MAST EXPLORER Rough Terrain Forklift Trucks · safety and the safety of others at risk and affect...

MAST EXPLORER Rough Terrain Forklift Trucks

H50/60DA range operation and maintenance manual of 88



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 [email protected] 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.



INTRODUCTION This manual has been written by staff at MECANO CONTINENTAL S.A in order to provide all the necessary information for correct operation of the forklift and to ensure correct and safe maintenance. Safety and troubleshooting sections are also included.

WARNING

Read and understand this manual before starting, operating and maintaining the forklift.

This manual is divided into the following sections:

A) GENERAL INFORMATION

B) OPERATION AND OPERATING INSTRUCTIONS

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.

These sections are in turn sub-divided into sequentially numbered chapters and paragraphs to make it easier to find information. The quickest way to find information is to use the table of contents page. If you have any trouble understanding this manual, or parts of the manual, we recommend contacting the Mecano Continental S.A. Technical Support department or the After-Sales department.

IMPORTANT

Due to continually improving our forklift models and in order to improve our products further, there may be slight differences between your model and the model described in this manual. In this case, contact the MECANO CONTINENTAL S.A. Technical Support department for possible clarifications or updates.



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. In this manual, when such situations put the operator's safety and the safety of others at risk and affect the forklift's efficiency and its correct operation, specific instructions displaying a SPECIAL SYMBOL to highlight such situations are given to minimise risks. There are five special (or safety) symbols used in the manual and these are always accompanied by other key words that classify the situations according to the potential hazard. Each symbol is accompanied by text describing the likelihood of a situation, what to look out for and the recommended method or behaviour to be adopted. When necessary, this text includes prohibitions or appropriate instructions to avoid risks. In some cases the text may be accompanied by illustrations. The special (or safety) symbols are shown below in order of importance:

HAZARD

Warns you of situ ations 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 ser ious electrical hazards, which may even result in death.

WARNING

Warns you of situations that endanger your safety and the safety of others with risks of minor accidents or injury, or that risk compromising the forklift's efficiency.

IMPORTANT

Makes you aware of important technical information or practical advice that can help you operate the forklift more efficiently and safely.

ENVIRONMENTAL

PROTECTION

Makes you aware of important environmental protection information.



TABLE OF CONTENTS

A) GENERAL INFORMATION

B) OPERATION AND OPERATING INSTRUCTIONS

C) MAINTENANCE

D) SAFETY

E) TROUBLESHOOTING F) APPENDICES



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



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



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



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



A-1 CONVENTIONAL REFERENCES

A-1.1 Information on the forklift (instruction stic kers) 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:



A-1.2 Forklift layout The following photo shows the layout of the forklift. This is to ensure that any reference to the different parts of the forklift (front, rear, etc.) in this manual is clear in order to avoid errors in terms of name and position.

Main external components:

Number Description

1 FRONT DRIVE AXLE

2 REAR AXLE

3 COUNTERWEIGHT

4 ENGINE

5 REAR LIGHTS AND INDICATORS

6 STEERING WHEEL

7 OVERHEAD GUARD

8 MAST

9 CARRIAGE

10 SEAT

11 CHASSIS NUMBER

12 FUEL TANK

TOP

BOTTOM

FRONT

RIGHT SIDE REAR

LEFT SIDE

1

2

3

4

5

6

7

8

9

10 11

12



A-2 FORKLIFT INFORMATION

IMPORTANT

Check that you have the right operation manual. If you need further information or technical support, you must specify the model and type of forklift plus the chassis number.

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 • Engine power in HP/kW • CE mark • Tyre pressure

A-2.1 Manufacturer The forklift truck manufacturer is MECANO CONTINENTAL, S.A. This company has developed 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 forklift since Mecano Continental S.A meets the requirements set out in Directive 2006/42/EC on the approximation of the laws of Member states relating to machinery.

A-2.2 Model and type. Chassis number To correctly identify the forklift model and type, Mecano Continental S.A has engraved a number on the front 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



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 to the mast model fitted:

RATED CAPACITY OF THE MAST

H50 DA (5,000 kg) K

H60DA (6,000 kg) L

The MAST EXPLORER H50/60DA rough terrain forklift trucks have been designed to carry and lift loads vertically. The forklift truck is a self-contained vehicle suitable for carrying hanging loads and is designed for such use. FORKLIFT INFORMATION: To be able to understand the model's code we must understand the following:

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

HAZARD

The following diagrams are valid for a lift height of 3300, 4300 and 6000 mm (without additional attachments fitted)

Load diagrams for the H50DA and H60DA models are shown below: The load is given in kg on the vertical axis and the distance from the centre of gravity (CG) to the carriage is given in mm along the horizontal axis, with CG being 500 mm for the standard load. FOR H50 DA MODEL:

FOR H60DA MODEL:

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 below and are adhered to the forklift:

Mast height 3300 mm Mast height 4300 mm Mast height 6000 mm Load

CG_Qe (mm)

Mast height 3300 mm Mast height 4300 mm Mast height 6000 mm Load (kg)

CG_Qe (mm)



IMPORTANT

The capacity loss chart s shown here are for illustrative purposes only as only those charts tha t apply to a specific model are adhered to that forklift according to each model's rated specifications.

A-2.4 Main measurements and specifications The forklifts' main weights and measurements are given below.

IMPORTANT The weights and measurements given below are exclusively for the models indicated. Any modification made to the forklift that may affect i ts load capacity invalidates the original diagram. FOR H50 DA MODELS (2WD and 4WD)

H7

M2

M1

H6

X2 Y X1

L L2

H1

L1

FORKLIFT WEIGHTS

TOTAL UNLADEN WEIGHT (kg) 6,950

WEIGHT ON AXLES WITH LOAD (FRONT/REAR) (kg) 11,050 / 900

WEIGHT ON AXLES WITHOUT LOAD (FRONT/REAR) (kg) 3,170 / 3,780

MAXIMUM PERMISSIBLE WEIGHT (kg) 11,950

MAIN MEASUREMENTS

TOTAL LENGTH (mm) L1 5,075

LENGTH TO FORK CARRIAGE (mm) L2 3,575

DISTANCE FROM LOAD TO FRONT AXLE (mm) X1 700

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

FRONT/REAR TREAD (mm) C1/C2 1,560 / 1,560

TOTAL HEIGHT WITH MAST (mm) H1 3,050

TOTAL HEIGHT WITH MAST EXTENDED (mm) H4 7,087

GROUND CLEARANCE, MINIMUM M1 300

GROUND CLEARANCE, CENTRE OF WHEEL BASE M2 380

TURNING RADIUS (mm) (2WD) WA 4,610


DRIVING SEAT HEIGHT (mm) H7 1,390

B C1

C2

WA

PERMISSIBLE WEIGHTS

SERVICE WEIGHT (kg) 6,950

GVWR / GVW (kg) 11,950

GVWR / GVW, FRONT (kg) 12,100

GVWR / GVW, REAR (kg) 4,200

FOR H60DA MODELS (2WD and 4WD)

H7

M2

M1

H6

X2 Y X1

L L2

H1

L1



FORKLIFT WEIGHTS

TOTAL UNLADEN WEIG HT (kg) 7,560

WEIGHT ON AXLES WITH LOAD (FRONT/REAR) (kg)

12,500 / 1060

WEIGHT ON AXLES WITHOUT LOAD (FRONT/REAR) (kg) 3,010 / 4,550

MAXIMUM PERMISSIBLE WEIGHT (kg) 13,560

MAIN MEASUREMENTS

TOTAL LENGTH (mm) L1 5,075

LENGTH TO FORK CARRIAGE (mm) L2 3,575

DISTANCE FROM LOAD TO FRONT AXLE (mm) X1 700

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

FRONT/REAR TREAD (mm) C1/C2 1,560 / 1,560

TOTAL HEIGHT WITH MAST (mm) H1 3,050

TOTAL HEIGHT WITH MAST EXTENDED (mm) H4 7,087

GROUND CLEARANCE, MINIMUM M1 300

GROUND CLEARANCE, CENTRE OF WHEEL BASE M2 380



DRIVING SEAT HEIGHT (mm) H7 1,390

B C1

C2

WA

PERMISSIBLE WEIGHTS

SERVICE WEIGHT (kg) 7,560

GVWR / GVW (kg) 13,560

GVWR / GVW, FRONT (kg) 13,700

GVWR / GVW, REAR (kg) 5,000

FOR H50/60DA MODELS (2WD and 4WD)

MAST

TYPE TRIPLEX

MAXIMUM HEIGHT (mm) 6,000

WEIGHT (kg) 2,000

FORK LENGTH (L) (mm) 1,500

TOTAL LIFT HEIGHT (H3) mm 6,000

FREE LIFT (H2) mm 1,963

LOAD CENTRE OF GRAVITY (CG) mm 600

FORK CARRIAGE FEM IV B

TILT FORWARD/BACKWARD º/º 10 / 12

MAXIMUM LOAD LIFTING SPEED m/s 0.4

MAXIMUM LOAD LOWERING SPEED m/s 0.5

A-2.5 Engine specifications

ENGINE

MAKE / MODEL Perkins / 1104D -44T

NO. CYLINDERS / DISPLACEMENT 4 / 4400 cm 3

ACTUAL OUTPUT HP / KW 100 / 74.5

RATED OUTPUT HP / KW 21.37 / 15.72

A-2.6 Fluid capacity

FLUID CAPACITIES

ENGINE OIL (l) 11

HYDRAULIC SYSTEM (l) 130

COOLING SYSTEM (l) 25

FUEL (l) 110

A-2.7 Wheels and brakes

WHEELS AND BRAKES

FRONT WHEELS 16/70x16.5 / 14PR

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

SERVICE BRAKE HYDRAULIC

PARKING BRAKE NEGATIVE-ACTING MULTIPLE-DISC



A-2.8 Other data of interest

OTHER DATA OF INTEREST

TRAVEL SPEED WITHOUT LOAD 24 km/h

TRAVEL SPEED WITH LOAD 20 km/h

RATED DRAWBAR PULL WITHOUT LOAD 4WD/2WD 4,300/3,450 daN

GRADEABILITY WITHOUT LOAD 4WD/2WD 35 / 30 %

GRADEABILITY WITH LOAD 4WD/2WD 30 / 25 %

FORWARD/REVERSE GEAR SHIFT ELECTRIC

DRIVE TYPE HYDROSTATIC

DRIVE UNIT PRESSURE 420 bar

AUXILIARY PRESSURE / FLOW CONNECTION 200 bar / 57 l/min

BATTERY 12V 70 AH 570 A

SOUND POWER LEVEL <104 dB (A)

HYDROSTATIC PUMP LINDE HPV75-02 RCA

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 loads with front dimensions greater than the standard considered by Mecano Continental S.A., generally 1000 mm, are to be lifted (centre of gravity of 500mm):

X= (S×N) / L where: X = residual capacity of the forklift with bulky load S = distance between the vertical axis of the front wheels and the rated load centre (500 mm) N= forklift's rated capacity L =distance between the vertical axis of the front wheels and the centre of gravity of the load to be transported

WARNING

This formula is only valid in terms of lifting capacity. The stability and risks presented by the vehicle when moving depend on many other factors that are not taken into account in the formula above.

A-3 PERMITTED USES

The MAST EXPLORER forklift trucks have been designed and manufactured to lift, move and carry products. Any other use is not permitted and is therefore considered improper use. Strict compliance with the operation, maintenance and repair conditions specified by Mecano Continental S.A is an essential element of permitted use. The forklift must only be used and maintained by people who are fully acquainted with its specifications and safety procedures. It is also necessary to respect all accident prevention standards, generally recognised occupational health and safety standards and all traffic standards.

WARNING

Any type of modification or change to the forklift, except for modifications cont emplated in this manual for normal maintenance purposes, is prohibited.

A-4 IMPROPER USE

Using the MAST EXPLORER forklift trucks according to operating criteria that do not comply with the instructions contained in this manual and that could be dangerous for the operator or others is understood to be improper use.

HAZARD Some of the most common and dangerous cases of improper use are listed below:

− Transporting people on the forks

− Not following the operation and maintenance instructions given in this manual to the letter

− Exceeding mast, height and load limits

− Working on unstable pit/ditch edges

− Travelling across slopes instead of up and

down them

− Working during heavy storms

− Working in excessively steep conditions as there is a risk of overturning



− Using the equipment for jobs other than for which it was designed

− Working in potentially explosive areas

− Working in enclosed or poorly ventilated

areas



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



B-1 BEFORE CLIMBING INTO THE FORKLIFT

WARNING

This sect ion contains support material for the operator that outlines how to operate the MAST EXPLORER forklift truck.

Once the operator has taken up his or her position inside the operator's cabin and has completed the 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 ensure correct usage during operation and fast, timely intervention by the operator should sudden manoeuvres become necessary to protect the safety of the operator and the forklift.

IMPORTANT

Learn to operate the forklift and predict how it wi ll respond. Learn how to use the controls in an open, safe space with no obstacles or people nearby. Never jerk the controls; use them with caution until you are sure what effect they have on the forklift in order to reduce risks.

Inspection and cleaning: -Clean the windows, lights and rear-view mirrors. -Check the wheel nuts, articulated machine parts (mast) and overall condition of the forklift. -Check for oil, fuel or coolant leaks. -Check the tyre pressure. -Check for possible cracks in covers..

HAZARD

A burst tyre could cause serious injury. Do not use the forklift with damaged, under-inflated or worn tyres.

To check tyre wear and pressure, see the following table:

Model Tyre Pressure

H50/H60 (2WD and 4WD)

Rear 400x60-15.5 4 bar

H50/H60 (2WD and 4WD) Front 16x70-16.5 4.5 bar

B-2 CLIMBING INTO THE FORKLIFT

B-2.1 Entering the cabin Two steps or rungs plus a handhold on the cabin frame are provided to make it easier to climb into the vehicle.

WARNING

Always make sure your hands and footwear are dry and clean before climbing onto the step to reach the driving seat. Always use the step to climb into or out of the cabin, holding onto the special supports provided.

The forklift truck has been designed and manufactured to be operated by an operator from the driving seat located at the front of the forklift in compliance with the operating instructions given in this manual. All the necessary components to drive the vehicle and operate the vertical load lifting system are operated from the driving seat. The operator should check the position of the battery cut-off device. In a horizontal position, the battery will be connected to the forklift's electrical circuits and in a vertical position, the battery will be disconnected from the forklift's electrical circuit.



B-2.2 Adjusting the seat Careful seat adjustment ensures that the operator can drive safely and comfortably. The seat has several devices for adjusting the seat's distance from the controls. For this purpose, the seat has a knob and lever on the right-hand side. By using these devices, the seat can be adjusted to the desired position.

WARNING The operator should adjust the seat's distance in order to be able to safely operate all of the forklift's instruments and controls.

B-2.3 Putting on the seat belt

IMPORTANT

The operator should fasten hi s or her seat belt before operating the forklift in any way. The overall condition and operation of the seat belt should be checked periodically.

Sit correctly in the driving seat before doing the following: -The seat belts have retractors. To fasten the seat belts, pull the tongue 1 and clip it into the buckle 2. -To unfasten the seat belt, press the button 3 and release the tongue from the buckle. -Check that the seat belt is positioned across the waist and not the stomach.

-Adjust the length of the seat belt at both ends, keeping the buckle in the middle.

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. -Adjust the tilt of the steering wheel. -Tighten the handle.

HAZARD

Before driving, check that the steering wheel adjusting handle is locked to prevent accidents.

WARNING

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.

To adjust the seat



B-2.5 Adjusting the rear-view mirrors The forklift cabin is fitted with two exterior rear-view mirrors attached to the overhead guard.

WARNING

Adjust the position of the rear -view mirrors by rotating the mirror head by hand until you have a clear view of the area behind the forklift.

B-3 OPERATOR'S CONTROL PANEL

BEFORE STARTING THE ENGINE

WARNING To ensure the safety of the operator and others and a long machine service life, do an all-round check before starting the engine, as described below. -Remove all dirt from inside the cabin, particularly from the area near the pedals and control levers. -Remove all oil, grease or mud from the pedals and control levers. -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 positions: -Position 1: Off: The forklift is not running. -Position 2: Heat: Engine preheating. Hold for 5 seconds and repeat the operation if the engine does not start or if the outside temperature is very low.

-Position 3: On: The on position (the beacon comes on). -Position 4: Start: Starter.

HAZARD

After starting the engi ne, if you climb down from the driving seat, the engine will still be running. DO NOT LEAVE THE DRIVING SEAT WITHOUT FIRST TURNING OFF THE ENGINE, LOWERING THE MAST AND PUTTING THE PARKING BRAKE ON!

B-3.2 Instruments and controls The forklift's main instruments and controls are described below:

WARNING The photo above shows a 2WD model with no differential lock. On 4WD models, the differential lock button is replaced by the rear light switch.



(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)

3 Forward -reverse lever and gear shift, 1st and 2nd gears

4 Parking brake

5 Indicators, headlights, horn

6 Key switch

7 Accelerator pedal

8 Service brake pedal

9 Hour meter

Detailed description: 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.

WARNING

On 4WD models, the forklift has perman ent traction to all 4 wheels. The differential lock button must be used if one of the wheels loses traction.

Parking brake switch Press to the right to activate.

HAZARD

This brake must be activated with the forklift stationary to prevent accidents.

Moving: -If the parking brake is off: 1) Forward drive: push the forward-reverse lever forward and step on the accelerator. The forklift will move forward.

2) Reverse: move the forward-reverse lever backward and step on the accelerator. The acoustic warning alarm will sound. Gear shift: Both the 2WD and 4WD high-end H50/60DA forklifts have 2 gears. To change gear:

a) Turn the gear stick lever clockwise to select 1st gear (I).

b) Turn the gear stick lever anti-clockwise to select 2nd gear (II).

HAZARD

On putting the forklift into gear, the forklift can move slowly even without stepping on the accelerator.

3) If the parking brake is on, the forklift will start but will not begin to move. 4) If the parking brake is off but the forklift is in gear, the forklift will not start. 5) The parking brake can be activated if the forklift is not in gear (in neutral).

1

2

3

6

4

5

7

8

9



HAZARD

If the forklift is in gear and the button is presse d, the brake does not work.

Light switch : -Position 0: lights off Position 1: side lights and lights panel on -Position 2: headlights on -Button 3: windscreen wiper -Button 4: horn

Horn: Located on the end of the light switch. To sound the horn, simply press the button.

Pedals:

1) Service brake (left pedal) and emergency brake pedal.

2) Accelerator pedal (right pedal)

To travel downhill with a load, drive with the rear of the forklift downhill while accelerating to control the descent speed. When the parking brake is applied, the wheel motors lock, ensuring that the forklift is totally immobilised.

WARNING

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:

(The photo above shows a joystick from a

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

1 2



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 -Button C: optional for 4th valve -Button D: optional for 4th valve -Button E: hydraulic brake

WARNING

Before moving the forks, make sure nobody is within the forklift's operating radius

Diagram of reversed function option The client may ask for a joystick with the functions in a different order.

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:

1) Hydraulic oil level window on the service tank (mast and steering).

2) Hydraulic oil level window on the hydrostatic transmission tank.

HAZARD

If the oil level is not high enough, th e tank should be topped up with the oil specified in the maintenance section.

HAZARD

If the hydraulic oil temperature exceeds 100ºC, contact the Mecano Continental S.A. after- sales department or qualified staff to check.

B-3.5 Lights panel and hour meter The MAST EXPLORER forklift trucks have an hour meter that also shows other information as described below:

1

2



NUMBER DESCRIPTION

1 Hour meter

2 Side lights

3 Air filter change

4 Transmission filter change

5 Engi ne 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

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 beacon

15

2 Windscreen wiper 25

3 Hour meter 5

4 Forward drive/reverse 10

5 Full-beam headlight

15

6 Dipped headlights 15

7 Right rear light 7.5

8 Left rear light 7.5

9 Indicators 10

10 Horn 10

11 Engine heater 30

12 Battery level indicator 7.5

13 Gear stick 10

14 Fuel level 15

15 Work light 15

16 Negative brake 15

17 Service brake 10

18 Forward drive 5

19 Reverse 5

20 Heating 25

21 General fuse (large) 50

2

1

3

4

5 6

7

8

9

10

11



WARNING

Only use fuses with the indicated amperage. Failure to do so could lead to damage to or fire in the printed circuit board.

The fuse box is accessed by lifting the bonnet located at the rear of the forklift. It should be accessed in accordance with the instructions given in the maintenance section of this manual. 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

When jump starting from a nother battery that is not part of the forklift, avoid contact between the cable clamps once connected to the battery to prevent sparks.

HAZARD

Batteries produce a flammable gas that could be ignited by the sparks, causing the battery to explode. Do not smoke when checking the electrolyte.

ELECTRICAL

HAZARD

Keep the positive cable (+) from the battery away from any metal object, such as buckles, watch straps, etc., that could cause a short circuit between the battery terminal and nearby metal , resulting in the risk of burns for the operator.

IMPORTANT

The battery used for jump starting must have the same voltage (12V) and capacity as the battery fitted in the forklift.

To start the engine using an external battery, proceed as explained below: -Disconnect the forklift battery using the cut-off device fitted.

-Connect the two batteries by first connecting the positive terminals (+) and then the negative terminals using the clamps provided for this purpose. -Proceed to start the forklift's engine using the start switch. -Disconnect the cables by first removing the negative cable (-) from the earthing point and then from the auxiliary battery. -Disconnect the positive cable (+) from the forklift's battery and then from the auxiliary battery.

HAZARD

Only use a 12V battery as other devices (battery chargers, etc.) could cause the battery to explode or damage the electrical installation.

B-5.2 Disconnecting the battery If any type of repair or maintenance work is required on the forklift, particularly work involving welding, it is necessary to turn off the general battery switch located beneath the seat on the left-hand side.

B-5.3 Battery location 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.



B-5.4 Battery disposal

ENVIRONMENTAL

PROTECTION

The lead -acid batteries used cannot be disposed of with regular industrial solid waste; instead they must be collected, disposed of and/or recycled according to the laws of the country where the forklift is located.

B-6 TRANSPORTING THE FORKLIFT

B-6.1 Transporting and towing the broken-down forklift If the forklift breaks down and needs to be transported, take the following into account: -The load capacity (permissible load) of the transport vehicle must be greater than the weight of the forklift. -Keep a safe distance from edges, ramps, work platforms, etc. -Completely lower the forks -Put the parking brake on. Remove the key -Put 2 chocks in front of and behind front and rear wheels to prevent movement -Secure with ropes and tighten.

WARNING

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.

B-6.2 Transporting by crane Loading by crane is only considered for the initial transportation of the forklift when commissioned. If frequent loading of the forklift by crane is required at the work site, consult Mecano Continental S.A.

HAZARD Only people with adequate experience using the appropriate securing and lifting devices may load the forklift for transportation.

IMPORTANT To lift the forklift, use loading devices and tackl e that have sufficient load capacity. Textile devices may be used to protect edges. Secure the forklift using the eyebolt attached to the forklift's rear counterbalance and the mast at the front.

B-7 CLEANING AND WASHING THE FORKLIFT

To clean the forklift correctly, follow these instructions: -Clean dirty areas affected by oil or grease using dry solvents or volatile mineral alcohol. -Before assembling new spare parts, remove all protective material (anti-rust, grease, wax, etc.) -If there are signs of rust on metal parts of the forklift, clean using sandpaper and cover with adequate protection (anti-rust, varnish, oil, etc.).

Exterior washing Before washing, check that the engine is off and that doors and windows are closed. Do not use fuel for cleaning; use only water or a steam jet. In cold climates, dry locks after washing or moisten with antifreeze. Before using the forklift, reset all pre-wash conditions. Interior washing Wash the interior of the forklift using water and a sponge. Never use pressurised water. After washing, dry with a clean cloth. Engine washing Wash the engine after applying water-proofing to the air 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

ENVIRONMENTAL

PROTECTION

At the end of the fork lift's service life, we recommend not leaving the forklift discarded as waste but rather to contract specialised companies to dispose of the forklift in compliance with curre nt regulations.



Section C

MAINTENANCE

CONTENTS

C-1 HEALTH AND SAFETY STANDARDS C-2 SCHEDULED FORKLIFT MAINTENANCE

C-3 MAINTENANCE ON THE PERKINS 1104D-

44T ENGINE

C-3.1 Main engine components C-3.2 Engine identification C-3.3 Inspection of the engine alternator

C-3.4 Inspection of the alternator belt C-3.5 Instructions for replacing the belt

C-3.6 Changing the coolant C-3.7 Checking the coolant level

C-3.8 Replacing the air filter

C-3.9 Cleaning the air filter C-3.10 Engine oil level C-3.11 Changing the engine lubricating oil C-3.12 Changing the engine oil filter C-3.13 Fuel injectors C-3.14 Priming the fuel system C-3.15 Changing the primary fuel filter C-3.16 Changing the secondary fuel filter

C-4 HYDROSTATIC SYSTEM MAINTENANCE

C-4.1 Changing the hydrostatic pump's

hydraulic oil filter C-4.2 Maintaining the hydrostatic pump

C-4.3 Hydrostatic regulation and pressure

measurement C-4.4 Releasing the hydrostatic pump for towing

C-5 ELECTRICAL SYSTEM MAINTENANCE

C-5.1 Battery C-5.2 Fuses and relays

C-6 TRANSMISSION SYSTEM MAINTENANCE. GREASING THE FORKLIFT C-7 FORK CHECK C-8 MAST MAINTENANCE AND GREASING C-9 TYRE PRESSURE C-10 TIGHTENING OF WHEEL BOLTS C-11 TECHNICAL SPECIFICATIONS OF

FORKLIFT FLUIDS C-12 MAINTENANCE PROGRAMME FOR THE

PERKINS 1104D-44T ENGINE



INTRODUCTION Regular, correct maintenance will give the operator a forklift that is always safe and operational. For this reason, after having worked in particularly adverse conditions (muddy, dusty terrain, heavy work, etc.), washing, greasing and correct maintenance of the forklift is recommended. Always check that all forklift components are in good working condition, there are no oil leaks and safety guards and devices are efficient. If this is not the case, find and resolve the causes.

WARNING

Mecano Continental S.A. recommends using ORIGINAL MAST EXPLORER SPARE PARTS to ensure adequate operation of the forklift.

Maintenance operations are scheduled according to the number of service hours completed by the forklift. Keep track of service hours to be able to correctly determine maintenance intervals. For this purpose an hour meter is fitted on the steering column.

Non-compliance with the scheduled maintenance standards indicated in this manual automatically cancels the guarantee given by Mecano Continental S.A.

IMPORTANT

For engine maintenance, carefully follow the 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.

Storage Always store oils in an enclosed place out of the reach of children. Never leave lubricant containers open and without a label indicating their contents to avoid mistakes. Disposal Disposing of new or used oil is highly contaminating for the environment. Carefully store new oil and keep used oil in special containers for subsequent disposal by specific waste disposal centres. Spillage In the event of accidental oil spills, use sand or a suitable granulate to soak up the oil. Scrape off the compound obtained and dispose of as chemical waste. Emergencies -Eyes: If oil comes into contact with the eyes, rinse with copious amounts of running water. If irritation continues, go to the nearest hospital. -Ingestion: If oil is ingested, do not induce vomiting. See a doctor. -Skin: In cases of excessive and prolonged contact with the skin, wash with soap and water. -Fire: In the event of fire, use CO2, dry powder or foam fire extinguishers. Do not use water.

C-2 SCHEDULED MAINTENANCE

IMPORTANT

Incorrect maintenance or no maintenance at all may make the forklift dangerous for the o perator and others in the surrounding area.

Make sure maintenance and lubrication are done regularly as indicated by Mecano Continental S.A. in this manual in order to keep the forklift safe and operational. Make sure all faults detected during maintenance are immediately resolved prior to using the forklift again.



WARNING

All operations marked by the following symbol must be done by a specialised technician.

Within the first 10 service hours

Check the engine oil and fuel levels

Check the hydraulic oil level in the tank

Check the wheel bolt tightening torque

Check the torque of all screws/bolts

Check for possible oil leaks from the hydraulic connections

Check the coolant level in the radiator

Clean the engine radiator

Check parking brake operation

Check the cleanliness of the hydraulic tank breather and check that it is not blocked

Check the tyre pressure

Within the first 50 service hours

Change the engine oil for the first time

Change the hydrostatic pump's hydraulic oil filter

Every 10 service hours or daily

Check the engine oil level

Clean the air intake filter

Clean the radiator, if necessary

Check the hydraulic oil level in the tank

Check that the components of the mast sections are well greased to ensure that rollers slide along rails

Check for correct operation of the electrical lighting installation

Check for correct operation of the brake system and parking brake

Check that the steering system is working properly

Check for correct operation of the service brake

Every 50 service hours or weekly

Operations to be carried out in addition to daily operations

Check the alternator belt tension

Check the tyre pressure

Check the wheel bolt tightening torque

Check the friction of the air intake tube between the engine and the filter and check that it is in good condition

After 250 service hours or monthly

Operations to be carried out in addition to others mentioned above:

Grease roller bearings, bushings and articulations

Grease lifting chains and mast guides

Check for correct operation of the lifting cylinders

Check the condition of the engine's air filter cartridge; replace if necessary

Check that the terminals are tightly fastened to the battery posts

Check that the hydraulic tubes are not worn as a result of rubbing against the chassis or other mechanical components

Check for wear to the rollers on the mast sections

Check the battery fluid level

Inspect forks and mast

Every 500 service hours

Operations to be carried out in addition to others mentioned above

Visually check the amount of fumes from the exhaust pipe

Check that the bolts attaching the engine to the silent blocks are tight

Check that there is no excessive play between bolts and bushings at all joints

Change hydraulic oil filter

Check brake linings or disc brake pads

Change engine oil filter, air filter and fuel filter

Change the engine oil

Check for correct operation of the hydrostatic pump

Check mast bushings

Grease mast support pins

Every 1000 service hours or every yea r

Operations to be carried out in addition to others mentioned above

Check the brake discs and parking brake

Grease the wheel hubs and bearings

Change brake fluid

Change hydraulic oil



Change coolant

Check front differential carrier oil level

Check front differential assembly oil level

Check rear wheel motor oil level

After each repair affecting the hydraulic system

Change hydraulic filters

Change hydraulic oil

WARNING

These service hours / intervals are recommendations when operating th e forklift under normal conditions. Depending on usage and work environment, these intervals may be longer or shorter.

IMPORTANT

It is vital that these maintenance intervals be followed in order to claim a repair under the guarantee.

HAZARD

All m aintenance work must be carried out with the engine stopped, the parking brake on and the mast resting on a flat surface on the ground.

WARNING

Before any maintenance operation involving the lifting of a component, secure the component to be lifted to keep it safe and steady prior to movin g.

WARNING

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

WARNING

Before working on the hydraulic lines or components, make sure there is no pressure in the system. To do this, after turning off the engine an d 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

The high -pressure lines may only be replaced by qualified staff. Any impurity in the closed circuit rapidly deteriorates the transmission and hydrostatic pump.

IMPORTANT

The qualified staff performing maintenance on the hydraulic circuit must carefully clean the surrounding areas before carrying out any operation.

ENVIRONMENTAL

PROTECTION

Used oils should be handled and disposed of in compliance with national standards and regulations. Make sure there are authorised disposal sites.



C-3 MAINTENANCE ON THE PERKINS 1104D-44T ENGINE

C-3.1 Main engine components

Numbe r 1 Pulley 2 Alternator 3 Front lifting eyebolt 4 Water outlet 5 Valve gear cover 6 Rear lifting eyebolt 7 Air intake 8 Secondary fuel filter 9 Fuel injection pump 10 Oil filter 11 Crankshaft pulley 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

C-3.2 Engine identification All Perkins engines are identified by a serial number. This number appears on the serial number data plate attached to the left side of the engine block, near the rear of the engine.

IMPORTANT

To order spare parts, Mecano Continental S.A may need the data plate number to determine which components are included in the engine.



Number

1 Data plate 2 Temporary Parts List number 3 List number 4 Serial number 5 Type

C-3.3 Inspection of the engine alternator Inspect the alternator to check that there are no loose connections or that the battery is properly charged. To check that the battery is properly charged, start the forklift and turn the battery cut-off device. If the alternator is working correctly, the forklift should not stop.

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 the engine is only run for short periods, the batteries may not fully charge. A battery with a low charge freezes more easily than a battery with a full charge.

WARNING

If the batteries are properly charged, the ammeter reading should be very near zero. (0 A)

C-3.4 Inspection of the alternator belt The belt will be inspected and replaced with the engine stopped. Check that the belt tension is correct. To properly check the belt tension, use a Burroughs gauge. To maximise the engine performance, inspect the belt for wear and/or cracking (1). Replace the belt if it is worn or damaged as follows: -If the belt (1) has more than four cracks per 25.4mm (1 inch), it must be replaced. -Inspect the belt for cracks, tears, glazing, grease and splitting.


Check the belt tension every 50 service hours or weekly

ALTERNATOR



C-3.5 Instructions for replacing the belt: To replace the alternator belt or check belt tension, follow the instructions given below: -Fit the gauge as indicated in the following diagram (1) at the centre of the longest free length and check the 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.

C-3.6 Changing the coolant

HAZARD To change the coolant, make sure the vehicle is on level ground, the cooling circuit is not pressurise d and the temperature is adequate. Then follow the instructions below for draining: -Stop the engine and allow to cool. Remove the filler cap at the top of the cooling system.

-Remove the drain plug from the side of the engine block to drain the engine. Make sure the drain hole is not blocked. -Open the drain valve or remove the drain plug (1) from the engine. If the radiator does not have a tap or a drain plug, disconnect the hose at the bottom of the radiator.

-If the system is dirty or contains stagnant water, flush the cooling system with clean water. -Close the radiator drain tap. Connect the radiator hose if this was removed.


Change coolant every 2000 service hours or 2 years

HAZARD

Do not drain the coolant while the engine is still hot and the system is under pressure because dangerous hot coolant could be discharged.



-Fill the system with an approved antifreeze mixture. The maximum fill rate 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 vary. Check the level again after running the engine for a few hours.

C-3.7 Checking the coolant level

HAZARD

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. Check the coolant level only when the engine is stopped and cool. 1) Slowly remove the cooling system filler cap to relieve the pressure. 2) Fill the coolant level to within 13 mm of the bottom of the filler pipe. If the engine has a sight gauge, fill the coolant to the proper level on the sight gauge.

3) Clean the cooling system filler cap and check its condition. Replace the cap if the gaskets are damaged. Refit the filler cap. 4) Inspect the cooling system for leaks.

WARNING

Fill the cooling system on level ground with the engine cold.

C-3.8 Replacing the air filter

IMPORTANT

Never run the engine without an air filter element fitted or with a damaged air filter. Do not use air filter elements with damaged pleats or gaskets. Dir t entering the engine causes damage to components and wear.

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.

AIR FILTER




Clean the filter daily or every 8 hours Change every year or every 1000 service hours

Also: -Check the pre-filter (if fitted) and the dirt cup daily for accumulation of dust or dirt. Remove the dust and dirt as required.

WARNING

Depending on the operating conditions (dust, dirt and particles), more frequent maintenance of the air filter element may be required.

-This replacement should be performed regardless of the number of cleanings.

Follow the instructions given below to change the air filter: 1) Release the 3 fasteners and remove the cover. Remove the air filter. 2) Cover the air inlet with tape in order to keep dirt out. 3) Clean the inside of the air filter cover and body with a clean, dry cloth. 4) Remove the tape from the air inlet. Install the secondary element. Install a new or clean primary element. 5) Install the air filter cover every time the dirty air filter elements are replaced with clean elements or proceed 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.

C-3.9 Cleaning the air filter The primary element must be replaced at least once a year. This replacement should be performed regardless of the number of cleanings. Instructions for cleaning the air filter are given below.

WARNING

Do not tap or strike the air filter element. Do not wash the primary air filter element.

IMPORTANT

Visually inspect the filter before cleaning for damage to the gasket and the outer cover. Discard any damaged air filter elements.

There are two common methods for cleaning primary air filter elements:

HAZARD

Compressed air can cause pers onal injury. Use a mask and protective clothing when using compressed air. The maximum air pressure in the nozzle must be below 207 kPa for cleaning purposes.

Compressed air Compressed air can be used to clean filters that have not been cleaned more than two times. Compressed air will not remove deposits of carbon and oil. Use filtered, dry air with a maximum pressure of 207 kPa (2.07 bar).



When the primary element is cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Aim the hose so that the air flows inside the element along the filter in order not to damage the paper pleats. Do not aim jets of air directly at the primary air filter element. Dirt could be forced into the pleats. Vacuum cleaning Vacuum cleaning is a good method for cleaning primary filter elements that require daily cleaning because of a dry, dusty environment. Cleaning with compressed air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.

C-3.10 Engine oil level. Check

HAZARD

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to touch the skin.

To inspect the oil level: -Maintain the oil level between the MIN mark (Y) and the MAX mark (X) on the engine oil dipstick. Do not fill the oil pan above the MAX mark (X).

C-3.11 Changing the engine lubricating oil

HAZARD

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 th e 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 suspended in the oil to be drained properly. Failure to follow this recommended procedure will cause the waste particles to be recirculated through the engine lubrication system with the new oil. The oil pan drain plug is shown below.


Change the engine lubricating oil every 500 service hours



IMPORTANT

Drain the oil when the oil is warm and the contaminants are suspended and not settled in the oil pan.

Use one of the following methods to drain the oil from the engine oil pan: -If the engine is equipped with a drain valve, turn the 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 engine is equipped with a shallow oil pan, remove the bottom oil drain plugs from the ends of the oil pan. -After draining the oil, the oil drain plugs must be cleaned and refitted. It is necessary to replace the gasket on the drain plug to prevent oil leaks.

C-3.12 Changing the engine oil filter Follow the recommendations given below to replace the filter properly: 1) Remove the oil filter using a suitable tool. 2) Clean the sealing surface of the oil filter. Make sure the union on the oil filter head is secure. 3) Apply clean engine oil to the oil filter seal. Do not fill the oil filters before installing them as this oil would not be filtered and could be contaminated.

4) Install the oil filter.

IMPORTANT

Tighten the oil filter by hand (do not use tools) according to the instructions given on the oil filt er. Do not over-tighten.


Change engine oil filters every 500 service hours

ENVIRONMENTAL

PROTECTION

Used filter waste should be handled by companies authorised for this purpose according to the country where the forklift is located.

To fill the engine with oil 1) Remove the engine oil filler cap. 2) Start the engine and run at “low idle” for two minutes. Perform this procedure in order to ensure that the lubrication system has oil and the oil filters are filled. Inspect the filters for leaks. 3) Stop the engine and allow the oil to drain back into 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. The fuel injectors should not be cleaned as cleaning with incorrect tools can damage the nozzles. Only specialised staff must clean the injectors.



The fuel injectors should only be renewed if a fault occurs or if a specialised injection system technician orders their renewal. Some of the problems that may indicate that new fuel injectors are needed are listed below: -The engine does not start or it is difficult to start. -It does not have enough power. -The engine misfires or runs erratically. -High fuel consumption.

-Black exhaust smoke. -The engine knocks or there is vibration in the engine. -Excessive engine temperature.

C-3.14 Priming the fuel system If air enters the fuel system, the air must be purged from the fuel system before starting the engine. Air can enter the fuel system when the following conditions occur: -The fuel tank is empty or partially drained. -The low-pressure fuel lines are disconnected or break. -There is a leak in the low-pressure fuel system. -The fuel filter is replaced. -A new injection pump has been installed. Use the following procedure to purge air from the fuel system: -Remove the fuel injector cover. -Turn the ignition key to the ON position. Leave the key switch in the ON position for three minutes. -Turn the ignition key to the OFF position.

-Loosen the flare nuts (1) on the high-pressure fuel lines on all fuel injectors. -Observe the flare nut connection. Operate the starter motor and run the engine until the air is removed from the fuel. -Tighten the flare nuts (1) to a torque of 30 N.m. -Start the engine.

HAZARD

The fuel injection pump, battery and starter motor can be damaged if the starter motor is used excessively to bleed or purge air from the fuel system.

C-3.15 Changing the primary fuel filter The Perkins engine fuel filter is located on the right side of the engine.

WARNING Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire. To prevent possible accidents, turn the start switch to the off position when preparing to change fuel filters or water separator elements. Clean up fuel spills and the area around the fuel system component to be disconnected immediately. Do not allow dirt to enter the fuel system.



Number 1 Screw 2 Element 3 Bowl 4 Bottom cover 5 Drain 6 Sensor connections

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.

c) Open the drain (5). d) Tighten the drain (5) by hand pressure only. e) Hold the element (2) and remove the screw (1).

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.

WARNING

The seals must be properly seated to prevent fuel leaks or to prevent air entering.


Change primary fuel filter every 500 service hours

C-3.16 Changing the secondary fuel filter

WARNING Fuel leaked or spilled onto hot surfaces or electri cal components can cause a fire.

a) Close the fuel supply valves (if installed). b) Clean the outside of the filter assembly. Open

the fuel drain (2) and drain the fuel into a suitable container.



c) Remove the filter bowl (1) from the filter head (3). Apply pressure to the element (4). Turn the element to the left to release it from the filter bowl and remove the element from the bowl. Dispose of the used element.

d) Remove the seal (5) from the filter bowl and clean the bowl. Check that the filter bowl threads are not damaged.

e) Fit a new seal (5) onto the filter bowl (1). f) Install the filter bowl (1) into the top of the filter

head (3). g) Tighten the filter bowl by hand until the bowl

makes contact with the filter head. Turn the filter bowl 90 degrees.

WARNING

Do not use any tools to tighten the filter bowl.

h) Open the fuel supply valves (if installed).


Change secondary fuel filter every 500 service hours

C-4 HYDROSTATIC SYSTEM MAINTENANCE

Regular maintenance operations for the forklift's hydraulic installation include: A) Checking and filling the hydraulic oil level as necessary B) Cleaning and maintaining the radiating surfaces. C) Changing the hydrostatic filters. D) Changing the hydraulic oil.

WARNING

Extraordinary maintenance operations are usually necessary as a result of forklift component malfunction.

Extraordinary maintenance also includes: -Adjusting and regulating the pump during the initial start-up. -Disassembling and reassembling the pump and the engine, or parts thereof.

The following is recommended to ensure that the hydrostatic system is in good condition: -Carrying out all operations in a clean, dust-free environment so that no foreign particles enter the components. -Covering all pressure inlets with plastic plugs as soon as the hydraulic lines are disconnected. -Replacing the seals every time the components are opened. We therefore recommend having several seal kits to hand before working on the components.

WARNING

The main tenance intervals for filter and oil changes stated in this manual must be complied with in order for the guarantee to remain valid.

C-4.1 Changing the hydrostatic pump's hydraulic oil filter The frequency of filter maintenance and replacement depends on the pump's rotation rate, the type of fluid used, the pump's starting and operating temperatures and accidental or systematic contamination in the forklift.

WARNING

It is very important to change the hydraulic oil fi lter after the first 50 hours of op eration. If it is not changed, the supplier's guarantee will be lost in the event of any breakdown.

Under normal operating conditions, the hydraulic oil filters should be replaced:


Change hydrostatic oil filter after the first 50 hours

every 500 hours

During maintenance cycles, avoid contaminating the intake circuit whenever the filter cartridge is changed. Use the hydraulic oil recommended by Mecano Continental S.A that contains additives, according to viscosity grade ISO VG 46. Also always use original MAST EXPLORER hydraulic filters.



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 oil or mechanical elements.

WARNING

It is necessary for the main connection operations to be carried out in a clean, dust-free environment with any type of dirt that could enter the circuit being immediately removed.

To guarantee that the operating temperature of the hydraulic system remains within the permissible limits, the condition and cleanliness of the oil-air heat exchanger installed on the forklift must be checked.

After changing any mechanical element or oil, follow the instructions given below: Before starting the forklift -Check the cleanliness of all the parts of the installation that come into contact with the circuit's hydraulic fluid (tank, tubes, heat exchangers, filters, etc.). -Make sure nothing is blocking the pump's normal intake and check for loose connections that could cause air to 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, two for high pressure (400 bar) and one for the supply pressure (10-30 bar). Filling the hydraulic tank

IMPORTANT

Before filling the tank, check that it is clean and with no signs of residue, particles, rust, etc. inside.

IMPORTANT

Use a 10-micron filter when filling the hydraulic fluid to prevent foreign bodies from entering the installation.

Even new oil may contain impurities. Also fill the tank and all other large-capacity components with fluid (filters, heat exchangers). Fill the hydraulic pump and motor with oil via one of the drain ports and make sure the casing is at least 50% full.

HAZARD

Do not run the engine and the hydraulic pump before filling. The components may be seriously damaged.

On starting the forklift The vehicle must be started and all of the air present in the hydraulic circuit eliminated before said circuit is used to lift heavy loads.

To do this, with the emergency stop connected (the forklift will not be able to start), keep the engine turning over with only the starter motor (at less than 500 rpm) until the entire circuit has filled with oil (this operation tends to require two or three start phases lasting some 5 seconds each).

IMPORTANT

Make sure the pump is set to the zero displacement position (the gear stick must be in 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).



-Run the pump in both directions and make sure the direction of rotation of the driven parts is correct. -Run the transmission until you are sure that all air has been eliminated and there is no mixture of air and oil. This usually takes a few minutes. -Increase the rotation speed and check that the pressure in the loading circuit reaches 18-20 bar and that the depression on the intake line pressure gauge does not exceed values of 0.5 bar with cold oil and 0.2 bar with hot oil. -Gradually increase the load, monitoring the maximum 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. Checking the hydrostatic pump performance To check the pump's performance, install one pressure gauge (up to 60 bar) at the supply pressure intake and another (up to 600 bar) at the high-pressure intake.

Always pay maximum attention to moving parts and comply with all current safety standards.

HAZARD

Carry out this test in the shortest time possible t o avoid overheating the pump and the installation.

For closed circuit pumps, make sure the external maximum pressure relief valve is correctly attached to 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 pressure of the pump. -Turn the pump at 1200 rpm with zero displacement; with the oil at around 50ºC, check that the supply pressure is around 18-20 bar.

-Slightly increase the pump displacement; check that the supply pressure does not suddenly drop and the operating pressure is the same as the rating pressure of the maximum pressure relief valves. -If the supply pressure suddenly drops and the pump does not open the maximum pressure relief valves, the wear and internal play of the components have probably reached such a level that the component needs overhauling or replacing.

C-4.3 Hydrostatic regulation and pressure measurement

HAZARD

Any modification to the hydrostatic pump must be communicated to and authorised by the Mecano Continental, S.A. Technical Support Department.

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 transmission. If possible, the forklift should be repaired on site at its current location. If there is no other option but to tow it, the following instructions must be followed:

IMPORTANT The H50/60 4WD models cannot be towed as they have a negative brake on the front differential and it is preferable for the forklift to be repaired on si te.

IMPORTANT

For the H50/60 2WD models, the following operations should be carried out.



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.

Method two: Loosen the high-pressure valves B and B' by 3 or 4 turns.

C-5 ELECTRICAL SYSTEM MAINTENANCE

HAZARD

All m aintenance work on the electrical system must be carried out with the engine off, the parkin g 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. -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.



-To disconnect the battery, first disconnect the negative terminal (-) from the earthing point. -To connect the battery, first connect the positive terminal (+). -Recharge the battery away from the forklift in a well-ventilated area. -Never approach with objects that could produce sparks or open flames or cigarettes. -Avoid placing metal objects on top of the battery. This could cause dangerous short circuits, especially during recharging. -Given that the electrolyte is highly corrosive, avoid any contact with the forklift chassis or with electrical or electronic components. If this does occur, contact an authorised support centre.

ELECTRICAL

HAZARD

There is a risk of the battery exploding or short circuiting. An explosive mixture of hydrogen gas forms when recharging the battery.

HAZARD

The battery electrolyte contains caustic sulphuric acid. If it contacts the skin, immediately wash off with soap and plenty of water. If the acid contacts the eyes, 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.

IMPORTANT

Do not use fuses with a higher amperage than indicated as this may damage the electrical installation.

FUSE No. NAME AMPERAGE (A)

1 Rotating beacon

15

2 Windscreen wiper 25

3 Hour meter 5

4 Forward drive/reverse 10

5 Full-beam headlights 15

6 Dipped headlights 15

7 Right rear light 7.5

8 Left rear light 7.5

9 Indicators 10

10 Horn 10

11 Engine heater 30

12 Battery charge indicator 7.5

13 Gear stick 10

14 Fuel level 15

15 Work light 15

16 Negative brake 15

17 Service brake 10

18 Forward drive 5

19 Reverse 5

20 Heating 25

21 General fuse (large) 50



C-6 TRANSMISSION SYSTEM MAINTENANCE. GREASING THE FORKLIFT.


Grease axles, mast and mast pins every 30 days or 200 service hours

The rear axle, mast, tilt cylinder linkage, mast pins and other elements requiring lubrication must be greased as shown in the following figures using adequate amounts of grease. Greasing the rear axle: the axle has two grease points per wheel as shown in the following diagram:

Rear axle grease points on H50/60DA:

WARNING

The rear axle has 2 grease points per wheel and the front axle has no grease points as it is a live axle


Grease the 2 grease points every 30 days of operation

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.

WARNING

All hinges, fork heads and other articulations must be lubricated prior to use as required.



C-8 MAST MAINTENANCE AND GREASING

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

There may be slight differences between the photos shown belo w and your specific mast depending on whether your forklift has a duplex or triplex mast.

Details on each area are given below:

Area A

Below is a close-up of elements 1, 3 and 5:

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:



Area C Points 1, 2, 3 and 4

Point 4 is on the lower face:

Area D

We must also consider the two grease points on the tilt cylinder linkage and the mast pins as shown below:

Checking the mast chains:


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

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.



C-9 TYRE PRESSURE

The air pressure used has a direct effect on the tyre's service life. The tyre pressure must be checked every 100 service hours when the forklift is unloaded. Check that the tyre pressure complies with the following table:


Check the pressure every 100 service hours

Model Tyre Pressur

e H50/60 (2WD and 4WD)

Rear 400x60-15.5 4 bar

H50/60 (2WD and 4WD)

Front 16x70-16.5 4.5 bar

IMPORTANT

If the tyre pressure is wrong, correct as soon as possible to prevent hazards. Operating a forklift truck with low tyre pressure will have the following effect on the tyres: -Excessive flexing. -Overheating. -Excessive strain on fabric. -Bulging of sidewalls. This results in damaged sidewalls and stretched individual strands of fabric.

IMPORTANT

A high pressure is dangerous as it transmits excessive tensile strain to the fabric and the tyre is therefore susceptible to punctures and cuts.

Take the following precautions when servicing the tyres: -Always stand to the side of the tyre so you are shielded by the vehicle to protect yourself against possible explosions. -On filling a tyre on a split-rim wheel, check exactly if the loose ring pieces are in the right position as a ring flying off the rim may cause fatal injuries. -Use a safety nozzle (that you do not have to hold manually) with a hose that is long enough for you to stand outside the danger zone when filling the tyre. -Never cut or solder a rim if the tyre contains pressurised air. -Never assemble rim pieces of different sizes and never use damaged or faulty pieces. See the service manual for authorised tyre and rim sizes. Do not fit tyres with a different tread. -Remove the air before removing foreign bodies from the tyre. -Put the valve dust caps back on after checking or filling the tyres. -For special operations, for example on sandy terrain, the air pressure can be modified after consulting the after-sales department or the tyre manufacturer. C-10 TIGHTENING OF WHEEL BOLTS


Check bolt torque every 50 service hours

Tighten all wheel bolts daily during the first week of operation.



IMPORTANT

The tightening torque is 270 N·m for the front differential, 270 N·m for the rear differe ntial on the 4WD model and 300 N·m for the rear axle on the 2WD model.

Wheel nuts must also be tightened daily after each wheel change during the first week of operation.

C-11 TECHNICAL SPECIFICATIONS OF FORKLIFT FLUIDS

The following table shows the fluids used in the forklift:

LIST OF LUBRICANTS USED

LUBRICANTS TYPE

Engine oil ISO 10W-40

Hydraulic oil ISO VG 46

Chains Chain spray

Mast Extreme -pressure adhesive

grease

Fuel Diesel

Differential carrier oil SAE 75W-80, API GL-4

Differential oil SAE 75W-80, API GL-4

Brake fluid LHM Super mineral oil

Grease points

Lithium soap -based grease (DIN 51825-KPF2 N-20

Penetration grade 2, lithium soap)

HYDRAULIC OIL PROPERTIES 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 high viscosity index, the oil maintains a suitable viscosity throughout the forklift's entire operating temperature range. This oil complies with the following standards:

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 optimum performance of the mechanical parts present in the hydraulic circuits. It is also characterised by an extremely low freezing point and a very high viscosity index and can therefore be used without drawbacks over a wide temperature range.

Specification Typical values

Density at 15ºC (kg/l) 0.835

Kinematic viscosity -

-40ºC (cP) 1100

40ºC (cSt) 18.2

100ºC (cSt) 6.2

Viscosity index >300

Colour green

Flash point (OC) 125ºC

Pour point -60ºC

ANTIFREEZE Antifreeze is usually made of three elements: water, additives and glycol. We recommend using an antifreeze with a minimum concentration of 50% in engine cooling systems.

APPLY TORQUE IN A CRISS -CROSS PATTERN



IMPORTANT

Do not use the following types of water in cooling systems: Hard water, soft water that has been softened with salt and seawater.

Many engine failures are a result of the cooling system. The condition of the coolant is also important for it to do its job properly. Never work on an engine without a thermostat in the cooling system. Thermostats help keep the engine coolant at the right operating temperature. The coolant's glycol content helps protect against boiling over, freezing and water pump cavitation. A 1:1 mixture of water and glycol is used.

C-12 MAINTENANCE PROGRAMME FOR THE PERKINS 1104D-44T SERIES ENGINE

WARNING

Before performing any maintenance work or procedure, make sure you have read and understood all the safety information, warnings and instructions.

The following programmes must be performed according to the interval that comes first: PERKINS maintenance programme

When required Daily or every 8 service hours Every 50 service hours or weekly Every 500 service hours Every 500 service hours or year Every 1000 service hours Every 2000 service hours Every 3000 service hours Every 3000 service hours or 2 years Every 4000 service hours Every 12,000 service hours or 6 years

KEY FOR FOLLOWING TABLE

The preventive maintenance intervals are indicated for normal operating conditions. When engine performance must be adjusted to local standards, it may be necessary to adapt the maintenance intervals and procedures to guarantee correct engine performance. As part of good preventive maintenance, look for leaks or loose fasteners during each check.

When required Replace the battery Disconnect the battery or battery cable Clean the engine Clean or replace the air filter Prime the fuel system

Daily Check th e coolant level Clean the air filter Check the oil level Drain the primary fuel filter or water separator Inspect belts Walk-around inspection of engine

Every 50 service hours or weekly Drain fuel tank water or sediment

Every 250 service hours Adj ust, inspect or replace the alternator belt

Every 500 service hours or year Check the battery condition Check the condition of the engine breather Clean or replace the engine air filter Replace the primary fuel filter Change engine oil and oil filter Replace the secondary fuel filter Inspect hoses and clamps Clean the radiator

Every 1000 service hours Inspect the engine valve lash

Every 2000 service hours Inspect the aftercooler core Inspect the alternator Inspect the engine mounts Inspect t he starter motor Inspect the turbocharger Inspect the water pump

Every 3000 service hours Inspect, adjust or replace the alternator belt Test or change the injectors

Every 3000 service hours or 2 years Change the cooling system coolant

Every 4000 s ervice hours Clean and test the fan core

Every 12,000 service hours or 6 years Change the cooling system coolant



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 ELECTRIC AL SYSTEM D-11 PERSONAL PROTECTION



D-1 GENERAL OBSERVATIONS

This forklift has been designed in accordance with the provisions of section 1.1.2 “Principles of safety integration” of point 1 “Essential health and safety requirements” of annex I of Directive 2006/42/EC on the approximation of the laws of Member states relating to machinery. Most accidents involving forklifts and their maintenance or repair are the result of not complying with the most basic safety precautions. It is therefore necessary to always be aware of potential risks that could arise as a result of operating the forklifts, paying constant attention to the effects that each action performed could have.

IMPORTANT

Being aware of potentially dangerous sit uations could prevent an accident.

D-2 CONDITIONS TO BE MET BY OPERATORS

The person that usually operates the forklift must meet the following conditions: Medical: Before operating the forklift and during operation, the operator must not consume alcoholic beverages, drugs or other substances that could impair his or her psychological and physical condition and consequently the ability to drive the forklift. Physical: The operator must have good eyesight, good hearing, good coordination and the ability to safely perform the functions needed to operate the forklift as specified in this manual. Mental: The ability to understand and apply established safety standards, rules and precautions. The operator must be alert and use good judgement for his or her own safety and that of others and must make every effort to do the work correctly and responsibly. Training: The operator must have carefully read and studied this manual, the attached charts and diagrams and the warning and hazard stickers. He or she must be specialised and competent in all aspects regarding operation and use of the forklift.

D-3 RESIDUAL RISKS

Although Mecano Continental S.A has made every possible effort to ensure this forklift's safety by way of its design and manufacture, it considers that residual risks may occur as a result of the operator's actions during operation. Some examples are given below: -Risks due to working or driving too fast for the loading conditions or the area of operation.

-Risks due to using incorrect methods for checking or replacing a hydraulic valve (residual pressure not discharged – uncontrolled movements).

-Risks due to using incorrect methods for disassembling parts, such as cylinders without having secured moving parts correctly (risk of the moving part accidentally falling).

-Risks due to the forklift accidentally overturning without the operator using the seat belt.

D-4 NOISE EMISSIONS AND VIBRATIONS

All MAST EXPLORER forklifts have a guaranteed sound power level according to Directive 2000/14/EC of the European Parliament and of the Council on the approximation of the laws of the Member States relating to the noise emission in the environment by equipment for use outdoors. In accordance with the provisions of EN 12053 and EN-ISO 4871, the sound pressure level reaching the driving seat, for a complete operational cycle, does not exceed the 80 dB limit established by applicable legislation.

WARNING

Noise measurements have been taken under the following operating conditions: idling, lifting and movement.

The vibration level to which the operator's body is exposed has been measured using representative and technically comparable forklifts as indicated in EN 14253:2004, Royal Decree 1311/2005 and Royal Decree 1311/2005 Technical Guidelines in order to minimise risks for the operator. These measurements have been taken by an authorised control body with the forklift in motion and values not exceeding 0.74 have been obtained.



IMPORTANT

Any arbitrary modification to the forklift causes the sound power values to vary.

D-5 DESCRIPTION AND SAFETY DEVICES

All MAST EXPLORER forklifts have all of the means necessary to guarantee their safe use. In designing these forklifts, all possible risks have been taken into account. As such, covers and guards have been fitted to protect the operator from any hazards that may be encountered during operation of the forklift, such as becoming trapped in the engines and moving parts of the transmission, electrical system, etc.

HAZARD

If the safe ty 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. Emergency stop: the emergency stop is located on the right-hand side of the driver, next to the hydraulic joystick. It automatically brings the engine to a halt in the event of an emergency or problem. On those vehicles fitted with a negative brake, this will come on when the emergency stop button is pushed.

WARNING

If the emergency stop button is pushed, the engine will not start.

Safety cabin: this robust element protects the driver in the event of the load falling off the forks or the forklift overturning. Fork carriage: this is a rigid element located on the front of the mast which moves along with the load platform. It increases the support surface of the loads, preventing them from falling on top of the operator. Bonnet: protects the engine from any unauthorised 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.

Acoustic warning alarm: when the forklift is moving in reverse, an audible signal is activated. Seat belt: located on the seat and worn by the operator.

HAZARD

Wearing the seat belt is compulsory to prevent injury in the event of an accident.

Key: locking device that prevents any unauthorised persons from using the vehicle.



D-6 SAFETY RECOMMENDATIONS

The driver of any motorised industrial forklift must be at least 18 years of age and be expressly assigned by the company.

IMPORTANT

Make sure that new operators are trained, monitored and assisted by expert staff who are qualified to operate forklifts.

Nobody who fails to meet these requirements should be allowed to drive an industrial forklift truck.

IMPORTANT

The dri ver 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 listed below: -Never exceed the forklift's load capacity. Failure to follow this rule may cause the vehicle to overturn, risking injury to both the driver and to his or her colleagues. See load diagrams on the forklift for this purpose.

-Do not, under any circumstances, increase the weight of the counterweight by adding additional loads, especially not by having people climb onto the vehicle. If the load capacity of the forklift is never exceeded, resorting to such tricks will never be necessary. -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 should only be attempted in exceptional circumstances and under the supervision of the head maintenance technician. -To lift a load safely, fully insert the forks underneath the load , lift the load slightly and immediately tilt the mast backwards. -Before driving, check that the load is balanced an d 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.

-Before undertaking any manoeuvre, check that there is nobody in the immediate vicinity of the forklift , especially when reversing. -When raising or lowering the forks, the driver must make sure his or her hands or feet, or those of any colleague, cannot become trapped.

-Do not point the forks towards people working close to walls or boxes.



-Nobody should stand or walk under the raised forks, even when the vehicle is unladen. -Never leave the forklift with a raised load.

D-7 RULES ON DRIVING THE FORKLIFT

-Do not allow yourself to become distracted from the task of driving. -Look in the direction in which the vehicle is moving, maintaining good visibility at all times. -Drive at a reasonable speed. -Avoid accelerating, changing direction or stopping suddenly. -Take all turns at a low speed, using the horn to warn anyone nearby. -Indicate each manoeuvre that is to be carried out with sufficient advance warning. -Use the horn when approaching bridges, crossroads, pedestrians, animals, etc.

IMPORTANT

If the size of the load prevents good forward visibility, the driver should proceed in reverse.

-Drive slowly over any wet, slippery or uneven terrain. -Brake progressively, not sharply. -Respect the signs and driving rules established by the company. -Only follow the set routes. -The forklift truck must not be used to carry passengers. The driver will be held responsible for any consequences resulting from failing to obey this rule. -Do not drive with the load in the raised position since doing so would greatly decrease the stability of the vehicle. The load should always be carried in the lowest possible position.

-With platform forklifts, the vehicle should be driven with the load in front. The driver would then not be crushed in the event of a fall. -When driving with the vehicle unladen, the forks should 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.



-Stacks of material should be placed tidily and safely. If stacking reels, remember that they can roll around. Pay attention to where they are left and make sure they are secured using wedges. -Do not use the forklift to push other vehicles. If it is necessary to tow another vehicle, this must be done using a rigid bar at a very low speed. -Make sure that the combined weight of the forklift and the transported goods do not exceed the maximum capacity for the terrain. -Before driving onto walkways, platforms, gangways, etc., make sure that they can bear the weight of the vehicle. -When driving behind another vehicle, maintain a distance equal to approximately three times the length of the forklift. This will help prevent accidents in the event that the other vehicle needs to brake suddenly. -When passing through narrow passages, the driver must take care that his or her head, arms and legs do not stick out past the width of the vehicle. -When tilting the forks or the backplate forwards, the stability of the vehicle is reduced. When it is necessary to put down a load using these mechanisms, do not lift it any higher than necessary and, when lowering, do so slowly. -Tin and sheet metal bundles can break and shoot out at nearby co-workers. Avoid accelerating or braking sharply, as well as turning at speed. -If during the course of a job it is necessary to stop, unless said stop is for a very short period of time, the engine should always be turned off.

D-8 AT THE END OF THE DAY

-At the end of the working day, the forklift should be parked in the place specifically set aside for this purpose, where it will be protected from the elements. -When parking the forklift, the engine will be switched off, the parking brake applied, the battery disconnected and the key removed from the ignition. -The forks should be left in the lowest possible position resting on the ground. -The forklift should always be parked on level ground. If for any exceptional reason it is necessary to leave it parked on a slope, the wheels must be carefully blocked using wedges and the parking brake applied.

-The driver must not make any repairs or adjustments to the forklift. Any anomaly observed during work, no matter how small, must be duly reported to a senior member of staff. -The operator must never stand between the mast and the overhead guard of the forklift. If it is necessary to do so, lock all controls to prevent any unexpected movement of the mast.

D-9 GENERAL SAFETY MEASURES REGARDING THE ENGINE

This section indicates the basic safety precautions that must be followed. Read and make sure you fully understand the basic precautions that appear in this section before operating, lubricating, carrying out maintenance on or repairing this product. The operator in charge of engine maintenance must observe the following safety recommendations: -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. -Do not wear any clothing or jewellery that could become trapped in or wrapped around the controls or any parts of the engine. -Make sure that all guards and covers are correctly fitted on the engine. -Keep the engine free from foreign materials. Remove any rubbish, oil, tools and other items from the walkways and from the steps. -Never store maintenance fluids in glass containers. Drain all liquids into a suitable container. -Do not disassemble any component or part of the hydraulic system without having first released the pressure from the system. Failure to do so could result in injury.



-Do not touch any part of the engine whilst it is running. Allow the engine to cool before carrying out any 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 servicing the batteries. Wash your hands after touching the batteries or the connectors. The use of gloves is recommended.

-Do not smoke whilst filling the fuel tank. -Do not carry out any welding on pipes or tanks that contain flammable liquids. -Do not bend pressurised pipes. Do not hit pressurised pipes. Do not install pipes that are bent or damaged. -Do not place any objects near the moving fan blades. The fan blades will launch or cut any objects that touch them. Wear protective goggles to prevent possible eye injuries caused by flying objects. -Clean up any spilled fuel. -Any materials that have been splashed with fuel should be set aside at a safe distance. -While running, the engine cannot be cleaned or 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. -Keep other people at a safe distance whilst either the engine or any auxiliary equipment is running. -Keep loose clothing and long hair away from moving parts.

-Keep away from moving parts when the engine is running.

IMPORTANT

Some moving parts are not visible when the engine is running.

-Do not start the engine if any of the safety guards have been removed. -Do not remove the filler cap or any component of the cooling system whilst the engine is hot and the coolant is under pressure. Doing so could cause dangerous hot coolant to overflow. -Do not allow any sparks or naked flames in the vicinity of the batteries (especially during the battery recharging process). The gases given off by the electrolyte are highly flammable. The battery fluid is harmful to the skin and especially to the eyes. -There should only be one person at the engine controls. -Make sure that the engine is only controlled from the control panel or from the operator's seat. -If the pressurised fuel comes into contact with anyone's skin, seek medical attention immediately. -Fuel and oil (especially used oil) can be harmful to some people's skin. Wear protective gloves or use a special protective solution for the skin.

HAZARD

Before working on pressurised lines (hydraulic oil, compressed air) and/or disconnecting hydraulic elements, make sure the line is not pressurised and no longer contains hot fluid.

-Do not wear clothing that has been stained with lubricant. Do not put materials that have been stained with oil in your pockets.



-Dispose of used lubricant in accordance with local environmental pollution regulations. -The material used to make some of the engine components (some of the seals, for example) can be extremely dangerous if burned. Never allow this burnt material to come into contact with skin or eyes. -Make sure that the transmission control lever is in the neutral position before starting the engine. -Take extreme care when carrying out emergency repairs in adverse conditions. -Do not allow compressed air to come into contact with skin. If compressed air breaks the surface of your skin, seek immediate medical attention.

WARNING

Do not cl ean the engine whilst it is running. If cold cleaning fluids ar e applied to a hot engine, some engine components can become damaged.

D-10 GENERAL SAFETY MEASURES REGARDING THE ELECTRICAL SYSTEM

-Work on the electrical system should only be carried out by specialised personnel with suitable work and verification methods. -Stop the engine before working on the electrical system. -All wires and plugs should be marked up before being disconnected and must be protected against making contact with metal parts, by fitting them with protective caps or taping them with insulation tape, for example. -Any defects in the electrical installation (broken insulation, for example) must be repaired immediately. -The battery's negative (-) cable must always be disconnected before starting any cleaning operation. It is not enough to simply turn off the battery's cut-off switch. -If it is necessary to clean the interior of the cabin with water or water-soluble detergents, it is important to take special care not to damage the electronics system. Use only authorised solvents. Avoid breathing in the fumes from any thinners used. -After the cleaning operation, make sure all electrical components are completely dry before reconnecting the battery.

-The electrical conductors must be protected against wear and should be checked regularly for damage; change as required. -Unprotected electrical conductors should not be allowed to rest on pipes containing oil or brake fluid.

D-11 PERSONAL PROTECTION

All forklift truck drivers must be provided with the following personal protective equipment: Protective helmet, compulsory when the operator's cabin does not feature an overhead guard. In any case, it is essential that all drivers have a helmet for use outside the forklift. Non-slip safety boots , with reinforced toecap. Safety gloves . Although not necessary for driving, they should be available for use in any possible emergency and for handling materials. Work clothes . Forklift truck drivers should not wear any loose clothing that could get trapped in or around the moving parts of the vehicle. Ear protectors . When the noise level exceeds the established safety margin and in any case when it is above 80 dB (A), the use of earphones or earplugs will be compulsory. The forklift is not designed for working with hazardous materials such as explosives, toxic, flammable or harmful substances, nor for working in explosive environments or in bad weather. It is therefore prohibited to use the vehicle in environments containing flammable or explosive materials.

IMPORTANT

The service life of the fork lift is estimated at 6 years, after which time the vehicle should either b e decommissioned or MECANO CONTINENTAL, S.A. should be asked to carry out a thorough inspection.

IMPORTANT

MECANO CONTINENTAL, S.A. will not be held responsible for improper use of the forklift, whatever the circumstances.



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



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 m ust 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

The forklift runs OK in one direction but does nut run properly in the other direction

-blown fuse -gear stick not sending signal to change direction -electro-valve not working

-change fuse -change electro-valve -check hydraulic circuit pressures

The forklift will not go in either direction but the engine will start

-engine coupling to the hydrostatic pump broken -negative parking brake on -driver not in seat -fuses, gear stick

-check engine coupling -take off parking brake

The forklift will not go in either direction and will not rotate or pick up loads

-engine coupling defect -check nylon flywheel coupling between engine and pump

The forklift moves without touching the accelerator

-the forklift is cold -engine unbalance

-wait until the working temperature is reached -adjust engine revolutions to 900 to 950 rpm -adjust hydrostatic pump starting point

The forklift has no power -hydrostatic pump filter blocked -change filter

The forklift is losing power when hot -degraded oil -change oil -check fuses -check operating pressures

The forklift won't go into 2nd gear -electro-valve error -insufficient pressure

-check gear stick -check electro-valve -check minimum pump pressure

The forklift won't turn Swap the gear pump outlets to check operation. If the forklift then turns, the problem is the gear pump and if it still does not turn, change the steering unit.

The steering is stiff -priority vale not regulated -pump is damaged

-change pump -regulate valve



E-2.2 Electrics


The hour meter is not working -blown fuse, short circuit in wire, alternator

Check fuses and alternator charge

The indicators, headlights and horn are not working

-no power reaching them -poor connections

-check fuses, connections or horn -if there is power, replace bulbs

E-2.3 Brakes


The brakes don't work and the pedal goes to the floor

-no brake fluid in the tank -no pressure to the pump

-fill tank -bleed circuit to expel air -change seals -change pump

E-2.4 Mast


The load isn't lifted -oil temperature above 90ºC -distributor not regulated -gear pump

-check thermostat and thermostat fuse to see if fan comes on -regulate distributor -check gear pump

The engine stalls on touching the mast

-inadequate temperature -low idle -distributor not regulated -gear pump

-regulate distributor -wait for temperature to rise -adjust starting point

The mast does not go up or tilt -the levers are not working -no pressure to distributor

-change levers -change gear pump

The 4th valve is not working -no current reaching electro-valve

-check lever -change distributor -change gear pump

The load is automatically lowered -leaks in distributor or lines -faulty lifting cylinder

-resolve hydraulic leaks -raise cylinders, close valve and wait to see if it drops; if it does, cylinders faulty



E-2.5 Engine


The engine doesn't start

-engine not turning over -no fuel reaching the pump -no fuel reaching the injectors -heaters

-check battery -check battery cut-off device -check starter motor -emergency stop on -check fuses -key cylinder -no fuel -heaters not receiving 12V

The engine starts with difficulty

-air getting into circuit -low fuel level -fuel filter blocked -pump error -injectors

-check circuit -add fuel -replace fuel filter -change hoses -change water separator (first hot-wire to check)

The engine has no power

-check air filters -check turbocharger -check valve setting -check fuel filter

Oil is coming out of the exhaust -oil level too high -adjust oil level -check turbocharger

Too much smoke is coming out of the exhaust

-poor fuel quality -oil level too high -fuel pump damaged

-check oil level -check air filters -check fuel quality -check pump

The engine cuts out after starting

-check fuel level -check for leaks in lines -check filters -check water separator -clean turbocharger



Section F

APPENDICES

CONTENTS

F-1 HYDRAULIC DIAGRAM H50/60 (2WD) F-2 HYDRAULIC DIAGRAM H50/60 (4WD)

F-3 TIGHTENING TORQUES F-4 LOAD DIAGRAMS F-5 MAINTENANCE REPORT TEMPLATES



F-1 HYDRAULIC DIAGRAM H50/60 (2WD)



F-2 HYDRAULIC DIAGRAM H50/60 (4WD)



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

D

(mm

)

P

(mm

)

Property class

8.8

Property class

9.8

Property class

10.9

Property class

12.9

Torqu

e (Nm)

Ten-

sion (N)

Torqu

e (Nm)

Ten-

sion (N)

Torqu

e (Nm)

Ten-

sion (N)

Torqu

e (Nm)

Ten-

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



ZINC-PLATED WHITWORTH SCREWS

Measurement Grade 2 Grade 5 Grade 8

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.



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).

FOR H50DA MODEL:

CG_Qe (mm)

X1

Y_Qe

XiCDG_Qe

CDG_Qi

Xe

CDG_Qm

Qe

Qi

Qm

+Y

+X

QM

CDG_QM

Load (kg)

Mast height 3300 mm Mast height 4300 mm Mast height 6000 mm



FOR H60DA MODEL:

F-5 MAINTENANCE REPORT TEMPLATES

CG_Qe (mm)

Mast height 3300 mm Mast height 4300 mm Mast height 6000 mm Load (kg)



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



200 AND 500-HOUR MAINTENANCE REPORT

Forklift ID Number:




Bumps Seal

Overhead guard Hydraulic in stallation




Noise Oil level

Clearances Filters




Oil level Radiator

Pump Belts

Motor Starter motor





Trave l controls Cylinder seal


Gear stick Greasing




Safety system Seal







Greasing Others






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






Forklift ID Number:


Chassi s check Brake system


Bumps Seal





Noise Oil level

Clearances Filters




Oil level Radiator

Pump Belts

Motor Starter motor


Wheels and bea rings Mast, carriage and forks





Gear stick Greasing




Safety system Seal







Greasing Others






Forklift ID Number:




Bumps Seal





Noise Oil level

Clearances Filters




Oil level Radiator

Pump Belts

Motor Starter motor







Gear stick Greasing




Safety system Seal


Horn and acoustic warning alarm Batter y





Greasing Others






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






Forklift ID Number:


Chassis check Brake syste m


Bumps Seal





Noise Oil level

Clearances Filters




Oil level Radiator

Pump Belts

Motor Starter motor







Gear stick Greasing




Safety system Seal







Greasing Others






Forklift ID Num ber:




Bumps Seal





Noise Oil level

Clearances Filters




Oil level Radiator

Pump Belts

Motor Starter motor







Gear stick Greasing

Electrical sy stem Tilt cylinders and accessories



Safety system Seal







Greasing Others






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



MAST EXPLORER Rough Terrain Forklift Trucks · safety and the safety of others at risk and affect...

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Transcript of MAST EXPLORER Rough Terrain Forklift Trucks · safety and the safety of others at risk and affect...