pressure will have the following effect on the tyres:
-Excessive flexing.
-Overheating.
-Excessive strain on fabric.
-Bulging of sidewalls.
This results in damaged sidewalls and stretched

individual strands of fabric.
Grease the chains

IMPORTANT
The lifting chains are safety elements. Chemical
cleaning products, acids and bleach must not be
IMPORTANT
used as they may damage the chains. Apply spray
grease recommended for this purpose. A high pressure is dangerous as it transmits
excessive tensile strain to the fabric and the tyre is
therefore susceptible to punctures and cuts.
C-9 TYRES
Take the following precautions when servicing the

The air pressure used has a direct effect on the tyre's
tyres:
service life. The tyre pressure must be checked every
100 service hours when the forklift is unloaded.
-Always stand to the side of the tyre so you are
Check the tyre pressure according to the following
shielded by the vehicle to protect yourself against
table:
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.

Page 49 of 85
-Use a safety nozzle (that you do not have to hold C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT
manually) with a hose that is long enough for you to FLUIDS
stand outside the danger zone when filling the tyre. The following table shows the fluids used in the
forklift:
-Never cut or solder a rim if the tyre contains
pressurised air. LIST OF LUBRICANTS USED
-Never assemble rim pieces of different sizes and
never use damaged or faulty pieces. See the service LUBRICANTS TYPE
manual for authorised tyre and rim sizes. Do not fit
Engine oil ISO 10W-40
tyres with a different tread.
Hydraulic oil ISO VG 46
-Remove the air before removing foreign bodies from
the tyre. Chains Chain spray
Extreme-pressure adhesive
Mast
-Put the valve dust caps back on after checking or grease
filling the tyres. Fuel Diesel
-For special operations, for example on sandy terrain, Differential carrier oil SAE 75W-80, API GL-4
the air pressure can be modified after consulting the
Differential oil SAE 75W-80, API GL-4
after-sales department or the tyre manufacturer.
Brake fluid LHM Super mineral oil
C-10 TIGHTENING OF WHEEL BOLTS
Lithium soap-based grease
(DIN 51825-KPF2 N-20
Grease points
MAINTENANCE INTERVAL Penetration grade 2, lithium
soap)
Check bolt torque
every 50 service hours HYDRAULIC OIL PROPERTIES
The hydraulic oil used in our forklift trucks allows high-

pressure operation without hardly any variation in
Tighten all wheel bolts daily during the first week of viscosity as temperature changes. Thanks to a
operation. suitably high viscosity index, the oil maintains a
suitable viscosity throughout the forklift's entire
operating temperature range.
IMPORTANT This oil complies with the following standards:
The tightening torque is 270 N·m for the front ISO/DIS 6743 Part 4 Category HV
differential and 270 N·m for the rear differential. DIN 51524 Part 2 and 3 Category HLP/HLPV
AFNOR NF E 48602 Category HV

Wheel nuts must also be tightened daily after each
AFNOR NF E 60 200 Category HV
wheel change during the first week of operation.
Specification Method Typical values
ISO grade --- 46
Density at 15ºC (g/ml) ASTM D-4052 0.870
Kinematic viscosity (cSt) ASTM D 115
40ºC 4.6
100ºC 8.6
Viscosity index ASTM D-2270 150

APPLY TORQUE IN A CRISS- Flash point (ºC) ASTM D-93 202
CROSS PATTERN Pour point (ºC) ASTM D-97 -39
Demulsibility 40/40/0 (min) ASTM D-1401 10

Page 50 of 85
Specification Typical values
Colour
Physical state
Amber
Liquid at ambient temperature

IMPORTANT
Odour Characteristic mineral oil Do not use the following types of water in cooling
Vapour pressure <0.1 Pa at 20ºC systems: Hard water, soft water that has been
softened with salt and seawater.
Initial boiling point 280ºC
Water solubility Negligible Many engine failures are a result of the cooling
Upper flammable limit 10% (v/v) system. The condition of the coolant is also important
for it to do its job properly.
Lower flammable limit 1% (v/v)
Auto-ignition temperature >320ºC Never work on an engine without a thermostat in the

cooling system. Thermostats help keep the engine
BRAKE FLUID coolant at the right operating temperature.
The brake fluid is a green, special, mineral oil-based The coolant's glycol content helps protect against
fluid that is to be used to initially fill and successively boiling over, freezing and water pump cavitation. A 1:1
refill the combined brake-suspension circuits. mixture of water and glycol is used.
This fluid offers notable lubricating power, which C-12 MAINTENANCE PROGRAMME FOR THE
PERKINS 800 D SERIES ENGINE
favours optimum performance of the mechanical parts
present in the hydraulic circuits.
It is also characterised by an extremely low freezing

point and a very high viscosity index and can
therefore be used without drawbacks over a wide
WARNING
temperature range. Before performing any maintenance work or
procedure, make sure you have read and understood
Specification Typical values all the safety information, warnings and instructions.
Density at 15ºC (kg/l) 0.835 The following programmes must be performed
according to the interval that comes first:
Kinematic viscosity -
-40ºC (cP) 1100 PERKINS maintenance programme

40ºC (cSt) 18.2 A - When required
B - Daily or every 8 service hours
100ºC (cSt) 6.2
C - Every 50 service hours
Viscosity index >300 D - Every 250 service hours or 6 months
E - Every 500 service hours or 12 months
Colour green
F - Every 1000 service hours
Flash point (OC) 125ºC G - Every 2000 service hours
Pour point -60ºC
H - Every 3000 hours
KEY FOR FOLLOWING TABLE
ANTIFREEZE
The preventive maintenance intervals are indicated
Antifreeze is usually made of three elements: water, for normal operating conditions. When engine
additives and glycol. We recommend using an performance must be adjusted to local standards, it
antifreeze with a minimum concentration of 50% in may be necessary to adapt the maintenance intervals
engine cooling systems. and procedures to guarantee correct engine
performance.
As part of good preventive maintenance, look for
leaks or loose fasteners during each check.

Page 51 of 85
A B C D E F G H PERKINS 800 D 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 52 of 85
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 53 of 85
D-1 GENERAL OBSERVATIONS

D-3 RESIDUAL RISKS
This forklift has been designed in accordance with the
provisions of section 1.1.2 “Principles of safety Although Mecano Continental S.A has made every
integration” of point 1 “Essential health and safety possible effort to ensure this forklift's safety by way of its
requirements” of annex I of Directive 2006/42/EC on the design and manufacture, it considers that residual risks
approximation of the laws of Member states relating to may occur as a result of the operator's actions during
machinery. operation.
Most accidents involving forklifts and their maintenance Some examples are given below:
or repair are the result of not complying with the most
basic safety precautions. -Risks due to working or driving too fast for the loading
conditions or the area of operation.
It is therefore necessary to always be aware of potential
risks that could arise as a result of operating the forklifts, -Risks due to using incorrect methods for checking or
paying constant attention to the effects that each action replacing a hydraulic valve (residual pressure not
performed could have. discharged – uncontrolled movements).
-Risks due to using incorrect methods for disassembling
IMPORTANT parts, such as cylinders without having secured moving

parts correctly (risk of the moving part accidentally
falling).
Being aware of potentially dangerous situations -Risks due to the forklift accidentally overturning without
could prevent an accident. the operator using the seat belt.
D-2 CONDITIONS TO BE MET BY OPERATORS D-4 NOISE EMISSIONS AND VIBRATIONS

All MAST EXPLORER forklifts have a guaranteed
The person that usually operates the forklift must meet sound power level according to Directive 2000/14/EC
the following conditions: of the European Parliament and of the Council on the
approximation of the laws of the Member States
Medical: relating to the noise emission in the environment by
Before operating the forklift and during operation, the equipment for use outdoors.
operator must not consume alcoholic beverages, drugs
or other substances that could impair his or her In accordance with the provisions of EN 12053 and
psychological and physical condition and consequently EN-ISO 4871, the sound pressure level reaching the
the ability to drive the forklift. driving seat, for a complete operational cycle, does not
exceed the 80 dB limit established by applicable
Physical: legislation.
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:
The ability to understand and apply established safety Noise measurements have been taken under the
standards, rules and precautions. The operator must be following operating conditions: idling, lifting and
alert and use good judgement for his or her own safety movement.
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
Training: exposed has been measured using representative and
The operator must have carefully read and studied this technically comparable forklifts as indicated in EN
manual, the attached charts and diagrams and the 14253:2004, Royal Decree 1311/2005 and Royal
warning and hazard stickers. He or she must be Decree 1311/2005 Technical Guidelines in order to
specialised and competent in all aspects regarding minimise risks for the operator.
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 54 of 85
IMPORTANT WARNING
Any arbitrary modification to the forklift causes If the emergency stop button is pushed, the engine
the sound power values to vary. will not start.
Safety cabin: this robust element protects the driver in

D-5 DESCRIPTION OF SAFETY DEVICES. the event of the load falling off the forks or the forklift
All MAST EXPLORER forklifts have all of the means overturning.
necessary to guarantee their safe use.
Fork carriage: this is a rigid element located on the
In designing these forklifts, all possible risks have been front of the mast which moves along with the load
taken into account. As such, covers and guards have platform. It increases the support surface of the loads,
been fitted to protect the operator from any hazards that preventing them from falling on top of the operator.
may be encountered during operation of the forklift,
such as becoming trapped in the engines and/or moving Bonnet: protects the engine from any unauthorised
parts of the transmission, electrical system, etc. handling.
Chassis: the forklift is totally protected to prevent any

contact with the electrical circuits, tyres, etc.
Signalling beacon: light indicating that the forklift is

running. It is located on top of the rear of the cabin.
HAZARD
If the safety covers and guards are removed
(which is only authorised during maintenance),
they should be refitted as soon as the repair is
completed.
The forklift has an emergency stop button located next

to the hydraulic controls and the corresponding risk
Acoustic warning alarm: when the forklift is moving in
indicator diagrams.
reverse, an audible signal is activated.
Emergency stop: the emergency stop is located on the
Seat belt: located on the seat and worn by the operator.
right-hand side of the driver, next to the hydraulic
joystick. 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.
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.

Page 55 of 85
D-6 SAFETY RECOMMENDATIONS -Do not, under any circumstances, increase the
weight of the counterweight by adding additional
The driver of any motorised industrial forklift must be at
loads, especially not by having people climb onto the
least 18 years of age and be expressly assigned by the
vehicle. If the load capacity of the forklift is never
company.
exceeded, resorting to such tricks will never be
necessary.
IMPORTANT -Do not use two forklifts simultaneously to move

heavy or very large loads as this is a dangerous
operation that requires very special precautions. This
Make sure that new operators are trained, should only be attempted in exceptional circumstances
monitored and assisted by expert staff who are and under the supervision of the head maintenance
qualified to operate forklifts. technician.
-To lift a load safely, fully insert the forks

Nobody who fails to meet these requirements should be
underneath the load, lift the load slightly and
allowed to drive an industrial forklift truck.
immediately tilt the mast backwards.
-Before driving, check that the load is balanced and

IMPORTANT secure on its support. Whenever the forklift is laden,
keep the forks lowered and with the load tilted back
towards the driver. This will ensure greater stability.
The driver must be aware that, in addition to those
accidents that he or she may suffer, the equipment
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 -Before undertaking any manoeuvre, check that there
listed below: is nobody in the immediate vicinity of the forklift,
especially when reversing.
-Never exceed the forklift's load capacity. Failure to
follow this rule may cause the vehicle to overturn, -When raising or lowering the forks, the driver must
risking injury to both the driver and to his or her make sure his or her hands or feet, or those of any
colleagues. See load diagrams on the forklift for this colleague, cannot become trapped.
purpose.
-Do not point the forks towards people working

close to walls or boxes.

Page 56 of 85
-Nobody should stand or walk under the raised -Drive slowly over any wet, slippery or uneven terrain.
forks, even when the vehicle is unladen.
-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
doing so would greatly decrease the stability of the
vehicle. The load should always be carried in the lowest
-Never leave the forklift with a raised load. 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. -With platform forklifts, the vehicle should be driven with
the load in front. The driver would then not be crushed
-Indicate each manoeuvre that is to be carried out with in the event of a fall.
sufficient advance warning.
-When driving with the vehicle unladen, the forks should
-Use the horn when approaching bridges, crossroads, be kept at around 15 cm from the ground.
pedestrians, animals, etc.
-Take special care with the loads when passing
underneath bridges or through doorways.
-If it is necessary to drive on slopes, proceed forwards

when going up and in reverse when going down. Do not
turn on a slope.
IMPORTANT
If the size of the load prevents good forward
visibility, the driver should proceed in reverse.

Page 57 of 85
-Stacks of material should be placed tidily and safely. If -The driver must not make any repairs or adjustments to
stacking reels, remember that they can roll around. Pay the forklift. Any anomaly observed during work, no
attention to where they are left and make sure they are matter how small, must be duly reported to a senior
secured using wedges. member of staff.
-Do not use the forklift to push other vehicles. If it is -The operator must never stand between the mast and
necessary to tow another vehicle, this must be done the overhead guard of the forklift. If it is necessary to do
using a rigid bar at a very low speed. so, lock all controls to prevent any unexpected
movement of the mast.
-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.
-When tilting the forks or the backplate forwards, the

stability of the vehicle is reduced. When it is necessary D-9 GENERAL SAFETY MEASURES REGARDING
to put down a load using these mechanisms, do not lift it THE ENGINE
any higher than necessary and, when lowering, do so This section indicates the basic safety precautions that
slowly. must be followed. Read and make sure you fully
understand the basic precautions that appear in this
-Tin and sheet metal bundles can break and shoot out section before operating, lubricating, carrying out
at nearby co-workers. Avoid accelerating or braking maintenance on or repairing this product.
sharply, as well as turning at speed.
The operator in charge of engine maintenance must
-If during the course of a job it is necessary to stop, observe the following safety recommendations:
unless said stop is for a very short period of time, the
engine should always be turned off. -Make sure that all warning stickers are clearly legible.
Clean or replace any stickers that cannot easily be read
or that have illustrations that cannot be seen.
D-8 AT THE END OF THE DAY
-Do not wear any clothing or jewellery that could
-At the end of the working day, the forklift should be
become trapped in or wrapped around the controls or
parked in the place specifically set aside for this
any parts of the engine.
purpose, where it will be protected from the elements.
-Make sure that all guards and covers are correctly
-When parking the forklift, the engine will be switched
fitted on the engine.
off, the parking brake applied, the battery disconnected
and the key removed from the ignition.
-Keep the engine free from foreign materials. Remove
any rubbish, oil, tools and other items from the
-The forks should be left in the lowest possible position
walkways and from the steps.
resting on the ground.
-Never store maintenance fluids in glass containers.
-The forklift should always be parked on level ground. If
Drain all liquids into a suitable container.
for any exceptional reason it is necessary to leave it
parked on a slope, the wheels must be carefully blocked
-Do not disassemble any component or part of the
using wedges and the parking brake applied.
hydraulic system without having first released the
pressure from the system. Failure to do so could result
in injury.

Page 58 of 85
-Do not touch any part of the engine whilst it is running. -Keep away from moving parts when the engine is
Allow the engine to cool before carrying out any running.
maintenance work on it.
-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
IMPORTANT
servicing the batteries. Wash your hands after touching
the batteries or the connectors. The use of gloves is Some moving parts are not visible when the engine
recommended. 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
of the batteries (especially during the battery recharging
-Do not carry out any welding on pipes or tanks that process). The gases given off by the electrolyte are
contain flammable liquids. 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

skin, seek medical attention immediately.
-Do not bend pressurised pipes. Do not hit pressurised
pipes. Do not install pipes that are bent or damaged. -Fuel and oil (especially used oil) can be harmful to
some people's skin. Wear protective gloves or use a
-Do not place any objects near the moving fan blades. special protective solution for the skin.
The fan blades will launch or cut any objects that touch
them. Wear protective goggles to prevent possible eye
injuries caused by flying objects.
-Clean up any spilled fuel.

HAZARD
-Any materials that have been splashed with fuel should Before working on pressurised lines (hydraulic oil,
be set aside at a safe distance. compressed air) and/or disconnecting hydraulic
elements, make sure the line is not pressurised
-While running, the engine cannot be cleaned or and no longer contains hot fluid.
adjusted, and neither lubricant nor fuel can be added.
-Do not make any kind of adjustment without first

learning how to do so correctly.
-Make sure that the engine is not started in any location

where doing so could lead to a high concentration of
toxic emissions.
-Do not wear clothing that has been stained with
-Keep other people at a safe distance whilst either the lubricant. Do not put materials that have been stained
engine or any auxiliary equipment is running. with oil in your pockets.
-Keep loose clothing and long hair away from moving

parts.

Page 59 of 85
-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
following personal protective equipment:
-Take extreme care when carrying out emergency
repairs in adverse conditions.
Protective helmet, compulsory when the operator's
cabin does not feature an overhead guard. In any case,
-Do not allow compressed air to come into contact with
it is essential that all drivers have a helmet for use
skin. If compressed air breaks the surface of your skin,
outside the forklift.
seek immediate medical attention.
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 established safety margin and in any case when it is
THE ELECTRICAL SYSTEM
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. The forklift is not designed for working with hazardous
materials such as explosives, toxic, flammable or
-Stop the engine before working on the electrical harmful substances, nor for working in explosive
system. environments or in bad weather. It is therefore
prohibited to use the vehicle in environments containing
-All wires and plugs should be marked up before being flammable or explosive materials.
disconnected and must be protected against making
contact with metal parts, by fitting them with protective
caps or taping them with insulation tape, for example.
-Any defects in the electrical installation (broken

IMPORTANT
insulation, for example) must be repaired immediately.
The service life of the forklift is estimated at 6
-The battery's negative (-) cable must always be years, after which time the vehicle should either be
disconnected before starting any cleaning operation. It decommissioned or MECANO CONTINENTAL, S.A.
is not enough to simply turn off the battery's cut-off should be asked to carry out a thorough
switch. inspection.
-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
IMPORTANT
from any thinners used.
MECANO CONTINENTAL, S.A. will not be held
-After the cleaning operation, make sure all electrical responsible for improper use of the forklift,
whatever the circumstances.
components are completely dry before reconnecting the
battery.

Page 60 of 85

Page 61 of 85

Page 62 of 85
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 63 of 85
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 64 of 85
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 65 of 85
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 66 of 85
Section F
APPENDICES
CONTENTS
F-1 HYDRAULIC DIAGRAM H35/40DA (2WD and 4WD)
F-2 TIGHTENING TORQUES
F-3 LOAD DIAGRAMS
F-4 MAINTENANCE REPORT TEMPLATES

Page 67 of 85
F-1 HYDRAULIC DIAGRAM H35/40DA (2WD and 4WD)

Page 68 of 85
F-2 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 69 of 85
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 70 of 85
F-3 LOAD DIAGRAMS
Load diagrams for the MAST EXPLORER rough terrain forklift truck models H35/40DA 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 H35DA MODEL:
Mast height 3300 mm

Mast height 4300 mm
CG_Qe (mm)

Page 71 of 85
FOR H40DA MODEL:
Mast height 3300 mm

Mast height 4300 mm
CG_Qe (mm)
F-4 MAINTENANCE REPORT TEMPLATES

Page 72 of 85
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 73 of 85
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 74 of 85

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 75 of 85

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 76 of 85

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 77 of 85

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 78 of 85

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 85

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 85

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 85

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 85

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 85

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 85

Page 85 of 85

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MAST EXPLORER Rough Terrain Forklift Trucks

H35/40DA high-end range operation and maintenance manual

WHERE WE ARE LOCATED:

(Authorised dealer stamp)

H35/40DA high-end range operation and maintenance manual:

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

H35/40DA high-end range operation and maintenance manual

H35/40DA high-end range operation and maintenance manual

INTRODUCTION Section F: additional information such as hydraulic and

WARNING If you have any trouble understanding this manual, or

This manual is divided into the following sections:

C) MAINTENANCE 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

H35/40DA high-end 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

H35/40DA high-end range operation and maintenance manual

B) OPERATION AND OPERATING

H35/40DA high-end range operation and maintenance manual

SECTION A: GENERAL INFORMATION

SECTION B: OPERATION AND OPERATING INSTRUCTIONS

H35/40DA high-end range operation and maintenance manual

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

H35/40DA high-end range operation and maintenance manual

H35/40DA high-end 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

H35/40DA high-end range operation and maintenance manual

A-1 CONVENTIONAL REFERENCES

A-1.1 Information on the forklift (instruction stickers)

H35/40DA high-end range operation and maintenance manual

A-1.2 Forklift layout Main external components:

RIGHT SIDE 13 FRONT AXLE

FRONT LEFT SIDE

H35/40DA high-end 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):

H35DA and H40DA

4WD (4 wheel drive):

H35DA and H40DA

H35/40DA high-end range operation and maintenance manual

RATED CAPACITY OF THE MAST HAZARD