Manual h50 60da en

MAST EXPLORER Rough Terrain Forklift Trucks
H50/60DA 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)
H50/60DA range operation and maintenance manual:

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

Page 3 of 88

Page 4 of 88
INTRODUCTION
These sections are in turn sub-divided into sequentially
This manual has been written by staff at MECANO numbered chapters and paragraphs to make it easier to
CONTINENTAL S.A in order to provide all the find information. The quickest way to find information is
necessary information for correct operation of the forklift to use the table of contents page.
and to ensure correct and safe maintenance. Safety and
troubleshooting sections are also included. If you have any trouble understanding this manual, or
parts of the manual, we recommend contacting the
Mecano Continental S.A. Technical Support department
WARNING or the After-Sales department.
Read and understand this manual before starting,

operating and maintaining the forklift. IMPORTANT
This manual is divided into the following sections:
Due to continually improving our forklift models
and in order to improve our products further, there
A) GENERAL INFORMATION may be slight differences between your model and
the model described in this manual.
B) OPERATION AND OPERATING
In this case, contact the MECANO CONTINENTAL
INSTRUCTIONS S.A. Technical Support department for possible
clarifications or updates.
C) MAINTENANCE
D) SAFETY
E) TROUBLESHOOTING
F) APPENDICES
Section A: general information about the machine and

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

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

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

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

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

electrical drawings, load diagrams, recommended
torques, etc.

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SYMBOLS USED
While operating the forklift, the operator may find

himself in situations that require him to consult the
considerations and clarifications given in this manual.
WARNING
In this manual, when such situations put the operator's Warns you of situations that endanger your safety
safety and the safety of others at risk and affect the and the safety of others with risks of minor
forklift's efficiency and its correct operation, specific accidents or injury, or that risk compromising the
instructions displaying a SPECIAL SYMBOL to highlight forklift's efficiency.
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
potential hazard.
IMPORTANT
Each symbol is accompanied by text describing the Makes you aware of important technical
likelihood of a situation, what to look out for and the information or practical advice that can help you
recommended method or behaviour to be adopted. operate the forklift more efficiently and safely.
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
order of importance:
PROTECTION
Makes you aware of important environmental
HAZARD protection information.
Warns you of situations that endanger your safety

and the safety of others with risks of serious harm
to personnel or the forklift, which may even result
in death.
ELECTRICAL
HAZARD
Warns you of situations that endanger your safety
and the safety of others with serious electrical
hazards, which may even result in death.

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

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

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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 ..................................................................................................................................... 17
A-2.6 Fluid capacity................................................................................................................................................. 17
A-2.7 Wheels and brakes ........................................................................................................................................ 17
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 .................................................................................................................................................. 18
SECTION B: OPERATION AND OPERATING INSTRUCTIONS

B-1 BEFORE CLIMBING INTO THE FORKLIFT ........................................................................................................ 22
B-2 CLIMBING INTO THE FORKLIFT ........................................................................................................................ 22
B-2.1 Entering the cabin ......................................................................................................................................... 22
B-2.2 Adjusting the seat .......................................................................................................................................... 23
B-2.3 Putting on the seat belt.................................................................................................................................. 23
B-2.4 Adjusting the steering wheel.......................................................................................................................... 23
B-2.5 Adjusting the rear-view mirrors ...................................................................................................................... 24
B-3 OPERATOR'S CONTROL PANEL ........................................................................................................................ 24
B-3.1 Key positions ................................................................................................................................................. 24
B-3.2 Instruments and controls ............................................................................................................................... 24
B-3.3 Joystick .......................................................................................................................................................... 26
B-3.4 Hydraulic oil level gauges.............................................................................................................................. 27
B-3.5 Lights panel and hour meter.......................................................................................................................... 27
B-4 ELECTRICAL SYSTEM ........................................................................................................................................ 28
B-5 STARTING ............................................................................................................................................................ 29
B-5.1 Starting using external power source ............................................................................................................ 29
B-5.2 Disconnecting the battery .............................................................................................................................. 29
B-5.3 Battery location .............................................................................................................................................. 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 HEALTH AND SAFETY STANDARDS ................................................................................................................. 32
C-2 SCHEDULED MAINTENANCE ............................................................................................................................ 32
C-3 MAINTENANCE ON THE PERKINS 1104D-44T ENGINE .................................................................................. 35
C-3.1 Main engine components .............................................................................................................................. 35
C-3.2 Engine identification ...................................................................................................................................... 35
C-3.3 Inspection of the engine alternator ................................................................................................................ 36
C-3.4 Inspection of the alternator belt ..................................................................................................................... 36
C-3.5 Instructions for replacing the belt: ................................................................................................................. 37
C-3.6 Changing the coolant .................................................................................................................................... 37
C-3.7 Checking the coolant level ............................................................................................................................ 38
C-3.8 Replacing the air filter ................................................................................................................................... 38
C-3.9 Cleaning the air filter ..................................................................................................................................... 39
C-3.10 Engine oil level. Check ................................................................................................................................ 40
C-3.11 Changing the engine lubricating oil ............................................................................................................. 40
C-3.12 Changing the engine oil filter....................................................................................................................... 41
C-3.13 Fuel injectors ............................................................................................................................................... 41
C-3.14 Priming the fuel system ............................................................................................................................... 42
C-3.15 Changing the primary fuel filter ................................................................................................................... 42
C-3.16 Changing the secondary fuel filter .............................................................................................................. 43
C-4 HYDROSTATIC SYSTEM MAINTENANCE ......................................................................................................... 44
C-4.1 Changing the hydrostatic pump's hydraulic oil filter ...................................................................................... 44
C-4.2 Maintaining the hydrostatic pump ................................................................................................................. 45
C-4.3 Hydrostatic regulation and pressure measurement ...................................................................................... 46
C-4.4 Releasing the hydrostatic pump for towing the forklift .................................................................................. 46
C-5 ELECTRICAL SYSTEM MAINTENANCE ............................................................................................................ 47
C-5.1 Battery ........................................................................................................................................................... 47
C-5.2 Fuses and relays ........................................................................................................................................... 48
C-6 TRANSMISSION SYSTEM MAINTENANCE. GREASING THE FORKLIFT........................................................ 49
C-7 FORK CHECK ...................................................................................................................................................... 49
C-8 MAST MAINTENANCE AND GREASING ............................................................................................................ 50
C-9 TYRE PRESSURE ............................................................................................................................................... 52
C-10 TIGHTENING OF WHEEL BOLTS ..................................................................................................................... 52
C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT FLUIDS .................................................................................. 53
C-12 MAINTENANCE PROGRAMME FOR THE PERKINS 1104D-44T SERIES ENGINE ...................................... 54

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SECTION D: SAFETY
D-1 GENERAL OBSERVATIONS ................................................................................................................................ 56
D-2 CONDITIONS TO BE MET BY OPERATORS...................................................................................................... 56
D-3 RESIDUAL RISKS ................................................................................................................................................ 56
D-4 NOISE EMISSIONS AND VIBRATIONS .............................................................................................................. 56
D-5 DESCRIPTION AND SAFETY DEVICES ............................................................................................................. 57
D-6 SAFETY RECOMMENDATIONS ......................................................................................................................... 58
D-7 RULES ON DRIVING THE FORKLIFT ................................................................................................................ 59
D-8 AT THE END OF THE DAY .................................................................................................................................. 60
D-9 GENERAL SAFETY MEASURES REGARDING THE ENGINE .......................................................................... 60
D-10 GENERAL SAFETY MEASURES REGARDING THE ELECTRICAL SYSTEM ................................................ 62
D-11 PERSONAL PROTECTION ................................................................................................................................ 62
SECTION E: TROUBLESHOOTING
E-1 MALFUNCTION AND FAULT FINDING................................................................................................................ 66
E-2 PROBLEMS - CAUSES - SOLUTIONS................................................................................................................ 66
E-2.1 Movements .................................................................................................................................................... 66
E-2.2 Electrics ......................................................................................................................................................... 67
E-2.3 Brakes ........................................................................................................................................................... 67
E-2.4 Mast ............................................................................................................................................................... 67
E-2.5 Engine ........................................................................................................................................................... 68
SECTION F: APPENDICES
F-1 HYDRAULIC DIAGRAM H50/60 (2WD) ............................................................................................................... 70
F-2 HYDRAULIC DIAGRAM H50/60 (4WD) ............................................................................................................... 71
F-3 TIGHTENING TORQUES ..................................................................................................................................... 72
F-4 LOAD DIAGRAMS ................................................................................................................................................ 74
F-5 MAINTENANCE REPORT TEMPLATES .............................................................................................................. 75

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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 H50 DA 4WD model. The instruction stickers on
the H60DA models are in the locations shown below:

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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 FRONT DRIVE AXLE
order to avoid errors in terms of name and position. 2 REAR AXLE
3 COUNTERWEIGHT
4 ENGINE
TOP
5 REAR LIGHTS AND INDICATORS
6 STEERING WHEEL
7 OVERHEAD GUARD
8 MAST
LEFT SIDE FRONT 9 CARRIAGE
10 SEAT
11 CHASSIS NUMBER
12 FUEL TANK
RIGHT SIDE
REAR
BOTTOM
7
8
6
9 4
10 11
2
12

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A-2 FORKLIFT INFORMATION A-2.1 Manufacturer

The forklift truck manufacturer is MECANO
CONTINENTAL, S.A. This company has developed
IMPORTANT various models of H50/60DA rough terrain forklift

trucks with different capacities and specifications. Each
forklift truck will be identified by a serial number
recorded on the CE mark data plate attached to the
Check that you have the right operation manual. If forklift since Mecano Continental S.A meets the
you need further information or technical support, requirements set out in Directive 2006/42/EC on the
you must specify the model and type of forklift approximation of the laws of Member states relating to
plus the chassis number. 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
• CE mark To correctly identify the forklift model and type, Mecano
Continental S.A has engraved a number on the front
• Tyre pressure
right-hand side of the chassis forklift behind the mast,
as shown in the following photo.
The different available configurations of the MAST

EXPLORER H50/60DA range are:
2WD (2 wheel drive):
H50DA, H60DA
4WD (4 wheel drive):
H50DA, H60DA

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A H50/60DA rough terrain forklift truck can be

described as a self-propelled machine that has a mast
with a determined rated load capacity for lifting loads
using forks. Load capacities are given below according
HAZARD
to the mast model fitted:
The following diagrams are valid for a lift height of
3300, 4300 and 6000 mm (without additional
RATED CAPACITY OF THE MAST attachments fitted)
H50 DA (5,000 kg) K
H60DA (6,000 kg)
Load diagrams for the H50DA and H60DA models are
L
shown below: The load is given in kg on the vertical
axis and the distance from the centre of gravity (CG) to
The MAST EXPLORER H50/60DA rough terrain forklift the carriage is given in mm along the horizontal axis,
trucks have been designed to carry and lift loads with CG being 500 mm for the standard load.
vertically. The forklift truck is a self-contained vehicle
suitable for carrying hanging loads and is designed for
such use. FOR H50 DA MODEL: Mast height 3300 mm
Mast height 4300 mm
Load Mast height 6000 mm
FORKLIFT INFORMATION:
To be able to understand the model's code we must

understand the following:
CG_Qe (mm)
FOR H60DA MODEL: Mast height 3300 mm

Mast height 4300 mm
Load (kg) Mast height 6000 mm
CG_Qe (mm)
For greater heights, the loss of capacity charts adhered

to the forklift truck will be used to ensure that the
operator uses the forklift truck safely.
The loss of capacity charts are similar to the one shown

A-2.3 Permissible loads per model
below and are adhered to the forklift:
The maximum permissible load of each forklift will vary
according to the forklift model and the mast fitted.

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MAIN MEASUREMENTS
TOTAL LENGTH (mm) L1 5,075
LENGTH TO FORK CARRIAGE (mm) L2 3,575
DISTANCE FROM LOAD TO FRONT AXLE
X1 700
(mm)
WHEEL BASE (mm) Y 2,125
REAR OVERHANG (mm) X2 750
TOTAL WIDTH (mm) B 1,960
TOTAL HEIGHT WITHOUT MAST (mm) H6 2,430
1,560 /
FRONT/REAR TREAD (mm) C1/C2
1,560
TOTAL HEIGHT WITH MAST (mm) H1 3,050
IMPORTANT TOTAL HEIGHT WITH MAST EXTENDED

(mm)
GROUND CLEARANCE, MINIMUM
H4
M1
7,087
300
GROUND CLEARANCE, CENTRE OF
M2 380
The capacity loss charts shown here are for WHEEL BASE
illustrative purposes only as only those charts that TURNING RADIUS (mm) (2WD) WA 4,610
apply to a specific model are adhered to that TURNING RADIUS (mm) (4WD) WA 4,930
forklift according to each model's rated
DRIVING SEAT HEIGHT (mm) H7 1,390
specifications.
A-2.4 Main measurements and specifications

The forklifts' main weights and measurements are given
W A
below.
IMPORTANT
C1
C2
B
The weights and measurements given below are

exclusively for the models indicated. Any
modification made to the forklift that may affect its
load capacity invalidates the original diagram. PERMISSIBLE WEIGHTS
SERVICE WEIGHT (kg) 6,950
FOR H50 DA MODELS (2WD and 4WD) GVWR / GVW (kg) 11,950
GVWR / GVW, FRONT (kg) 12,100
GVWR / GVW, REAR (kg) 4,200
FOR H60DA MODELS (2WD and 4WD)

H1
H6
H7
M1
M2
X1 Y X2
H1
H6
L L2
H7
L1
M1
FORKLIFT WEIGHTS
M2
TOTAL UNLADEN WEIGHT (kg) 6,950 X1 Y X2

L L2
WEIGHT ON AXLES WITH LOAD (FRONT/REAR)
11,050 / 900 L1
(kg)
WEIGHT ON AXLES WITHOUT LOAD
3,170 / 3,780
(FRONT/REAR) (kg)
MAXIMUM PERMISSIBLE WEIGHT (kg) 11,950

Page 16 of 88
FOR H50/60DA MODELS (2WD and 4WD)

FORKLIFT WEIGHTS
TOTAL UNLADEN WEIGHT (kg) 7,560 MAST
WEIGHT ON AXLES WITH LOAD (FRONT/REAR) 12,500 / TYPE TRIPLEX

(kg) 1060 MAXIMUM HEIGHT (mm) 6,000
WEIGHT ON AXLES WITHOUT LOAD WEIGHT (kg) 2,000
3,010 / 4,550
(FRONT/REAR) (kg)
FORK LENGTH (L) (mm) 1,500
MAXIMUM PERMISSIBLE WEIGHT (kg) 13,560
TOTAL LIFT HEIGHT (H3) mm 6,000
MAIN MEASUREMENTS FREE LIFT (H2) mm 1,963
TOTAL LENGTH (mm) L1 5,075 LOAD CENTRE OF GRAVITY (CG) mm 600
LENGTH TO FORK CARRIAGE (mm) L2 3,575 FORK CARRIAGE FEM IV B
DISTANCE FROM LOAD TO FRONT AXLE TILT FORWARD/BACKWARD º/º 10 / 12

X1 700
(mm) MAXIMUM LOAD LIFTING SPEED m/s 0.4
WHEEL BASE (mm) Y 2,125 MAXIMUM LOAD LOWERING SPEED m/s 0.5
REAR OVERHANG (mm) X2 750
TOTAL WIDTH (mm) B 1,960 A-2.5 Engine specifications
TOTAL HEIGHT WITHOUT MAST (mm) H6 2,430
1,560 / ENGINE
FRONT/REAR TREAD (mm) C1/C2
1,560 MAKE / MODEL Perkins / 1104D-44T
TOTAL HEIGHT WITH MAST (mm) H1 3,050 NO. CYLINDERS / DISPLACEMENT 4 / 4400 cm3
TOTAL HEIGHT WITH MAST EXTENDED ACTUAL OUTPUT HP / KW 100 / 74.5
H4 7,087
(mm)
RATED OUTPUT HP / KW 21.37 / 15.72
GROUND CLEARANCE, MINIMUM M1 300
GROUND CLEARANCE, CENTRE OF
M2 380
WHEEL BASE A-2.6 Fluid capacity
TURNING RADIUS (mm) (2WD) WA 4,610
TURNING RADIUS (mm) (4WD) WA 4,930 FLUID CAPACITIES
DRIVING SEAT HEIGHT (mm) H7 1,390 ENGINE OIL (l) 11

HYDRAULIC SYSTEM (l) 130
COOLING SYSTEM (l) 25
FUEL (l) 110

W A
A-2.7 Wheels and brakes
WHEELS AND BRAKES

C1
FRONT WHEELS 16/70x16.5 / 14PR

C2
B
REAR WHEELS (4WD) 400/60-15,5 / 14PR

SERVICE BRAKE HYDRAULIC
NEGATIVE-ACTING
PARKING BRAKE
MULTIPLE-DISC
PERMISSIBLE WEIGHTS
SERVICE WEIGHT (kg) 7,560
GVWR / GVW (kg) 13,560
GVWR / GVW, FRONT (kg) 13,700
GVWR / GVW, REAR (kg) 5,000

Page 17 of 88
A-2.8 Other data of interest A-3 PERMITTED USES

The MAST EXPLORER forklift trucks have been
OTHER DATA OF INTEREST designed and manufactured to lift, move and carry
TRAVEL SPEED WITHOUT LOAD 24 km/h products. Any other use is not permitted and is therefore
considered improper use. Strict compliance with the
TRAVEL SPEED WITH LOAD 20 km/h
operation, maintenance and repair conditions specified
RATED DRAWBAR PULL WITHOUT LOAD by Mecano Continental S.A is an essential element of
4,300/3,450 daN
4WD/2WD
permitted use.
GRADEABILITY WITHOUT LOAD 4WD/2WD 35 / 30 %
GRADEABILITY WITH LOAD 4WD/2WD 30 / 25 %

The forklift must only be used and maintained by people
who are fully acquainted with its specifications and
FORWARD/REVERSE GEAR SHIFT ELECTRIC safety procedures. It is also necessary to respect all
accident prevention standards, generally recognised
DRIVE TYPE HYDROSTATIC
occupational health and safety standards and all traffic
DRIVE UNIT PRESSURE 420 bar standards.
AUXILIARY PRESSURE / FLOW
200 bar / 57 l/min
CONNECTION
BATTERY
SOUND POWER LEVEL

12V 70 AH 570 A
<104 dB (A)
WARNING
LINDE HPV75-02
HYDROSTATIC PUMP
RCA
Any type of modification or change to the forklift,
except for modifications contemplated in this
manual for normal maintenance purposes, is
prohibited.
A-2.9 Forklift's residual capacity
To improve safety when operating the forklift trucks, it is
recommended that the following formula be used if A-4 IMPROPER USE
loads with front dimensions greater than the standard
considered by Mecano Continental S.A., generally 1000 Using the MAST EXPLORER forklift trucks according to
mm, are to be lifted (centre of gravity of 500mm): 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
X= (S×N) / L improper use.
where:
X = residual capacity of the forklift with

HAZARD
bulky load
S = distance between the vertical axis of the front Some of the most common and dangerous cases of
wheels and the rated load centre (500 mm) improper use are listed below:
N= forklift's rated capacity
L =distance between the vertical axis of the front wheels − Transporting people on the forks
and the centre of gravity of the load to be transported
− Not following the operation and
maintenance instructions given in this
WARNING −
manual to the letter
Exceeding mast, height and load limits
This formula is only valid in terms of lifting − Working on unstable pit/ditch edges
capacity. The stability and risks presented by the
vehicle when moving depend on many other − Travelling across slopes instead of up and
factors that are not taken into account in the down them
formula above.
− Working during heavy storms
− Working in excessively steep conditions as

there is a risk of overturning

Page 18 of 88
− 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 88

Page 20 of 88
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 gauges
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-6 TRANSPORTING THE FORKLIFT
B-6.1 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 88
B-1 BEFORE CLIMBING INTO THE FORKLIFT Model Tyre Pressur

e
H50/H60 (2WD
Rear 400x60-15.5 4 bar
WARNING and 4WD)
H50/H60 (2WD
and 4WD)
Front 16x70-16.5 4.5 bar
This section contains support material for the

operator that outlines how to operate the MAST B-2 CLIMBING INTO THE FORKLIFT
EXPLORER forklift truck.
B-2.1 Entering the cabin
Once the operator has taken up his or her position Two steps or rungs plus a handhold on the cabin frame
inside the operator's cabin and has completed the are provided to make it easier to climb into the vehicle.
preliminary adjustment operations, he or she must then
study and learn the position of all the controls and
instruments inside the cabin.
Becoming well acquainted with their position is vital to

WARNING
ensure correct usage during operation and fast, timely
intervention by the operator should sudden manoeuvres Always make sure your hands and footwear are
become necessary to protect the safety of the operator dry and clean before climbing onto the step to
and the forklift. reach the driving seat. Always use the step to
climb into or out of the cabin, holding onto the
special supports provided.
IMPORTANT The forklift truck has been designed and manufactured
to be operated by an operator from the driving seat
Learn to operate the forklift and predict how it will located at the front of the forklift in compliance with the
respond. Learn how to use the controls in an open, operating instructions given in this manual.
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.
-Check the tyre pressure.
-Check for possible cracks in covers..
HAZARD
A burst tyre could cause serious injury. Do not All the necessary components to drive the vehicle and
use the forklift with damaged, under-inflated or operate the vertical load lifting system are operated
worn tyres. from the driving seat.
The operator should check the position of the battery

To check tyre wear and pressure, see the following
cut-off device. In a horizontal position, the battery will be
table:
connected to the forklift's electrical circuits and in a
vertical position, the battery will be disconnected from
the forklift's electrical circuit.

Page 22 of 88
B-2.2 Adjusting the seat

Careful seat adjustment ensures that the operator can
drive safely and comfortably. The seat has several
devices for adjusting the seat's distance from the
controls. For this purpose, the seat has a knob and
lever on the right-hand side. By using these devices,
the seat can be adjusted to the desired position.
WARNING -Adjust the length of the seat belt at both ends, keeping
the buckle in the middle.
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 left-hand side of the steering column as follows:
-Turn the handle anti-clockwise to loosen.
To adjust the seat -Adjust the tilt of the steering wheel.
-Tighten the handle.
HAZARD
B-2.3 Putting on the seat belt
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
and release in the appropriate position.
Sit correctly in the driving seat before doing the
following:
-The seat belts have retractors. To fasten the seat belts,

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

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

and not the stomach.

Page 23 of 88
B-2.5 Adjusting the rear-view mirrors -Position 3: On: The on position (the beacon comes
The forklift cabin is fitted with two exterior rear-view on).
mirrors attached to the overhead guard. -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
HAZARD
WARNING After starting the engine, if you climb down from
the driving seat, the engine will still be running.
DO NOT LEAVE THE DRIVING SEAT WITHOUT
To ensure the safety of the operator and others and FIRST TURNING OFF THE ENGINE, LOWERING
a long machine service life, do an all-round check THE MAST AND PUTTING THE PARKING BRAKE
before starting the engine, as described below. ON!
-Remove all dirt from inside the cabin, particularly B-3.2 Instruments and controls
from the area near the pedals and control levers. The forklift's main instruments and controls are
described below:
-Remove all oil, grease or mud from the pedals and
control levers.
-Make sure your hands and footwear are clean and

dry.
-Make sure the seat belt is secure.
-Check that the lights, gauges, indicators, emergency

lights and acoustic warning alarm are in correct working
order.
-Adjust the seat so you can comfortably reach all

control levers and fully depress the brake pedal with
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
WARNING
positions:
The photo above shows a 2WD model with no
-Position 1: Off: The forklift is not running.
differential lock. On 4WD models, the differential
-Position 2: Heat: Engine preheating. Hold for 5
lock button is replaced by the rear light switch.
seconds and repeat the operation if the engine does not
start or if the outside temperature is very low.

Page 24 of 88
3 4 HAZARD
This brake must be activated with the forklift
stationary to prevent accidents.
5
Moving:
6 -If the parking brake is off:
2
8 1) Forward drive: push the forward-reverse lever
7
1 forward and step on the accelerator. The forklift will
9 move forward.
(The photo above shows the H50/60DA 4WD model.

The position of the parking brake and differential
lock buttons can be seen on the image on the
previous page)
NUMBER DESCRIPTION
1 Steering column adjuster
2 Differential lock (4WD)
Forward-reverse lever and gear shift, 1st and

3
2nd gears
2) Reverse: move the forward-reverse lever backward
4 Parking brake
and step on the accelerator. The acoustic warning
5 Indicators, headlights, horn alarm will sound.
6 Key switch
Gear shift:
7 Accelerator pedal Both the 2WD and 4WD high-end H50/60DA forklifts
8 Service brake pedal have 2 gears. To change gear:
9 Hour meter a) Turn the gear stick lever clockwise to select 1st
gear (I).
Detailed description: b) Turn the gear stick lever anti-clockwise to select
2nd gear (II).
Indicators: move the lever to the right of the steering
wheel up (left) or down (right) according to the direction
of travel.
Differential lock button:(4WD models only): To lock

the traction of all 4 wheels if one of the wheels loses
traction. Keep the button depressed until all 4
wheels regain traction.
HAZARD
On putting the forklift into gear, the forklift can
move slowly even without stepping on the
WARNING accelerator.
3) If the parking brake is on, the forklift will start but will
On 4WD models, the forklift has permanent not begin to move.
traction to all 4 wheels. The differential lock 4) If the parking brake is off but the forklift is in gear, the
button must be used if one of the wheels loses forklift will not start.
traction. 5) The parking brake can be activated if the forklift is not
in gear (in neutral).
Parking brake switch
Press to the right to activate.

Page 25 of 88
HAZARD 2) Accelerator pedal (right pedal)
To travel downhill with a load, drive with the rear of the

forklift downhill while accelerating to control the
If the forklift is in gear and the button is pressed, descent speed.
the brake does not work.
When the parking brake is applied, the wheel motors
Light switch: lock, ensuring that the forklift is totally immobilised.
-Position 0: lights off

Position 1: side lights and lights panel
on
-Position 2: headlights on
WARNING
-Button 3: windscreen wiper
-Button 4: horn On this model, the parking brake is a negative
brake on both the 2WD and the 4WD models. This
brake is activated using the emergency stop
button or when the corresponding button is
pressed.
B-3.3 Joystick
The MAST EXPLORER H50/60DA 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:
Horn: Located on the end of the light switch. To

sound the horn, simply press the button.
(The photo above shows a joystick from a

H50/60DA forklift)
Movements of the H50/60DA joystick:
-Forward: tilts the mast forward
1 2
-Backward: tilts the mast backward
-Left: lifts the mast

Pedals: -Right: lowers the mast
1) Service brake (left pedal) and emergency brake

pedal.

Page 26 of 88
WARNING
For this option, the forklift's movements will be
ordered as indicated in the diagram above.
B-3.4 Hydraulic oil level gauges

The forklift has 2 gauges or indicators to warn the
operator as shown below:
Movements of the H50/60DA side-shifter:
-Button A: shifts the mast carriage to the left
-Button B: shifts the mast carriage to the right 2

-Button C: optional for 4th valve
-Button D: optional for 4th valve
-Button E: hydraulic brake 1) Hydraulic oil level window on the service tank
(mast and steering).
2) Hydraulic oil level window on the hydrostatic
WARNING transmission tank.
Before moving the forks, make sure nobody is

within the forklift's operating radius HAZARD
Diagram of reversed function option
The client may ask for a joystick with the functions in a If the oil level is not high enough, the tank should
different order. 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 information as described
below:

Page 27 of 88
Specifications of the electrical system are given below:
-The fuse box, which is shown in the photo below, is

located next to the engine on the rear left-hand side of
the forklift.
-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:
FUSE No. NAME AMPERAGE (A)
1 Rotating 15
beacon
2 Windscreen wiper 25
3 Hour meter 5
4 Forward drive/reverse 10
6
5 7 5 Full-beam 15
headlight
4 8 6 Dipped headlights 15
7 Right rear light 7.5

3 11 9 8 Left rear light 7.5
9 Indicators 10
2 10
10 Horn 10
11 Engine heater 30
12 Battery level indicator 7.5
13 Gear stick 10
1 14 Fuel level 15
15 Work light 15
16 Negative brake 15
17 Service brake 10
18 Forward drive 5
NUMBER DESCRIPTION
19 Reverse 5
1 Hour meter 20 Heating 25
2 Side lights 21 General fuse (large) 50
3 Air filter change
4 Transmission filter change
5 Engine oil pressure
6 Battery charge
7 Preheating
8 Engine water temperature
9 Indicators
10 Headlights
11 Fuel level
B-4 ELECTRICAL SYSTEM

Electric power is provided by a maintenance-free, DC
battery located beneath the driving seat as follows: 12
volt, 70 Ah and 570 A for the H50/60DA range.
ELECTRICAL
HAZARD
Page 28 of 88
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
Decree 1580/2006, transposing the 2004/108/EC
directive on Electromagnetic Compatibility, and the
UNE-EN 1175 regulation on safety of industrial trucks.
B-5 STARTING
B-5.1 Starting using external power source
HAZARD -Connect the two batteries by first connecting the

positive terminals (+) and then the negative terminals
using the clamps provided for this purpose.
When jump starting from another battery that is
not part of the forklift, avoid contact between the -Proceed to start the forklift's engine using the start
cable clamps once connected to the battery to switch.
prevent sparks.
-Disconnect the cables by first removing the negative
cable (-) from the earthing point and then from the
auxiliary battery.
HAZARD -Disconnect the positive cable (+) from the forklift's

battery and then from the auxiliary battery.
Batteries produce a flammable gas that could be

ignited by the sparks, causing the battery to
explode. Do not smoke when checking the
electrolyte.
HAZARD
Only use a 12V battery as other devices (battery
chargers, etc.) could cause the battery to explode
ELECTRICAL or damage the electrical installation.
HAZARD B-5.2 Disconnecting the battery

If any type of repair or maintenance work is required on
the forklift, particularly work involving welding, it is
Keep the positive cable (+) from the battery away necessary to turn off the general battery switch located
from any metal object, such as buckles, watch beneath the seat on the left-hand side.
straps, etc., that could cause a short circuit
between the battery terminal and nearby metal, B-5.3 Battery location
resulting in the risk of burns for the operator. The MAST EXPLORER forklift truck battery is located
beneath the foot rest, inside the cabin. To access the
battery, the foot rest must be removed.

Page 29 of 88
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 88
Section C
MAINTENANCE
CONTENTS
C-1 HEALTH AND SAFETY STANDARDS C-4 HYDROSTATIC SYSTEM MAINTENANCE
C-2 SCHEDULED FORKLIFT MAINTENANCE C-4.1 Changing the hydrostatic pump's

hydraulic oil filter
C-3 MAINTENANCE ON THE PERKINS 1104D-
44T ENGINE C-4.2 Maintaining the hydrostatic pump
C-3.1 Main engine components C-4.3 Hydrostatic regulation and pressure

measurement
C-3.2 Engine identification
C-4.4 Releasing the hydrostatic pump for towing
C-3.3 Inspection of the engine alternator
C-5 ELECTRICAL SYSTEM MAINTENANCE
C-3.4 Inspection of the alternator belt
C-5.1 Battery
C-3.5 Instructions for replacing the belt
C-5.2 Fuses and relays
C-3.6 Changing the coolant
C-3.7 Checking the coolant level C-6 TRANSMISSION SYSTEM MAINTENANCE.

GREASING THE FORKLIFT
C-3.8 Replacing the air filter
C-7 FORK CHECK
C-3.9 Cleaning the air filter
C-8 MAST MAINTENANCE AND GREASING
C-3.10 Engine oil level
C-9 TYRE PRESSURE
C-3.11 Changing the engine lubricating oil
C-10 TIGHTENING OF WHEEL BOLTS
C-3.12 Changing the engine oil filter
C-11 TECHNICAL SPECIFICATIONS OF
C-3.13 Fuel injectors FORKLIFT FLUIDS
C-3.14 Priming the fuel system C-12 MAINTENANCE PROGRAMME FOR THE
PERKINS 1104D-44T ENGINE
C-3.15 Changing the primary fuel filter
C-3.16 Changing the secondary fuel filter

Page 31 of 88
INTRODUCTION Storage
Always store oils in an enclosed place out of the reach
Regular, correct maintenance will give the operator a of children. Never leave lubricant containers open and
forklift that is always safe and operational. For this without a label indicating their contents to avoid
reason, after having worked in particularly adverse mistakes.
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 used
Always check that all forklift components are in good oil in special containers for subsequent disposal by
working condition, there are no oil leaks and safety 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
suitable granulate to soak up the oil. Scrape off the
WARNING compound obtained and dispose of as chemical waste.
Emergencies
-Eyes: If oil comes into contact with the eyes, rinse with
Mecano Continental S.A. recommends using copious amounts of running water. If irritation continues,
ORIGINAL MAST EXPLORER SPARE PARTS to go to the nearest hospital.
ensure adequate operation of the forklift.
-Ingestion: If oil is ingested, do not induce vomiting. See
a doctor.
-Skin: In cases of excessive and prolonged contact with

the skin, wash with soap and water.
Maintenance operations are scheduled according to the -Fire: In the event of fire, use CO2, dry powder or foam
number of service hours completed by the forklift. Keep fire extinguishers. Do not use water.
track of service hours to be able to correctly determine
maintenance intervals. For this purpose an hour meter C-2 SCHEDULED MAINTENANCE
is fitted on the steering column.
IMPORTANT
Incorrect maintenance or no maintenance at all
may make the forklift dangerous for the operator
Non-compliance with the scheduled maintenance and others in the surrounding area.
standards indicated in this manual automatically cancels
the guarantee given by Mecano Continental S.A.
Make sure maintenance and lubrication are done
regularly as indicated by Mecano Continental S.A. in
IMPORTANT this manual in order to keep the forklift safe and

operational.
Make sure all faults detected during maintenance are

For engine maintenance, carefully follow the immediately resolved prior to using the forklift again.
specific operation and maintenance manual
supplied by Mecano Continental S.A with the
forklift.
C-1 HEALTH AND SAFETY STANDARDS

Health
Prolonged contact of oils with the skin may cause
irritation. Therefore rubber gloves and goggles are
recommended. After handling oils, thoroughly wash your
hands with soap and water.

Page 32 of 88
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 rollers
Check parking brake operation on the mast sections
Check the cleanliness of the hydraulic tank breather Check the battery fluid level
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
Change the engine oil for the first time mentioned above
Change the hydrostatic pump's hydraulic oil filter Visually check the amount of fumes from the
Every 10 service hours or daily exhaust pipe
Check the engine oil level Check that the bolts attaching the engine to the silent
blocks are tight
Clean the air intake filter
Check that there is no excessive play between
Clean the radiator, if necessary bolts and bushings at all joints
Check the hydraulic oil level in the tank Change hydraulic oil filter
Check that the components of the mast Check brake linings or disc brake pads
sections are well greased to ensure that rollers slide
along rails Change engine oil filter, air filter and fuel filter
Check for correct operation of the electrical Change the engine oil
lighting installation Check for correct operation of the hydrostatic pump
Check for correct operation of the brake Check mast bushings
system and parking brake
Grease mast support pins
Check that the steering system is working properly
Check for correct operation of the service brake
Every 1000 service hours or every year
Every 50 service hours or weekly
Operations to be carried out in addition to others
Operations to be carried out in addition to daily mentioned above
operations
Check the brake discs and parking brake
Check the alternator belt tension
Grease the wheel hubs and bearings
Check the tyre pressure
Change brake fluid
Check the wheel bolt tightening torque
Change hydraulic oil

Page 33 of 88
Change coolant
Check front differential carrier oil level WARNING
Check front differential assembly oil level
Check rear wheel motor oil level Operations on the hydraulic system are strictly
prohibited unless carried out by authorised staff.
After each repair affecting the hydraulic system This forklift's hydraulic installation has high-
Change hydraulic filters pressure connections and lines that could cause
serious personal injury if not disconnected prior
Change hydraulic oil to carrying out maintenance on the system.
WARNING
These service hours / intervals are
WARNING
recommendations when operating the
forklift under normal conditions. Before working on the hydraulic lines or
Depending on usage and work components, make sure there is no pressure in the
environment, these intervals may be system. To do this, after turning off the engine and
longer or shorter. putting the parking brake on, move the distributor
control levers (in the opposite direction to the
operating direction) to release pressure from the
hydraulic circuit.
IMPORTANT
It is vital that these maintenance intervals be
followed in order to claim a repair under the
IMPORTANT
guarantee.
The high-pressure lines may only be replaced by
qualified staff. Any impurity in the closed circuit
rapidly deteriorates the transmission and
HAZARD hydrostatic pump.
All maintenance work must be carried out with the

engine stopped, the parking brake on and the mast
resting on a flat surface on the ground.
IMPORTANT
The qualified staff performing maintenance on the
hydraulic circuit must carefully clean the
WARNING surrounding areas before carrying out any

operation.
Before any maintenance operation involving the

lifting of a component, secure the component to ENVIRONMENTAL
be lifted to keep it safe and steady prior to moving.
PROTECTION
Used oils should be handled and disposed of in
compliance with national standards and
regulations. Make sure there are authorised
disposal sites.

Page 34 of 88
C-3 MAINTENANCE ON THE PERKINS 1104D-44T

ENGINE
C-3.1 Main engine components
C-3.2 Engine identification

All Perkins engines are identified by a serial number. This
Number number appears on the serial number data plate attached
1 Pulley to the left side of the engine block, near the rear of the
2 Alternator engine.
3 Front lifting eyebolt
4 Water outlet
5
6
7
Valve gear cover
Rear lifting eyebolt
Air intake
IMPORTANT
8 Secondary fuel filter
9 Fuel injection pump To order spare parts, Mecano Continental S.A may
10 Oil filter need the data plate number to determine which
11 Crankshaft pulley
components are included in the engine.
12 Water pump
Number
13 Flywheel
14 Flywheel housing
15 Fill tube cap
16 Exhaust manifold
17 Turbocharger
18 Oil dipstick
19 Oil pan
20 Starter motor
21 Oil drain plug
22 Primary fuel filter

Page 35 of 88
WARNING
If the batteries are properly charged, the ammeter
reading should be very near zero. (0 A)
C-3.4 Inspection of the alternator belt

The belt will be inspected and replaced with the engine
Number stopped. Check that the belt tension is correct. To
1 Data plate properly check the belt tension, use a Burroughs gauge.
2 Temporary Parts List number
3 List number To maximise the engine performance, inspect the belt
4 Serial number for wear and/or cracking (1). Replace the belt if it is
5 Type worn or damaged as follows:
-If the belt (1) has more than four cracks per 25.4mm (1
C-3.3 Inspection of the engine alternator inch), it must be replaced.
Inspect the alternator to check that there are no loose
connections or that the battery is properly charged. -Inspect the belt for cracks, tears, glazing, grease and
splitting.
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.
ALTERNATOR
MAINTENANCE INTERVAL
Check alternator
every 500 hours
Inspect the ammeter (if fitted) while the engine is

running to ensure proper battery and electrical system
performance. Make repairs as required. Check the
alternator and the battery charger for correct operation.
When the engine is not run for long periods of time or if MAINTENANCE INTERVAL
the engine is only run for short periods, the batteries
may not fully charge. A battery with a low charge Check the belt tension
freezes more easily than a battery with a full charge. every 50 service hours or weekly

Page 36 of 88
C-3.5 Instructions for replacing the belt: -Remove the drain plug from the side of the engine
To replace the alternator belt or check belt tension, block to drain the engine. Make sure the drain hole is
follow the instructions given below: not blocked.
-Fit the gauge as indicated in the following diagram (1) -Open the drain valve or remove the drain plug (1) from
at the centre of the longest free length and check the the engine. If the radiator does not have a tap or a drain
plug, disconnect the hose at the bottom of the radiator.
tension. The correct tension is 535 N. If the belt tension
is below 250 N, adjust the belt to 535 N.
Adjust the belt as indicated below
-Loosen the pivot bolt of the alternator (2) and the

adjusting bolt (3).
-Move the alternator to increase or reduce the belt

tension. Tighten the pivot bolt of the alternator and the
adjusting bolt to 22 N·m.
-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.
C-3.6 Changing the coolant
Change coolant
HAZARD every 2000 service hours or 2 years
To change the coolant, make sure the vehicle is on

level ground, the cooling circuit is not pressurised
and the temperature is adequate. HAZARD
Then follow the instructions below for draining:
Do not drain the coolant while the engine is still
-Stop the engine and allow to cool. Remove the filler hot and the system is under pressure because
cap at the top of the cooling system. dangerous hot coolant could be discharged.

Page 37 of 88
-Fill the system with an approved antifreeze mixture.

The maximum fill rate is 5 litres per minute in order to
avoid air locks. Fill until water comes out of the engine
drain or bleed plug free of air bubbles. Tighten the
screw with the corresponding torque. Fit the filler cap.
-Clean up any remaining coolant. Check the engine for

coolant leaks.
WARNING
After running the engine, the coolant level may 3) Clean the cooling system filler cap and check its
vary. Check the level again after running the condition. Replace the cap if the gaskets are damaged.
engine for a few hours. Refit the filler cap.
4) Inspect the cooling system for leaks.
C-3.7 Checking the coolant level
WARNING
HAZARD Fill the cooling system on level ground with the
engine cold.
Hot coolant can cause serious burns. To open the
cooling system filler cap, stop the engine and wait
until the cooling system components are cool. C-3.8 Replacing the air filter
Check the coolant level only when the engine is stopped

and cool.
1) Slowly remove the cooling system filler cap to relieve

IMPORTANT
the pressure.
Never run the engine without an air filter element
2) Fill the coolant level to within 13 mm of the bottom of fitted or with a damaged air filter. Do not use air
the filler pipe. If the engine has a sight gauge, fill the filter elements with damaged pleats or gaskets. Dirt
coolant to the proper level on the sight gauge. entering the engine causes damage to components
and wear.
AIR
FILTER
Air filter elements prevent particles from entering the

engine's air inlet.
The air filter is located on the engine. To clean or

replace the air filter, release the 3 fasteners on the
cover and remove the filter.

Page 38 of 88
MAINTENANCE INTERVAL C-3.9 Cleaning the air filter

The primary element must be replaced at least once a
Clean the filter daily or every 8 hours year. This replacement should be performed regardless
Change every year or every 1000 service hours of the number of cleanings. Instructions for cleaning the
air filter are given below.
Also:
-Check the pre-filter (if fitted) and the dirt cup daily for
WARNING
accumulation of dust or dirt. Remove the dust and dirt
as required. Do not tap or strike the air filter element. Do not
wash the primary air filter element.
WARNING
IMPORTANT
Depending on the operating conditions (dust, dirt
and particles), more frequent maintenance of the Visually inspect the filter before cleaning for
air filter element may be required. damage to the gasket and the outer cover. Discard
any damaged air filter elements.
-This replacement should be performed regardless of
the number of cleanings. There are two common methods for cleaning primary air
filter elements:
Follow the instructions given below to change the
air filter:
1) Release the 3 fasteners and remove the cover.

Remove the air filter.
HAZARD
2) Cover the air inlet with tape in order to keep dirt out. Compressed air can cause personal injury. Use a
mask and protective clothing when using
3) Clean the inside of the air filter cover and body with a compressed air. The maximum air pressure in the
clean, dry cloth. nozzle must be below 207 kPa for cleaning
purposes.
4) Remove the tape from the air inlet. Install the
secondary element. Install a new or clean primary Compressed air
element. Compressed air can be used to clean filters that have
not been cleaned more than two times. Compressed air
5) Install the air filter cover every time the dirty air filter will not remove deposits of carbon and oil. Use filtered,
elements are replaced with clean elements or proceed dry air with a maximum pressure of 207 kPa (2.07 bar).
to clean.
Before installing the new filters, carefully check that

there are no tears and/or holes in the filter material and
in the pipes to the engine.
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.

Page 39 of 88
When the primary element is cleaned, always begin To inspect the oil level:
with the clean side (inside) in order to force dirt particles
toward the dirty side (outside). Aim the hose so that the -Maintain the oil level between the MIN mark (Y) and
air flows inside the element along the filter in order not the MAX mark (X) on the engine oil dipstick. Do not fill
to damage the paper pleats. Do not aim jets of air the oil pan above the MAX mark (X).
directly at the primary air filter element. Dirt could be
forced into the pleats. C-3.11 Changing the engine lubricating oil
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
HAZARD
recommended prior to vacuum cleaning. Vacuum
cleaning will not remove deposits of carbon and oil. Hot oil and hot engine components can cause
personal injury. Do not allow hot oil or hot
components to touch the skin.
IMPORTANT
Do not drain the oil when the engine is cold. As the
oil cools, suspended waste particles settle on the
bottom of the oil pan. The waste particles are not
removed on draining the cold oil.
Drain the oil pan with the engine stopped and the oil
warm. This draining method allows the waste particles
C-3.10 Engine oil level. Check suspended in the oil to be drained properly.
Failure to follow this recommended procedure will
HAZARD cause the waste particles to be recirculated through the

engine lubrication system with the new oil. The oil pan
drain plug is shown below.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to MAINTENANCE INTERVAL
touch the skin.
Change the engine lubricating oil
every 500 service hours

Page 40 of 88
IMPORTANT IMPORTANT
Drain the oil when the oil is warm and the Tighten the oil filter by hand (do not use tools)
contaminants are suspended and not settled in the according to the instructions given on the oil filter.
oil pan. Do not over-tighten.
Use one of the following methods to drain the oil from MAINTENANCE INTERVAL
the engine oil pan:
Change engine oil filters
-If the engine is equipped with a drain valve, turn the every 500 service hours
valve knob to the left to drain the oil. After draining the
oil, turn the drain valve knob to the right to close the
valve.
-If the engine is not equipped with a drain valve, remove

the oil drain plug (1) to allow the oil to drain. If the ENVIRONMENTAL
engine is equipped with a shallow oil pan, remove the
bottom oil drain plugs from the ends of the oil pan. PROTECTION
-After draining the oil, the oil drain plugs must be
cleaned and refitted. It is necessary to replace the Used filter waste should be handled by companies
gasket on the drain plug to prevent oil leaks. authorised for this purpose according to the
country where the forklift is located.
C-3.12 Changing the engine oil filter
Follow the recommendations given below to replace the To fill the engine with oil
filter properly:
1) Remove the engine oil filler cap.
1) Remove the oil filter using a suitable tool.
2) Start the engine and run at “low idle” for two minutes.
2) Clean the sealing surface of the oil filter. Make sure
Perform this procedure in order to ensure that the
the union on the oil filter head is secure.
lubrication system has oil and the oil filters are filled.
Inspect the filters for leaks.
3) Apply clean engine oil to the oil filter seal. Do not fill
the oil filters before installing them as this oil would not 3) Stop the engine and allow the oil to drain back into
be filtered and could be contaminated. the oil pan for a minimum of 5 minutes.
4) Maintain the oil level between the marks described

previously on the dipstick.
C-3.13 Fuel injectors
HAZARD
Fuel spilled onto hot surfaces or electrical
components can cause a fire.
Perkins recommends regularly maintaining the fuel

injectors.
4) Install the oil filter. The fuel injectors should not be cleaned as cleaning
with incorrect tools can damage the nozzles. Only
specialised staff must clean the injectors.

Page 41 of 88
The fuel injectors should only be renewed if a fault

occurs or if a specialised injection system technician
orders their renewal. -Loosen the flare nuts (1) on the high-pressure fuel lines
Some of the problems that may indicate that new fuel on all fuel injectors.
injectors are needed are listed below:
-Observe the flare nut connection. Operate the starter
-The engine does not start or it is difficult to start. motor and run the engine until the air is removed from
the fuel.
-It does not have enough power.
-The engine misfires or runs erratically. -Tighten the flare nuts (1) to a torque of 30 N.m.
-High fuel consumption. -Start the engine.
-Black exhaust smoke.
-The engine knocks or there is vibration in the engine.
-Excessive engine temperature.

HAZARD
C-3.14 Priming the fuel system The fuel injection pump, battery and starter motor
If air enters the fuel system, the air must be purged from can be damaged if the starter motor is used
the fuel system before starting the engine. Air can enter excessively to bleed or purge air from the fuel
the fuel system when the following conditions occur: system.
-The fuel tank is empty or partially drained. C-3.15 Changing the primary fuel filter
The Perkins engine fuel filter is located on the right side
-The low-pressure fuel lines are disconnected or break.
of the engine.
-There is a leak in the low-pressure fuel system.
-The fuel filter is replaced. WARNING

-A new injection pump has been installed.
Fuel leaked or spilled onto hot surfaces or electrical
Use the following procedure to purge air from the components can cause a fire.
fuel system:
To prevent possible accidents, turn the start switch to
-Remove the fuel injector cover. the off position when preparing to change fuel filters or
water separator elements.
-Turn the ignition key to the ON position. Leave the key
switch in the ON position for three minutes. Clean up fuel spills and the area around the fuel system
component to be disconnected immediately. Do not
-Turn the ignition key to the OFF position. allow dirt to enter the fuel system.

Page 42 of 88
WARNING
The seals must be properly seated to prevent fuel
leaks or to prevent air entering.
Change primary fuel filter

C-3.16 Changing the secondary fuel filter
Number
1
2
3
Screw
Element
Bowl
WARNING
4 Bottom cover
5 Drain Fuel leaked or spilled onto hot surfaces or electrical
6 Sensor connections components can cause a fire.
Draining operations:
-Place a tray under the fuel filter to catch any fuel that
might spill.
-Open the drain (5).
-When clean fuel drains from the water separator, close

the drain (5). Tighten the drain by hand only. Dispose of
the drained fluid correctly.
Operations to replace the primary fuel filter:
a) Turn the fuel supply valve (if installed) to the

OFF position.
b) Place a suitable container beneath the water
separator. a) Close the fuel supply valves (if installed).
c) Open the drain (5). b) Clean the outside of the filter assembly. Open
d) Tighten the drain (5) by hand pressure only. the fuel drain (2) and drain the fuel into a
e) Hold the element (2) and remove the screw (1). suitable container.
Remove the element and the bowl (3) from the
base. Dispose of the used element.
f) Clean the bowl (4). Clean the bottom cover (6).
g) Install the new seal. Install the bottom cover of
the new element. Install the assembly onto the
base.
h) Fit the screw (1) and tighten to a torque of 8
N.m.
i) Remove the fuel container.
j) Open the fuel supply valve.
k) Prime the fuel system.

Page 43 of 88
c) Remove the filter bowl (1) from the filter head The following is recommended to ensure that the
(3). Apply pressure to the element (4). Turn the hydrostatic system is in good condition:
element to the left to release it from the filter
bowl and remove the element from the bowl. -Carrying out all operations in a clean, dust-free
Dispose of the used element. environment so that no foreign particles enter the
d) Remove the seal (5) from the filter bowl and components.
clean the bowl. Check that the filter bowl
threads are not damaged. -Covering all pressure inlets with plastic plugs as soon
e) Fit a new seal (5) onto the filter bowl (1). as the hydraulic lines are disconnected.
f) Install the filter bowl (1) into the top of the filter
head (3). -Replacing the seals every time the components are
g) Tighten the filter bowl by hand until the bowl opened. We therefore recommend having several seal
makes contact with the filter head. Turn the filter kits to hand before working on the components.
bowl 90 degrees.
WARNING
WARNING
The maintenance intervals for filter and oil
Do not use any tools to tighten the filter bowl. changes stated in this manual must be complied
with in order for the guarantee to remain valid.
h) Open the fuel supply valves (if installed).
C-4.1 Changing the hydrostatic pump's hydraulic oil
filter
The frequency of filter maintenance and replacement
Change secondary fuel filter depends on the pump's rotation rate, the type of fluid
every 500 service hours used, the pump's starting and operating temperatures
and accidental or systematic contamination in the
forklift.
C-4 HYDROSTATIC SYSTEM MAINTENANCE

Regular maintenance operations
hydraulic installation include:
for the forklift's WARNING
A) Checking and filling the hydraulic oil level as It is very important to change the hydraulic oil filter
necessary after the first 50 hours of operation. If it is not
changed, the supplier's guarantee will be lost in
B) Cleaning and maintaining the radiating surfaces. the event of any breakdown.
C) Changing the hydrostatic filters. Under normal operating conditions, the hydraulic oil
filters should be replaced:
D) Changing the hydraulic oil.
WARNING Change hydrostatic oil filter

after the first 50 hours
every 500 hours
Extraordinary maintenance operations are usually
necessary as a result of forklift component During maintenance cycles, avoid contaminating the
malfunction. intake circuit whenever the filter cartridge is changed.
Use the hydraulic oil recommended by Mecano
Extraordinary maintenance also includes: Continental S.A that contains additives, according to
viscosity grade ISO VG 46. Also always use original
-Adjusting and regulating the pump during the initial MAST EXPLORER hydraulic filters.
start-up.
-Disassembling and reassembling the pump and the

engine, or parts thereof.

Page 44 of 88
C-4.2 Maintaining the hydrostatic pump

It is very important that all parts and components of the
hydraulic installation are cleaned properly. This should
be done before starting the forklift or after changing any
IMPORTANT
oil or mechanical elements.
Before filling the tank, check that it is clean and
with no signs of residue, particles, rust, etc.
WARNING inside.
It is necessary for the main connection operations

to be carried out in a clean, dust-free environment
IMPORTANT
with any type of dirt that could enter the circuit
being immediately removed. Use a 10-micron filter when filling the hydraulic
fluid to prevent foreign bodies from entering the
To guarantee that the operating temperature of the installation.
hydraulic system remains within the permissible limits,
the condition and cleanliness of the oil-air heat Even new oil may contain impurities. Also fill the tank
exchanger installed on the forklift must be checked. 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
damaged.
On starting the forklift

After changing any mechanical element or oil, follow the The vehicle must be started and all of the air present in
instructions given below: the hydraulic circuit eliminated before said circuit is
used to lift heavy loads.
Before starting the forklift
To do this, with the emergency stop connected (the
-Check the cleanliness of all the parts of the installation
that come into contact with the circuit's hydraulic fluid forklift will not be able to start), keep the engine turning
(tank, tubes, heat exchangers, filters, etc.). over with only the starter motor (at less than 500 rpm)
until the entire circuit has filled with oil (this operation
-Make sure nothing is blocking the pump's normal intake tends to require two or three start phases lasting some
and check for loose connections that could cause air to 5 seconds each).
enter the tubes, kinked or restricted lines, etc.
-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,
IMPORTANT
two for high pressure (400 bar) and one for the supply
pressure (10-30 bar). Make sure the pump is set to the zero
displacement position (the gear stick must be in
Filling the hydraulic tank the neutral position, i.e. not in either forward or
reverse).
Correct operation of the loading pump is indicated by

the pressure gauge installed in the pump's supply circuit
(minimum pressure port), which indicates a minimum
pressure of a few bar (10-25 bar).

Page 45 of 88
-Run the pump in both directions and make sure the -Slightly increase the pump displacement; check that
direction of rotation of the driven parts is correct. the supply pressure does not suddenly drop and the
operating pressure is the same as the rating pressure of
-Run the transmission until you are sure that all air has the maximum pressure relief valves.
been eliminated and there is no mixture of air and oil.
This usually takes a few minutes. -If the supply pressure suddenly drops and the pump
does not open the maximum pressure relief valves, the
-Increase the rotation speed and check that the wear and internal play of the components have probably
pressure in the loading circuit reaches 18-20 bar and reached such a level that the component needs
that the depression on the intake line pressure gauge overhauling or replacing.
does not exceed values of 0.5 bar with cold oil and 0.2
bar with hot oil.
C-4.3 Hydrostatic regulation and pressure
-Gradually increase the load, monitoring the maximum measurement
operating pressure on the high-pressure gauge.
-During the starting phase, check the hydraulic fluid

level in the tank and, if necessary, fill to the appropriate
level.
HAZARD
Checking the hydrostatic pump performance
Any modification to the hydrostatic pump must be
To check the pump's performance, install one pressure communicated to and authorised by the Mecano
gauge (up to 60 bar) at the supply pressure intake and Continental, S.A. Technical Support Department.
another (up to 600 bar) at the high-pressure intake.
HAZARD
The hydrostatic pumps must not be regulated or
adjusted on site. Contact the Mecano Continental
S.A. Technical Support Department.
C-4.4 Releasing the hydrostatic pump for towing the

forklift
Towing the forklift is only recommended if there is no
other alternative as it can cause serious damage to the
Always pay maximum attention to moving parts and transmission. If possible, the forklift should be repaired
comply with all current safety standards. on site at its current location.
If there is no other option but to tow it, the following
HAZARD instructions must be followed:
Carry out this test in the shortest time possible to

avoid overheating the pump and the installation.
IMPORTANT
The H50/60 4WD models cannot be towed as they
For closed circuit pumps, make sure the external have a negative brake on the front differential and it
maximum pressure relief valve is correctly attached to is preferable for the forklift to be repaired on site.
the pump and that it properly protects the pump. Follow
the procedure outlined below:
-Cover the high-pressure openings with plugs and seals

capable of withstanding at least double the maximum
IMPORTANT
pressure of the pump.
For the H50/60 2WD models, the following
-Turn the pump at 1200 rpm with zero displacement; operations should be carried out.
with the oil at around 50ºC, check that the supply
pressure is around 18-20 bar.

Page 46 of 88
There are 2 methods for releasing the Linde hydrostatic

pump:
Method one: Remove plugs A and A’ shown in the

following photos and join with a pigtail.
C-5 ELECTRICAL SYSTEM MAINTENANCE
HAZARD
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
ground.
C-5.1 Battery
The battery fitted on this forklift truck does not need
maintenance. Check:
-That all cable terminals are securely attached to the

battery posts. To tighten the terminals, always use a
spanner, not pliers.
Method two: Loosen the high-pressure valves B and B'
by 3 or 4 turns. -Protect the posts by coating them with pure vaseline or
battery terminal protector spray.
-If the forklift is not going to be used for a long period of

time, remove the battery and keep it in a dry place.
IMPORTANT
Battery electrolyte contains sulphuric acid which
can cause burns on contact with the skin or eyes.
Wear safety goggles and gloves and move the battery

carefully to avoid electrolyte leaks. Also:
-Keep all metal objects (watches, rings, chains) away

from the battery terminals as they could cause a short
circuit resulting in burns.
-Before connecting or disconnecting the battery, turn off

all switches in the cabin.

Page 47 of 88
-To disconnect the battery, first disconnect the negative

terminal (-) from the earthing point.
-To connect the battery, first connect the positive

IMPORTANT
terminal (+).
Do not use fuses with a higher amperage than
-Recharge the battery away from the forklift in a well- indicated as this may damage the electrical
ventilated area. installation.
-Never approach with objects that could produce sparks

or open flames or cigarettes. FUSE No. NAME AMPERAGE (A)
1 Rotating 15
-Avoid placing metal objects on top of the battery. This beacon
2 Windscreen wiper 25
could cause dangerous short circuits, especially during
recharging. 3 Hour meter 5
4 Forward drive/reverse 10
-Given that the electrolyte is highly corrosive, avoid any 5 Full-beam headlights 15
contact with the forklift chassis or with electrical or
electronic components. If this does occur, contact an 6 Dipped headlights 15
authorised support centre. 7 Right rear light 7.5
8 Left rear light 7.5
ELECTRICAL 9
10
Indicators
Horn
10
10
HAZARD 11
12
Engine heater
Battery charge indicator
30
7.5
13 Gear stick 10
There is a risk of the battery exploding or short 14 Fuel level 15
circuiting. An explosive mixture of hydrogen gas
15 Work light 15
forms when recharging the battery.
16 Negative brake 15
17 Service brake 10
HAZARD 18
19
Forward drive
Reverse
5
5
20 Heating 25
The battery electrolyte contains caustic sulphuric 21 General fuse (large) 50
acid. If it contacts the skin, immediately wash off
with soap and plenty of water. If the acid contacts
the eyes, flush with abundant water and see a
doctor.
ENVIRONMENTAL
PROTECTION
Properly process the used battery as waste to
protect the environment.
C-5.2 Fuses and relays

The electrical installation is protected by fuses installed
at the back of the cabin. Before replacing a blown fuse
with another of the same amperage, find and correct
whatever caused the fuse to blow otherwise the
problem will continue.
The fuse box that is located under the bonnet to the left
of the engine is shown below.

Page 48 of 88
C-6 TRANSMISSION SYSTEM MAINTENANCE.

GREASING THE FORKLIFT.
WARNING
The rear axle has 2 grease points per wheel and
Grease axles, mast and mast pins the front axle has no grease points as it is a live
every 30 days or 200 service hours axle
The rear axle, mast, tilt cylinder linkage, mast pins and
other elements requiring lubrication must be greased as MAINTENANCE INTERVAL
shown in the following figures using adequate amounts
of grease. Grease the 2 grease points
every 30 days of operation
Greasing the rear axle: the axle has two grease points
per wheel as shown in the following diagram:
C-7 FORK CHECK
Check the following critical points

every 30 days or 200 service hours
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.
Rear axle grease points on H50/60DA:
WARNING
All hinges, fork heads and other articulations must
be lubricated prior to use as required.

Page 49 of 88
C-8 MAST MAINTENANCE AND GREASING Area A
The runner blocks and rollers installed on the mast

guides must be greased.
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 the
areas shown below (A, B C and D).
WARNING
Below is a close-up of elements 1, 3 and 5:
There may be slight differences between the
photos shown below and your specific mast
depending on whether your forklift has a duplex or
triplex mast.
Points 2, 4 and 6 are in the same position on the other

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

Page 50 of 88
Area C
Points 1, 2, 3 and 4
Checking the mast chains:
Point 4 is on the lower face: Check mast chains

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

replace with an original spare part.
Grease the chains

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

cylinder linkage and the mast pins as shown below:
IMPORTANT
The lifting chains are safety elements. Chemical
cleaning products, acids and bleach must not be
used as they may damage the chains. Apply spray
grease that is recommended for this purpose.

Page 51 of 88
C-9 TYRE PRESSURE
The air pressure used has a direct effect on the tyre's

IMPORTANT
service life. The tyre pressure must be checked every
100 service hours when the forklift is unloaded. Check A high pressure is dangerous as it transmits
that the tyre pressure complies with the following table: excessive tensile strain to the fabric and the tyre is
therefore susceptible to punctures and cuts.
Take the following precautions when servicing the tyres:
Check the pressure
every 100 service hours -Always stand to the side of the tyre so you are shielded
by the vehicle to protect yourself against possible
explosions.
Model Tyre Pressur -On filling a tyre on a split-rim wheel, check exactly if the
e loose ring pieces are in the right position as a ring flying
H50/60 (2WD off the rim may cause fatal injuries.
Rear 400x60-15.5 4 bar
and 4WD)
H50/60 (2WD -Use a safety nozzle (that you do not have to hold
Front 16x70-16.5 4.5 bar
and 4WD) manually) with a hose that is long enough for you to
stand outside the danger zone when filling the tyre.
IMPORTANT -Never cut or solder a rim if the tyre contains

pressurised air.
-Never assemble rim pieces of different sizes and never

If the tyre pressure is wrong, correct as soon as
use damaged or faulty pieces. See the service manual
possible to prevent hazards.
for authorised tyre and rim sizes. Do not fit tyres with a
different tread.
Operating a forklift truck with low tyre pressure will have
the following effect on the tyres: -Remove the air before removing foreign bodies from
the tyre.
-Excessive flexing.
-Overheating. -Put the valve dust caps back on after checking or filling
-Excessive strain on fabric. the tyres.
-Bulging of sidewalls.
-For special operations, for example on sandy terrain,
This results in damaged sidewalls and stretched the air pressure can be modified after consulting the
individual strands of fabric. after-sales department or the tyre manufacturer.
C-10 TIGHTENING OF WHEEL BOLTS
Check bolt torque

Tighten all wheel bolts daily during the first week of

operation.

Page 52 of 88
HYDRAULIC OIL PROPERTIES
IMPORTANT The hydraulic oil used in our forklift trucks allows high-
pressure operation without hardly any variation in
viscosity as temperature changes. Thanks to a suitably
The tightening torque is 270 N·m for the front high viscosity index, the oil maintains a suitable
differential, 270 N·m for the rear differential on the viscosity throughout the forklift's entire operating
4WD model and 300 N·m for the rear axle on the temperature range.
2WD model.
This oil complies with the following standards:
Wheel nuts must also be tightened daily after each
wheel change during the first week of operation. ISO/DIS 6743 Part 4 Category HV
DIN 51524 Part 2 and 3 Category HLP/HLPV
AFNOR NF E 48602 Category HV
AFNOR NF E 60 200 Category HV
BRAKE FLUID
The brake fluid is a green, special, mineral oil-based

fluid that is to be used to initially fill and successively
refill the combined brake-suspension circuits.
This fluid offers notable lubricating power, which favours

APPLY TORQUE IN A CRISS- optimum performance of the mechanical parts present
CROSS PATTERN in the hydraulic circuits.
It is also characterised by an extremely low freezing

C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT point and a very high viscosity index and can therefore
FLUIDS be used without drawbacks over a wide temperature
range.
The following table shows the fluids used in the forklift: Specification Typical values
Density at 15ºC (kg/l) 0.835

LIST OF LUBRICANTS USED Kinematic viscosity -
-40ºC (cP) 1100

LUBRICANTS TYPE
40ºC (cSt) 18.2
Engine oil ISO 10W-40
100ºC (cSt) 6.2
Hydraulic oil ISO VG 46 Viscosity index >300
Chains Chain spray Colour green
Extreme-pressure adhesive Flash point (OC) 125ºC

Mast
grease
Pour point -60ºC
Fuel Diesel
Differential carrier oil SAE 75W-80, API GL-4 ANTIFREEZE
Differential oil SAE 75W-80, API GL-4 Antifreeze is usually made of three elements: water,
additives and glycol. We recommend using an
Brake fluid LHM Super mineral oil antifreeze with a minimum concentration of 50% in
Lithium soap-based grease engine cooling systems.
(DIN 51825-KPF2 N-20
Grease points
Penetration grade 2, lithium
soap)

Page 53 of 88
IMPORTANT
Do not use the following types of water in cooling
systems: Hard water, soft water that has been
When required
softened with salt and seawater.
Replace the battery
Disconnect the battery or battery cable
Many engine failures are a result of the cooling system. Clean the engine
The condition of the coolant is also important for it to do Clean or replace the air filter
its job properly.
Prime the fuel system
Never work on an engine without a thermostat in the Daily
cooling system. Thermostats help keep the engine Check the coolant level
coolant at the right operating temperature. Clean the air filter
Check the oil level
The coolant's glycol content helps protect against Drain the primary fuel filter or water separator
boiling over, freezing and water pump cavitation. A 1:1 Inspect belts
mixture of water and glycol is used. Walk-around inspection of engine
C-12 MAINTENANCE PROGRAMME FOR THE
Drain fuel tank water or sediment
PERKINS 1104D-44T SERIES ENGINE
Adjust, inspect or replace the alternator belt
Every 500 service hours or year
WARNING Check the battery condition
Check the condition of the engine breather
Clean or replace the engine air filter
Before performing any maintenance work or Replace the primary fuel filter
procedure, make sure you have read and Change engine oil and oil filter
understood all the safety information, warnings Replace the secondary fuel filter
and instructions.
Inspect hoses and clamps
Clean the radiator
The following programmes must be performed
according to the interval that comes first:
Inspect the engine valve lash
PERKINS maintenance programme
Inspect the aftercooler core
When required Inspect the alternator
Daily or every 8 service hours
Inspect the engine mounts
Every 500 service hours Inspect the starter motor
Every 500 service hours or year Inspect the turbocharger
Every 1000 service hours Inspect the water pump
Every 2000 service hours Every 3000 service hours
Every 3000 service hours Inspect, adjust or replace the alternator belt
Every 3000 service hours or 2 years Test or change the injectors
Every 3000 service hours or 2 years
Every 12,000 service hours or 6 years
Change the cooling system coolant
KEY FOR FOLLOWING TABLE Every 4000 service hours
Clean and test the fan core
The preventive maintenance intervals are indicated for Every 12,000 service hours or 6 years
normal operating conditions. When engine performance Change the cooling system coolant
must be adjusted to local standards, it may be
necessary to adapt the maintenance intervals and
procedures to guarantee correct engine performance.
As part of good preventive maintenance, look for leaks
or loose fasteners during each check.

Page 54 of 88
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 AND 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 55 of 88
D-1 GENERAL OBSERVATIONS D-3 RESIDUAL RISKS

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

falling).
-Risks due to the forklift accidentally overturning without

Being aware of potentially dangerous situations the operator using the seat belt.
could prevent an accident.
D-4 NOISE EMISSIONS AND VIBRATIONS

D-2 CONDITIONS TO BE MET BY OPERATORS 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 56 of 88
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 AND 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 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
indicator diagrams. Acoustic warning alarm: when the forklift is moving in
reverse, an audible signal is activated.
Emergency stop: the emergency stop is located on the
right-hand side of the driver, next to the hydraulic Seat belt: located on the seat and worn by the operator.
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 57 of 88
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 58 of 88
-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.
-Use the horn when approaching bridges, crossroads, -When driving with the vehicle unladen, the forks should
pedestrians, animals, etc. be kept at around 15 cm from the ground.
-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 59 of 88
-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 60 of 88
-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 61 of 88
-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 62 of 88

Page 63 of 88

Page 64 of 88
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 65 of 88
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 66 of 88
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 67 of 88
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 68 of 88
Section F
APPENDICES
CONTENTS
F-1 HYDRAULIC DIAGRAM H50/60 (2WD)
F-3 TIGHTENING TORQUES
F-4 LOAD DIAGRAMS
F-5 MAINTENANCE REPORT TEMPLATES

Page 69 of 88

Page 70 of 88

Page 71 of 88
F-3 TIGHTENING TORQUES
Whenever possible, apply the tightening torque by holding the head of the screw firm and turning the nut. To apply
the right torque (Nm) when tightening the screws, you must first know the following data:
• Screw diameter in mm (metric) or inches (Whitworth)

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

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

Page 72 of 88
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 73 of 88
F-4 LOAD DIAGRAMS
Load diagrams for the MAST EXPLORER rough terrain forklift truck models H50/60DA 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 H50DA MODEL: Mast height 3300 mm

Mast height 4300 mm
CG_Qe (mm)

Page 74 of 88
FOR H60DA MODEL:

Mast height 3300 mm
Mast height 4300 mm
CG_Qe (mm)
F-5 MAINTENANCE REPORT TEMPLATES

Page 75 of 88
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 76 of 88
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 77 of 88

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 88

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 88

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 88

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 88

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 88

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 88

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 88

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

Page 85 of 88

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

Page 86 of 88

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

Page 87 of 88

Page 88 of 88

Manual h50 60da en

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MAST EXPLORER Rough Terrain Forklift Trucks

H50/60DA range operation and maintenance manual

WHERE WE ARE LOCATED:

(Authorised dealer stamp)

H50/60DA range operation and maintenance manual:

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

H50/60DA range operation and maintenance manual

H50/60DA range operation and maintenance manual

WARNING or the After-Sales department.

Read and understand this manual before starting,

Section A: general information about the machine and

Section B: primarily for machine operators. All the

Section C: specifically for maintenance manager and

Section D: for staff responsible for forklift operation,

Section E: its purpose is to diagnose and solve

Section F: additional information such as hydraulic and

H50/60DA 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

HAZARD protection information.

Warns you of situations that endanger your safety

H50/60DA range operation and maintenance manual

B) OPERATION AND OPERATING

H50/60DA range operation and maintenance manual

SECTION A: GENERAL INFORMATION

SECTION B: OPERATION AND OPERATING INSTRUCTIONS

H50/60DA range operation and maintenance manual

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

H50/60DA range operation and maintenance manual

H50/60DA 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

H50/60DA range operation and maintenance manual

A-1 CONVENTIONAL REFERENCES

A-1.1 Information on the forklift (instruction stickers)

H50/60DA range operation and maintenance manual

A-1.2 Forklift layout Main external components:

H50/60DA range operation and maintenance manual

A-2 FORKLIFT INFORMATION A-2.1 Manufacturer

IMPORTANT various models of H50/60DA rough terrain forklift

Forklift information can be found on the data plate fitted

This data plate gives the following information:

The different available configurations of the MAST

2WD (2 wheel drive):

4WD (4 wheel drive):

H50/60DA range operation and maintenance manual

A H50/60DA rough terrain forklift truck can be

To be able to understand the model's code we must

FOR H60DA MODEL: Mast height 3300 mm