MT6034T

Telescopic Handler
Operator/Service Manual
Catalog 50960089 Revision A
Beginning with S/N 16251
 Indicator and Operation Symbols

Read Operator’s Fasten Seat Belt Parking Brake Brake Failure Safety Alert Hazard Flasher
Manual

Ignition Off Ignition ON Engine Start Engine Oil Engine Oil Engine Coolant
Pressure Temperature

Starting Aid Volume Full Volume Half Full Volume Empty Fuel Diesel Fuel
Injection

Transmission Transmission Beacon Turn Signals Lights Work Lights

Oil Temperature

Fan Clutch Disengaged Clutch Engaged Crab Steer 2-Wheel Steer 4-Wheel Steer

Raise Load Lower Load Tilt Rearward Tilt Forward Retract Load Extend Load

Brake Fluid Frame Level Left Frame Level Right Wiper/Washer Horn Hourmeter

Hydraulic Oil Female Auxiliary Male Auxiliary Battery Transmission

Hydraulic Coupler Hydraulic Coupler Temperature
 Manitou Americas, Inc.
One Gehl Way
P.O. Box 179
West Bend, WI 53095-0179

MT6034T
Telescopic Handler
Operator/Service Manual
Catalog 50960089 Revision A
Beginning with S/N 16251

For parts orders contact your Manitou Americas Dealer or call:

Factory Parts Department (262) 334-6653.
Website: www.us.manitou.com / www.manitouamericasdealer.com
 THIS OPERATOR’S MANUAL IS PROVIDED
FOR OPERATOR AND SERVICING USE
DO NOT REMOVE
FROM THIS MACHINE

Do not start, operate or work on this machine until you have carefully read and thor-
oughly understand the contents of the operator’s manual.

Failure to follow safety, operating and maintenance instructions could result in seri-
ous injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of this

machine, contact your dealer or the service department of Manitou Americas Inc.
before starting or continuing operation.

California Proposition 65 Warnings

Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer and birth defects or other reproductive harm.

Battery posts, terminals and related accessories contain lead and lead com-
pounds, chemicals known to the State of California to cause cancer and birth
defects or other reproductive harm. Wash hands after handling battery.

IDENTIFICATION INFORMATION

Write your Manitou Americas Inc. Telescopic Handler serial number below.
Refer to these numbers when inquiring about parts or service from your Manitou Americas Inc. dealer.

MODEL NO. MT6034T

SERIAL NO.

The model and serial numbers for this machine are on a decal located inside the operator’s station.
 Table of Contents
Chapter Description Page

Indicator and Operation Symbols . . . . . . . . . . . . . . . . . . .Inside Front Cover

1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
3 Check Lists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5, 7
4 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
5 Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
6 Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
8 Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
9 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Engine Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

PRINTED IN U.S.A. 1 50960089/AP0914

 Chapter 1
INTRODUCTION
The information in this Operator’s Manual was written to give the owner/operator assistance in preparing, adjust-
ing, maintaining and servicing of the Telescopic Handler. More important, this manual provides an operating plan
for safe and proper use of the machine. Major points of safe operation are detailed in the SAFETY chapter of this
manual.
Manitou Americas Inc. asks that you read and understand the contents of this manual
COMPLETELY and become familiar with the machine before operating it.
This Telescopic Handler is primarily intended for use as a material handler. However, it may be equipped with an
optional system: the Personnel Work Platform (PWP) System, which is intended for use when lifting personnel.
When there is no other practical option available, this machine, when equipped with the PWP System, is approved
for use to lift personnel, but only with an approved work platform, with the PWP System activated, and in full com-
pliance with the “Mandatory Work Platform Safety Rules” (see SAFETY chapter).
Refer to the seperate operator’s/parts manual for information related to the optional Radio Remote Boom Control
System.
The use of this Telescopic Handler is subject to certain hazards that cannot be eliminated by mechanical means,
but only by the exercise of intelligence, care and common sense. It is therefore essential to have competent and
careful operators, who are not physically or mentally impaired, and who are thoroughly trained in the safe opera-
tion of the equipment and the handling of the loads.
Throughout this manual information is provided that is set in italic type and introduced by the word IMPORTANT
or NOTE. Be sure to read carefully and comply with the message or directive given. Following this information
will improve operating or maintenance efficiency, help to avoid breakdowns and damage, and extend the
machine’s life. A chart of standard hardware torques is located in the back of this manual.
A storage pocket in the back of the seat is provided for storing the Operator’s Manual. After using the manual,
please return it to the pocket and keep it with the unit at all times! If this machine is resold, this manual should be
given to the new owner.
If this machine was purchased “used,” or if the owner’s address has changed, please provide your Manitou
Americas Inc. dealer or Manitou Americas Inc. Service Department with the owner’s name and current address,
along with the machine model and serial number. This will allow the registered owner information to be updated,
so that the owner can be notified directly in case of an important product issue, such as a safety update program.
“Right” and “left” are determined from a position sitting on the seat and facing forward.
The wide Manitou Americas Inc. dealership network stands ready to provide any assistance required, including
providing genuine Manitou Americas Inc. service parts. All parts should be obtained from or ordered through your
Manitou Americas Inc. dealer. Give complete information about the part, and include the model and serial number
of the machine. Record the serial number in the space provided on the previous page, as a handy record for quick
reference.
Manitou Americas Inc. reserves the right to make changes or improvements in the design or construction of any
part without incurring the obligation to install such changes on any unit previously delivered.
Manitou Americas Inc, in cooperation with the Society of Automotive
Engineers, has adopted this

Safety Alert Symbol

to identify potential safety hazards, which, if not properly avoided, could
result in injury. When you see this symbol in this manual or on the
machine itself, you are reminded to BE ALERT! Your personal safety is
involved!

50960089/AP0914 2 PRINTED IN U.S.A.

 Identification
Boom Angle
Indicator Telescopic
Boom
Dash Indicators Slave
and Controls Cylinder

Extend
Cylinder

Tilt
Cylinder

Quick-attach
System

Seat
Operator’s
Station

Auxiliary
Lift Cylinder Hydraulics

Rear Boom
Access Cover

Side View
Mirror
Air
Cleaner

Frame Leveling
Cylinder

Access Cover
with Rear Lights
and Backup
Alarm Exhaust Fuel
Pipe Tank Hydraulic
Reservoir

PRINTED IN U.S.A. 3 50960089/AP0914

 Chapter 2
SPECIFICATIONS
Lifting Performance Steering System Axles (front and rear)
Maximum lift capacity: Steer Valve: Fixed displacement rotary Type: Dana
6000 lbs. (2721 kg) Displacement/Rev: 17.9 cu. in. (293 cc) Drive/steer, open differential, double
System pressure: 2000 psi (138 bar) reduction planetary, full-time four-
Maximum lift height: Steer cylinders: 1 per axle
34’-3” (10.44 m) wheel drive
Steer mode valve: Overall ratio: 15.4:1
Capacity at maximum lift height: 3-position, 4-way solenoid with
4000 lbs. (1820 kg) dash-mounted switch actuation Engine Options
Steer modes: 2-wheel, 4-wheel, crab
Max. forward reach to load center: Features:
23’-3” (7.09 m) Braking System Turbocharged In-line 4-cycle,
Capacity at maximum forward reach: Service brakes: Oil-immersed inboard 4-cylinder, direct-injection diesel fuel
900 lbs. (408 kg) hydraulic wet-disc type; separate front system, in-line fuel filter w/water
and rear systems; trap, positive pressure lubrication,
Maximum below grade reach: liquid pressurized cooling system,
Manual foot pedal actuation
24” (610 mm) 20” (508 mm) suction fan,
Parking brake: Spring-applied, hydraulic- dry dual-element air cleaner,
Frame leveling:
release disc-type in front axle spin-on oil filter.
10o left/10o right
Actuation is electric switch with engine Engine make and model:
General Dimensions running, automatic with engine off. Deutz TD3.6 L4 Tier 4
Based on standard machine equipped 221 cu. in. (3.621 L) displacement
Electrical System
with listed tires, 48” masonry carriage 74.3 hp (55.4 kW) @ 2300 rpm
Type: 12-volt, negative ground
and 48” pallet forks. Oil capacity w/filter: 9.5 qts. (8.9 L)
Battery: 950 cold cranking amps
Recommended tire type: Circuit protection: Fuse panel Hydraulic System
15.00 x 19.5 12-ply Backup alarm: 107 dB(A)
Inflate to 60 psi (415 kPa) Horn: 111 dB(A) Type: Open-center
Pump: Single-section gear type
Overall length, less forks: Standard features:
16’-0” (4.88 m) Brake lights, rear backup light, neutral Displacement / revolution:
start switch 2.7 cu. in. (44.3 cc)
Overall width:
7’-10” (2.39 m) Alternator: 95-amp Flow @ 2500 RPM:
29 gpm (110 L/min)
Overall height: Service Capacities
7’-9” (2.36 m) Main relief pressure:
Cooling System: 4.3 gallons (16.3 L) 3000 psi (207 bar)
Ground clearance: 14” (356 mm) 50/50 mixture Steer relief pressure:
Wheel base: 9’-2” (2.8 m) Anti-freeze protection: -34oF (-31oC) 2000 psi (138 bar)
Outside turn radius: 12’-6” (3.81 m) Pressure cap: 16 psi (110 kPa)
Hydraulic filter:
Machine weight: Fuel tank: 29 gals. (110 L) In-tank return type, 10 micron
15,100 lbs. (6855 kg) Hydraulic reservoir and media, replaceable element.
system: 35 gals. (133 L) Rated flow: 100 gpm (379 L/min)
Instrumentation Transmission and cooler: 24 qts. (22.7 L) Rated pressure: 100 psi (690 kPa)
Multi-Function Display Screen: Axles: By-pass pressure (full flow):
Fuel level, Engine coolant temperature, Differentials: 9.6 qts. (9 L) ea. 25 psi (172 kPa)
Engine oil pressure, Voltmeter, Hubs: 0.6 qts. (0.5 L) ea.
Hourmeter, Maintenance reminder, Air Hydraulic strainer:
filter restriction, and Error fault codes. Transmission In-tank suction, 149 micron media,
Indicator Lamps: replaceable element.
Type: Clark Powershift T12000 Rated flow: 50 gpm (189 L/min)
Low fuel, Brake failure, Transmission
Speeds: 3 fwd / 3 rev By-pass pressure: 3 psi (21 kPa)
oil temperature, Engine pre-heat indi
Torque converter:
cator, Alternator, Engine coolant tem
Single-stage, dual-phase
perature and Engine oil pressure.
Visual indicators: Travel Speeds:
Boom angle, frame angle 1st gear: 3.5 mph (5.6 km/h)
2nd gear: 7.4 mph (11.9 km/h)
3rd gear: 18.0 mph (29 km/h)

50960089/AP0914 4 PRINTED IN U.S.A.

 Chapter 3
CHECKLISTS
PRE-DELIVERY I acknowledge that the pre-delivery procedures were per-
The following Checklist is an important reminder of the formed on this unit as outlined above.
inspections that MUST be made before delivering the
Telescopic Handler to the customer. Check off each item Dealership’s Name
after the prescribed action is taken.
√ Check that: Dealer Representative’s Name
q NO parts of machine have been damaged in shipment.
Check for such things as dents and loose or missing parts; Date Checklist Filled Out
correct or replace components as required.
Machine Model # Machine Serial # Engine Serial #
q Battery is securely mounted and not cracked. Cable con-
nections are tight. Electrolyte at proper level. DELIVERY
q Cylinders, hoses and fittings are not damaged, leaking or √ Check that:
loosely secured. The following Checklist is a reminder of the important infor-
q Oil, fuel and air filters are not damaged, leaking or loosely mation that MUST be passed on to the customer at the time
secured. the unit is delivered. Check off each item as it is explained
q All grease fittings have been properly lubricated and no fit- to the customer.
tings are missing; see Lubrication chapter of this manual.
q Wheel nuts are torqued to 450 ft.-lbs. (610 Nm).
q Review with the customer the contents of this manual and
the AEM Safety Manual for the following:
q Tires are inflated to 60 psi (415 kPa) cold.
q Hydraulic system reservoir, engine crankcase, engine q The Index at the back, for quickly locating topics;
coolant, transmission and axles are filled to the proper q The Safety, Indicators and Controls, and Operation and
operating fluid levels. Adjustment chapters for information regarding safe use of
q All adjustments have been made to comply with the set- the machine.
tings given in this manual and in the separate engine man-
ual. q The Lubrication and Service and Storage chapters for
information regarding proper maintenance of the machine.
q All guards, shields and decals are in place and securely Explain that regular lubrication and maintenance are
attached. required for continued safe operation and long life.
q Model and serial numbers for this unit are recorded in
space provided on this page and page 1. q Give this Operator’s Manual and the AEM Safety Manual
to the customer and instruct them to be sure to read and
Start the machine and test-run the unit while completely understand their contents before operating the
checking that proper operation is exhibited by all unit.
controls. q Remind the customer of U.S. OSHA regulation 1910.178
(l), which specifies operator training requirements.
√ Check that:
q Explain that the customer must consult the engine manual
q All indicators (lamps, switches, etc.) function properly. (provided) for related specifications, operating adjustments
q All hand and foot controls operate properly. and maintenance instructions.
q The PWP System operates properly (if equipped). Refer to q Completely fill out the Owner’s Registration, including
Service and Storage chapter for the procedure to check the customer’s signature, and return it to the Company.
PWP System. q Explain that a copy of the product warranty is included on
q Boom, Quick-attach™ System with attachment tool and the inside back cover of this Operator’s Manual.
frame level control all function properly.
q No hydraulic system leaks when under pressure.
Customer’s Signature
q Listen for abnormal noises or vibrations; if detected, deter-
mine their cause and repair as necessary.
Date Delivered

(Dealer’s File Copy - Remove at Perforation)

PRINTED IN U.S.A. 5 50960089/AP0914

 INTENTIONALLY BLANK

(To be removed as Dealer’s file copy)

50960089/AP0914 6 PRINTED IN U.S.A.

 Chapter 3
CHECKLISTS
PRE-DELIVERY I acknowledge that the pre-delivery procedures were per-
The following Checklist is an important reminder of the formed on this unit as outlined above.
inspections that MUST be made before delivering the
Telescopic Handler to the customer. Check off each item Dealership’s Name
after the prescribed action is taken.
√ Check that: Dealer Representative’s Name
q NO parts of machine have been damaged in shipment.
Check for such things as dents and loose or missing parts; Date Checklist Filled Out
correct or replace components as required.
Machine Model # Machine Serial # Engine Serial #
q Battery is securely mounted and not cracked. Cable con-
nections are tight. Electrolyte at proper level. DELIVERY
q Cylinders, hoses and fittings are not damaged, leaking or √ Check that:
loosely secured. The following Checklist is a reminder of the important infor-
q Oil, fuel and air filters are not damaged, leaking or loosely mation that MUST be passed on to the customer at the time
secured. the unit is delivered. Check off each item as it is explained
q All grease fittings have been properly lubricated and no fit- to the customer.
tings are missing; see Lubrication chapter of this manual.
q Wheel nuts are torqued to 450 ft.-lbs. (610 Nm).
q Review with the customer the contents of this manual and
the AEM Safety Manual for the following:
q Tires are inflated to 60 psi (415 kPa) cold.
q Hydraulic system reservoir, engine crankcase, engine q The Index at the back, for quickly locating topics;
coolant, transmission and axles are filled to the proper q The Safety, Indicators and Controls, and Operation and
operating fluid levels. Adjustment chapters for information regarding safe use of
q All adjustments have been made to comply with the set- the machine.
tings given in this manual and in the separate engine man-
ual. q The Lubrication and Service and Storage chapters for
information regarding proper maintenance of the machine.
q All guards, shields and decals are in place and securely Explain that regular lubrication and maintenance are
attached. required for continued safe operation and long life.
q Model and serial numbers for this unit are recorded in
space provided on this page and page 1. q Give this Operator’s Manual and the AEM Safety Manual
to the customer and instruct them to be sure to read and
Start the machine and test-run the unit while completely understand their contents before operating the
checking that proper operation is exhibited by all unit.
controls. q Remind the customer of U.S. OSHA regulation 1910.178
(l), which specifies operator training requirements.
√ Check that:
q Explain that the customer must consult the engine manual
q All indicators (lamps, switches, etc.) function properly. (provided) for related specifications, operating adjustments
q All hand and foot controls operate properly. and maintenance instructions.
q The PWP System operates properly (if equipped). Refer to q Completely fill out the Owner’s Registration, including
Service and Storage chapter for the procedure to check the customer’s signature, and return it to the Company.
PWP System. q Explain that a copy of the product warranty is included on
q Boom, Quick-attach™ System with attachment tool and the inside back cover of this Operator’s Manual.
frame level control all function properly.
q No hydraulic system leaks when under pressure.
Customer’s Signature
q Listen for abnormal noises or vibrations; if detected, deter-
mine their cause and repair as necessary.
Date Delivered

(Pages 5 and 6 have been removed at perforation)

PRINTED IN U.S.A. 7 50960089/AP0914

 Chapter 4
SAFETY
The above Safety Alert Symbol means ATTENTION! Manitou Americas ALWAYS takes the operator’s safe-
ALWAYS BE ALERT! YOUR SAFETY IS ty into consideration when designing its machinery,
INVOLVED! It stresses an attitude of safety aware- and guards exposed moving parts for his/her protec-
ness and can be found throughout this Operator’s tion. However, some areas cannot be guarded or
Manual and on the machine itself. shielded in order to assure proper operation. Further,
this Operator’s Manual, the Safety Manual and decals
on the machine warn of additional hazards and should
Before operating this equipment, read and be read and observed closely.
study the following safety information. In
addition, be sure that everyone who operates It is the responsibility of the operator to read and
or works with this equipment is familiar with understand the Operator’s Manual and other informa-
these safety precautions. tion provided and use the correct operating procedures.
Machines should be operated only by qualified opera-
tors.
REMEMBER! It is the owner’s responsibility for com-
DANGER municating information on the safe use and proper
maintenance of this machine! This includes providing
“DANGER” indicates an imminently haz- understandable interpretations of these instructions for
ardous situation, which, if not avoided, will operators who are not fluent in reading English.
result in death or serious injury.

MANDATORY SAFETY SHUTDOWN

WARNING PROCEDURE
BEFORE cleaning, adjusting, lubricating or ser-
“WARNING” indicates a potentially hazardous vicing the unit:
situation, which, if not avoided, could result in
death or serious injury. 1. Stop machine on a level surface. (Avoid parking
on a slope, but if necessary, park across the
slope and block the tires.)
2. Fully retract the boom and lower the attach-
CAUTION ment tool to the ground. Idle engine for gradual
cooling.
“CAUTION” indicates a potentially hazardous
3. Place controls in neutral and apply parking
situation, which, if not avoided, may result in
brake.
minor or moderate injury. It may also alert to
unsafe practices. 4. Shut off the engine and remove the key.
ONLY when you have taken these precautions can
you be sure it is safe to proceed. Failure to follow
the above procedure could lead to death or serious
bodily injury.

50960089/AP0914 8 PRINTED IN U.S.A.

 SAFETY
Additional Safety Reminders
WARNING Ü User/operator safety practices, as indicated by
industry standards, are included in this Operator’s
U.S. OSHA regulations require employers in Manual and intended to promote safe operation of
general industry and the construction, ship- the machine. These guidelines do not, of course,
yard and cargo-handling industries (excepting preclude the use of good judgment, care and com-
agricultural operations) to ensure that forklift mon sense that may be necessary for the particular
operators are competent, as demonstrated by jobsite conditions.
successful completion of a training course. Ü It is essential that operators be physically and men-
The training course must consist of a combi- tally fit and free of mind-altering drugs and chem-
nation of formal instruction and practical icals, and thoroughly trained in the safe operation
training, including both forklift-related and of the machine. Such training should be presented
workplace-related topics, and evaluation of completely to all new operators and not condensed
the operator’s performance in the workplace. for those claiming previous experience.
Information on operator training is available from
All operator training and evaluation is to be several sources, including the manufacturer.
conducted by persons who have the know- Ü Some illustrations used in this manual may show
ledge, training and experience to train and doors, guards and shields open or removed for
evaluate operators. illustration purposes ONLY. BE SURE that all
doors, guards and shields are in their proper oper-
ating positions BEFORE starting the engine.

Before Operation Safety Reminders

Ü Perform a pre-start walk-around inspection before
starting the engine at the beginning of each work
WARNING shift. Contact with a running engine or moving
parts during the pre-start inspection could cause
ALWAYS maintain a safe distance from elec- death or serious injury. Refer to the pre-start
tric power lines and avoid contact with any walk-around inspection checklist in the
electrically charged conductor or gas line. It is “Operation and Adjustment” chapter.
not necessary to make direct contact with a
power line for power to ground through the Ü Walk around the machine and warn all personnel
structure of the machine. Keep the boom and who may be servicing the machine or who are in
load at least 10 ft. (3 m) from all power lines. the machine path prior to starting. DO NOT start
Accidental contact or rupture can result in until all personnel are clearly away from the
electrocution or an explosion. Contact the machine.
“Call Before You Dig” referral system number Ü Check brakes, steering, and hydraulic system prior
at 8-1-1 in the U.S., or 888-258-0808 in the U.S. to starting operation. Operate all controls to ensure
and Canada, to locate any underground utility proper operation. Observe all gauges and indica-
lines BEFORE starting to dig. tors for proper operation. If any malfunctions are
found, correct the cause prior to using the machine.
Ü ALWAYS wear appropriate personal protective
equipment for the job and working conditions.
Hard hats, goggles, protective shoes, gloves,
reflector-type vests, respirators and ear protection

PRINTED IN U.S.A. 9 50960089/AP0914

 SAFETY
are examples of types of equipment that may be ALWAYS look in the direction of travel. Look to
required. DO NOT wear loose fitting clothing, the rear before backing.
long hair, jewelry or loose personal items while Ü ALWAYS use the recommended handholds and
operating or servicing the machine. steps with at least three points of support when get-
Ü ALWAYS check the job site for terrain hazards, ting on and off the machine. Keep steps and plat-
obstructions and people. Remove all objects that form clean. Face the machine when climbing up
do not belong in or on the machine and its equip- and down.
ment. Ü DO NOT raise or drop a loaded fork or bucket sud-
Ü Manitou Americas telescopic handlers are denly. Abrupt movements under load can cause
designed and intended to be used only with serious instability.
Manitou Americas attachments and approved Ü Study the load chart carefully. It shows maximum
attachments. To avoid possible personal injury, capacity to be lifted and placed at specific outward
equipment damage and performance problems, use and upward distances. ALWAYS be aware of load
attachments that are approved for use on and with- weights prior to attempting lift and placement with
in the operating capacity of the machine. Contact this machine.
your dealer or Manitou Americas for information
on attachment approval and compatibility with Ü DO NOT exceed the machine’s rated operating
specific machine models. Manitou Americas can- capacity for the type of attachment tool being used.
not be responsible if the machine is used with a Ü DO NOT allow minors or any unqualified person-
non-approved attachment. nel to operate or be near the machine unless prop-
erly supervised.
Operation Safety Reminders
Ü DO NOT start the engine or operate any controls
Ü Any or all of the following elements may affect the unless properly seated in the operator’s seat!
stability of the machine: terrain, engine speed, type
of load being carried and placed, improper tire Ü DO NOT run the engine in an enclosed area with-
inflation, weight of the attachment tool, and abrupt out providing proper ventilation for the exhaust.
movement of any control lever. IF YOU ARE Exhaust gases contain carbon monoxide, an odor-
NOT CAREFUL WHILE OPERATING THIS less and deadly gas. Internal combustion engines
MACHINE, ANY OF THE ABOVE FACTORS deplete the oxygen supply within enclosed spaces
COULD CAUSE THE MACHINE TO TIP, and may create a serious hazard unless the oxygen
AND YOU COULD BE THROWN OUT OF is replaced. This includes the atmosphere within
THE OPERATOR’S STATION, WHICH the cab when equipped.
COULD RESULT IN SERIOUS INJURY OR Ü DO NOT leave the operator’s station with the
DEATH! boom and attachment tool raised. ALWAYS lower
the boom and attachment tool to the ground, shut
Ü ALWAYS wear the seat belt provided to prevent
being thrown from the machine. If you are in an off the engine and engage the park brake before
overturn: leaving the operator’s station.

- DO NOT jump! Ü NEVER travel with the boom above the carry
- Hold on tight and stay with the machine! position (attachment tool should be at minimum
- Lean away from the fall! ground clearance.) Boom should be fully retract-
ed.
Ü ALWAYS keep hands, feet and arms inside of the
operator’s station when operating the machine! Ü DO NOT drive too close to an excavation or ditch.
Ü DO NOT depend on the backup alarm to clear BE SURE that the surrounding ground has ade-
bystanders out of the path of the machine. quate strength to support the weight of the machine
and the load it is carrying.

50960089/AP0914 10 PRINTED IN U.S.A.

 SAFETY
Ü DO NOT turn quickly while traveling on a slope or 1. Forklift, lift equipment and rigging have
operate the machine beyond the grade and slope been inspected (each shift, month and
limits noted in the Operation and Adjustments year) and are in good, safe condition and
chapter of the Operator’s Manual. properly installed.
Ü NEVER allow any riders on this machine. This is 2. An operator's manual and applicable load
strictly a single-seat, NO-passenger machine. charts are on the forklift.
Ü NEVER use as a lift for personnel unless the 3. Work zone ground conditions can support
machine is equipped with the Personnel Work the equipment and load. Any hazardous
Platform (PWP) System. conditions in the work area have been
Ü When road travel is required, know and use the identified, and the operator notified.
signaling devices on the machine. Provide an 4. Equipment is being used within its rated
escort and Slow-Moving Vehicle (SMV) emblem capacity and in accordance with the manu-
when required. facturer's instructions.
Ü If necessary to park on a slope, park across the 5. Operator and crew members have been
slope and block the tires. trained in the safe use and operation of the
equipment, including how to avoid electro-
Suspended Load Safety Reminders
cution.
The handling of suspended loads by means of a truss
6. During use, no part of the equipment, load
boom, winch, boom mounted lift hook or other similar
line or load will be within the minimum
device can introduce dynamic forces affecting the sta-
clearance distance specified by OSHA [10
bility of the machine that are not considered in the sta-
feet (3.0 m), and more for lines rated over
bility criteria of industry test standards. Grades and
50 kV] of any energized power line, and
sudden starts, stops and turns can cause the load to
any taglines used are non-conductive.
swing and create a hazard. Refer to the following
guidelines for handling suspended loads. 7. In addition, for lift equipment with a rated
capacity greater than 2000 lbs. (907 kg),
the employer must ensure that:
WARNING a.) An accessible fire extinguisher is on
U.S. OSHA regulations effective November 8, the forklift;
2010 (29 CFR Part 1926, Subpart CC - Cranes b.) Monthly and annual inspections are
and Derricks in Construction) include require- performed and documented, and
ments for employers that use powered indus- records retained (three months for
trial trucks ("forklifts") configured to hoist (by monthly, one year for annual);
means of a winch or hook) and move sus-
pended loads horizontally. In particular, this c.) Before November 10, 2014, operators
regulation applies to any rough-terrain forklift must have had the additional training
(e.g., "telescopic handler") equipped with a jib and qualification / certification required
or truss boom with a hook (with or without a by OSHA regulations §1926.1427 and
winch), or a hook assembly attached to the §1926.1430.
forks. [Note: This regulation is in addition to Note: Refer to the full text of the OSHA crane
the OSHA regulation that requires specific regulation (29 CFR Part 1926, Subpart CC) for
forklift operator training: §1910.178(l).] a detailed description of the regulatory
requirements.
When a forklift / telescopic handler is config-
ured and used for hoisting, the employer must
ensure that:

PRINTED IN U.S.A. 11 50960089/AP0914

 SAFETY
Ü DO NOT exceed the rated capacity of the tele- detailed in the Service and Storage chapter.
scopic handler as equipped for handling suspend- Ü NEVER use your hands to search for hydraulic
ed loads. The weight of the rigging must be fluid leaks. Instead use a piece of paper or card-
included as part of the load. board. Escaping fluid under pressure can be invis-
Ü During transport, the length of the rigging ible and can penetrate the skin, causing serious
between the attachment and load should be as injury. If any fluid is injected into your skin, see a
short as possible to reduce booms height and doctor at once. Injected fluid MUST be surgically
movement. DO NOT raise the load more than 12 removed by a doctor familiar with this type of
inches (305 mm) above the ground, or raise the injury or gangrene may result.
boom more than 45 degrees. Ü ALWAYS wear safety glasses with side shields
Ü Only lift the load vertically – NEVER drag it hor- when striking metal against metal. In addition, it is
izontally. recommended that a softer (chip-resistant) materi-
al be used to cushion the blow. Failure to heed
Ü Use multiple pickup points on the load when pos- could lead to serious injury to the eyes or other
sible. Use taglines to restrain the load from parts of the body.
swinging and rotating.
Ü DO NOT refill the fuel tank when the engine is
Ü Start, travel, turn and stop SLOWLY to prevent hot. Allow engine to cool down before refilling to
the load from swinging. DO NOT exceed walking prevent hot engine parts from igniting the fuel if it
speed. should spill or splash.
Ü Inspect rigging before use. Rigging must be in Ü DO NOT smoke while filling the fuel tank, while
good condition and in the U.S. comply with working on the fuel or hydraulic systems, or while
OSHA regulation §1910.184, “Slings,” or working around the battery.
§1926.251, “Rigging equipment for material han- Ü DO NOT fill the fuel tank completely. Allow room
dling.” for expansion. Maintain control of the fuel filler
Ü Rigging equipment attached to the forks must be nozzle when filling the tank. Use the correct fuel
secured such that it cannot move either sideways grade for the operating season.
or fore and aft. The load center must not exceed Ü Static electricity can produce dangerous sparks at
24 inches (610 mm). the fuel-filling nozzle. Do not wear polyester, or
polyester-blend clothing while fueling. Before
Ü DO NOT lift the load with anyone on the load,
fueling, touch the metal surface of the machine
rigging or lift equipment, and NEVER lift the
away from the fuel fill to dissipate any built-up
load over personnel.
static electricity. Do not re-enter the machine but
Ü Beware of the wind, which can cause suspended stay near the fuel filling point during refueling to
loads to swing, even with taglines. minimize the build-up of static electricity. Do not
use cell phones while fueling. Make sure the stat-
Ü DO NOT attempt to use frame-leveling to com-
ic line is connected from the machine to the fuel
pensate for load swing.
truck before fueling begins.
Servicing Safety Reminders Ü Ultra-Low Sulfur Diesel (ULSD) poses a greater
static ignition hazard than earlier diesel formula-
Ü ALWAYS be aware of and avoid pinch point areas
on the machine, such as wheels-to-frame, cylin- tions. Avoid death or serious injury from fire or
ders-to-frame, boom-attachment-tool-to-frame. explosion; consult with your fuel or fuel system
supplier to ensure the entire fuel delivery system
Ü NEVER attempt to by-pass the keyswitch to start is in compliance with fueling standards for prop-
the engine. ONLY use the jump-starting procedure er grounding and bonding practices.

50960089/AP0914 12 PRINTED IN U.S.A.

 SAFETY
Ü NEVER use fuel for cleaning purposes. Safety Guards and Warning Devices
Ü DO NOT remove the radiator cap after the engine Ü This machine is fitted with a Roll-Over Protective
has reached operating temperature or if it is over- Structure (ROPS) and Falling Object Protective
heated. At operating temperatures, the engine Structure (FOPS) in accordance with industry stan-
coolant will be extremely hot and under pressure. dards. It is intended to offer protection to the oper-
ALWAYS wait for the engine to cool before ator from falling objects, and in case of an over-
attempting to relieve pressure and remove the radi- turn, but it cannot protect against every possible
ator cap. Failure to heed this warning could result hazard. Therefore it should not be considered a
in severe burns. substitute for good judgment and safe practices in
Ü DO NOT loosen or disconnect any hydraulic lines, operating the machine. If the ROPS / FOPS struc-
hoses or fittings without first relieving hydraulic ture is damaged, it must be replaced to restore the
circuit pressure. Also, be careful not to touch any protection it provides.
hydraulic components that have been in recent Ü This machine is equipped with a horn and backup
operation, because they can be extremely hot and alarm. The user must determine if operating condi-
can burn you! tions require the machine to be equipped with
Ü DO NOT use the boom to lift or support the additional devices (mirrors, rotating beacon, etc.)
machine for maintenance or service. and be responsible for providing and maintaining
such devices.
Ü Avoid lubrication or mechanical adjustments with
the machine in motion or the engine operating. If Personnel Work Platform (PWP) System
the engine must be running to make certain adjust-
ments, place the transmission in neutral, apply the
parking brake, place the equipment in a safe posi- WARNING
tion, securely block the tires and use extreme cau-
tion. The machine must not be used to lift or carry
Ü To ensure continued safe operation, replace dam- personnel, or be fitted with any form of per-
aged or worn-out parts with genuine Manitou ser- sonnel work platform unless fitted with the
vice parts before using this equipment. optional PWP System.
If fitted with the PWP System, the Mandatory
Modifications, Nameplates, Markings and
Work Platform Safety Rules must be followed
Capacities at all times while lifting personnel.
Ü Modifications and additions that affect capacity or
safe operation shall not be performed without the
manufacturer’s prior written approval. Where such The Mandatory Work Platform Safety Rules must be
authorization is granted, any applicable markings adhered to at all times while elevating personnel.
are to be changed accordingly. These rules are based on ANSI/ITSDF Standard
B56.6-2005, “Safety Standard for Rough Terrain
Ü All attachment tools MUST be marked to identify
the attachment tool and the total capacity with the Forklift Trucks.” (A copy of this and related standards
attachment tool at maximum elevation with the can be obtained from the Industrial Truck Standards
load laterally centered. Development Foundation, 1750 K Street NW, Suite
460, Washington DC 20009; or downloaded from:
Ü ALWAYS be sure all nameplates, warnings and www.itsdf.org.) The rules apply to the owner, operator
instruction markings are in place and legible. and the personnel in the work platform.
Local government regulations may require specif-
ic decals, which then become the responsibility of
the owner or user to provide.

PRINTED IN U.S.A. 13 50960089/AP0914

 SAFETY
14. Be sure the path of platform travel is clear of haz-
MANDATORY WORK PLATFORM ards, such as scaffolds, electrical wires and over-
head obstructions.
SAFETY RULES
1. The work platform must comply with 15. The operator must keep hands and feet clear of
ANSI/ITSDF B56.6-2005, Sec. 8.24, “Platforms controls that are not in use.
for Elevating Personnel.” (See page 14, “Work 16. Personnel must be lifted and lowered smoothly
Platform Design Requirements.”) and cautiously, and only at their request.
2. The platform must be securely attached to the car- 17. The platform must be lowered fully before moving
riage or forks, and the carriage securely attached to the forklift. Do not drive the forklift with person-
the boom. nel on the platform.
3. The carriage and forks must be secured to prevent 18. Elevated personnel must always be alerted before
them from pivoting upward. raising or lowering the platform.
4. If the machine is equipped with a rotating or 19. A trained operator must be in position to operate
swinging carriage, the rotation or swing must be the forklift and boom controls at all times.
deactivated. (This occurs automatically when the 20. The combined weight of the platform, personnel
“PWP System” is switched on.) and load must not exceed one-third of the materi-
5. Personnel on the platform must be provided pro- al-handling capacity of the forklift.
tection from any moving parts on the forklift that 21. Platform personnel must maintain firm footing on
may present a hazard. the platform floor. A harness is to be worn and a
6. If overhead hazards exist for platform personnel, lanyard attached to the platform or boom when
overhead protection must be provided. working from an elevated work platform, in accor-
7. Be sure that the lifting mechanism is operating dance with OSHA regulations. Use of railings,
smoothly throughout its entire range, both empty planks, ladders, etc. on platform for the purpose of
and loaded, and that any lift-limiting devices and achieving additional reach or height is prohibited.
latches are functional. 22. Workers on the platform must keep all parts of
8. Be sure that the frame is level, to ensure a vertical their bodies inside the work platform during rais-
lift. ing and lowering.

9. Be sure the platform is horizontal before lifting. 23. Be sure that the personnel and equipment on the
platform do not exceed the available space.
10. Be sure that the forklift has a firm footing.
24. The platform must be fully lowered for personnel
11. Be sure that any required restraining means (rail- to enter and exit. Personnel must not climb on any
ings, chains, harnesses, etc.) are in place and prop- part of the forklift in attempting to enter and exit.
erly used.
25. Any harness, body belt, lanyard, or deceleration
12. Before lifting personnel, shift the transmission into device that has sustained permanent deformation
Neutral, apply the parking brake, and activate the or is otherwise damaged must be replaced.
"PWP System" mode switch.
26. Modifications to the platform that are detrimental
13. Before lifting personnel, the area should be to its safe use are prohibited.
marked to warn others of work by elevated per-
sonnel.

50960089/AP0914 14 PRINTED IN U.S.A.

 SAFETY
Work Platform Design Requirements
WARNING (Per ANSI/ITSDF B56.6-2005, Sec. 8.24)
1. A platform floor having a slip-resistant surface
Use ONLY an approved work platform for ele- located not more than 8 inches (200 mm) above the
vating personnel. normal load-supporting surface of the forks.
NEVER move the machine with the work plat- 2. Floor dimensions, which shall not exceed two
form in a raised position or with personnel on times the load center distance of 24 inches (610
board. mm) listed on the forklift nameplate, measured
parallel to the longitudinal center plane of the fork-
NEVER tilt the platform forward, rearward, or lift, nor have a width greater than the overall width
to the side with personnel aboard. of the forklift [measured across the load-bearing
tires] plus 10 inches (250 mm) on either side.
ALWAYS engage the PWP System and follow
Minimum space for each person on the platform
the Mandatory Work Platform Safety Rules
shall not be less than 18 inches (450 mm) in either
when elevating personnel.
direction.
3. A 4 inch (100 mm) minimum height toe plate,
which may be omitted at the access opening.
4. An overhead protective device, when requested by
the user.
Work Platform 5. Protection for personnel in their normal working
System Switch
position on the platform from moving parts of the
forklift that may present a hazard.
6. Information prominently indicated on the plat-
form:
a. maximum work load including personnel and
equipment, and
Electrical
Connection b. weight of empty platform.
7. Means so that the platform can only be centered
PWP
laterally on the forklift, and retained against the
Remote vertical face of the forks, carriage or lifting mech-
Shutdown anism.
Switch
8. A means to securely attach the platform to the lift-
ing mechanism, and to prevent the platform from
inadvertently pivoting.
Remote Shutdown Switch 9. Restraining means such as a guardrail or a means
with Coiled Wire Connector for securing personnel such as a body harness and
lanyard. A guardrail or similar structure shall have
a nominal height to the platform floor of 42 inches
(1066 mm) around its upper periphery and include
a midrail. It may be hinged, removable, or of
chains, and used to provide an access opening, if
proper positioning is easily accomplished and a
secure condition is discernable. Such restraining

PRINTED IN U.S.A. 15 50960089/AP0914

 SAFETY
means shall be capable of withstanding a concen-
trated horizontal force of 200 lbs. (890 N) applied
at the point of least resistance without permanent
deformation. A body harness and lanyard is to have
an attachment point provided overhead for free-
dom of movement, and its length is to limit free-
fall to 5 feet (1500 mm) measured from the point
of attachment to the operator. The complete system
shall be capable of withstanding three consecutive
drop tests to simulate a 250-pound (113 kg) person
falling 6 feet (1800 mm) without allowing the test
weight to fall free to the ground. A deceleration
device may be included.
NOTE: Fall protection should comply with applic-
able U.S. OSHA regulations: 1910.67 (c)(2)(v) (for
General Industry) or 1926.453 (b)(2)(v) (for
Construction).
10. Lanyards, when provided, shall be arranged so as
not to cause a tripping hazard.
11. Body harnesses, when provided, should have a
width of at least 1.75 inches (44 mm).
12. Structural safety factor-All load-supporting struc-
tural elements of the work platform shall have a
structural safety factor of not less than 2-to-1 based
on the minimum yield strength of the materials
used.

50960089/AP0914 16 PRINTED IN U.S.A.

 SAFETY
808027 808030 808029

808026
808029

808030
808027

808035

808032

808031 808032

808031 808026
808035

PRINTED IN U.S.A. 17 50960089/AP0914

 SAFETY
808036
808036

808035
809291

808035

808033

808036

808033 809291

808034

808034 808033

50960089/AP0914 18 PRINTED IN U.S.A.

 SAFETY
808033
808033

808054

808054

808031

808033

808031

808038

RED
808038

PRINTED IN U.S.A. 19 50960089/AP0914

 SAFETY
PWP Safety Decals

808041

808040
808042
808039
808039

808041
808042 808039

808040

50960089/AP0914 20 PRINTED IN U.S.A.

 Chapter 5
INDICATORS AND CONTROLS
GUARDS AND SHIELDS
CAUTION Whenever possible and without affecting machine
operation, guards and shields are used to protect poten-
Become familiar with and know how to use
tially hazardous areas. In many places, decals are also
ALL safety devices and controls on the
provided to warn of potential hazards and to display
Telescopic Handler BEFORE operating it.
special operating procedures.
Know how to stop the machine operation
BEFORE operating it. This Manitou Americas
machine is designed and intended to be used
ONLY with a Manitou Americas attachment WARNING
tool, or a Manitou Americas approved acces-
sory or referral attachment tool. Manitou Read and thoroughly understand all safety
Americas cannot be responsible for product decals on the Telescopic Handler BEFORE
safety if the machine is used with a non- operating it. DO NOT operate the machine
approved accessory or attachment tool. unless all factory-installed guards and shields
are properly secured in place.

Boom Control Auxiliary

Boom Angle
Joystick Hydraulics Control
Indicator

Frame Angle
Indicator
Frame Level and
Attachment Joystick

Instrument and
Speed and Travel
Switch Panel
Direction Lever
Horn Two Joystick Controls

Tri-Function Frame Level

Steering Joystick Control
Wheel Load Zone
Charts
Brake
Pedal

Ignition Switch
Throttle Pedal Tri-Function Joystick Control

Operator’s Compartment and Indicators/Controls Locations

PRINTED IN U.S.A. 21 50960089/AP0914

DASH PANEL AREA

Ignition Switch
Key Switch OFF: When the key is vertical in
the ignition switch, power is disconnected from
the battery to the control and instrument panel Instrumentation and Switch Panel
electrical circuits. This is the only position in which the Located to the right of the steering wheel, this panel
key can be inserted and removed. contains the multi-function display with indicator
Key Switch ON: When the key is turned one lamps and the function rocker switches.
position clockwise from the vertical (OFF) posi-
tion, power from the battery is supplied to all
controls and multi-function display panel electrical cir-
cuits. All indicator lamps in the multi-function display
will illuminate momentarily as a lamp check.
When the key is in this position, the engine glow plug
indicator will stay on until the engine is pre-heated. In
colder temperatures the glow plug indicator will stay
lit for 3-30 seconds. When the glow plug indicator
light goes out the engine can be started.
Start: Turn the ignition switch to this position Multi-Function Display with Indicator
to activate the starter. Release the ignition
Lamps
switch as soon as the engine starts.

NOTE: If the engine requires repeated attempts A F

to start, the key MUST be returned to the OFF I
E
position between starting attempts to prevent bat-
tery run down.

WARNING H B D

Do not use starting fluid (ether) with engine G C

glow plug preheat systems. An explosion can
result, which can cause engine damage, injury
or death.

Horn: Located in the center of the steering wheel, A - Multi-Function Display Screen: This screen dis-
press the horn button to activate warning sound. plays the following functions:
Load Zone Charts: A series of flip charts show lift • fuel level displayed at all times on the lower por-
height and reach limits relative to the load weight tion of the display,
being handled with various attachment tools.

50960089/AP0914 22 PRINTED IN U.S.A.

• engine coolant temperature, Indicator Lamps
• engine oil pressure, C - Low Fuel Lamp: This lamp indicates a low fuel
• voltmeter situation. The fuel tank should be filled as soon as pos-
• hourmeter sible.
• 250 hour maintenance reminder D - Brake Failure Lamp: This lamp indicates the con-
• air filter restriction message dition of the service brake systems. The front and rear
• error fault codes brakes are on independent systems. If a loss of pressure
occurs in either system during normal operation with
B - Scroll Button: Pressing this button changes the
the brake pedal depressed, this lamp will come on.
function displayed in the gauge display panel.
Failure in one of the brake systems does not affect the
A1 - Fuel Level Gauge: The fuel level is displayed at
operation of the other system. However, the MANDA-
all times in the lower portion of the display. It indicates
TORY SAFETY SHUTDOWN PROCEDURE (p. 8)
the amount of fuel remaining in the fuel tank.
should be followed and any necessary repairs made
A2 - Engine Coolant Temperature: Press button “B” immediately.
until “TEMP” is displayed. It indicates the temperature
E - Transmission Oil Temperature Lamp: This lamp
of the engine coolant. Under normal conditions, this
indicates whether or not the transmission oil is at the
should indicate approximately 185°F (85°C).
proper temperature. During normal operation this lamp
A3 - Engine Oil Pressure: Press button “B” until should be off, indicating that the transmission oil sys-
“OIL” is displayed. This indicates the engine lubricat- tem is at the proper temperature.
ing oil pressure.
IMPORTANT: If this lamp comes on during nor-
A4 - Voltmeter: Press button “B” until “VOLTS” is mal operation, a problem may exist in the trans-
displayed. This indicates the voltage output from the mission oil system. Stop the machine immediate-
alternator. ly and investigate the cause of the problem!
A5 - Hourmeter: Press button “B” until “HRS” is dis- F - Engine Glow Plug Indicator Lamp: When light-
played. It indicates the total operating time of the ed this lamp indicates that the cold weather starting aid
machine and should be used for keeping the mainte- is in use.
nance log.
G - Alternator Lamp: This lamp indicates the condi-
A6 - Maintenance Reminder: After every 250 hours tion of the electrical charging system. During normal
a reminder will display: “ROUTINE MAINTENACE operation, this lamp should be off. If the charge rate is
IS REQUIRED ⎯ CHECK OPERATOR’S MANU- too high or too low, this lamp will come on.
AL.” Perform the required maintenance, and then clear
the message by pressing and holding button “B” until H - Coolant Temperature Lamp: This lamp indicates
the message is cleared. if the temperature of the engine coolant is too high.

NOTE: The maintenance reminder message IMPORTANT: If this lamp comes on during nor-
must display at least three minutes before it can mal operation with the engine running, STOP the
be cleared by pressing and holding button “B”. engine as soon as possible and check the engine
cooling system.
A7 - Air Filter Restriction: This message will appear
anytime the air cleaner is restricted. Check the air I - Engine Oil Pressure Lamp: This lamp indicates
cleaner for a clogged element and replace if necces- whether the engine lubricating oil pressure is suffi-
sary. The message will clear when the air cleaner cient. During normal operation, with the engine run-
restriction is corrected. ning, this lamp should be off. During starting and when
the ignition is on but the engine is not running, this
A8 - Error Fault Code: Error codes and a short error lamp will be on.
description are displayed in this screen. The error code
will clear when the error is corrected. IMPORTANT: If this lamp comes on during nor-
mal operation, stop the engine immediately! After
allowing the oil to drain down for a few minutes,
check the engine oil level. Maintain oil level at the
FULL mark on the dipstick.

PRINTED IN U.S.A. 23 50960089/AP0914

Switch Panel C - Engine Emergency Override Switch: Pressing
and holding the bottom of the engine emergency over-
The switch panel contains three rows of switches for
ride switch will override an ECU engine shutdown sig-
the operation of standard and optional equipment on
nal.
the telescopic handler.
The switch must be pressed within 30 seconds of the
Top Row Switches engine shutdown signal from the ECU to prevent unde-
Switches have graphic symbols to indicate function sired shutdown of the engine. Pressing the switch will
and effect. The following descriptions start with the override the engine shutdown for 30 seconds at a time
first switch on the left. to move the machine to a safe location and to lower the
boom to the ground. If the engine shuts down, the igni-
tion switch must be turned off for 30 seconds and then
back on before the engine can be restarted.
NOTE: Holding the switch continously “ON” will
not reset the 30-second timer.
Refer to the error fault code displayed in the multi-
A B C D function display to determine the cause of the engine
shutdown signal.
NOTE: Some switches are optional and may not D - Parking Brake: When the machine is parked, this
be on machine. switch should be pressed to actuate the parking brake
mechanism in the front axle.
A - Steering Mode: This 3-position switch is used to
select among the three steering modes. The upper posi-
tion engages the 4-wheel-steer mode. This mode pro-
vides all-wheel steering, used for making tighter turns,
WARNING
usually on a jobsite. The center position engages the 2- UNATTENDED MACHINE HAZARD
wheel-steer mode. This mode provides front-wheel
steering only, used for higher speed travel. The lower Activate parking brake switch and lower
position engages the crab-steer mode. This mode is attachment tool to ground before leaving
used when a small amount of side shift is needed for machine. An unattended machine can move or
picking or placing a load. roll and cause death or serious injury to oper-
ator or bystanders.
NOTE: The rear wheels are not self-centering.
Make sure all wheels are in a straight-ahead posi- Periodically check the parking brake opera-
tion before changing the steering mode. tion to maintain adequate holding power.
Always be sure the parking brake switch is off
Any of the steering modes can be used in forward and when resuming machine operation.
reverse travel. The operator should learn to anticipate
changes in machine movement if the steering mode
must be changed.
B - Clutch Cutout: When activated, this switch allows
faster engine acceleration and more power to the
hydraulic system, without power to the drive axles,
while the service brake pedal is pressed.
In the “OFF” position, the clutch mechanism of the
transmission remains engaged when the brakes are
applied. In the “ON” position, the clutch mechanism is
disengaged when the brakes are applied.
Normal brake force will hold the machine in position
while accelerating the engine to power hydraulic con-
trol functions during load placement.

50960089/AP0914 24 PRINTED IN U.S.A.

Middle Row Switches NOTE: Some switches are optional and may not
Switches have graphic symbols to indicate function be on machine.
and effect. The following descriptions start with the I1 and I2 - Wiper/Washer: The windshield and top
first switch on the left. window of the operator’s station are each equipped
with a wiper and washer mechanism. Switch “I1”oper-
ates the wiper and washer on the windshield; switch
“I2” operates the wiper and washer on the top window.
J - Personnel Work Platform: This is a red switch
used to activate the Personnel Work Platform (PWP)
System. When activated, an amber lamp in the switch
E F G H will be on.

NOTE: This lamp will flash on and off, indicating

NOTE: Some switches are optional and may not that the system is not yet fully functional, until the
be on machine. brakes are held on for three or more seconds.

E - Head Lights/Work Lights: Pressing the top of the K - Blank:

switch will illuminate the lights mounted on the top of
the operator’s station and the red tail lights, for use in Heater Controls
forward travel operations. Pressing the bottom of the
switch will illuminate the lights at the end of the boom
in addition to the lights on the operator’s station, for
additional lighting in working operations.
F - Turn Signal: This switch is used to indicate the
direction of a turn with the tail lights. Depress the right
arrow for a right turn; depress the left arrow for a left
turn. Return the switch to the center position after the
turn is completed. Temperature
G - Hazard: This switch can be activated to make the Control Knob
tail lights flash on and off in case the machine is stalled
or temporarily stopped in a traffic area on the road or Fan Speed Knob
jobsite.
H - Strobe Light: When a stobe light is installed on
the machine, activating this switch will produce a
strobe light on and off flashing, for working in condi- Temperature Control: This is the upper knob located
tions that may obscure view of the machine. to the left of the steering wheel. This knob is used to
adjust the temperature output of the heater. Turning the
Bottom Row Switches knob clockwise will increase the temperature output of
the cab heater.
Switches have graphic symbols to indicate function
and effect. The following descriptions start with the Fan Speed: This knob is located below the tempera-
first switch on the left. ture control knob. Rotating the knob clockwise will
increase the fan speed for increased air circulation.

I1 I2 J K

PRINTED IN U.S.A. 25 50960089/AP0914

Heater A/C Controls
Position “F” (Forward)
Fan Speed
Knob Position “N” (Neutral)

Position “R” (Reverse)

Speed Range: Twisting the lever end clockwise or

counter-clockwise will change the transmission speed
between low, medium and travel ranges.
Position “3” (Travel Range)
Temperature
Position “2” (Medium Range)
Control Knob
Position “1” (Low Range)

Fan Speed: This is the upper knob located to the left IMPORTANT: Care should be taken when down-
of the steering wheel. The fan is in the off position shifting or changing direction, because damage to
when the knob is rotated completely to the left. the transmission can occur if shifting is forced or
Rotating the knob clockwise will switch the fan on and attempted at too high a speed. Allow engine
increase the fan speed for increased air circulation. speed to slow before any downshift or directional
Temperature Control: This knob is located below the change is attempted.
fan speed knob. It is used to adjust the temperature out-
put of the heater A/C unit. Turning the knob clockwise Steering
from the midpoint position will increase the tempera- Turn the steering wheel to the right or left to turn the
ture output of the cab heater. Turning the knob counter- machine in that direction.The power steering system is
clockwise from the midpoint position will switch the designed to provide low-effort steering without shock
A/C unit on and decrease the temperature output of the reaction from the tires to the steering wheel.
cab A/C.
FLOOR AND SEAT AREA
Travel Lever
Located on the left side of the steering wheel column, Throttle Pedal: This pedal, operated by the right foot,
this lever is used to change travel direction (forward or controls the engine speed to match power require-
reverse) and speed. ments. Pushing down on the pedal increases engine
speed; letting up on the pedal decreases engine speed.
Service Brake Pedal: Pressing this pedal activates
inboard hydraulic wet-disc-type brakes on all four
wheels. Separate front and rear brake systems allow
bringing the machine to a safe stop if either system
loses pressure.

Throttle Pedal

Brake Pedal

Travel Direction: The lever MUST be in “N”

(Neutral) position before the starter will engage to start
the engine.

NOTE: Backup alarm automatically sounds with

travel lever in “R” (Reverse). Brake
Reservoir

50960089/AP0914 26 PRINTED IN U.S.A.

Brake Fluid Reservoirs: Located under the hinged
cover on the cab floor directly in front of the seat.
WARNING
Seat Positioning: The seat is mounted on rails for for-
ward and rearward repositioning, for comfort and to Use extreme caution when raising or extend-
accommodate the operator’s size. A spring-loaded ing the boom. The Telescopic Handler MUST
latch handle under the front of the seat actuates the be level. Loaded or empty, the machine can tip
adjustment mechanism. over if it is not level.
ALWAYS place the transmission in neutral,
apply the parking brake and keep the service
Slide brakes fully applied before raising or extend-
Adjustment ing the boom.
Lever
NEVER exceed the specified lift and reach
capacities of the machine, or serious machine
damage and personal injury may result. Refer
to the load charts at the operator’s station or
this manual.
Suspension Seat Option: This option is available for
additional operator comfort. It is adjustable for a soft If a boom circuit hose fails with the boom up,
or firm ride. with or without a load, shut down the machine
following the MANDATORY SAFETY SHUT-
DOWN PROCEDURE. DO NOT attempt repairs.
Slide Instead, call your Manitou Americas dealer for
Adjustment assistance.
Lever
The truss boom and winch attachment tools
should ONLY be used to lift and place loads
when the machine is in a stationary position.
Transporting suspended loads must ALWAYS
Ride
be done slowly and cautiously, with the boom
Adjustment
Knob and load as low as possible. Use taglines to
restrict loads from swinging, to avoid over-
turn.
Seat Belt: This machine has a retractable seat belt.
Grasp the belt on the left side of the seat, pull the belt NEVER use winch for lifting or moving per-
over your lap, and insert the belt into the buckle on the sonnel. NEVER exceed the maximum rated
right side of the seat until you hear it lock in place. capacity of the winch (3000 lbs./1360 kg) or
exceed the load chart rating for winch appli-
cations.
Seat Belt DO NOT tilt the truss boom back more than
45o from horizontal. DO NOT attempt to use
the optional rotating carriage as a load level-
ing function. ALWAYS level the frame prior to
raising a load.
Failure to heed could result in death or seri-
ous injury.

RIGHT SIDE PANEL This machine is equipped with one of two types of
boom and attachment joystick control configurations,
Joystick Controls: These controls and indicators are either a two-joystick configuration, or a single tri-func-
used to position the frame, boom and attachment. tion joystick.
Graphic symbols on the side panel indicate the control
actions and effect.

PRINTED IN U.S.A. 27 50960089/AP0914

Two-Joystick Configuration Auxiliary Hydraulics Control: This two-position
lever is for attachment tools that require additional
Frame Level and Boom Control hydraulics.
Attachment Joystick Joystick
Tri-Function Joystick Configuration
Boom, Attachment
and Auxiliary
Hydraulic Joystick
Frame Level
Control

Auxiliary
Hydraulics Control

Two-Joystick Configuration

Frame Level/Attachment Tilt Joystick: The machine Single Tri-Function Joystick Configuration
may be tilted slowly as much as 10° to the left or right
to level the frame and boom in relation to the ground. Tri-Function Joystick: This joystick handle is
Move the joystick handle to the left to tilt to the left; equipped with two yellow buttons and two blue but-
move the joystick handle to the right to tilt to the right. tons on the upper rear of the handle, and a trigger
switch on the front of the handle. The yellow buttons
operate the attachment tilt. The blue buttons operate
WARNING the auxiliary hydraulics. The trigger switch increases
the function speed of both the attachment tilt and aux-
DO NOT level the frame with the boom raised iliary hydraulics.
or extended. Level the frame ONLY while
stopped, with the boom fully retracted and the To extend the boom, move the joystick to the right; to
attachment raised just enough to clear the retract the boom, move the joystick to the left. To raise
ground. the boom, move the joystick rearward; to lower the
boom, move the joystick forward.

To tilt the attachment tool up, move the joystick handle To tilt the attachment tool up, depress and hold the
rearward. To tilt the attachment tool down, move the lower yellow button on the left side of the joystick han-
joystick handle forward. dle; to tilt the attachment tool down, depress and hold
the upper yellow button on the left side of the joystick
After the operator tilts the attachment tool to a desired handle.
angle, that angle will be maintained as the boom is
raised and lowered, extended and retracted, until a new To operate the auxiliary attachment hydraulics, depress
angle is set. and hold either the upper or lower blue button on the
right side of the joystick handle. The upper blue button
Boom Control Joystick: This machine has a will cause the reverse effect of the lower blue button.
hydraulic-type boom with telescopic sections. The sec-
tions extend by means of a hydraulic cylinder and Depressing and holding the trigger on the front side of
chain system inside the boom, sequenced for uniform the joystick handle will increase the speed of the
extension of each section. attachment tilt and auxiliary hydraulic functions.

To extend the boom, move the joystick handle to the NOTE: The joystick handle does not need to be
right; to retract the boom, move the joystick handle to moved to operate the tilt or auxiliary hydraulic
the left. To raise the boom, move the joystick handle functions.
rearward; to lower the boom, move the joystick handle
forward.

50960089/AP0914 28 PRINTED IN U.S.A.

Speed Control Knobs: The tri-function joystick incor- NOTE: There is a locking knob located forward of
porates a manually adjusted speed control. Speed the adjusting knob, which must be loosened
adjustment is accomplished through the manual adjust- before the adjusting knob can be turned. After
ment of pilot-pressure apply valves located next to the adjustment has been made, tighten the locking
main valve at the rear of the machine. knob to maintain the selected speed.
Frame Level Control: This control is located to the
rear of the tri-function joystick. The machine may be
tilted slowly as much as 10° to the left or right to level
the frame and boom in relation to the ground.

WARNING
DO NOT level the frame with the boom raised
or extended. Level the frame ONLY while
stopped, with the boom fully retracted and the
attachment raised just enough to clear the
ground.
Attachment Tilt Pilot- Auxiliary Hydraulics
Pressure Apply Valve Pilot-Pressure Apply
12 Volt Accessory Power Port: Use this power port to
Valve
power small electrical devices.
Locking Pilot-Pressure
Knobs Apply Valve
12 Volt
Power Port

FUNCTION INDICATORS

Speed Control L71378 Frame Angle Indicator: Located in front of the oper-
Knobs Decal ator on the ROPS upper cross tube, the position of the
ball indicates when the frame is level relative to a slop-
If the machine is equipped with auxiliary hydraulics, ing ground surface.
there will be two pilot-pressure apply valves, each hav-
ing two speed-control knobs. The top pilot valve con- Frame Angle
trols the auxiliary hydraulics, and the lower pilot valve Indicator
controls the attachment tilt function. On the attachment
tilt pilot valve, the left knob controls the attachment
Boom Angle Indicator: Mounted on the left side of
tilt-back speed, and the right knob controls the attach-
the outer boom, the movement of a ball indicates the
ment tilt-forward speed. On the auxiliary hydraulic
angle of boom elevation relative to the ground.
pilot valve, the function of the knobs will depend on
the type of attachment requiring auxiliary hydraulics.
Turning a knob clockwise will increase the speed of its
associated function. Turning a knob counter-clockwise
will decrease the speed of its associated function. Boom Angle
Indicator

PRINTED IN U.S.A. 29 50960089/AP0914

SERVICE AND SAFETY FEATURES Backup Alarm: Located inside the rear frame cover,
this alarm produces a loud warning sound when the
Coolant Level: Visually check the level of the engine machine is in reverse.
coolant through the sight gauge located on the back of
the radiator as shown. Remove the radiator cap to add Backup Alarm
coolant.

Radiator
Cap

Side-View Mirror: Located on the front outside cor-

ner of the fuel tank, this mirror provides the operator
with a view toward the rear of the machine.
Coolant Level
Sight Gauge Hydraulic Reservoir Oil Level and Fill Cap: The
dipstick on the fill cap of the reservoir indicates the
Engine Oil Level: The dipstick is located on the right level of the hydraulic oil in the reservoir.
side of the engine. Open the door to gain access to the
engine oil dipstick, filter and filler. Side-View
Mirror
Engine Oil
Filter
Engine Oil
Engine Oil Hydraulic Fill
Filler
Dipstick Cap/Dipstick

Air Filter Restriction: This message will appear in

Hydraulic Pressure Test Ports: A gauge can be the multi-function display anytime the air cleaner is
attached to these ports to check main valve, joystick restricted. Check the air cleaner for a clogged element
and steering pressures. and replace if neccessary. The message will clear when
the air cleaner restriction is corrected.
Transmission Oil Level: The dipstick is located under
the access cover on the front hood section. Fuse and Relay Access Compartment: This compart-
ment is located under the load chart panel. Remove the
Battery Compartment: The battery is located under four screws to gain access to the fuses and relays.
the access cover on the front hood section.

Transmission Hydraulic
Dipstick Test Ports
Fuse and
Relay Access

Battery

50960089/AP0914 30 PRINTED IN U.S.A.

Fuses and Relays Functions: Remove the covers to ATTACHMENT TOOLS
access the fuses and relays. Refer to the illustration and
following description for the fuse and relay functions. Manitou Americas offers a range of attachment tools to
meet various lifting and material-handling applica-
tions. Contact your Manitou Americas dealer for spec-
D C ifications and ordering information.

ACCESSORIES
A Manitou Americas also offers a range of special acces-
1
sories for this machine. Contact your Manitou
2 Americas dealer for specifications and ordering infor-
E
3 mation.

B F
4 NOTE: All accessories are field-installed unless
otherwise noted. Information and parts for
6
installing accessories are provided by your
5 Manitou Americas Telescopic Handler dealer or
Manitou Americas.
FUSES:
1. 15 AMP fuse: Ignition Switch, Horn, Brake Lights,
and Clutch Cutout.
2. 20 AMP fuse: Transmission, Park Brake, PWP,
Steer Select, and Backup Alarm.
3. 15 AMP fuse: Lights.
4. 25 AMP fuse: Heater and Display.
5. 25 AMP fuse: Top Wiper Motor.
6. 25 AMP fuse: Front Wiper Motor.
RELAYS:
A. 40 AMP change-over relay: Ignition.
B. 40 AMP change-over relay: Ignition.
C. 20 AMP relay: Front Wiper.
D. 20 AMP relay: Park Brake.
E. 20 AMP relay: Lights.
F. 20 AMP relay: Top Wiper.

PRINTED IN U.S.A. 31 50960089/AP0914

 INTENTIONALLY BLANK

50960089/AP0914 32 PRINTED IN U.S.A.

 Chapter 6
OPERATION AND ADJUSTMENTS
GENERAL INFORMATION PRE-START WALK-AROUND INSPEC-
TION
CAUTION It is the operator’s responsibility to perform a pre-start
inspect of the machine before the start of each work-
BEFORE starting the engine and operating the day. Every pre-start inspection must include more than
Telescopic Handler, review and comply with simply checking the fuel and oil levels. It is a good
ALL safety recommendations in the SAFETY practice to personally inspect any machine you are
chapter of this manual. Know how to STOP the assigned to use, even though it has already been put
machine before starting it. Also, BE SURE to into service by other personnel.
fasten and properly adjust the seatbelt.
The pre-start inspection is designed to discover if the
machine has incurred any damage or is in need of rou-
ENGINE BREAK-IN tine service.
A new engine does not require extensive “break-in.” Any needed repairs are to be made by a qualified ser-
However, for the first 100 hours of operation: vice technician.
• Allow the engine to idle for a few minutes after Refer to the illustration and checklist on the next two
every cold start. pages for the “Pre-Start Walk-Around Inspection.”
• DO NOT idle the engine for long periods of time.
• DO NOT operate the engine at maximum power
for long periods of time.
• Vary the engine speed and load.
• Check the oil level frequently, and replenish as
necessary with the oil specified in the engine man-
ual.
After the first 100 hours of operation, change the oil
and replace the oil filter. Consult the Lubrication chap-
ter or the engine manual for the type of oil to use in the
engine. Refer to the Service and Storage chapter for the
proper service intervals.

PRINTED IN U.S.A. 33 50960089/AP0914

 Pre-Start Walk-Around Inspection Illustration
PRE-START WALK-AROUND INSPECTION Any needed repairs or service noted during the inspec-
PROCEDURE tion must be performed by a qualified service techni-
cian before operating the machine.
Refer to the following illustration and checklist to per-
form the inspection. Begin with item 1 at the left front The illustration and checklist page can be copied for
of the machine and walk toward the rear of the future pre-start walk-around inspections.
machine on the left side and around the back and
toward the front on the right side of the machine.

4
6

1 12

13

14
2 3

10 11
9
7
8

18

27

16
26
24
17

15 28

19
20 21 22 23
25

50960089/AP0914 34 PRINTED IN U.S.A.

 Pre-Start Walk-Around Inspection Checklist
Note the condition of safety decals during the walk-around o13. Boom Hydraulic Hoses: No visible damage or exte-
inspection. Replace missing or illegible safety decals. rior wear; no evidence of leaking.
o1. Attachment Tool: Check for broken, missing or o14. Rear Light Assembly: Properly secured; no visible
damaged parts. When using a personnel work plat- damage; no loose or disconnected wires; no malfunc-
form, check to see if the platform meets ANSI/ITSDF tions.
standards and that it is secured to the forks and fork
o15. Hydraulic Control Valve Assembly: No loose or
carriage. When using forks, check for welds, cracks missing parts; no evidence of leaking; no damaged or
or misalignment. Replace the forks in sets when the leaking hoses.
condition of the forks is questionable.
o16. Exhaust System: No loose or missing parts; no visi-
IMPORTANT: DO NOT use forks that have been ble damage; no obstructions to the outlet.
repaired by welding.
o17. Engine Air Filter: No loose or missing parts; no vis-
o2. Attachment Tool Mount: No loose or missing parts; ible damage; no obstructions to the evacuator; pre-
no visible damage. cleaner free from dirt; restriction indicator proper
o3. Attachment Tool Mounting Pins: No visible dam- reading.
age; pin fit is secure and properly lubricated.
o18. Boom Hose Guards: Properly secured; no visible
o4. Boom Chain: No loose or missing parts; no visible damage.
damage; sheave pin fit is secure and properly lubri-
o19. Engine Compartment:
cated.
o Engine oil level, add if needed;
o5. Boom Sections and Wear Pads: No loose or missing
o Coolant level, add if needed;
parts; no visible damage or excessive wear.
o No evidence of engine oil or coolant leaks;
NOTE: Wear pads that measure 3/8” (9.5 mm) thick or
o Belts and hoses in good condition, properly secured
less need to be replaced.
and adjusted
o6. Boom Angle Indicator: Properly secured; no visible o20. Fuel Tank: No visible damage; no evidence of leak-
damage; bubble is visible. ing; level of fuel; breather cap secure and working.
o7. Tire and Wheel Assemblies: Properly secured; no o21. Hydraulic Oil Reservoir: No visible damage; no
loose or missing lug nuts; no visible tire damage (cuts evidence of leaking; recommended oil level; breather
or abrasions); proper inflation. cap secure and working.
o8. Front and Rear Axles: No loose or missing parts; no o22. Battery Compartment (under cover): Proper elec-
visible damage; tie rod end studs locked; no evidence trolyte level; no loose or damaged cables; no visible
of leaking; properly lubricated. damage or corrosion.
o9. Operator Compartment: o23. Mirror Assembly: No loose or missing parts; no vis-
o Seat belt undamaged; operates properly; mounting ible damage; properly adjusted.
hardware secure.
o24. Cowling and Latches: All cowling, doors and latch-
o Switches and levers undamage; es in working condition; properly secure; no loose or
o no loose or missing parts; missing parts; all components operate properly.
o load charts properly secured and legible; o25. Frame: No visible damage; no cracked welds; no
o levers and switches operate properly; control mark- loose or missing parts.
ings legible;
o26. Frame Tilt Cylinder: Properly secured; no evidence
o frame level indicator secured and undamaged, bub- of leaking; properly lubricated.
ble is visible.
o27. Tilt and Auxiliary Hydraulic Hoses: No visible
o10. Lift Cylinder: Properly secured; no visible damage; damage or excessive wear; no evidence of leaking.
no evidence of leaking from the cylinder; properly
lubricated. o28. Attachment Tilt Cylinder: Properly secured; no vis-
ible damage; no evidence of leaking from the cylin-
o11. Slave Cylinder: Properly secured; no visible dam- der; properly lubricated.
age; no evidence of leaking from the cylinder; prop-
erly lubricated.
o12. Boom Pivot Assembly: Properly secured; no visible
damage or excessive wear; properly lubricated.

Date: _________________Initials: _______________

PRINTED IN U.S.A. 35 50960089/AP0914

BEFORE STARTING ENGINE 6. Check that indicators are in their normal operating
conditions.
Before mounting the operator’s compartment, walk
7. Verify that there are no fuel, oil or engine coolant
completely around the machine to be sure no one is
leaks, and no abnormal noises or vibrations.
under, on, or close to it. Let others in the area know
you are going to start up. Wait until everyone is clear COLD STARTING PROCEDURES
of the machine before starting it up. The engine is equipped with a block heater. This block
Before starting the engine and running the machine, heater or other starting aid is required for starting in
refer to the Indicators and Controls chapter and temperatures below 32°F (0°C). See your Manitou
become familiar with the various operating controls, Americas dealer for additional starting aids.
indicators and safety features.

STARTING THE ENGINE

WARNING
Do not use starting fluid (ether) with engine
glow plug preheat systems. An explosion can
WARNING result, which can cause engine damage, injury
or death.
ALWAYS fasten your seat belt BEFORE start-
ing the engine. Leave the parking brake
If the battery becomes discharged and has insufficient
applied until the engine is running and you are
power to start the engine, jumper cables can be used
ready to operate the machine.
for starting assistance. Refer to the jump starting
instructions in the Service and Storage chapter of this
The following procedure is recommended for starting manual for safe jump starting procedures.
the engine:
STOPPING
1. Grasp the handholds and step up into the opera-
tor’s compartment. The following procedure is the recommended
sequence for stopping the machine:
2. Adjust the seat and fasten the seatbelt.
3. Check that all controls are in their “neutral” posi- 1. Bring the machine to a stop on a level surface.
tions, except the parking brake switch, which Avoid parking on a slope, but if necessary park
should be in the “ON” position. across the slope and block the wheels.

4. Turn the key switch clockwise one position to the 2. Fully retract the boom and lower the attachment to
“ON” position. When the pre-heat indicator lamp the ground.
in the multi-function display goes out, the engine 3. Idle the engine for at least 2 minutes for gradual
can be started. cooling.
5. Turn the key switch clockwise until the engine 4. Place controls in neutral. Apply the parking brake.
starter activates. Release the key switch when the 5. Turn the ignition switch key to the “OFF” position.
engine starts. If the key switch is released before Remove the key.
the engine starts, turn the key switch to the “OFF”
position and wait one minute before attempting to 6. Unfasten the seatbelt, and grasp the handholds
start again. while climbing out of the operator’s compartment.

IMPORTANT: Crank the starter until the engine FIRST TIME OPERATION
starts. If the engine fails to start within 20 sec- Make sure the engine is warm, and then go through the
onds, return the key to the “OFF” position, wait following procedures:
one minute, and try to start the engine. Cranking
the engine for longer than 20 seconds will result
in premature failure of the starter.
5. After the engine starts, allow several minutes
warm-up time before operating the controls. Allow
a longer warm-up time in cold weather.

50960089/AP0914 36 PRINTED IN U.S.A.

 CHANGING ATTACHMENT TOOLS
CAUTION The Telescopic Handler boom nose will accept
Manitou Americas Quick-attach™ System attachment
Be sure the area being used for test-running is
tools. The Quick-attach™ System has a quick-release
clear of spectators and obstructions. Initially,
hookup and locking mechanism for mounting framing-
operate the machine with an empty attach-
type or masonry-type attachment tools to the boom
ment tool.
nose.
Place the travel lever in Forward or Reverse and select
a speed range. Switch off the parking brake and move Attaching Procedure
ahead slowly, while testing the steering and brakes. To pick up an attachment tool, proceed as follows:
Stop and operate all boom, attachment tool functions
and frame leveling controls, checking for smooth 1. Raise the boom slightly, extend it two to three feet
response. (600 to 900 mm) for better visibility, and tilt the
tool carrier forward.
Apply the service brakes, stop the machine and move 2. Align the tool carrier squarely with the back of the
the travel lever to the opposite direction (forward or attachment tool.
reverse).
3. Slowly extend the tool carrier and lower the hooks
Shifting to the next higher gear may be done at any under the attachment tool hookup bar.
engine speed while the machine is in motion.
DO NOT overspeed the engine when down-shifting.
Allow the machine to slow down before shifting to the
next lower gear.

ENGINE SHUTDOWN PROTECTION

The engine is equipped with a WARNING and SHUT-
DOWN feature to warn of critical engine related fault
errors. These fault errors will be displayed in the multi- Attachment Quick-attach System Tilted
function display. If the cause of the error code is not Tool Forward for Hookup
corrected, the engine power will be reduced automati-
cally, or the engine will shut down. 4. Tilt the tool carrier back so that the lock plate
PARKING BRAKE engages the attachment tool. This secures the
attachment tool to the Quick-attach™ System.
NOTE: The parking brake mechanism within the
front axle is not designed for, and not intended to
be used as, the primary means of stopping move-
ment of the machine. Hydraulic braking provided Attachment Tool
through the service brakes within the axles is the Shown Locked to
primary means for stopping movement. The axle- Quick-attach
System
by-axle split brake system is the secondary
means of stopping movement.
The proper sequence for correct machine operation is
to always engage the parking brake switch before shut-
ting off the engine; and to disengage the parking brake
ONLY after the engine is running. In an emergency Quick-attach System Attaching Detail
however, if it becomes necessary to stop movement,
activate the parking brake switch to “ON.”
5. For an attachment tool with auxiliary hydraulics,
connect the hoses to the quick-disconnect connec-
tors on the boom nose.

PRINTED IN U.S.A. 37 50960089/AP0914

Detaching SELF-LEVELING
To detach the attachment tool, proceed as follows:
The machine is equipped with a hydraulic self-leveling
1. Raise the boom slightly and extend it two to three feature. This feature is designed to keep the attachment
feet (600 to 900 mm) for better visibility. Lower tool level while the boom is being raised.
the boom until the attachment tool is approximate-
ly 12” (0.3 m) off the ground. GENERAL MACHINE OPERATION
2. Tilt the carrier rearward as far as it will go. Once Check the Telescopic Handler to be sure all systems
the carrier is tilted back all the way, perform the are in good operating condition. Perform the following
Mandatory Safety Shutdown Procedure (Safety steps before starting the machine the first time each
chapter, page 8). day:
3. With the engine off, leave the operator’s station 1. Check the engine oil, coolant, transmission oil and
and manually raise the lock spring and flip the lock hydraulic oil levels.
plate up and outward at least 180° so it is in posi-
tion to re-lock onto the next attachment tool. 2. Make sure weekly lubrication has been done.
3. Visually inspect for leaks, broken or malfunction-
ing parts. Make sure all caps, covers and safety
Attachment Tool
Shown Unlocked
shields are in place.
for Release from 4. Check tires for cuts, bulges, nails, correct pressure,
Quick-attach
loose wheel nuts, etc.
System
5. Inspect the work area. Be sure you know where
you will make load pickups, placements, lifts, and
turns. Look over the terrain of the jobsite for holes,
obstacles, slippery surfaces, and soft or deep mud.
6. Check clearances of ramps, doorways and
passageways. Check overhead clearances if you
Quick-attach System Detaching Detail will travel and place loads near power or telephone
4. Tilt the Quick-attach™ System forward to allow lines.
the attachment tool to roll out, then lower the boom If the machine is found to be in need of repair or in any
so that the hook ears clear the hookup bar on the way unsafe, or contributes to an unsafe condition, the
attachment tool. matter must be reported immediately to the user’s des-
NOTE: One side of the lock plate has a bright red ignated authority. The machine should not be operated
decal to indicate the unlocked position. until it has been restored to a safe operating condition.

5. If the attachment tool has auxiliary hydraulics, dis-

connect the hoses from the quick-disconnects on WARNING
the boom nose.
Exhaust fumes can kill. Ensure proper ventila-
6. Start the engine and roll the Quick-attach™ System tion when starting indoors or in enclosed
forward. Slowly back the machine until the attach- areas.
ment tool is free from the boom nose.
Use proper hand-holds, NOT the steering
wheel or control levers as handholds when
WARNING mounting and dismounting.
Modifications, alterations to, or use of attach- NEVER operate the machine with safety
ment tools not authorized by Manitou guards or covers removed.
Americas (or the manufacturer) in writing can
void warranty and cause machine damage Over-inflated tires can explode and cause
and/or serious personal injury or death. injury or death. Tire repairs MUST be made
only by authorized personnel using proper
tools and equipment.

50960089/AP0914 38 PRINTED IN U.S.A.

Operate the travel controls gradually and smoothly 2. DO NOT travel up or down a grade or slope that
when starting, stopping, turning and reversing direc- exceeds 22% or 12° while loaded.
tion. 3. DO NOT place or retrieve loads on a side hill with
a slope or grade that exceeds 12% or 7°.
Grade and Slope Precautions Regardless of the terrain or position of the wheels,
The Telescopic Handler complies with industry stabil- the FRAME MUST BE LEVEL, as indicated by
ity test requirements and is stable when properly oper- the frame angle indicator on the ROPS/FOPS
ated. However, improper operation, faulty mainte- crossmember.
nance, and poor housekeeping can contribute to a con- 4. DO NOT travel across a side hill that exceeds 18%
dition of instability. or 10° grade. Regardless of the terrain or position
The amount of forward and rearward tilt to be used is of the wheels, the FRAME MUST BE LEVEL,
governed by the application. Although use of maxi- as indicated by the frame angle indicator on the
mum rearward tilt is allowable under certain condi- ROPS/FOPS crossmember. The attachment tool
tions, such as traveling with the load fully lowered, the MUST be maintained at the “carry” position with
stability of the machine, as determined by the industry the boom fully retracted, and attachment tool at
standard tests, does not encompass consideration for minimum ground clearance.
excessive tilt at high elevations, or the handling of off- When ascending or descending grades in excess of 5%
center loads. or 3°, the machine should be driven with the load
upgrade. An unloaded machine should be operated on
Only handle loads within the capacity limits of the all forward grades with the load handling attachment
machine, and which are stable and safely arranged. tool downgrade, tilted back if applicable, and raised
When attachments are used, extra care should be taken only as far as necessary to clear the road surface.
in securing, manipulating, positioning and transporting
the load. On grades, ramps and inclines, use extreme caution
and avoid turning if possible. Normally travel straight
Grade Limits up and down the slope.
NOTE: Grade limits are based on ANSI/ITSDF Traffic Flow Patterns
standard B56.6-2005.
Know and understand the traffic flow patterns of your
The telescopic handler meets or exceeds the safety jobsite. Know all Telescopic Handler hand signals for
standard (ANSI/ITSDF B56.6) stability limits for safety. Utilize signal persons and be sure you can see
rough terrain forklifts. The stability tipping limits the signal person and acknowledge the signals given.
cover specific, controlled test conditions, which are
extremes, and which are not intended to be achieved Safety Hand Signals
during normal worksite operations. The following
specifications are provided only as information to the
operator, and must not be used as a guideline for oper-
ating the telescopic handler. For safe operation, always
follow the instructions and warnings provided in this
manual.

WARNING
DO NOT level the frame with the boom raised
or extended. Only level the frame while
stopped, and with the boom fully retracted,
and the attachment tool raised just enough to
clear the ground.

1. DO NOT place or retrieve loads on an up or down

slope or grade that exceeds 7% or 4°.
Safety Hand Signals Continued on Next Page

PRINTED IN U.S.A. 39 50960089/AP0914

 Safety Hand Signals Continued provided in operating areas. Where operating condi-
tions dictate, the operator/user is responsible for hav-
ing the machine equipped with lights.
Provisions should be made to prevent trucks, semi-
trailers and railroad cars from being moved during
loading and unloading. Wheel stops, parking brakes, or
other positive holding means should be used to prevent
movement during loading and unloading.
DO NOT move railroad cars and trailers with the
Telescopic Handler.
DO NOT use the boom and attachment for leverage to
push the machine out of mud.

IMPORTANT: DO NOT lower boom at high

engine speed when attachment tool is at maxi-
mum rearward tilt. Damage to slave cylinders may
result.

GENERAL LOAD HANDLING

NEVER operate controls except from the operator’s
seat. NEVER jerk or use fast movements. Avoid sud-
den stops, starts and changes in direction.
Operation of the hydraulic system depends on engine
speed and the distance the controls are moved. When
operating these controls it is important to develop a
technique called “feathering.” Feathering the control
means starting the desired motion by moving the con-
trol a small distance away from neutral. Then, after
movement has started, the control can be eased to full
travel. Use the same feathering technique to slow and
stop the motion.

When ramps must be used in transporting loads with

WARNING
the machine, the following shall be the minimum Excessive speed can be hazardous. ALWAYS
widths for safe travel: exercise caution and good judgement while
Compacted dirt, gravel, etc. 12 ft. (3.6 m) operating the machine.
Woodboard, concrete, etc. 10 ft. (3.0 m) ALWAYS maintain a safe distance from elec-
tric power lines and avoid contact with any
Permanent aisles, roadways, passageways, floors and
electrically charged conductor and gas line. It
ramps should be marked or defined in some fashion.
is not necessary to make direct contact with a
Permanent or temporary protrusion of loads, equip-
power line for power to ground through the
ment, material and construction facilities into the usual
structure of the machine. Keep the boom and
operating area should be guarded, clearly and distinc-
load at least 10 ft. (3 m) from all power lines.
tively marked, or clearly visible.
Accidental contact with a power line or rup-
Maintain a safe distance from the edge of ramps, plat- ture of a gas line can result in electrocution or
forms and other similar working surfaces. an explosion. Contact the “Call Before You
Dig” referral system number at 8-1-1 in the
Controlled lighting of adequate intensity should be U.S., or 888-258-0808 in the U.S. and Canada,

50960089/AP0914 40 PRINTED IN U.S.A.

to locate any underground utility lines Analysis: See “Typical Load Zone Chart” below.
BEFORE starting to dig.
Projecting up from the 15-foot reach mark on the hor-
Keep all body parts inside the operator’s sta- izontal axis to intersect a line through the 20-foot
tion while operating the machine. BE SURE of height mark on the vertical axis shows that a load up to
clearance for the attachment tool when turn- 2000 lb. can be placed in that zone.
ing, working around buildings, etc.
During placement, the operator should observe when
Turning corners too fast can tip the machine, the boom extension mark number “4” on the boom is
or cause a load to slide off the attachment. visible and stop further extension. The operator knows
Sudden slowing or stopping of the machine the maximum safe extension distance with the 2000 lb.
may cause the load to fall off the attachment load has been reached.
tool.
Be certain you can control both speed and
direction before moving. Always place the
machine in neutral and set the parking brake
before raising or extending the boom. NEVER BOOM
EXTENSION
drive the machine up to someone standing in MARKERS
front of the load.

HEIGHT ABOVE GROUND

NEVER leave the operator’s station without
first lowering the attachment tool to the
ground. Then set the parking brake, place con-
trols in neutral, shut off engine and remove
the key. AVOID parking the machine on a
slope, but if necessary, park across the slope
and block the tires.

Load Capacity and Reach

The machine has flip-charts in the operator’s station
that provide, at a glance, the load capacity limits at var-
ious positions of attachment tool extension and eleva-
tion. A set of the load zone charts is reproduced at the
end of this manual for reference. DISTANCE LOAD IS EXTENDED

A typical load zone chart is shown on the next page. Typical Load Zone Chart
The scale on the left indicates height in feet above the
ground level. The scale on the bottom shows the dis-
tance in feet from the front of the machine. The arc WARNING
lines noted by the numbers “1” through “5” correspond
with the position extension markers on the operator NEVER exceed the rated operating capacity of
side of the intermediate boom section. the Telescopic Handler as shown on the load
zone charts.
The following example illustrates proper use of the
load zone charts for the Telescopic Handler:
HANDLING NON-SUSPENDED LOADS
Example: The operator, using a standard carriage
attachment tool, wants to raise a 2000 lb. load 20 feet
Picking Up the Load
high, and can only get to within 15 feet of the load
placement point. Can it be done within the capacity of Inspect the load before picking it up. If it appears
the machine? unstable, DO NOT attempt to move it. DO NOT
attempt lifting double-tiered loads, or straddling side-
by-side pallets with one on each fork. NEVER add
extra unauthorized counterweights to the machine.

PRINTED IN U.S.A. 41 50960089/AP0914

Approach the load slowly and squarely with the For elevated or overhead placement, bring the machine
machine straight and level. Adjust the space between as close as possible to the landing point, and then:
forks, if necessary. Engage the load equally on the
forks until the load touches the carriage backrest. Tilt 1. Level the machine BEFORE raising the load. Use
the forks back to position the load for travel. extreme caution for high placement. Be sure per-
sonnel are clear of the area where the load or the
machine could fall or tip.
WARNING 2. Set the parking brake, hold the service brake pedal
fully applied and slowly raise the load, maintain-
Operating conditions such as slopes or soft
ing a slight rearward tilt to cradle the load.
ground can reduce the machine’s safe operat-
ing capacity. Exceeding the capacity when 3. As the load approaches the desired height, feather
raising or extending the boom will cause the the boom control at minimum speed until the load
machine to tip forward. is slightly higher than the landing point.
4. Continuing the feathering technique, lower the
Carrying the Load load into place.
If the load obstructs your view, get someone to direct 5. Free the forks from the load by alternately retract-
you. Maintain ground speeds consistent with ground ing and raising the boom. If this process is not pos-
conditions and that permit stopping in a safe manner. sible, very slowly and carefully reverse the tele-
scopic handler to free the forks from the load.
6. Lower the forks to travel height.

WARNING
The machine becomes less stable as the load
is raised higher.
NEVER use frame leveling to position an ele-
vated load. Always lower the load to the
ground and reposition the machine.
WARNING If a hydraulic boom circuit hose should break
with the boom up, shut down the machine. DO
NEVER travel with the boom above the carry NOT attempt to bring down the boom or make
position (attachment tool should be at mini- repairs. Call your Manitou Americas dealer
mum ground clearance). Boom should be fully immediately.
retracted.
As lift height increases, depth perception
Use lower gear when traveling down an decreases. High elevation placement may
incline. NEVER coast with the transmission in require a signal person to guide the operator.
neutral. Travel up and down grades slowly.
DO NOT ram the lift cylinders to the end of the
DO NOT operate the machine on a slope or stroke. The resulting jolt could spill the load.
grade that exceeds 22% or 12o. A jib or truss boom should ONLY be used to
lift and place loads when the machine is sta-
tionary and the frame is level. Transporting
Load Elevation and Placement suspended loads must ALWAYS be done slow-
For ground level load placement, be sure the area ly and cautiously, with the boom and load as
under the load and around the machine is clear of low as possible. Use taglines to restrict loads
equipment and personnel. Lower the load to the from swinging, to avoid overturn.
ground, tilt the forks to the horizontal position, and
then carefully back away to disengage the forks from
the load.

50960089/AP0914 42 PRINTED IN U.S.A.

HANDLING SUSPENDED LOADS 1. Rigging between the load and attachment should
be as short as possible to reduce boom height.
Determine the weight and load center of the load to be
handled. Refer to the telehandler load chart to deter- 2. Do not raise the load more than 12 inches (305
mine if the load can safely be handled. mm) above the ground or raise the boom more
than 45 degrees.
NOTE: Refer to the standard carriage load chart
when using the boom mounted hook. 3. All telehandler movements should be performed
slowly and cautiously to prevent load swing.
Avoid abrupt movement. Do not exceed walking
WARNING speed.

NEVER exceed the rated operating capacity of 4. Use a signal person anytime the load restricts the
the telehandler as shown on the load zone operators view or assistance is required. The sig-
charts. nal person should remain in contact (verbally or
visually) with the operator at all times until the
load is placed.

WARNING Ground Level Suspended Load Placement

1. Be sure the area under the load and around the
Operating conditions can reduce the telehan- telehandler is clear of equipment and personnel.
dler’s safe operating capacity. Exceeding the
2. Lower the load to the ground till load is stationary
capacity when raising or extending the boom
and the rigging is loose from the load. Have sig-
will cause the telehandler to tip forward.
nal person disconnect the rigging from the load.
3. Raise boom enough to clear the rigging from the
Picking Up Suspended Load load before backing the telehandler away from the
1. Rigging should be in good condition and rated for load.
the load being lifted.
Elevated Suspended Load Placement
2. Rigging should comply with OSHA regulation
1. Bring the telehandler as close as possible to the
§1910.184, “Slings,” or §1926.251, “Rigging
landing point.
equipment for material handling.”
2. Level the telehandler BEFORE raising the load.
3. Be sure the rigging equipment is clear of any part
Use extreme caution for high placement. Be sure
of the machine or machine attachment before lift-
personnel are clear of the load landing area.
ing the load.
3. Set the parking brake, shift the transmission into
4. Avoid lifting double-tiered or any unstable loads.
neutral, hold the service brake pedal fully applied
5. Only lift loads vertically and clear from any adja- and slowly raise the load.
cent obstacles. Never drag the load horizontally.
4. As the load approaches the landing point, feather
6. Use multiple lift points and taglines to restrain the the boom control at minimum speed until the load
load from swinging or rotating. is just above the landing point.

Carrying Suspended Load 5. With the assistance of a signal person, continue

the feathering technique to lower the load into
place.

WARNING
NEVER place the signal person between the
load and the telehandler or other stationary
objects.

PRINTED IN U.S.A. 43 50960089/AP0914

6. Once the load is stationary on the landing point
and the rigging is loose from the load, have the
signal person disconnect the rigging from the
WARNING
load. The PWP must meet ANSI/ITSDF B56.6-2005,
7. Raise boom enough to clear the rigging from the Section 8.24. (See page 15 in the Safety chap-
load. Slowly and carefully, reverse the telehandler ter for PWP design requirements.) If the PWP
till the rigging is clear of the load. being used does not offer means to secure the
PWP to the forks and to secure the forks from
8. Lower the boom to travel height. pivoting, as shown in steps 2 and 3, then an
alternate method must be used.
Installing a Personnel Work Platform
(PWP) 4. Connect the coiled wire from the remote shutdown
switch to the connector on the end of the boom.
WARNING Secure the remote shutdown switch to the PWP
using the strap attached to the switch, as shown
The machine must not be used to lift or carry below.
personnel or be fitted with any form of per-
sonnel work platform unless fitted with the Electrical
Connection
optional PWP System.
If fitted with the PWP System, the Mandatory
PWP
Work Platform Safety Rules (p. 14) must be fol- Remote
lowed at all times while lifting personnel. Shutdown
Switch
1. Center the forks on the carriage, spaced apart to
match the distance required to engage the PWP.
2. After the forks are fully engaged in the PWP, Remote Shutdown Switch
secure the PWP to the forks. This can be accom-
plished by means of a retaining pin behind the heel 5. Secure the lanyard from the body harness to the
of the forks, as shown. PWP or the boom. Each person in the PWP should
have a body harness with a lanyard attached to the
PWP.

Elevating Personnel
The Telescopic Handler is primarily intended for use as
a material handler. It should only be used to elevate
Retaining personnel if it is equipped with the (optional) PWP
Pin System when there is no other practical option. If this
machine is to be used to elevate personnel, then use
3. Secure the forks from pivoting upward in case the only an approved work platform, lift personnel only
PWP is lowered onto an obstruction. This can be with the PWP System activated, and follow the
accomplished by using the chain supplied with the “Mandatory Work Platform Safety Rules” (p. 14
PWP to secure the lower portion of the PWP to the Safety chapter).
bottom of the carriage, as shown below. If the Telescopic Handler is equipped with a PWP
System and is to be used for elevating personnel, the
system must be activated, by the "PWP System" mode
Chain switch, which is located in the instrument and switch
panel. To activate the system, press the top of the PWP
rocker switch, apply and hold the service brakes on for
three or more seconds. The system is activated when
the lamp in the PWP rocker switch is on continuously.

50960089/AP0914 44 PRINTED IN U.S.A.

NOTE: If the light is flashing, apply the service
brakes until the light stops flashing. WARNING
In an emergency, if the platform worker has
WARNING activated the remote shut-off switch and then
is not able to re-activate the switch, such as if
ALWAYS check the PWP System for proper
the worker fainted, then the Telescopic
operation prior to use. (See page 53 for PWP
Handler operator is permitted to turn off the
System checking procedure.)
PWP System to regain control of the boom
functions, in order to lower the work platform
When the PWP System is active: and come to the aid of the worker. But, under-
stand this is only permitted in case of an
l transmission is de-clutched into Neutral, emergency. Otherwise, the PWP System must
l parking brake is applied, be used at all times when there are workers on
l auxiliary hydraulic and carriage tilt and swing the platform. This is the only exception!
functions are disabled,
l machine inclination sensor is activated, with
the result that the Telescopic Handler must be level ROAD TRAVEL
laterally (side-to-side) and longitudinally (front-to-
For short distance highway travel, attach a Slow-
back) to within the factory pre-set limits before the
Moving Vehicle (SMV) emblem (purchased locally) to
boom control joystick will function, and
the rear of the Telescopic Handler. For highway opera-
l remote shutdown switch is activated, meaning that
tion, obtain and install an amber flashing beacon.
the switch must be connected and in the “on” posi-
tion for the boom control joystick to function. NOTE: ALWAYS follow ALL state and local regu-
Pressing the shutdown switch will disengage the lations regarding the operation of equipment on or
boom control joystick, and stop all platform move- across public highways. Whenever there is an
ment. The remote shutdown switch box is supplied appreciable distance between jobsites, or if
with a coiled electrical cable that must be connect- driving on public highway is prohibited, transport
ed to the outlet on the front of the innermost boom the machine using a vehicle of appropriate size
section near the carriage. The switch must be and capacity.
accessible by the platform personnel at all times
when the platform is to be moved. TRANSPORTING BETWEEN JOB-
To de-activate the PWP System, apply and hold the SITES
service brakes on for three or more seconds, and press
the bottom of the PWP System rocker switch. The sys- ALWAYS abide by the following recommended proce-
tem is de-activated when the lamp in the PWP System dures and guidelines when using ramps to load the
rocker switch is off. machine onto (and unload it from) a truck or trailer.
Failure to heed can result in damage to equipment and
NOTE: If the lamp in the PWP system rocker serious personal injury or death!
switch is flashing, apply the service brakes until
the lamp goes off. Tie-down eyes are provided for inserting chains
through to secure the machine during transporting.

Front Tie-Down Rear Tie-Down

PRINTED IN U.S.A. 45 50960089/AP0914

Loading Machine Using Ramps
NOTE: A matched pair of ramps is required. WARNING
NEVER adjust travel direction (even slightly)
while traveling on the ramps. Instead, back
down off the ramps, and then realign the
machine with the ramps.

WARNING
NEVER transport the machine with the boom
raised or extended. BE SURE to secure the
machine to the truck or trailer bed using chain
Ramp Placement and binders or steel cables, to prevent any
1. The ramps MUST be of sufficient strength to sup- movement while transporting.
port the machine. The use of strong steel ramps is
recommended, as well as center supporting blocks. THEFT DETERRENTS
2. The ramps MUST be firmly attached to the truck
or trailer bed with NO step between the bed and Manitou Americas has recorded all major component
the ramps. part numbers and serial numbers. Users should take as
many of the following actions as possible to discour-
3. The incline of the ramps MUST be less than 15
age theft, to aid in the recovery of the machine in the
degrees. For a four-foot high truck bed, ramp
event it is stolen, and to reduce vandalism:
length must be at least 16 feet (4.9 m) long.
4. Ramp width MUST be at least 1-1/2 times the tire 1. Remove keys from unattended machines.
width. 2. Attach, secure, and lock all anti-vandalism and
5. Block the front and rear of the tires on the truck or anti-theft devices on the machine.
trailer. Engage the parking brake. 3. Lock doors of cabs when not in use.
6. Position the machine with the boom facing toward 4. Inspect the gates and fences of the equipment stor-
the front of the truck or trailer so that it is straight age yard. If possible, keep machines in well-light-
in line with the ramps. ed areas. Ask the local law enforcement agency to
7. Slowly (at the lowest engine speed possible) and make frequent checks around the storage and work
carefully drive the machine up the ramps. sites, especially at night, during weekends, and on
holidays.
8. Secure the machine to the bed of the truck or trail-
er with tie-down chains/cables. 5. Report any theft to your dealer and insurance com-
pany. Provide the model and serial numbers.
Unloading Machine Using Ramps Request your dealer to forward this information to
NOTE: A matched pair of ramps is required. Manitou Americas.

Repeat steps 1 through 5 and proceed as follows to

unload the machine:
6. Remove the tie-down chains/cables.
7. If necessary, adjust the machine so that the wheels
are in line and centered with the ramps.
8. Slowly (at the lowest engine speed possible) and
carefully drive the machine down the ramps.

50960089/AP0914 46 PRINTED IN U.S.A.

 Chapter 7
LUBRICATION
GENERAL INFORMATION Hydraulic System Reservoir
Use an oil that contains anti-rust, anti-foam
and anti-oxidation additives and conforms to
WARNING ISO VG46/VG32.
Factory filled with CHS Cenex Indol
NEVER lubricate or service this unit when any Alternative oil: Mobil DTE 15M or equivalent
part of the machine is in motion. ALWAYS Capacity: 35 gallons (133 liters)
exercise the MANDATORY SAFETY SHUT-
DOWN PROCEDURE (p. 8, SAFETY chapter) Engine Crankcase Oil
before lubricating or servicing this equipment. Ambient Temperature Grade*
-22°F - 86°F (-30°C - 30°C) SAE 5W-30
-22°F - 104°F (-30°C - 40°C) SAE 5W-40
NOTE: The Maintenance chapter (Chapter 10) -4°F - 86°F (-20°C - 30°C) SAE 10W-30
in this manual has provisions for recording the -4°F - 104°F (-20°C - 40°C) SAE 10W-40
dates and hourmeter readings after lubrication or 5°F - 104°F (-15°C - 40°C) SAE 15W-40
other service has been performed; use those
IMPORTANT: Refer to the Engine Operator’s Manual for specific
spaces to keep a log for maintaining a current ser- oil recommendations and additional information.
vice interval record. Proper routine lubrication is *API Service Classification: CJ-4
an important factor in preventing excessive part Capacity: 9.5 quarts (8.9 liters)
wear and early failure.
Diesel Fuel
LUBRICANTS
Use only ultra low sulfer (ULSD) diesel
The chart on this page lists the locations, temperature fuel with a maximum of 15 PPM sulfer
ranges and recommended types of lubricants to be used content specified to EN590 or ASTM D975.
when servicing the machine. Refer to the separate
engine manual for additional information regarding Engine Coolant
recommended engine lubricants, quantities and grades IMPORTANT: Use an ethylene glycol based
required. Extended Life Coolant and quality water mix-
ture suitable for heavy duty diesel engines. Coolant
NOTE: Refer to Operator Services topic in the should be a phosphate-free, silicate-free, nitrite-free
Service and Storage chapter of this manual for and borate-free formula with corrosion inhibitors to
detailed information regarding periodic checking provide wet sleeve liner cavitation and corrosion pro-
and replenishing of lubricants. tection of all cooling system metals.
Factory filled with: FINAL CHARGE 50/50
PRE-DILUTED Global Extended Life
Transmission Oil
Coolant/Antifreeze.
Temp. Range -25°F - 75°F (-32°C - 24°C)
Use Dexron® II or equivalent Axle Gear Oil
Factory filled with CHS Cenex Auto Gold D/M Factory filled with CHS Cenex Qwiklift HTB
Temp. Range 0°F - 100°F (-18°C - 38°C) Alternative oil: MobilFluid® 424 or equivalent
Use Allison C-4 30W or equivalent Differential capacity: 9.6 quarts (9.0 liters)
Capacity: 24 quarts (23 liters) Planetary capacity: 0.6 quarts each (0.5 liters)

Brake System All Grease Fittings

Use Multi-ATF Dexron® II/III or equivalent Use No. 2 lithium-based grease

PRINTED IN U.S.A. 47 50960089/AP0914

 REPLACEMENT FILTER CHART
AIR FUEL ENGINE HYDRAULIC TRANS.
ENGINE TYPE FILTER OIL FILTER STRAINER OIL

Deutz TD3.6 L4 Primary Filter

50352454 50302441 132023 L97489 L49327 L99184
Safety Separator
50352455 Filter
50303847

GREASING BOOM AREA

9 Boom-to-frame-upright pivot pins . . . . . . . .2
Refer to the illustrations and listings for fitting loca- 10 Rod end, slave cylinder pivot pins . . . . . . . .2
tions. Wipe dirt from the fittings before greasing them 11 Rod end, lift cylinder pins . . . . . . . . . . . . . .2
to prevent contamination. Replace any missing or dam- 12 Extend cylinder pivot pins . . . . . . . . . . . . . .2
aged fittings. To minimize dirt build-up, avoid exces- 13 Chain sheave pins . . . . . . . . . . . . . . . . . . . . .2
sive greasing. 14 Quickattach-to-boom-nose pivot pins . . . . .2
15 Tilt cylinder pivot pins . . . . . . . . . . . . . . . . .2
BASIC MACHINE 16 Rotate cylinder pivot pins . . . . . . . . . . . . . .2
GREASE FITTINGS LOCATIONS 17 Rotate carriage wear pads . . . . . . . . . . . . . .3
18 Rotate pivot bearing . . . . . . . . . . . . . . . . . . .1
Every 50 Hours (or weekly)
19 Boom slide pads - as required, front and rear
Refer to the illustration on the facing page for loca-
tions.
CHASSIS AREA
1 Brake foot pedal linkage . . . . . . . . . . . . . . .1
2 Wheel spindle pins (per axle) . . . . . . . . . . . .4
3 Axle-to-frame pivot pins (per axle) . . . . . . .2
4 Drive shaft, slip joint (per shaft) . . . . . . . . .1
5 Drive shaft, u-joint (per shaft) . . . . . . . . . . .2
6 Level cylinder pivot pins . . . . . . . . . . . . . . .2
7 Base end, lift cylinder pivot pins . . . . . . . . .2
8 Base end, slave cylinder pivot pins . . . . . . .2
17

18
FRONT
SIDE

16

50960089/AP0914 48 PRINTED IN U.S.A.

 1
6

3 4

13
9 11
12

10
7
8
UNDER
COVER

13

15

14

19 12 15
19

Grease Fittings Locations

PRINTED IN U.S.A. 49 50960089/AP0914

 Chapter 8
SERVICE AND STORAGE
GENERAL INFORMATION When a problem occurs, do not overlook simple caus-
es such as an empty fuel tank. Check for leaks and bro-
ken connections. Make note of any specific symptoms,
WARNING noises, etc. and contact your local Manitou Americas
dealer.
BEFORE performing any service on the IMPORTANT: Always dispose of waste lubricating
Telescopic Handler, unless expressly instruct- oils, anti-freeze and hydraulic fluids according to
ed to the contrary, exercise the MANDATORY local regulations or take them to a recycling cen-
SAFETY SHUTDOWN PROCEDURE (p. 8, ter for disposal. DO NOT pour them onto the
Safety chapter). After service has been per- ground or into a drain.
formed, BE SURE to restore all guards,
shields and covers to their original positions DEALER SERVICES
BEFORE resuming machine operation.
The following areas of internal components service
replacement and operating adjustments should only be
performed by (or under the direction of) an authorized
NOTE: All service routines, with the exception of Manitou Americas Telescopic Handler dealer.
those described under the “Dealer Services”
topic, are owner-operator responsibilities. All IMPORTANT: DO NOT service or repair major
operator services described under the subtopics components, unless authorized to do so by your
are also referred to on a decal located on the Manitou Americas dealer. Any unauthorized repair
inside right side panel of the operator’s station. will void the warranty.
Refer to the Lubrication chapter of this manual for
POWERTRAIN COMPONENTS
lubrication information.
The engine and transmission are coupled directly to
NOTE: This Service and Storage chapter details
each other. All service routines related to the internal
procedures to follow for making routine mainte-
components are precise and critical to proper power-
nance checks, adjustments and replacements.
train operation. The axle differential and planetary
The majority of the procedures are also referred
ends are also sophisticated assemblies that require spe-
to in the Maintenance chapter of this manual. For
cial know-how and tools for servicing.
engine-related adjustments and servicing proce-
dures, refer to the engine manual provided. IMPORTANT: If any powertrain components are
suspected of faulty operation, contact your
PRECAUTIONS Manitou Americas dealer for assistance.
DO NOT perform any maintenance or repair without
HYDRAULIC SYSTEM COMPONENTS
the owner’s prior authorization. Allow only trained
personnel to service the machine. Valves, pumps, motors and cylinders are sophisticated
assemblies, which require special know-how and tools
Warranty repairs can only be done by a Manitou
for servicing. All cylinders are appropriately designed
Americas dealer. Dealers know what portions of the
with particular strokes, diameters, checks and hose
machine are covered under the terms of the Manitou
connection provisions unique to the machine applica-
Americas Warranty and what portions are covered by
tion requirements. A hydraulic schematic (located at
other vendor warranties.
the back of this manual) can be used as a guide for ser-
vice reference, as required.

50960089/AP0914 50 PRINTED IN U.S.A.

 ELECTRICAL COMPONENTS
WARNING An electrical system schematic is provided, which
includes instrumentation, electrical components and
Tilt, lift, extend and leveling cylinders have
switch connections. It is located at the back of this
counterbalance valves. These valves keep
manual and can be used as a guide for service refer-
hydraulic fluid from entering and exiting the
ence, as required.
cylinders while not being used, and are under
extremely high pressure. Before removing OPERATOR SERVICES
any of these valves, it is REQUIRED to call the
your Manitou Americas Service Department. Some of the operator-related services will require
Failure to do so may result in serious injury or access to components located inside the superstructure,
death. under shields, hoods and covers. The chart on this page
notes the components accessed in each particular area.
Internal service on any of these components should
only be performed by (or under the direction of) an
authorized Manitou Americas Telescopic Handler
dealer.

ACCESS TO COMPONENTS CHART

Component Operator’s Frame Front Mid-Rear

Station Cover Hood

Axle (underside) l
Engine l
Transmission (center area) l
Drive Shafts (underside) l
Main Control Valve (rear) l
Muffler (underside) l
Air Cleaner (between boom supports) l
Battery l
Radiator l
Brake Valve (underside) l
Travel Controls (dash area) l
Boom Controls (right side) l
Hydraulic Test Ports l
Hourmeter (dash) l
Switches/Indicators (dash) l
Hydraulic Pump l
Hydraulic Filter (Reservoir) l
Misc. Hydraulic Valves l
Heater (lower front) l

PRINTED IN U.S.A. 51 50960089/AP0914

 Block the tires. Remove the ignition key. Remove only
WARNING guards or covers that provide needed access. Wipe
away excess grease and oil.
DO NOT smoke or allow any open flames in Excessively worn or damaged parts can fail and cause
the area while checking or servicing injury or death. Replace any cracked or damaged parts.
hydraulic, battery or fuel systems; all contain Use only genuine Manitou Americas parts for service.
highly flammable liquids or explosive gases,
which can cause an explosion or fire if ignited. Use care not to damage machined and polished sur-
faces. Clean or replace all plates and decals that are
Wear a face shield when disassembling
damaged or painted over and cannot be read.
spring-loaded components or working with
battery acid. Wear a helmet or goggles with
special lenses when welding or cutting with a
torch. WARNING
When working beneath a raised machine, NEVER leave guards off or access doors open
always use blocks, jack-stands or other rigid when the machine is unattended. Keep
and stable supports. Wear appropriate protec- bystanders away if access doors are open.
tive clothing, gloves, and shoes. Keep feet,
clothing, hands and hair away from moving
After servicing, check the work performed, that no
parts.
parts are left over, etc. Install all guards and covers.
Always wear safety glasses or goggles for eye
protection from electric arcs from shorts, flu-
Service Every 10 Hours or Daily
ids under pressure, and flying debris or loose
material when the engine is running or tools
are used for grinding or pounding.
NEVER weld on bucket, forks, boom, support WARNING
frame or ROPS/FOPS without the consent of
the manufacturer. These components may be Static electricity can produce dangerous
made with metals that require special welding sparks at the fuel-filling nozzle. Do not wear
techniques, or with designs that do not allow polyester, or polyester-blend clothing while
weld repairs. NEVER cut or weld on fuel lines fueling. Before fueling, touch the metal sur-
or tanks. face of the machine away from the fuel fill to
dissipate any built-up static electricity. Do not
If repair welding is ever required, BE SURE to re-enter the machine but stay near the fuel fill-
attach the ground (-) cable from the welder as ing point during refueling to minimize the
close as possible to the area to be repaired. build-up of static electricity. Do not use cell
Also, remove positive (+) battery terminal con- phones while fueling. Make sure the static line
nection before welding. is connected from the machine to the fuel
truck before fueling begins.
Choose a clean, level work area. Be sure there is suffi-
cient room, clearances, and adequate ventilation. Clean
the walking and working surfaces. Remove oil, grease Ultra-Low Sulfur Diesel (ULSD) poses a
and water to eliminate slippery areas. Use sand or oil greater static ignition hazard than earlier
absorbing compound, as necessary, while servicing the diesel formulations. Avoid death or serious
Telescopic Handler. injury from fire or explosion; consult with your
fuel or fuel system supplier to ensure the
Before starting inspection and repair, move the entire fuel delivery system is in compliance
machine onto a level surface, shut down engine, and with fueling standards for proper grounding
release all hydraulic pressure. Always block the boom and bonding practices.
securely, or lower it to full ground contact. Place all
controls in neutral.

50960089/AP0914 52 PRINTED IN U.S.A.

CHECKING FUEL TANK LEVEL IMPORTANT: Drain water into a suitable contain-
er and dispose of properly.
The fuel level is shown by the fuel level gauge in the
multi-function display on instrument panel. After oper- 1. Disconnect the water level sensor electrical con-
ation each day, the fuel tank should be filled to prevent nector (A).
water from condensing in the tank. To fill, remove the 2. Loosen vent screw (C) on the top of the filter head
filler cap and add fuel. See the Lubrication chapter for several turns.
the diesel fuel requirements.
3. Loosen drain plug (B) until fluid runs out. Let
CHECKING FUEL FILTER drain until pure diesel fuel flows from the drain.
4. When fuel starts to drain out, tighten drain plug
securely.
5. Re-connect the water level sensor electrical con-
A
B nector.
6. Tighten vent screw (C).
A drain plug is also provided in the bottom of the fuel
tank for removing condensation and other foreign
materials. Open the plug and allow water and fuel to
drain into a container until only clear fuel is flowing
from the tank.

NOTE: The primary fuel filter/water separator (A) CHECKING ENGINE OIL LEVEL
and secondary fuel filter (B) will require occasion-
al replacement to maintain a clean and adequate
fuel flow for maximum engine horsepower. The
frequency of filter replacement will be determined Engine Oil
by the cleanliness of available fuel, the care used Engine Oil
Filler
Dipstick
in storing fuel supplies, and the operating condi-
tions in which the machine is used.
Check the primary fuel filter/water separator (A) for
water and debris.

C
With the machine on level ground, and the engine
stopped for ten minutes or more, remove the engine oil
dipstick. Wipe it clean, re-insert it and remove to
obtain a reading. If the oil level is below the crosshatch
pattern on the dipstick, fill with the required amount of
oil to bring the level to within the crosshatch pattern.
Oil levels anywhere within the crosshatch are consid-
ered full. See the Lubrication chapter for the type of oil
to use.

IMPORTANT: Low engine oil level and overfilling

B
A engine oil can lead to engine damage.

Primary Fuel Filter/Water Separator

PRINTED IN U.S.A. 53 50960089/AP0914

CHECKING RADIATOR COOLANT LEVEL CHECKING HYDRAULIC OIL LEVEL
Radiator The machine must be on level ground with boom low-
Cap
ered and completely retracted. The fluid MUST be cool
when checking the reservoir level, to reduce the possi-
bility of overfilling the hydraulic system.
Locate the filler cap next to the side-view mirror on the
right side of the machine. Remove the filler cap and
check the level on the dipstick. Oil levels anywhere
between the upper mark and lower mark on the dip-
Coolant Level stick is considered full. If the oil is below the lower
Sight Gauge mark on the dipstick, fill with the required type of oil
With the machine on level ground, visually check the to bring the level to within the FULL area. See the
level of the engine coolant through the sight gauge Lubrication chapter for the type of oil to use.
located on the back of the radiator as shown. Coolant
IMPORTANT: Be careful when removing the
should fill the sight gauge.
reservoir filler cap so that no dirt or other foreign
matter enters the hydraulic system. DO NOT
WARNING OVERFILL.

DO NOT remove the radiator cap when the CHECKING BRAKE RESERVOIR
engine is running hot or overheated. Coolant LEVEL
is extremely hot and under pressure and it can
Flip up the cover on the cab floor in front of the seat.
burn your skin. Allow sufficient time for the
The transparent reservoir on the brake valve has maxi-
radiator to cool BEFORE relieving the pres-
mum and minimum fill marks on the right side.
sure and removing the radiator cap.
Visually verify that the fluid level is between these
marks. If low, remove the reservoir cap and fill to the
If the coolant level is low, remove the radiator cap and
proper level with the correct fluid. See the Lubrication
slowly add a low-silicate ethylene glycol based coolant
chapter for the type of fluid to use.
mixed with quality water and supplemental coolant
additives (SCAs) suitable for heavy-duty diesel CHECKING TIRE PRESSURES
engines untill the sight glass is filled with coolant. See
your engine manual for additional information. To ensure proper operating stability and extend tire
Replace the radiator cap securely. life, proper and equal tire pressure should be main-
tained in all four tires.
NOTE: Do not fill the radiator to the top of the
radiator tank. Check tire pressures “cold.” Inflate as necessary per
the chart below:
NOTE: If the engine is operated with a loose radi-
ator cap, the pressure bypass will not work and 15.00 x 19.5 - 12 PR: 60 psi (415 kPa)
the engine will run hot. NOTE: If the tires have been filled with water or
calcium chloride for ballast, a calcium chloride tire
CHECKING TRANSMISSION OIL pressure gauge MUST be used to check the tire
LEVEL pressure.
The machine must be on level ground. With the engine
and transmission at operating temperature, parking WARNING
brake on, transmission in neutral and engine speed at
low idle, remove the access cover to the transmission Inflating or servicing tires can be dangerous.
and hydraulic pump. Remove the dipstick and check Whenever possible, trained personnel should
the oil level. Add the required amount of oil to bring service and mount tires. To avoid possible
the level to the FULL mark. See the Lubrication chap- death or serious injury, follow these safety
ter for the type of oil to use. precautions:

50960089/AP0914 54 PRINTED IN U.S.A.

 CHECKING GENERAL MACHINE
1. BE SURE the rim is clean and free of rust.
OPERATION AND CONDITION
2. Lubricate both the tire beads and rim
flanges with a soap solution. DO NOT use Are any decals missing or damaged? Are all guards,
oil or grease. shields and covers in place? Do all controls function
3. DO NOT place fingers on the tire bead or smoothly and properly? Are there any abnormal vibra-
rim during inflation. Use a clip-on tire tions or noises? Are any hose or fitting connections
chuck with a remote hose and gauge, leaking? Is the engine exhaust color normal?
which allows standing clear of the tire
CHECKING PERSONNEL WORK PLAT-
while inflating it.
FORM (PWP) SYSTEM (if used)
4. NEVER inflate beyond 35 psi (240 kPa) to
seat the beads. If the beads have not seat-
ed by the time the pressure reaches 35 psi
(240 kPa), deflate the assembly, reposition
WARNING
the tire on the rim, relubricate both parts If the PWP System fails to operate properly
and re-inflate. Inflation pressure beyond 35 during any of the System checks, DO NOT
psi (240 kPa) with unseated beads may USE the machine until the cause has been cor-
break the bead or rim with explosive force rected. Contact your dealer (or Manitou
sufficient to cause death or serious injury. Americas Company) for service information
5. After seating the beads, adjust the inflation and parts.
pressure to the recommended operating
pressure listed.
6. DO NOT weld, braze, or otherwise attempt Machine Position
to repair and use a damaged rim. The following must be performed before beginning the
PWP System checking procedures:
To ensure proper load carrying capability, original
equipment tires comply with the specifications pub- 1. Machine on level surface,
lished in the Tire and Rim Association Yearbook. 2. Boom fully lowered,
Replacement tires MUST meet the same specifica-
3. Frame level,
tions. When replacing tires, be sure all tires are of the
same type, quality and load rating, and the same size as 4. Transmission in “N” (Neutral),
the original equipment. When removing tires, follow 5. Parking brake switch “OFF,”
industry safety practices. Deflate completely prior to
6. PWP System switch “OFF,”
removal. After assembly of the tire on the rim, use a
safety cage or restraining device while inflating. 7. Remote switch plugged in and “ENGAGED.”

CHECKING WHEEL NUT TORQUE Activation Tests

To test the PWP System activation logic:
On new machines, or anytime a wheel has been
removed, re-torque wheel nuts until 450 ft.-lbs. (610 1. Start the engine and press the PWP rocker switch
Nm) is maintained. to “ON.”
CHECKING INSTRUMENTS OPERA- l The PWP System lamp in the switch should be
flashing.
TION
2. Apply the service brakes.
Allow the engine to warm up for about five minutes
l The PWP switch lamp should be illuminated
before beginning operation. Indicator lamps should be
continuously after three seconds, indicating that
off and gauges should register normal readings. Tilt the
the PWP System has been activated.
frame from side to side with the frame leveling control
and note the frame angle indicator movement. l The parking brake should engage, as indicated
by the lamp in the parking brake switch illumi-
nating.

PRINTED IN U.S.A. 55 50960089/AP0914

 l The carriage tilt and auxiliary functions should three seconds of brake pedal application.
now be disabled. The joystick control should If PWP System fails to perform properly, troubleshoot
continue to function normally for boom using the chart on page 67. Contact your dealer for ser-
raise/lower and extend/retract. vice information and parts.
Lockout Tests
To test the transmission and joystick control lockout Service Every 50 Hours or Weekly
logic:
1. Shift transmission into “F” (Forward) and increase LUBRICATE GREASE POINTS
the engine speed slightly.
Refer to the Lubrication chapter of this manual for
l The transmission should remain de-clutched, grease fitting locations and other related details.
allowing the engine to increase speed easily.
l Return the transmission selector to “N” 100 Hours (New Machine Only)
(Neutral) after the check.
2. Have an assistant move the remote shutdown The following initial oil and filter changes should be
switch to “Dis-engaged.” performed at 100 hours on a new machine. Thereafter
l The joystick control should now be disabled, so these changes should be performed at the regular main-
that boom raise/lower and extend/retract will no tenance intervals. Refer to the maintenance schedules
longer function. for the necessary procedures.
l Have the assistant move the remote shutdown Engine Oil and Filter (250 Hours)
switch to “Engaged” after the check. Transmission Oil and Filter (1000 Hours)
3. Tilt the frame to the right slightly more than two Hydraulic Return Filter Element (1000 Hours)
degrees.
Torque the boom chains after the first 100 hours of
l The joystick control should now be disabled so operation on new machines or anytime a chain has
that boom raise/lower and extend/retract no been replaced. Thereafter the boom chains should be
longer function. inspected for wear and proper tension at the regular
l Repeat the procedure with the frame tilted to service interval of 250 hours. Refer to the boom chain
the left. torquing procedure in the 250 hour service interval.
l Return the frame to a level position after the
checks. Service Every 250 Hours or Quarterly
De-activation Tests
To test the PWP System de-activation logic: NOTE: Perform all other service requirements
1. Turn the key switch to “OFF” and wait for the up to this point, as well as the following:
engine to stop. Then turn the key switch back to
CHECKING AXLE OIL LEVELS
“ON.”
l The PWP switch lamp and the parking brake Differentials
switch lamp should both be illuminated.
NOTE: The Telescopic Handler should be on a
2. Turn the key switch to “OFF” and then turn the
level surface for this procedure.
PWP rocker switch to “OFF.” Turn the key switch
back to “ON.” Remove the oil check plug. See illustration below. Oil
l The PWP switch lamp should be flashing and should flow from the hole. If low, remove the oil fill
the parking brake switch lamp should be on plug and add oil until it flows from the check hole.
continuously. Replace the plug, wait 10 to 15 minutes and repeat the
fill procedure. Continue this process until the differen-
3. Start the engine and apply the service brakes.
tial is full. See the Lubrication chapter for the proper
l The PWP switch lamp and the parking brake oil specification. Replace the check and fill plugs.
switch lamp should go off after approximately

50960089/AP0914 56 PRINTED IN U.S.A.

 Check Plug The frequency of filter replacement will be determined
Fill Plug
by the cleanliness of available fuel, the care used in
storing fuel supplies and the operating conditions in
which the machine is used.

WARNING
NEVER service the fuel system while smok-
ing, while near an open flame, or after the
engine has been operated and is hot.

Drain Plug Primary Fuel Filter/Water Separator

Replacement
Planetary Hubs
NOTE: The planetary hubs can be checked with- D
out jacking up the machine.
The planetary hubs have one plug each used for filling E

and draining. See illustration below. For checking the

level and filling, position the wheel until the oil level
arrow is horizontal. Remove the plug. If oil does not
A
run out, add oil until it overflows. Check the remaining
hubs the same way. Refer to the oil specifications
found in the Lubrication chapter of this manual.

Plug in fill and

check position.
B C

Primary Fuel Filter/Water Separator

CHANGING FUEL FILTER 1. Thoroughly clean fuel filter assembly and sur-
rounding area.
2. Loosen vent screw (D) on the top of the filter
head several turns.
A 3. Disconnect water sensor wiring (B) from the (A)
B
filter.
4. Loosen drain plug (C) and drain fuel into a suit-
able container.
5. When fuel has drained, turn the drain plug out
completely.
6. Using a filter wrench, remove the filter (A) from
the filter head.
7. Inspect filter head for cleanliness. Clean as
This telehandler is equipped with a primary fuel fil- required.
ter/water separator (A) and a secondary fuel filter (B).

PRINTED IN U.S.A. 57 50960089/AP0914

8. Apply a small amount of fuel to the sealing gas- 1. Thoroughly clean fuel filter assembly and sur-
ket of the replacement filter. rounding area.
9. Turn replacement filter onto filter head until the 2. Using a filter wrench, remove the filter from the
filter contacts the filter head, then turn an addi- filter head.
tional 3/4 turn. 3. Inspect filter head for cleanliness. Clean as
10. Turn drain plug into filter and re-connect the required.
water sensor wire. 4. Apply a small amount of fuel to the sealing gas-
11. To release the fuel priming pump, grasp fuel ket of the replacement filter.
priming pump knob (A) and push in while turning 5. Turn replacement filter onto filter head until the
it counter-clockwise. filter contacts the filter head, then turn an addi-
tional 3/4 turn.
B
6. Loosen vent screw (A) on the top of the filter
head several turns.
7. Turn the ignition key to the “ON” position until
fuel flows from the vent screw.
A
8. Tighten the vent screw.

WARNING
Escaping diesel fuel under pressure can have
sufficient force to penetrate the skin. Before
applying pressure to the fuel system, BE
SURE all connections are tight and lines and
Primary Fuel Filter/Water Separator hoses are not damaged. Use a piece of wood
Priming Pump and Vent Screw or cardboard to search for suspected leaks. If
injured by escaping fuel, see a doctor familiar
12. Operate the priming pump until fuel flows from
with this type of injury at once or gangrene
the vent screw (B) on the top of the filter head.
may result.
13. Return the priming pump to the locked position
by pushing it fully in and turning it clockwise. After fuel filter replacement, start the engine and oper-
Then tighten the vent screw (B). ate approximately 5 minutes at low idle. Check for fuel
leaks.
Secondary Fuel Filter Replacement
Diesel Fuel Injectors
Whenever faulty or plugged injectors are indicated, see
your authorized engine dealer.

NOTE: Only an authorized engine dealer can per-

form warranty service on the engine.

CHANGING ENGINE OIL AND FILTER

A
Change the engine oil and filter using the following
procedure:
1. With the engine warm, remove the crankcase drain
plug located on the left side of the engine oil pan.
IMPORTANT: DO NOT discharge oil onto ground.
Catch and dispose of per local waste disposal
Secondary Fuel Filter regulations.

50960089/AP0914 58 PRINTED IN U.S.A.

 Engine Oil corroded or have a buildup, disconnect the cables and
Filter clean the terminals and clamps with the same alkaline
Engine Oil solution.
Engine Oil
Filler
Dipstick NOTE: The battery in the machine is warranted
by the supplier. See the punch tag on the top of
the battery for warranty information.

WARNING
Explosive gas is produced while a battery is in
2. The engine oil filter should be changed at every oil use or being charged. Keep flames and sparks
change interval. Using a suitable filter wrench, away from the battery. Make sure battery is
remove and discard the filter. charged in a well-ventilated area.
IMPORTANT: Filtration of oils is critical to proper NEVER lay a metal object on top of a battery,
lubrication. Always change filter with every oil because a short circuit can result.
change. Use only genuine OEM engine replace-
ment filters. Battery acid is harmful on contact with skin or
fabrics. If acid spills, follow these first aid tips:
3. Apply a thin coat of clean engine oil to the sealing
1. IMMEDIATELY remove any clothing on
gasket of the new oil filter.
which acid spilled.
4. Wipe the filter sealing surface on the engine with a
clean cloth. 2. If acid contacted the skin, rinse the affect-
ed area with running water for 10 to 15
5. Turn new oil filter on by hand until filter contacts minutes.
the sealing surface then turn the filter an addition-
al 3/4 turn. 3. If acid comes in contact with the eyes,
6. Clean and re-install the drain plug. flood the eyes with running water for 10 to
15 minutes. See a doctor at once. NEVER
7. Re-fill the crankcase with new oil. Follow specifi- use any medication or eye drops unless
cations in the Lubrication chapter for type and vis- prescribed by the doctor.
cosity of new oil.
4. To neutralize acid spilled on the floor, use
NOTE: The oil capacity listed is approximate.
one of the following mixtures:
Always verify oil level with the engine oil dipstick.
a. 1 pound (0.5 kg) of baking soda in 4
8. After new oil has been added, run the engine at idle quarts (4 liters) of water.
speed until the oil pressure lamp is off. Check for
leaks at the filter and drain plug. b. 1 pint (0.4 liters) of household ammo-
9. Verfy the oil level is at the “Full” mark on the nia in 4 quarts (4 liters) of water.
engine oil dipstick. Whenever battery is removed from the unit,
IMPORTANT: Low engine oil level and over full BE SURE to disconnect the negative (-) bat-
engine oil levels can cause engine damage. tery terminal connection first.

CHECKING THE BATTERY

Jump Starting
The battery furnished in the machine is a 12-volt, wet- If the battery becomes discharged or does not have
cell battery. enough power to start the engine, use jumper cables
and the following procedure to jump-start the engine.
The top of the battery must always be kept clean. Clean
the battery with a brush dipped in an alkaline solution IMPORTANT: BE SURE that the jumper battery
(ammonia or baking soda and water). After the foam-
is also a 12-volt D. C. battery, and the vehicle
ing has stopped, flush the top of the battery with clean
used for jump starting has a negative-ground
water. If the terminals and cable connection clamps are
electrical system.

PRINTED IN U.S.A. 59 50960089/AP0914

 6. After the machine has started and is running
WARNING smoothly, have the second person remove the
jumper cables (negative (-) jumper cable first)
The ONLY safe method for jump-starting a dis- from the jumper vehicle battery, and then from the
charged battery is for TWO PEOPLE to per- disabled machine, while being careful not to short
form the following procedure. The second per- the two cables together.
son is needed for removing the jumper cables, Allow sufficient time for the alternator to build up a
so that the operator does not have to leave the charge in the battery before operating the machine or
operator’s compartment while the engine is shutting off the engine.
running. NEVER connect the jumper cables
directly to the starter solenoid of either NOTE: If the battery frequently becomes dis-
engine. DO NOT start the engine from any charged, have the battery checked for possible
position other than the operator’s seat, and dead cells, or troubleshoot the electrical system
then ONLY after making sure all controls are in for possible short circuits or damaged wire insula-
“neutral.” tion.

Closely follow the jump-start procedures, in CHECKING AND TORQUING BOOM

the order listed, to avoid personal injury. In LEAF CHAINS
addition, wear safety glasses to protect your
eyes, and avoid leaning over the batteries Inspect the leaf chains for wear and proper tension.
while jump-starting. Two of the chains are on the top front of the boom. A
third chain is accessible from inside the rear of the
DO NOT attempt to jump-start the machine if boom (see boom illustration).
the battery is frozen, because this may cause
it to rupture or explode. Torque the two chains on the front of the three-section
boom to 25 ft.-lbs. (34 Nm). Lubricate with 80W-90
1. Turn the key switches on both units to OFF. Be oil.
sure that both units are in “Neutral” and NOT
IMPORTANT: On new machines or when chains
touching.
have been replaced, it is necessary to retorque
2. Connect one end of the (red) positive (+) jumper the front double chain assembly after one hun-
cable to the positive (+) battery terminal on the dis- dred (100) hours of operation. Failure to do so
abled machine first. DO NOT allow the positive may allow the chains to become slack, which can
(+) jumper cable clamps to touch any metal other result in a chain jumping off a sheave. If this
than the positive (+) battery terminals. Connect the occurs, it could result in severe damage to the
other end of the positive (+) jumper cable to the boom assembly.
jumper battery positive (+) terminal.
Two Front
3. Connect one end of the (black) negative (-) jumper One Rear Boom Chains
Boom Chain
cable to the jumper battery negative (-) terminal.
4. Make the final negative (-) jumper cable connec-
tion to the disabled machine’s engine block or
frame (ground) ⎯ NOT to the disabled machine
negative battery post. If making the connection to
the engine, keep the jumper cable clamp away
Inner
from the battery, fuel lines, and moving parts. Intermediate Section
Outer Section
NOTE: Twist the jumper cable clamps on the bat- Section
tery terminals to ensure a good electrical connec-
tion. Chain Hookup Detail
5. Start the engine. If it does not start immediately, Inspect the leaf chains for wear. Run the boom out
start the jumper vehicles engine to avoid excessive slowly to inspect. Conditions to look for include:
drain on the booster battery. cracked or broken plates, protruding or turned pins,
and excessive wear. With a steel tape, measure 16 links

50960089/AP0914 60 PRINTED IN U.S.A.

of the strand that flexes over the sheaves. If the section NOTE: When inserting shims in the side slide
measures 10.3” (262 mm) or more, the chain should be pads, be sure to place equal shims on both sides
replaced. DO NOT repair sections of a chain. Replace of the boom for even distribution of clearance.
the complete chain.
Re-apply Loctite® 271 (red) thread lock or equivalent
Chain anchors and sheaves also require inspection, for to the bolts and re-torque to 30 ft.-lbs. (40 Nm).
worn or broken fingers and worn flanges. Bottom slide pads should not be shimmed and should
After any chain has been replaced, operate under be replaced when the thickness is worn down to 3/8”
loaded conditions and re-check the torque. Adjust the (9.5 mm).
chains per the following procedure: Extend the boom
to its maximum length, then retract the boom slowly WARNING
until the chain slack allows the chain to rest on the top
of the boom. Torque the two chains on the front of the Failure to maintain proper slide pad clearance
boom to 25 ft.-lbs. (34 Nm). Lubricate with 80W-90 and thickness could cause damage to the
oil. boom, resulting in sudden boom failure.
CHECKING BOOM SLIDE PAD WEAR
AND CLEARANCE
Service Every 1000 Hours or Yearly
Rear Inner
Shim NOTE: Perform all other service requirements
up to this point as well as the following:
Pad
CHANGING TRANSMISSION OIL AND
FILTER
Operate the machine long enough to warm the trans-
mission oil to 150°-200°F (65°-93°C). Shut off the
engine. Access to filter is from under the access cover
Front Outer on the front hood section. Access to the drain plug is
from underneath the machine. Proceed as follows:
Slide Pad Detail
1. Remove the drain plug and drain oil. Replace the
The boom is equipped with special nylon low-friction drain plug.
slide pads between the telescopic sections (see illustra-
tion). These are pre-greased and initially worn-in at the
Transmission
factory. Normally greasing is not required, except for
Drain Plug
maintaining a light film of grease on the pad tracking
areas of the boom sections. An exception is if a boom
section has been replaced.
Visually check for loose pad bolts. The bolts are
torqued to 30 ft.-lbs. (40 Nm). If the bolts are re-
torqued at any time, Loctite® thread lock must be re-
applied to the bolts. IMPORTANT: DO NOT discharge oil onto ground.
Catch and dispose of per local waste disposal
If the boom starts to chatter under load, grease the slide regulations.
pads and wipe off the excess grease. Maintain a clear-
ance of 1/16” between the top or side slide pads and the 2. Remove and discard the oil filter. Wipe the sealing
boom. Shims can be added to achieve the proper clear- surface on the transmission with a clean cloth.
ance. Loosen the bolts and insert shims until proper Apply a thin coat of clean oil to the new oil filter
clearance is obtained. gasket. Hand tighten.

PRINTED IN U.S.A. 61 50960089/AP0914

3. Refill the transmission with new oil as shown in
the Lubrication chapter of this manual. Secondary
Filter Element
End Cap

Transmission
Filter

Restriction
Sensor

Primary Filter
Element
Dust
Evacuator
IMPORTANT: DO NOT OVERFILL! lf the oil level
is too high, oil foaming, excessively high oil tem- Air Cleaner Assembly
perature and oil leakage at the seals could result. The air cleaner assembly consists of an primary filter
element and an secondary filter element. An air filter
4. Start and run the machine long enough for the oil
restriction sensor for monitoring the condition of the
to circulate and warm slightly. Recheck the level
elements is located in the front of the air cleaner hous-
with the dipstick.
ing. If the air filter becomes restricted, this sensor will
CHANGING HYDRAULIC RETURN FIL- display an air filter restriction message in the multi-
TER ELEMENT function display panel.

NOTE: The air filter restriction message will clear

WARNING when the filter element(s) are replaced.

Lower the boom to the ground when servicing The primary element should be replaced whenever the
the hydraulic system. air filter restriction message displays. The secondary
element should be replaced every third time the prima-
ry element is replaced, unless the primary element is
The hydraulic return filter element is a cartridge-type
damaged or the secondary element is visibly dirty.
accessible from a housing on top of the hydraulic reser-
Along with a daily check of the multi-function display
voir. Initial replacement is after the first 100 hours. See
panel for air filter restrictions, check that the air clean-
illustration. Remove the top cover of the housing.
er intake hose and clamps, and the mounting hardware
Remove the element and discard. Insert the new ele-
are properly secure.
ment into the housing and replace the cover.
Unlatch the three latches on the air cleaner and remove
Housing Top the end cap. Clean out any dirt in the end cap.

Primary Element
Filter Element 1. Carefully pull the primary element out of the hous-
ing. Never remove the secondary element unless it
is to be replaced.
Filter Housing
2. Clean out any dirt in the housing. Leave the sec-
ondary element installed during this step to prevent
debris from entering the engine intake manifold.
Reservoir Filter Removal 3. Inspect the replacement primary filter for any dam-
age before installation. Replace the primary ele-
CHANGING AIR FILTER ELEMENTS
ment if any damage is found.
IMPORTANT: Failure to follow proper filter ser-
vicing instructions could result in catastrophic
engine damage.

50960089/AP0914 62 PRINTED IN U.S.A.

NOTE: Cleaning the primary filter element is not
recommended. Fill Plug Check Plug

Secondary Element
NOTE: Replace the secondary element only if it is
visibly dirty or if the primary element has been
replaced three times.
Before removing the secondary element from the hous-
ing, clean out any dirt in the housing. Leave the sec-
ondary element installed during this step to prevent Drain Plug
debris from entering the engine intake manifold.
Remove the secondary element. Axle Planetary Hubs
The axle hubs have one plug each used for draining
Reinstallation and filling (see illustration).
IMPORTANT: NEVER use an element that is 1. Position the wheel until the oil level arrow points
damaged. Severe engine wear and eventual fail- down. Remove the drain/fill plug and allow the oil
ure can result if dirt gets through a hole in the ele- to drain out. Replace the plug.
ment.
IMPORTANT: DO NOT discharge oil onto ground.
1. Check inside the housing for any damage that may Catch and dispose of per local waste disposal
interfere with the elements. regulations.
2. Be sure that the element sealing surfaces are clean.
3. Insert the element(s), making sure that they are
seated properly.
4. Secure the end cap to the housing with the three Plug in drain
latches. position.

5. Check the hose connections and make sure they

are all clamped and tightened properly.
6. Air filter restriction message in the mult-function
display will clear when the air filter(s) are
replaced. 2. Re-position the hub so the oil level arrow is hori-
zontal. Fill with fresh oil as specified in the
CHANGING AXLE DIFFERENTIAL AND Lubrication chapter. When the oil runs out, install
PLANETARY OIL the drain/fill plug. Repeat this procedure on the
three remaining hubs.
Differential
CHECKING ALTERNATOR AND FAN
1. Remove the three drain plugs and drain the oil.
BELT CONDITION
Replace the drain plugs (see illustration).
IMPORTANT: DO NOT discharge oil onto ground. Refer to the engine manual for proper fan belt tension
Catch and dispose of per local waste disposal adjustment and replacement procedures. If the belt is
regulations. worn or cut, it should be replaced. Order replacement
belts from your Manitou Americas dealer.
2. Remove the check and fill plugs. Fill the differen-
tial with oil as specified in the Lubrication chapter. CHECKING EXHAUST SYSTEM
When the oil flows out the check hole, replace the
plug. Wait 10 to 15 minutes and repeat this process Examine the muffler and tail pipe for possible holes.
until the axle is full. Repeat this procedure with the Re-tighten any loose clamps and make sure the mani-
other axle. fold outlet gasket is not leaking.

PRINTED IN U.S.A. 63 50960089/AP0914

 1. Remove the drain plug and drain oil. Wash or blow
Service Every 2000 Hours or Two Years
off any particles collected on the magnetic drain
plug.
NOTE: Perform all other service requirements
up to this point, as well as the following: IMPORTANT: DO NOT discharge oil onto ground.
Catch and dispose of per local waste disposal
CHECKING HYDRAULIC SYSTEM regulations.
RELIEF PRESSURES
Element Fill Cap
Dipstick
Pressure settings for relief valves are pre-set at the fac-
tory. Three test ports are provided under the front hood
access cover.
Access
Cover
Test ports under
access cover
Gasket

TOP OF
RESERVOIR

Before conducting any pressure checks, check the

Hydraulic Reservoir Sump Strainer Removal
engine speed. Engine speed must be 1000 RPM at idle 2. Remove the access cover and wash the inlet screen
and 2300 RPM at high idle with clean solvent. Remove and wash the sump fil-
ter strainer from the bottom inside of the reservoir.
Steering Relief Pressure If the strainer has any damage, holes, etc., it should
Plug a 3000 psi (207 bar) oil- or liquid-filled gauge be replaced.
into the test port labeled ”SP.” Turn the steering full to 3. Flush out the bottom of the reservoir with clean
the right or left. The gauge should read 2000 psi (138 hydraulic oil. Re-install all cleaned components
bar). and install the access cover on the reservoir with a
new gasket. Clean the filter/breather cap.
Joystick and Parking Brake Release 4. Fill the reservoir with fresh oil. Follow specifica-
Pressure tions in the Lubrication chapter of this manual.
Plug a 1000 psi (70 bar) gauge into the port labeled IMPORTANT: Hydraulic fluid and filters should be
“JP.” With the engine running, the gauge should read replaced any time contamination is present before
350 psi (24 bar). the normally scheduled change.

Main Relief Pressure

Plug a 3000 psi (207 bar) oil-or liquid-filled gauge into
WARNING
the test port labeled “MP.” Fully retract the boom over
Escaping hydraulic oil under pressure can
the relief valve. The gauge should read 3000 psi (207
have sufficient force to penetrate the skin.
bar).
Before applying pressure to the hydraulic sys-
CHANGING HYDRAULIC RESERVOIR tem, be sure all connections are tight and
lines and hoses are not damaged. Use a piece
OIL AND STRAINER of wood or cardboard to search for suspected
Clean all dirt and debris from around the top of the leaks. If injured by escaping hydraulic oil, see
reservoir, especially around the access cover. Refer to a doctor familiar with this type of injury imme-
illustration and use the following procedure: diately or gangrene may result.

50960089/AP0914 64 PRINTED IN U.S.A.

CHANGING RADIATOR COOLANT IMPORTANT: Fill the cooling system with a low-
silicate ethylene glycol based coolant mixed with
Drain old coolant, and fill with recommended coolant. quality water and supplemental coolant additives
(SCAs) suitable for heavy-duty diesel engines.
See the engine manual for additional information.
Radiator
Drain Cock 7. Inspect the radiator cap seal before installing it.
Replace it if it appears to be damaged.
8. Start the engine and run it until the engine reaches
operating temperature. Check the coolant level
through the sight glass. If the coolant is low, allow
the engine to cool before removing the radiator cap
to add coolant.
NOTE: Check the engine temperature gauge
every minute or two after coolant has been
changed. Air pockets can form and it may be nec-
essary to refill the cooling system after a short
period of use, as the air will naturally bleed out of
WARNING the system. Check the sight glass to verify the
coolant level before adding coolant.
Remove the radiator cap only when the engine
is cool, or painful burns could result. STORING THE MACHINE
If the Telescopic Handler will not be operated for a
1. Loosen the radiator cap to its stop to release any
period of three months or more, prepare and store it
pressure in the radiator. Remove the cap when all
using the following procedure:
pressure is bled off.
2. Place a collection container with a 5 gallon capac- NOTE: If the storage area is outdoors or in a
ity under the right end of the radiator. harsh environment, the storage procedure should
be followed if the Telescopic Handler is to be
IMPORTANT: DO NOT discharge coolant onto stored for one month.
ground. Catch and dispose of per local waste dis-
posal regulations. Before Storage
3. Attach a hose to the radiator drain cock and route Perform the following prior to placing the machine in
it to the collection container placed below the radi- storage:
ator.
1. Wash the entire machine.
4. Open the radiator drain cock to drain the radiator.
2. Lubricate all grease fittings as described in the
5. When coolant is completely drained, Close the Lubrication chapter of this manual.
radiator drain cock.
3. Change engine oil as outlined in the Service and
6. Slowly add coolant to the radiator until the sight Storage chapter of this manual.
glass is filled with coolant.
4. Apply grease to all exposed hydraulic cylinder rod
Radiator areas.
Cap
5. Disconnect the battery cable clamps and cover the
battery, or remove the battery from the machine
and store it separately.
6. If the ambient temperature (at any time during the
storage period) is expected to drop below freezing,
make sure the engine coolant is either completely
drained from the radiator and engine block or that
Coolant Level the concentration of anti-freeze is adequate to keep
Sight Gauge

PRINTED IN U.S.A. 65 50960089/AP0914

 the coolant from freezing. Refer to the engine
manual for anti-freeze recommendations and
quantities.

During Storage
1. About once each month, connect the battery, check
all fluid levels to make sure they are at the proper
level, and start the engine.
IMPORTANT: If it is desired to operate the
hydraulic cylinders at this time, BE SURE to wipe
the protective grease (and any adhering dirt) from
the cylinder rods prior to starting the engine. After
operating, if the machine is to be returned to stor-
age recoat the cylinder rods with grease.
2. Allow the engine to run until it warms up. Then
move the machine a short distance to help relubri-
cate the internal parts. Run the engine until the bat-
tery is recharged, and then shut it off.

After Storage
After removing the machine from storage and
BEFORE operating it, perform the following:
1. Change engine oil and filter to remove any con-
densation and residues.
2. Wipe off grease from cylinder rods.
3. Lubricate ALL grease fittings.
4. Follow the start-up and warm-up procedures out-
lined in the Operation and Adjustments chapter of
this manual.

50960089/AP0914 66 PRINTED IN U.S.A.

 PWP SYSTEM TROUBLESHOOTING
Problem Possible Cause Remedy

PWP System switch lamp flash-

es when switch is pressed “ON.”

Parking brake does not engage

when the PWP System switch is
pressed “ON.”
PWP System is not activated. With PWP System switch “ON,”
Carriage tilt and auxiliary func- apply service brakes for three
tions continue operating when seconds until PWP switch lamp
the PWP System switch is is lit continuously.
pressed “ON.”

Transmission does not remain

de-clutched when shifted into
“Forward or Reverse” when the
PWP switch is “ON.”

Boom control functions do not Machine is not level. Level the machine.
operate.
PWP System remote shutdown Engage the PWP System
switch is disengaged. remote shutdown switch.

PWP System remote shutdown Plug in and engage the PWP

switch is not plugged into the System remote shutdown
connector at the end of the switch.
boom.

PWP System angle sensor is Contact your Manitou Americas

unplugged or faulty. dealer for assistance.

PWP System switch lamp flash-

es when switch is turned “OFF.” With engine running, apply ser-
PWP System is not de-activated. vice brakes for three seconds
Parking brake switch lamp stays until PWP switch lamp goes off.
“ON” when PWP System switch
is “OFF.”

PRINTED IN U.S.A. 67 50960089/AP0914

 Chapter 9
DECAL LOCATIONS
GENERAL INFORMATION NEW DECAL APPLICATION
Before applying the new decals, surfaces must be free
from dirt, dust, grease and other foreign material. To
CAUTION apply a solid-formed decal, remove the smaller portion
of the decal backing paper and apply this part of the
ALWAYS read and follow the safety precau- exposed adhesive backing to the clean surface while
tions and information shown on decals. If any maintaining proper position and alignment. Slowly
decals are damaged or unreadable, or if the peel off the other portion of the backing paper while
unit is repainted, the decals must be replaced. applying hand pressure to smooth out decal surface. To
If repainting, BE SURE that all decals that apply a die-cut decal, first remove the backing paper.
apply to your machine are affixed in their Then, properly orient and position the decal onto the
proper locations clean mounting surface. After the decal is firmly
applied and smoothly pressed down, peel off the top
Decal location information is provided to assist in the covering paper.
proper selection and application of new decals, in the
event the original decals become damaged or the PAINT FINISH
machine is repainted. Use this list to order paint for refinishing:
For correct replacement of decals, compare the loca- 808020 One Gallon Red
tion photographs to the machine before starting to 808021 6 (12-oz. Spray Cans) Red
refinish the unit. Check off each required decal using 808043 One Gallon Gun-Metal Gray
808044 6 (12-oz. Spray Cans) Gun-Metal Gray
the illustration reference number to find the part num-
ber, description and quantity in the list. Refer to the
appropriate illustration for replacement locations.
Decal Kits
If there is a decal on a part that is being replaced, be
50220765 MT6034T Telescopic Handler without PWP
sure that the decal is applied to the replacement part. 50220766 MT6034T Telescopic Handler with PWP
NOTE: Refer to the Safety chapter of this manual
for specific information provided on the various
safety decals. NOTE: Decals may be purchased in kits or indi-
vidually.

50960089/AP0914 68 PRINTED IN U.S.A.

 9

14
8 6

5 4
2 1

3
14
16
11 13
7

4
12

17 10

DECAL LOCATIONS - FRAME AND BOOM

REF. DESCRIPTION PART NO.

NO.
01 DANGER - HANDS OUT 808036
02 WARNING - PINCH POINT 808033
03 WARNING - JUMP START 808034
04 MANITOU LOGO, SMALL 50380379
05 QUICK-ATTACH DIAGRAM 808046

06 MANITOU LOGO, LARGE 806320

07 ANTI-FREEZE 808047
08 HALF ZONE MARKER (5 ea.) 808048
09 NO. “0” EXTENSION MARKER (1 ea.) 809561
NO. “1” EXTENSION MARKER (1 ea.) 808049

NO. “2” EXTENSION MARKER (1 ea.) 808050

NO. “3” EXTENSION MARKER (1 ea.) 808051
NO. “4” EXTENSION MARKER (1 ea.) 808052
NO. “5” EXTENSION MARKER (1 ea.) 808053
10 COOLANT UNDER PRESSURE 808054

11 WARNING - NO RIDERS 808035

12 BRAKE FLUID 808055
13 OPERATOR MANUAL WARNING 808032
14 DANGER - PERSONNEL INJURY (units without PWP) 808031
15 CARRY LOAD LOW 808037

16 LUBE CHART 50305007

17 MT 6034 T 51200618

PRINTED IN U.S.A. 69 50960089/AP0914

 3
1

11
2

2
5 7

2
4

10

DECAL LOCATIONS - FRAME AND BOOM

REI. DESCRIPTION PART NO.

NO.
01 DANGER - HANDS OUT 808036
02 WARNING - PINCH POINT 808033
03 MANISCOPIC 51200619
04 HYDRAULIC OIL FILL 808057
05 WARNING - NO RIDERS 808035

06 MANITOU LOGO, SMALL 50380379

07 WARNING - CARRY LOAD LOW 808037
08 QUICK-ATTACH UNLOCKED 808038
09 DIESEL FUEL 50301416
10 MT 6034 T 51200618

11 HOT SURFACE 809291

50960089/AP0914 70 PRINTED IN U.S.A.

 6 6

12
2 7

11

13

9
Tri-Function
Joystick Control Two Joystick Control
4

10

DECAL LOCATIONS - OPERATOR STATION

REI. DESCRIPTION PART NO.

NO.
01 WARNING - TILT HAZARD/GENERAL OPERATOR 808027
02 WARNING - CARRY LOAD LOW 808026
03 F-N-R SHIFT 808059
04 MADE IN USA 808060
05 WARNING - PARK BRAKE/SEAT BELT 808030

06 STANDARD CARRIAGE LOAD CHART 809299

ROTATING CARRIAGE LOAD CHART 809301
BUCKET LOAD CHART 809300
TRUSS BOOM LOAD CHART 809302
WINCH LOAD CHART 809303
PWP LOAD CHART 809304

07 ATTACHMENT TILT/FRAME LEVEL 808061

08 BOOM CONTROL 808062
09 AUXILIARY HYDRAULIC CONTROL (Optional) 808064
10 IGNITION SWITCH 50304691
11 DANGER - HIGH VOLT./MOVING PARTS 808029

12 JOYSTICK CONTROL 51200536

13 FRAME LEVEL 809307

PRINTED IN U.S.A. 71 50960089/AP0914

 2

5 1

DECAL LOCATIONS - PWP EQUIPPED UNITS

REI. DESCRIPTION PART NO.

NO.
01 WARNING - PERSONNEL LIFT 808039
02 WARNING - WORK PLATFORM RULES 808040
03 PERSONNEL LIFT SAFETY RULES 808041
04 PWP LOAD CHART 809304
05 PWP SWITCH 808042

50960089/AP0914 72 PRINTED IN U.S.A.

 Chapter 10
MAINTENANCE
This Maintenance Interval Chart was developed to match the Service and Storage chapter of this manual. Detailed
information on each Service Procedure is in the Service and Storage chapter. A Maintenance Log follows the
Maintenance Interval Chart for recording the maintenance procedures performed. Recording the 10-Hour (or
Daily) service procedures is impractical and is therefore not recommended.

IMPORTANT: Under severe operating conditions, more frequent service than the recommended inter-
vals may be required. Users must decide if the severity of their operation requires more frequent service
than normal.
MAINTENANCE INTERVAL CHART

SERVICE PROCEDURE Every 10 Every 50 First 100 Every 250

Hours Hours Hours Hours (or
(or Daily) (or Weekly) Quarterly)

Check Fuel Tank Level l

Check Fuel Filter (Drain Water If Required) l
Check Engine Oil Level l
Check Radiator Coolant Level l
Check Transmission Oil Level l
Check Hydraulic Oil Level l
Check Brake Reservoir Level l
Check Tire Pressures l
Check Wheel Nut Torque l1,2
Check Instruments Operation l
Check General Machine Operation and Condition l
Check Personnel Work Platform Safety System l
Lubricate Grease Points l
Change Engine Oil and Filter l2
Change Transmission Oil and Filter l2
Change Hydraulic Oil Filter l2
Check Axle Oil Levels l
Change Fuel Filter l
Change Engine Oil and Filter l
Check Battery l
Check and Torque Boom Leaf Chains l3 l
1 - On new machines, or when a wheel has been removed, until 450 ft.-lbs. (610 Nm) is maintained.
2 - New machines only.
3 - On new machines or when a chain has been replaced. Chains should be torqued to 25 ft.-lbs. (34 Nm).

PRINTED IN U.S.A. 73 50960089/AP0914

 MAINTENANCE INTERVAL CHART (CONT.)

SERVICE PROCEDURE Every 250 Every 1000 Every 2000

Hours (or Hours (or Hours (or
Quarterly) Yearly) Two Years)

Check Boom Slide Pads Wear and Clearance l

Change Transmission Oil and Filter l
Change Hydraulic Return Filter Element l
Change Air Filter Element l
Change Axle Differential and Planetary Oil l
Check Alternator and Fan Belt Condition l
Check Exhaust System l
Check Hydraulic System Relief Pressures l
Change Hydraulic Reservoir Oil and Strainer l
Change Radiator Coolant l

MAINTENANCE LOG
Date Hours Service Procedure

50960089/AP0914 74 PRINTED IN U.S.A.

 MAINTENANCE LOG
Date Hours Service Procedure

PRINTED IN U.S.A. 75 50960089/AP0914

 MAINTENANCE LOG
Date Hours Service Procedure

50960089/AP0914 76 PRINTED IN U.S.A.

 ENGINE DIAGNOSTIC TROUBLE CODES (DTCs)
Engine diagnostic trouble codes are displayed in the The FMI identifies the type of failure that has
multi-function display screen. occurred; for example, FMI 03 indicates a value above
normal. Combining SPN 000110 with FMI 03 means
Diagnostic trouble codes are displayed as a two-part
the engine coolant temperature input voltage is too
code: Suspect Parameter Number (SPN) and Failure
high. This example would display in the multi-function
Mode Identifier (FMI), as shown on the following
display as error code 000110-03.
table.
Always contact your servicing engine dealer for help
The first part is a Suspect Parameter Number (SPN)
in correcting the diagnostic trouble codes that are dis-
followed by a Failure Mode Identifier (FMI). To deter-
played for the engine.
mine the exact type of failure, both parts (SPN and
FMI) of the code are needed. The fault code listing in the following tables are in
ascending SPN/FMI codes.
The SPN identifies the system or the component that
has the failure; for example, SPN 000110 indicates a
failure in the engine coolant temperature sensor.
DTC
SPN FMI Error Code Type Error Description

51 03 EGR Valve Actuator Error Actuator of the external EGR valve: the ECU
detects a short circuit to battery; short cut to bat-
tery on ECU pin A19 or pin A20;

51 04 EGR Valve Actuator Error Actuator of the external EGR valve: The ECU
detects a short circuit to ground; Short cut to
ground on ECU pin A19 is detected; measured
voltage by ECU is under limit

51 05 EGR Valve Actuator Error Actuator error EGR Valve: signal range check
low, measuredcurrent is blow target; open load
on ECU output is detected

51 06 EGR Valve Actuator Error Actuator error EGR Valve: signal range check
high, measured current by ECU is over target; too
high current is going into the actuator, output is
switched off; overload by short-circuit

51 07 EGR Valve Actuator Error Actuator position for EGR Valve is not plausible,
internal error, angular misalignment of the flap

51 11 EGR Valve Actuator Error Actuator EGR valve: temperature limit in power-
stage of the actuator is reached due to high cur-
rent

91 03 Accelerator Pedal Sensor Error Analog accelerator pedal sensor 1: the voltage
measured by ECU is out of the target

91 04 Accelerator Pedal Sensor Error Analog accelerator pedal sensor 1: the voltage
measured by ECU is out of the target

91 11 Accelerator Pedal Sensor Error Plausibility error between APP1 and idle switch

94 01 Low Fuel Pressure Sensor Error Low fuel pressure: the low fuel pressure calculat-
ed by ECU is underneath the target range; the
ECU activates a system reaction

94 03 Low Fuel Pressure Sensor Error Low fuel pressure: the voltage of sensor mea-
sured by ECU is out of the target range, high

PRINTED IN U.S.A. 77 50960089/AP0914

 DTC
SPN FMI Error Code Type Error Description

94 04 Low Fuel Pressure Sensor Error Low fuel pressure: the voltage of sensor mea-
sured by the ECU is out of the target range, low

97 03 Water in Fuel Sensor Error Fuel filter water level sensor: the voltage of sen-
sor measured by ECU is out of the target range,
high

97 04 Water in Fuel Sensor Error Fuel filter water level sensor: the voltage of sen-
sor measured by ECU is out of the target range,
low

97 12 Water in Fuel Sensor Error Fuel filter water level sensor: the maximum level
is exceeded

100 01 Oil Pressure Sensor Error Oil pressure is below the target range: warning,
power reduction or shutdown threshold

100 03 Oil Pressure Sensor Error Oil pressure sensor: the voltage of sensor mea-
sured by ECU is out of target range, high

100 04 Oil Pressure Sensor Error Oil pressure sensor: the voltage of sensor mea-
sured by ECU is out of target range, low

102 02 Charge Air Pressure Sensor Error Charge air pressure measured by sensor is
above the warning threshold or shutdown thresh-
old

102 03 Charge Air Pressure Sensor Error Charge air pressure sensor: the measured volt-
age of sensor by ECU is out of the target range,
high

102 04 Charge Air Pressure Sensor Error Charge air pressure sensor: the measured volt-
age of sensor by ECU is out of the target range,
low

105 00 Charge Air Temperature Sensor Error Charge air temperature downstream calculated
by ECU is above the taget range: the ECU acti-
vates a warning threshold or shutdown threshold

105 03 Charge Air Temperature Sensor Error Charge air temperature Sensor: the voltage of
sensor measured by ECU is out of target range,
high

105 04 Charge Air Temperature Sensor Error Charge air temperature Sensor: the voltage of
sensor measured by ECU is out of target range,
low

107 00 Air Filter Differential Pressure Sensor Error Air filter differential pressure: the pressure differ-
ence of the intake air between the filter inlet and
outlet calculated by ECU is above the target
range and the ECU activates a warning threshold

110 00 Coolant Temperature Sensor Error Coolant temperature: the coolant temperature
calculated by ECU is above the target range; the
ECU activates a warning power reduction or a
shutdown threshold

50960089/AP0914 78 PRINTED IN U.S.A.

 DTC
SPN FMI Error Code Type Error Description

110 03 Coolant Temperature Sensor Error Coolant Temperature sensor: the voltage of the
sensor measured by ECU is out of the target
range, high

110 04 Coolant Temperature Sensor Error Coolant Temperature sensor: the voltage of the
sensor measured by ECU is out of the target
range, low

111 01 Coolant Level Coolant Level: the coolant level calculated by the
ECU is underneath the allowed minimum

157 03 Rail Pressure Sensor Error Rail Pressure Sensor: the voltage of sensor mea-
sured by ECU is out of target range, high

157 04 Rail Pressure Sensor Error Rail Pressure Sensor: the voltage of sensor mea-
sured by ECU is out of target range, low

168 00 Battery Voltage Sensor Error Battery Voltage: the voltage measured by ECU is
out of the target range, high

168 01 Battery Voltage Sensor Error Battery Voltage: the voltage measured by ECU is
out of the target range, low

168 02 Battery Voltage Sensor Error Battery Voltage: the voltage measured by ECU is
out of the target range, battery voltage above
warning threshold

168 03 Battery Voltage Sensor Error Battery Voltage: the voltage measured by ECU is
out of the target range, battery voltage above
warning threshold, short cut to battery

168 04 Battery Voltage Sensor Error Battery Voltage: the voltage measured by ECU is
out of the target range, battery voltage above
warning threshold, short cut to ground

190 00 Engine Speed Maximum engine speed exceeded

190 02 Engine Speed ECU measures a offset angle between crankshaft

and camshaft sensor is too large

190 08 Engine Speed Camshaft Speed Sensor: ECU recieves no sig-

nal, uses crankshaft sensor to calculate engine
speed
Crankshaft Speed Sensor: disturbed signal

190 11 Engine Speed Engine Speed: the engine speed calculated by

ECU is above the target range, the ECU activates
a warning threshold

190 12 Engine Speed Crankshaft Speed Sensor Unavailable: ECU uses

camshaft speed sensor. Speed detection; out of
range, signal disrupted, erratic signal

190 14 Engine Speed Engine Speed: the engine speed calculated by

ECU is above the target range, the ECU activates
a engine speed warning threshold

630 12 EEPROM Error The ECU finds an erroe during the access to its
EEPROM memory or works with an alternative
value

PRINTED IN U.S.A. 79 50960089/AP0914

 DTC
SPN FMI Error Code Type Error Description

639 14 CAN-Bus error CAN-Bus “BusOff-Status”

651 03 Electrical Error Injector Cyl. 1: the current drop measure by ECU
is above the target range, shor circuit to injector 1

651 05 Electrical Error Injector Cyl. 1: interuption of electrical connection

652 03 Electrical Error Injector Cyl. 3: the current drop measure by ECU
is above the target range, shor circuit to injector 1

652 05 Electrical Error Injector Cyl. 3: interuption of electrical connection

653 03 Electrical Error Injector Cyl. 4: the current drop measure by ECU
is above the target range, shor circuit to injector 1

653 05 Electrical Error Injector Cyl. 4: interuption of electrical connection

654 03 Electrical Error Injector Cyl. 2: the current drop measure by ECU
is above the target range, shor circuit to injector 1

654 05 Electrical Error Injector Cyl. 2: interuption of electrical connection

677 03 Starter Relay Error Starter Relay (high side power stage): The cur-
rent drop measured by ECU is above the target
range; starter relay high side short circuit to bat-
tery.
Starter Relay (high side power stage): The cur-
rent drain measured by ECU is above the target
range; starter relay low side, short circuit to bat-
tery

677 04 Starter Relay Error Starter Relay (high side power stage): The cur-
rent drop measured by ECU is above the target
range; starter relay low side short circuit to
ground.
Starter Relay (high side power stage): The cur-
rent drain measured by ECU is above the target
range; starter relay high side, short circuit to
ground

677 05 Starter Relay Error Starter Relay (low side power stage): the current
drop measured by ECU is above the target
range; open circuit/disconection LowSide-Outout

677 12 Starter Relay Error Starter Relay (low side power stage): the current
drop measured by ECU is above the target
range; starter relay powerstage over temperature

898 09 Timeout Error Timeout error: limp mode activated

1079 13 (ECU) Erro Internal Hardware Monitoring: the ECU detects a

deviation of the target range of the power supply
voltage of sensor output 1

1080 13 (ECU) Error Internal Hardware Monitoring: the ECU detects a

deviation of the target range of the power supply
voltage of sensor output 2

1109 02 Engine Shut-off Error Operator ignors the engine shut off request within
an allowed period.

50960089/AP0914 80 PRINTED IN U.S.A.

 DTC
SPN FMI Error Code Type Error Description

1231 14 CAN BusOff Error CAN Bus 1: the ECU is not allowed to send mes-
sages, because the status “BusOff” is detected

1237 02 Override Switch Error Override Switch: the ECU receives a permanent
signal, plausibility error

523009 09 Pressure Relief Valve Error Rail Pressure Relief Valve: reached maximum
allowed opening count

523009 10 Pressure Relief Valve Error Rail Pressure Relief Valve: reached maximum
allowed opening time

523350 04 Injector Short Circuit Error Injector Cylinder - Bank 1: short circuit

523352 04 Injector Short Circuit Error Injector Cylinder - Bank 2: short circuit

523354 12 Injector Error ECU detects an error of its injector high current
output; injector powerstage output defect

523470 02 Pressure Relief Valve (PRV) Error PRV will be forced to open; performed by pres-
sure increase.
PRV: is open, will be forced to open, the forced
open failed; performed by pressure shock

523470 07 Pressure Relief Valve (PRV) Error Rail pressure is out of the expected range;
Maximum rail pressure in limp home mode
exceeded, monitoring for maximum rail pressure
in limp home mode with PRV

523470 11 Pressure Relief Valve (PRV) Error Rail pressure relief valve can’t be opened due to
rail pressure; PRV error; rail pressure out of toler-
ance range; average rail pressure is outside the
expected tolerance range

523470 12 Pressure Relief Valve (PRV) Error Rail pressure relief valve open; PRV forced to
open; system reaction initiated, fault path indicat-
ing shutoff condition in case of open PRV; power
reduction may result

523470 14 Pressure Relief Valve (PRV) Error Rail pressure relief valve open;PRV is open; PRV
in rail is open; power reduction may result

523550 12 T50 Start Switch Error Terminal 50: ECU receives a permanent signal;
T50 start switch active for too long; Start informa-
tion to starter T50 Switch erratic/defect

523601 13 Sensor Supply Voltage Monitor 3 Error Internal Hardware Monitoring:the ECU detects a
deviation of the target range of the power supply
voltage of sensor output 3

523612 12 Software Error ECU Internal software error; power reduction may
result.
Internal ECU monitoring detection reported error

523612 14 Software Error Internal Hardware Monitoring: ECU CPU reset

and cause is logged internally; no item created in
error memory; software reset CPU, software visi-
bility resets in DSM

PRINTED IN U.S.A. 81 50960089/AP0914

 DTC
SPN FMI Error Code Type Error Description

523613 00 Rail Pressure Error Rail Pressure: fuel pressure in rail below target
range dependant on engine speed; rail pressure
disrupted, Positive governor deviation; maximum
positive rail pressure deviation exceeded con-
cerning set fuel flow; power reduction may result

Rail Pressure: fuel pressure in rrail exceeds tar-

get range dependant on engine speed; rail pres-
sure disrupted, maximum negative rail pressure
deviation with metering unit on lower limit is
exceeded

Rail Pressure: fuel pressure in rail exceeds target

rage dependant on engine speed; rail pressure
disrupted, leakage detected based on fuel quanti-
ty balance; power reduction may result

Rail Pressurre: fuel pressure in rail exceeds tar-

get range dependant on engine speed; rail pres-
sure disrupted, maximum rail pressure exceeded

523613 01 Rail Pressure Error Rail Pressure: fuel pressure in rail calculated by
ECU is below the target range which is depen-
dant on engine speed; minimum rail pressure
exceeded

523613 02 Metering Unit Error Rail Pressure: fuel pressure in rail calculated by
ECU is below the target range which is depen-
dant on engine speed; setpoint of metering unit in
overun mode not plausible

523615 03 Metering Unit Error Fuel Metering Unit: current drain measured by
ECU is above the target range; short circuit to
battery high side; short circuit to battery low side

523615 04 Metering Unit Error Fuel Metering Unit: current drain measured by
ECU is above the target range; short circuit to
ground high side; short circuit to ground low side

523698 11 SCR Error Engine Shut Off request from supervisory moni-
toring function

523776 09 Timeout Error Timeout Error; limp mode activated

523777 09 Passive Timeout Error Passive Timeout Error; limp mode activated

523895 13 Injector Adjustment Error Missing or wrong injector adjustment value pro-
gramming (IMA) injector 1

523896 13 Injector Adjustment Error Missing or wrong injector adjustment value pro-
gramming (IMA) injector 3

523897 13 Injector Adjustment Error Missing or wrong injector adjustment value pro-
gramming (IMA) injector 4

523898 13 Injector Adjustment Error Missing or wrong injector adjustment value pro-
gramming (IMA) injector 2

50960089/AP0914 82 PRINTED IN U.S.A.

 DTC
SPN FMI Error Code Type Error Description

523906 03 Fuel Pump Error ECU detects short cut to battery in fuel feed
pump circuit; electric fuel pre-supply pump short
circuit to battery

523906 04 Fuel Pump Error ECU detects short cut to ground in fuel feed
pump circuit; electric fuel pre-supply pump short
circuit to ground

523906 05 Fuel Pump Error ECU detect open load on the electric fuel feed
pump output: electric fuel pre-supply pump open
load, cable break

523906 12 Fuel Pump Error ECU detects to high temperature in powerstage

of fuel pump circuit; electric fuel pre-supply pump
powerstage over temperature

523982 00 Powerstage Diagnosis Disabled Powerstage Diagnosis Disabled; high battery volt-
age

523982 01 Powerstage Diagnosis Disabled Powerstage Diagnosis Disabled; low battery volt-
age

524057 02 Fuel Pressure Error Electric Fuel Pump; fuel pressure build up error

524108 09 Timeout Error Missing CAN message of EGR throttle valve;

Timeout Error of CAN-Transmit-Frame
ComEGRTVActr, Missing CAN Bus message

524109 09 Timeout Error Missing message of EGR throttle valve; Timeout

error of CAN-Receive-Frame ComRxEGRTVActr,
Missing CAN Bus message

PRINTED IN U.S.A. 83 50960089/AP0914

 INTENTIONALLY BLANK

50960089/AP0914 84 PRINTED IN U.S.A.

 Hydraulic Schematic
for Two-Joystick Controls without PWP

PRINTED IN U.S.A. 85 50960089/AP0914

 Hydraulic Schematic
for Two-Joystick Controls with PWP

50960089/AP0914 86 PRINTED IN U.S.A.

 Hydraulic Schematic
for Tri-Function Joystick without PWP

PRINTED IN U.S.A. 87 50960089/AP0914

 Hydraulic Schematic
for Tri-Function Joystick with PWP

50960089/AP0914 88 PRINTED IN U.S.A.

 Electrical Schematic (including options)

PRINTED IN U.S.A. 89 50960089/AP0914

 Electrical Schematic (including options and Radio Remote)

50960089/AP0914 90 PRINTED IN U.S.A.

 Load Zone Charts

Decal 809299 Decal 809300

Standard Carriage 1.3-Cu.-Yd. Bucket

Decal 809301 Decal 809302

Rotating Carriage 8-Ft. Truss Boom

PRINTED IN U.S.A. 91 50960089/AP0914

 Load Zone Charts

Decal 809303 Decal 809304

Winch Boom PWP

50960089/AP0914 92 PRINTED IN U.S.A.

 Torque Specifications
Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread-forming and metal
screws) unless otherwise specified.

Unified National Grade 2 Grade 5 Grade 8

Thread Dry Lubed Dry Lubed Dry Lubed
8-32 19* 14* 30* 22* 41* 31*
8-36 20* 15* 31* 23* 43* 32*
10-24 27* 21* 43* 32* 60* 45*
10-32 31* 23* 49* 36* 68* 51*
1/4-20 66* 50* 9 75* 12 9
1/4-28 76* 56* 10 86* 14 10
5/16-18 11 9 17 13 25 18
5/16-24 12 9 19 14 25 20
3/8-16 20 15 30 23 45 35
3/8-24 23 17 35 25 50 35
7/16-14 32 24 50 35 70 55
7/16-20 36 27 55 40 80 60
1/2-13 35 35 75 55 110 80
1/2-20 40 40 90 65 120 90
9/16-12 55 55 110 80 150 110
9/16-18 60 60 120 90 170 130
5/8-11 75 75 150 110 220 170
5/8-18 85 85 180 130 240 180
3/4-10 130 130 260 200 380 280
3/4-16 150 150 300 220 420 320
7/8-9 125 125 430 320 600 460
7/8-14 140 140 470 360 660 500
1-8 190 190 640 480 900 680
1-14 210 210 710 530 1000 740

Metric Course Grade 8.8 Grade 10.9 Grade 12.9

Thread
Dry Lubed Dry Lubed Dry Lubed
M6-1 8 6 11 7 13.5 10*
24M8-1.25 19 14 27 20 32.5 24*
M10-1.5 37.5 28 53 39 64 47
M12-1.75 65 48 91.5 67.5 111.5 82
M14-2 103.5 76.5 145.5 108 176.5 131
M16-2 158.5 117.5 223.5 165.5 271 200

* All torque values are in lb-ft. except those marked with an *, which are in lb-in.
For metric torque value (Nm), multiply lb-ft value x 1.355, or lb-in value x 0.113.

PRINTED IN U.S.A. 93 50960089/AP0914

 Index
A D
Access to Components Chart . . . . . . . . . . . . . . . . . . . . . 51 Dealer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Adjustments Decals, applying new . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Slide Pads Clearance . . . . . . . . . . . . . . . . . . . . . . . . .61 Dimensions - See Chapter 2
Wheel Lug Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . .55
E
Air Filter
Electrical Components
Changing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Characteristics - See Chapter 2
Alternator
Controls and Indicators - See Chapter 4
Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Engine
Anti-freeze - See Radiator
Cold Starting Procedures . . . . . . . . . . . . . . . . . . . . . .36
Attachment Tools
Description - See Chapter 2
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Emergency Override Switch . . . . . . . . . . . . . . . . . . . . .24
Operating Methods - See Chapter 6
Oil Pressure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Axles
Engine Shutdown Protection . . . . . . . . . . . . . . . . . . . .37
Description - See Chapter 2
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . .23
See also Service
Engine Oil
Axle Oil
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Checking Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .47
Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .47
Engine Oil Filter, replacing . . . . . . . . . . . . . . . . . . . . . . . .58
B Exhaust System, checking . . . . . . . . . . . . . . . . . . . . . . . .63
Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
F
Battery
Fan Belt - See Alternator Belt
Charging Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Frame Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Frame Level Control and Indicator . . . . . . . . . . . . . . .28, 29
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Fuel - See Separate Engine Manual
Boom Travel
Fuel Filter
Function Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Checking and Draining . . . . . . . . . . . . . . . . . . . . . . . . .53
Function Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
C Fuse Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Capacities - See Chapter 2 Fuse Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Checklists, delivery and pre-delivery . . . . . . . . . . . . . . . .5,7
Controls
Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Floor and Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Cylinders
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

50960089/AP0914 94 PRINTED IN U.S.A.

 G L
General Load Handling Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Load Capacity and Reach . . . . . . . . . . . . . . . . . . . . . .41 Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . .22, 91
General Machine Operation Lubrication
Grade and Slope Precautions . . . . . . . . . . . . . . . . . . .39 See also Service Intervals
Grade Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Grease Fittings Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
M
Types of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Main Relief Pressure Check . . . . . . . . . . . . . . . . . . . . . . .64
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Maintenance
H
Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Handling Non-Suspended Loads
Scheduled Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Picking Up the Load . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Mandatory Safety Shutdown Procedure . . . . . . . . . . . .8
Carrying the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Mandatory Work Platform Safety Rules . . . . . . . . . . . .14
Load Elevation and Placement . . . . . . . . . . . . . . . . . .42
O
Handling Suspended Loads
Oils - See Lubrication
Picking Up Suspended Loads . . . . . . . . . . . . . . . . . . .43
Operation
Carrying Suspended Loadds . . . . . . . . . . . . . . . . . . . .43
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Ground Level Suspended Load Placement . . . . . . . . .43
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Elevated Suspended Load Placement . . . . . . . . . . . . .43
Symbols . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Operator’s Manual, storing . . . . . . . . . . . . . . . . . . . . . . . . .2
Hydraulic Components, servicing . . . . . . . . . . . . . . . . . . .50
Operator Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Hydraulic Oil
Operator’s Station
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Checking level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Heater/AC Controls . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Recommended Type . . . . . . . . . . . . . . . . . . . . . . . . . .47
Hydraulic Maintenance P
Oil Filters, replacing . . . . . . . . . . . . . . . . . . . . . . . . . .62
Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Oil Sump Strainer, replacing . . . . . . . . . . . . . . . . . . . .64
Park Brake Pressure Setting . . . . . . . . . . . . . . . . . . . . . . .64
Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Paint, refinishing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Hydraulic Pump, servicing . . . . . . . . . . . . . . . . . . . . . . . .50
Pump, Delivery Rates - See Chapter 2
Hydraulic Valves, servicing . . . . . . . . . . . . . . . . . . . . . . . .50
Personnel Work Platform Safety Decals . . . . . . . . . . . . . .20

I Personnel Work Platform Safety Rules . . . . . . . . . . . . . . .14

Personnel Work Platform Switch . . . . . . . . . . . . . . . . . . . .25
Identification Reference . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Personnel Work Platform (PWP) System . . . . . . . . . . . . .13
Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Personnel Work Platform Checking Procedure . . . . . . . . .55
Indicator Symbols . . . . . . . . . . . . . . . . . .Inside Front Cover
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Pre-Start Walk-Around Inspection . . . . . . . . . . . . . . . . . . .33
Pre-Start Walk-Around Inspection Illustration . . . . . . . .34
J
Pre-Start Walk-Around Inspection Checklist . . . . . . . .35
Joystick Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . .64

PRINTED IN U.S.A. 95 50960089/AP0914

 Q T
Quick-attach™ System Tables
Attach/Detach Mechanism . . . . . . . . . . . . . . . . . . . . . .37 Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Paint Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
R
Replacement Filters . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Radiator
Theft Deterrents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Checking coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Changing coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Flushing and Refilling . . . . . . . . . . . . . . . . . . . . . . . . .65
Traffic Flow Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Relay Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Transmission
Relay Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Description - See Chapter 2
Road Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .23

S Transmission Oil
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .47
Schematics
Transporting
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Seat, operator’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Travel Speed - See Controls
Service and Safety Features . . . . . . . . . . . . . . . . . . . . . . .30
Troubleshooting, PWP . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Service Intervals
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52 W
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . Inside Rear Cover
100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Water Trap - See Fuel Filter
250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . .25
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Work Platform Design Requirements . . . . . . . . . . . . . . . .15
2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Side-View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Steering - See Controls
Steering Relief Pressure Check . . . . . . . . . . . . . . . . . . . .64
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Suspended Loads
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

50960089/AP0914 96 PRINTED IN U.S.A.

 MANITOU AMERICAS INC.
WARRANTY
MANITOU AMERICAS, hereinafter referred to as Manitou, warrants new Manitou equipment
to the Original Retail Purchaser to be free from defects in material and workmanship for a
period of twelve (12) months from the Warranty Start Date.
MANITOU WARRANTY SERVICE INCLUDES:
Genuine Manitou parts and labor costs required to repair or replace equipment at the selling deal-
er's business location.

MANITOU MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY KIND,

EXPRESS OR IMPLIED (INCLUDING THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE), EXCEPT AS
EXPRESSLY STATED IN THIS WARRANTY STATEMENT.

ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL BE DEEMED

DELETED FROM THIS WARRANTY; ALL OTHER TERMS WILL CONTINUE TO APPLY.

SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF THESE

WARRANTIES AND YOU MAY HAVE GREATER RIGHTS UNDER YOUR STATE LAW.

MANITOU WARRANTY DOES NOT INCLUDE:

1. Transportation to selling dealer's business location or, at the option of the Original Retail
Purchaser, the cost of a service call.

2. Used equipment.

3. Components covered by their own non-Manitou warranties, such as tires, batteries, trade
accessories and engines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended

maintenance procedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited
to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Manitou has any authority to bind Manitou to any
warranty except as specifically set forth herein.

PRINTED IN U.S.A. 97 50960089/AP0914

50960089/AP0914 © 2014 Manitou Americas, Inc PRINTED IN U.S.A.
All Rights Reserved.