MT6642XT

MT8044XT
MT10044XT
MT10055XT
MT12042XT
Telescopic Handler
Operator/Service Manual
Catalog 50960025 Revision C
MT6642XT beginning with S/N 27251
MT8044XT beginning with S/N 28251
MT10044XT beginning with S/N 80151
MT10055XT beginning with S/N 80151
MT12042XT beginning with S/N 38101
 Indicator and Operation Symbols

Read Operator’s Parking Brake Brake Failure Safety Alert Turn Signals Hazard Flasher
Manual

Ignition Off Ignition ON Engine Start Hydraulic Oil Horn Engine Oil
Pressure

Volume Full Volume Half Full Volume Empty Battery Fuel Transmission
Temperature

Engine Coolant Starting Aid Wiper/Washer Hourmeter Lights Work Lights

Temperature Injection

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

Outriggers Up Outriggers Down Diesel Fuel Frame Level Left Frame Level Right
(right side shown) (right side shown)
 Manitou Americas, Inc.
One Gehl Way
P.O. Box 179
West Bend, WI 53095-0179

MT6642XT
MT8044XT
MT10044XT
MT10055XT
MT12042XT
Telescopic Handler
Operator/Service Manual
Catalog 50960025 Revision C
MT6642XT beginning with S/N 27251
MT8044XT beginning with S/N 28251
MT10044XT beginning with S/N 80151
MT10055XT beginning with S/N 80151
MT12042XT beginning with S/N 38101

For parts orders contact your Manitou Americas Dealer or call:

Factory Parts Department (262) 334-6653.
Website: www.manitou.com / www.mnadealers.com
 THIS OPERATOR’S MANUAL IS
PROVIDED FOR OPERATOR 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 model and serial numbers below.
Refer to these numbers when inquiring about parts or service from your Manitou Americas Inc. dealer.

MODEL NO.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6, 7
4 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5 Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
6 Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
8 Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
9 Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
10 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Engine Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Inside Back Cover

PRINTED IN U.S.A. 1 50960025/CP0514

 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 and 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 that may be required,
including 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.
Please be aware that 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!

50960025/CP0514 2 PRINTED IN U.S.A.

 Identification

Operator’s Lift Rear Boom

Station Cylinder Access
Stabilizer
Cylinder

Boom Angle
Indicator

Quick-attach Tilt
System Cylinder Rear Lights and
Backup Alarm Access

Hydraulic Frame Leveling

Extend Cylinder Reservoir Cylinder Telescopic
Lift (under cover)
Slave Boom
Cylinder Cylinder Access
Covers

Auxiliary
Hydraulics

Fuel Tank
Storage Battery Side View
Compartment Access Mirror

PRINTED IN U.S.A. 3 50960025/CP0514

 Chapter 2
SPECIFICATIONS
Lifting Performance General Dimensions Instrumentation
Maximum lift capacity: Based on standard machine equipped with Gauges:
MT6642: 6600 lbs. (2994 kg) listed tires, 48” masonry carriage and 48” pal- Fuel level, hourmeter, coolant temperature,
MT8044: 8000 lbs. (3629 kg) let forks. engine oil pressure and voltmeter
MT10044: 10,000 lbs. (4536 kg) Recommended tire types: Monitoring lights:
MT10055: 10,000 lbs. (4536 kg) Engine oil pressure, engine water tempera-
MT6642, MT8044
MT12042: 12,000 lbs. (5444 kg) ture, alternator, transmission oil tempera-
13.00 x 24 - 12 PR
Maximum lift height: Inflate to 65 psi (450 kPa) ture, brake failure, low fuel, glow plug
MT6642: 42’ (12.8 m) 13.00 x 24 - 12 PR Rock Visual indicators:
MT8044: 44’ (13.4 m) Inflate to 65 psi (450 kPa) Boom angle and frame level
MT10044: 44’ (13.4 m) 13.00 x 24 - 12 PR, foam filled
MT10055: 55’ 1” (16.8 m) 13.00 x 24 Solid rubber
Steering System
MT12042: 42’ 4” (12.9 m) Steer Valve: Fixed displacement rotary
MT10044, MT10055, MT12042
NOTE: Use the outriggers up 14.00 x 24 - 12 PR Displacement/Rev: 17.9 cu. in. (293 cc)
specification when machine is not Inflate to 62 psi (430 kPa) System pressure: 2500 psi (172 bar)
14.00 x 24 - 16PR Rock
equipped with outriggers. Steer cylinders: 1 per axle
Inflate to 70 psi (480 kPa)
Capacity at maximum lift height: 14.00 x 24 - 12 PR, foam filled Steer mode valve:
MT6642: 13.00 x 24 Solid rubber tire double aper- 3-position, 4-way solenoid with dash-
Outriggers up: 6600 lbs. (2994 kg) ture with conventional tread pattern mounted switch actuation
Outriggers down: 6600 lbs. (2994 kg) 13.00 x 24 Solid rubber tire single aperture Steer modes: 2-wheel, 4-wheel, crab
MT8044: with conventional tread pattern Braking System
Outriggers up: 7000 lbs. (3176 kg)
Overall length, less forks: Service brakes:
Outriggers down: 8000 lbs. (3629 kg)
MT6642: 19’ 1” (5.81 m) Oil-immersed inboard hydraulic wet-disc
MT10044:
MT8044: 19’ 10” (6.04 m) type; seperate front and rear systems; foot
Outriggers up: 8,000 lbs. (3629 kg)
MT10044: 20’ (6.1 m) pedal actuation
Outriggers down: 8,000 lbs. (3629 kg)
MT10055: 21’ (6.4 m)
MT10055: Parking brake:
MT12042: 19’ 3” (5.9 m)
Outriggers Up: 5,000 lbs. (2268 kg) Spring-applied, hydraulic-release disc-type
Outriggers down: 5,000 lbs. (2268 kg) Overall width: in front axle.
MT12042: MT6642, MT8044: 8’ (2.4 m) Actuation via electric switch with engine
Outriggers Up: 10,000 lbs. (4536 kg) MT10044/55, MT12042: 8’ 3” (2.5 m) running, automatic with engine off.
Outriggers down: 10,000 lbs. (4536 kg) Overall height:
MT6642, MT8044: 7’ 8” (2.34 m) Electrical System
Max. forward reach to load center:
MT6642: 28’ 3” (8.6 m) MT10044, MT12042: 7’ 11” (2.41 m) Type:12-volt, negative ground
MT8044: 30’ 5” (9.3 m) MT10055: 8’ 6” (2.59 m) Battery: 950 cold cranking amps
MT10044: 30’ 5” (9.3 m) Ground clearance: Circuit protection: Fuse panel
MT10055: 41’ 2” (12.5 m) MT6642, MT8044: 16” (406 mm)
Backup alarm: 107 dB(A)
MT12042: 27’ 11” (8.5 m) MT10044/55, MT12042: 18” (457 mm)
Horn: 111 dB(A)
Capacity at maximum forward reach: Wheel base:
MT6642: MT6642, MT8044: 119.5” (3.03 m) Standard on all models:
Outriggers up: 1000 lbs. (454 kg) MT10044/55, MT12042: 124” (3.15 m) Brake lights, rear backup light, neutral start
Outriggers down: 3000 lbs. (1361 kg) switch
Outside turn radius:
MT8044: MT6642, MT8044: 13’8” (4.2 m) Alternator: 90-amp
Outriggers up: 1000 lbs. (454 kg) MT10044/55, MT12042: 13’11” (4.24 m)
Outriggers down: 3000 lbs. (1361 kg) Machine weight:
MT10044: MT6642: 22,000 lbs. (9,980 kg)
Outriggers up: 1,500 lbs. (681 kg) MT8044: 23,500 lbs. (10,660 kg)
Outriggers down: 3,000 lbs. (1361 kg) MT10044: 25,300 lbs. (11,476 kg)
MT10055: MT10055: 27,800 lbs. (12,610 kg)
Outriggers up: 250 lbs. (114 kg) MT12042: 25,200 lbs. (11,431 kg)
Outriggers down: 2,000 lbs. (908 kg)
MT12042:
Outriggers up: 2,000 lbs. (908 kg)
Outriggers down: 4,000 lbs. (1815 kg)
Maximum below grade reach:
MT6642: 14” (355.6 mm)
MT8044: 16” (406.4 mm)
MT10044: 18” (457.2 mm)
MT10055: 29” (736.6 mm)
MT12042: 17” (431.8 mm)
Frame Leveling: 10° left/10° right

50960025/CP0514 4 PRINTED IN U.S.A.

Service Capacities Front axle: Drive/steer, limited-slip differ-
ential with internal SAHR parking brake
Cooling System: Overall ratio: 26.21:1
21.2 qts. (20.1 L), 50/50 mixture Rear axle: Drive/steer, open differential
Anti-freeze protection: -34°F (-31°C) Overall ratio: 26.21:1
Pressure cap:18 psi (124 kPa)
Fuel tank: 47 gallons (178 L)
Engine
Hydraulic reservoir and system: Turbocharged aspiration:
45 gallons (170 L) John Deere 4045T Interim Tier 4
Transmission and cooler: MT6642, 276 cu. in. (4.5 L) displacement,
MT8044 115 hp (86 kW) @ 2400 rpm
15.6 qts. (14.8 L) Oil capacity: 15.5 qts. (14.7 L)
In-line 4-cylinder, 4-cycle,
Transmission and cooler: MT10044,
direct injection diesel fuel system,
MT10055, MT12042
in-line fuel filter w/water trap,
16.4 qts. (15.5 L)
positive pressure lubrication,
Axles: MT6642, MT8044 liquid pressurized cooling system,
Differentials (2): 15.8 qts. (15 L) ea. dry dual-element air cleaner,
Hubs (4): 2.6 qts. (2.5 L) ea. spin-on oil filter.
Axles: MT10044, MT10055, MT12042
Front Differential: 14.8 qts. (14.0 L) Hydraulic System
Front Planetaries: 1.85 qts. (1.75 L) ea. Type: Open-center
Rear Differential: 14.25 qts. (13.5 L) Pump: Single-section gear type
Rear Planetaries: 1.85 qts. (1.75 L) ea.
Displacement / revolution:
Transmission 3.72 cu. in. (61 cc)
MT6642, MT8044 Flow @ 2500 rpm: 40 gpm (151 L/min)
Type:Dana Powershift T12000 Main relief pressure: 3000 psi (207 bar)
Speeds: 3 fwd / 3 rev Steer relief pressure: 2500 psi (172 bar)
Torque converter: Joystick and Parking Brake release Pressure:
Single-stage, dual-phase 350 psi (24 bar)
Travel Speeds: Hydraulic filter:
1st gear: 3.3 mph (5.3 km/h) In-tank return type, 10-micron media,
2nd gear: 7.3 mph (11.8 km/h) replaceable element
3rd gear: 18.8 mph (30.3 km/h) Rated flow: 100 gpm (379 L/min)
MT10044, MT10055, MT12042 Rated pressure: 100 psi (690 kPa)
By-pass pressure (full flow):
Type: Dana Powershift T13000
25 psi (172 kPa)
Speeds: 4 forward / 3 reverse
Hydraulic strainer:
Torque converter:
In-tank suction, 100-micron media, replace-
Single-stage, dual-phase
able element
Travel speeds: Rated flow: 100 gpm (379 L/min)
1st gear: 3.0 mph (4.8 km/h) By-pass pressure: 3 psi (21 kPa)
2nd gear: 6.5 mph (10.5 km/h)
3rd gear: 13.1 mph (21.1 km/h)
4th gear: 19.3 mph (31.1 km/h)
Axles (front and rear)
MT664242, MT8044
Type: Dana model 212HY
Drive/steer, open differential, full-time
four-wheel drive, internal SAHR parking
brake in front axle
Overall ratio: 22.67:1
MT10044, MT10055, MT12042
Type: Dana model 223

PRINTED IN U.S.A. 5 50960025/CP0514

 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. Date Checklist Filled Out
Check for such things as dents and loose or missing parts;
correct or replace components as required.
Machine Model No. Machine Serial No. Engine Serial No.
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
loosely secured. √ Check that:
q Oil, fuel and air filters are not damaged, leaking or loosely The following Checklist is a reminder of the important infor-
secured. mation that MUST be passed on to the customer at the time
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 Review with the customer the contents of this manual and
q Wheel nuts are torqued to 450 ft.-lbs. (610 Nm).
the AEM Safety Manual and for the following:
q Tires are inflated to:
q The Index at the back, for quickly locating topics;
13.00 x 24 - 12 PR: 65 psi (450 kPa) cold.
14.00 x 24 - 12 PR: 62 psi (430 kPa) cold. q The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
q Hydraulic system reservoir, engine crankcase, engine
the machine.
coolant, transmission and axles are filled to the proper
operating fluid levels. q The Lubrication and Service and Storage chapters for
information regarding proper maintenance of the machine.
q All adjustments have been made to comply with the set-
Explain that regular lubrication and maintenance are
tings in this manual and in the separate engine manual.
required for continued safe operation and long life.
q All guards, shields and decals are in place and securely
q Give this Operator’s Manual and the AEM Safety Manual
attached.
to the customer and instruct them to be sure to read and
q Model and serial number for this unit is recorded in space completely understand their contents before operating the
provided on this page and page 1. unit.
Start the machine and test-run the unit while q Remind the customer of U.S. OSHA regulation 1910.178
checking that proper operation is exhibited by all (l), which specifies operator training requirements.
controls. q Explain that the customer MUST consult the engine manu-
al (provided) for related specifications, operating adjust-
√ Check that: ments and maintenance instructions.
q All indicators (lamps, switches, etc.) function properly. q Completely fill out the Owner’s Registration, including
q All hand and foot controls operate properly. customer’s signature, and return it to the Company.
q The PWP System operates properly (if equipped). Refer to q Explain that a copy of the warranty is included on the
Service and Storage chapter for procedure to check the inside back cover of this Operator’s Manual.
PWP System.
q Boom, Quick-attach System with attachment tool and
Customer’s Signature
frame level control all function properly.
q No hydraulic system leaks when under pressure.
q Listen for abnormal noises or vibrations; if detected, deter- Date Delivered
mine their cause and repair as necessary.

(Pages 7 and 8 have been removed at perforation)

50960025/CP0514 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. Date Checklist Filled Out
Check for such things as dents and loose or missing parts;
correct or replace components as required.
Machine Model No. Machine Serial No. Engine Serial No.
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
loosely secured. √ Check that:
q Oil, fuel and air filters are not damaged, leaking or loosely The following Checklist is a reminder of the important infor-
secured. mation that MUST be passed on to the customer at the time
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 Review with the customer the contents of this manual and
q Wheel nuts are torqued to 450 ft.-lbs. (610 Nm).
the AEM Safety Manual and for the following:
q Tires are inflated to:
q The Index at the back, for quickly locating topics;
13.00 x 24 - 12 PR: 65 psi (450 kPa) cold.
14.00 x 24 - 12 PR: 62 psi (430 kPa) cold. q The Safety, Indicators and Controls, and Operation and
Adjustments chapters for information regarding safe use of
q Hydraulic system reservoir, engine crankcase, engine
the machine.
coolant, transmission and axles are filled to the proper
operating fluid levels. q The Lubrication and Service and Storage chapters for
information regarding proper maintenance of the machine.
q All adjustments have been made to comply with the set-
Explain that regular lubrication and maintenance are
tings in this manual and in the separate engine manual.
required for continued safe operation and long life.
q All guards, shields and decals are in place and securely
q Give this Operator’s Manual and the AEM Safety Manual
attached.
to the customer and instruct them to be sure to read and
q Model and serial number for this unit is recorded in space completely understand their contents before operating the
provided on this page and page 1. unit.
Start the machine and test-run the unit while q Remind the customer of U.S. OSHA regulation 1910.178
checking that proper operation is exhibited by all (l), which specifies operator training requirements.
controls. q Explain that the customer MUST consult the engine manu-
al (provided) for related specifications, operating adjust-
√ Check that: ments and maintenance instructions.
q All indicators (lamps, switches, etc.) function properly. q Completely fill out the Owner’s Registration, including
q All hand and foot controls operate properly. customer’s signature, and return it to the Company.
q The PWP System operates properly (if equipped). Refer to q Explain that a copy of the warranty is included on the
Service and Storage chapter for procedure to check the inside back cover of this Operator’s Manual.
PWP System.
q Boom, Quick-attach System with attachment tool and
Customer’s Signature
frame level control all function properly.
q No hydraulic system leaks when under pressure.
q Listen for abnormal noises or vibrations; if detected, deter- Date Delivered
mine their cause and repair as necessary.

(Dealer’s File Copy - Remove at Perforation)

PRINTED IN U.S.A. 7 50960025/CP0514

 INTENTIONALLY BLANK

(To be removed as Dealer’s file copy)

50960025/CP0514 8 PRINTED IN U.S.A.

 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 in order
Manual and on the machine itself. to assure proper operation. Further, this Operator’s
Manual, AEM Safety Manual and decals on the
machine warn of additional hazards, and should be
Before operating this equipment, read and read and observed closely.
study the following safety information. In
addition, be sure that everyone who operates REMEMBER! It is the owner’s responsibility for com-
or works with this equipment is familiar with municating information on the safe use and proper
these safety precautions. maintenance of this machine! This includes providing
understandable interpretations of these instructions
for operators who are not fluent in reading English.
It is the responsibility of the operator to read and
understand the Operator’s Manual and other informa-
tion provided and use the correct operating procedure.
DANGER Machines should be operated only by qualified opera-
tors.
“DANGER” indicates an imminently haz-
ardous situation, which, if not avoided, will
result in death or serious injury. MANDATORY SAFETY SHUTDOWN
PROCEDURE
BEFORE cleaning, adjusting, lubricating or ser-
vicing the unit:
WARNING 1. Stop machine on a level surface. (Avoid park-
“WARNING” indicates a potentially hazardous ing on a slope, but if necessary, park across the
situation, which, if not avoided, could result in slope and block the tires.)
death or serious injury. 2. Fully retract the boom and lower the attach-
ment tool to the ground. Idle engine for grad-
ual cooling.
3. Place controls in neutral and apply parking
CAUTION brake.
4. Shut off the engine and remove the key.
“CAUTION” indicates a potentially hazardous
situation, which, if not avoided, may result in ONLY when you have taken these precautions can
minor or moderate injury. It may also alert to you be sure it is safe to proceed. Failure to follow
unsafe practices. the above procedure could lead to death or serious
bodily injury.

PRINTED IN U.S.A. 9 50960025/CP0514

 SAFETY
Additional Safety Reminders
WARNING Ü User/operator safety practices, as established 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 as may be indicated by the particular
operators are competent, as demonstrated by jobsite work conditions.
successful completion of a training course.
Ü It is essential that operators be physically and
The training course must consist of a combi- mentally fit, free of mind altering drugs and
nation of formal instruction and practical chemicals and thoroughly trained in the safe oper-
training, including both forklift-related and ation of the machine. Such training should be pre-
workplace-related topics, and evaluation of sented completely to all new operators and not
the operator’s performance in the workplace. condensed for those claiming previous experi-
ence. Information on operator training is available
All operator training and evaluation is to be from several sources, including the manufacturer.
conducted by persons who have the know-
ledge, training and experience to train and Ü Some illustrations used in this manual may show
evaluate operators. doors, guards and shields open or removed for
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
WARNING starting the engine at the beginning of each work
shift. Contact with a running engine or moving
ALWAYS maintain a safe distance from elec- parts during the pre-start inspection could cause
tric power lines and avoid contact with any death or serious injury. Refer to the pre-start
electrically charged conductor or gas line. It is walk-around inspection checklist in the
not necessary to make direct contact with a “Operation and Adjustment” chapter.
power line for power to ground through the
structure of the machine. Keep the boom and Ü Walk around the machine and warn all personnel
load at least 10 ft. (3 m) from all power lines. who may be servicing the machine or who are in
Accidental contact or rupture can result in the machine path prior to starting. DO NOT start
electrocution or an explosion. Contact the until all personnel are clearly away from the
“Call Before You Dig” referral system number machine.
at 8-1-1 in the U.S., or 888-258-0808 in the U.S. Ü Check brakes, steering, and hydraulic system
and Canada, to locate any underground utility prior to starting operation. Operate all controls to
lines BEFORE starting to dig. ensure proper operation. Observe all gauges and
indicators for proper operation. If any malfunc-
tions are found, correct the cause prior to using
the machine.

50960025/CP0514 10 PRINTED IN U.S.A.

 SAFETY
Ü ALWAYS wear appropriate personal protective the rear before backing.
equipment for the job and working conditions.
Ü DO NOT raise or drop a loaded fork or bucket
Hard hats, goggles, protective shoes, gloves,
suddenly. Abrupt movements under load can
reflector-type vests, respirators and ear protection
cause serious instability.
are exampes of types of equipment that may be
required. DO NOT wear loose fitting clothing, Ü Study the load chart carefully. It shows maximum
long hair, jewelry or loose personal items while capacity to be lifted and placed at specific out-
operating or servicing the machine. ward and upward distances. ALWAYS be aware
of load weights prior to attempting lift and place-
Ü ALWAYS check the job site for terrain hazards,
ment with this machine.
obstructions and people. Remove all objects that
do not belong in or on the machine and its equip- Ü DO NOT exceed the machine’s rated operating
ment. capacity for the type of attachment tool being
used.
Operation Safety Reminders
Ü DO NOT use outriggers on soft or uneven sur-
Ü Any or all of the following elements may affect faces. BE SURE the surface can support the
the stability of the machine: terrain, engine speed, machine and load.
type of load being carried and placed, improper
Ü DO NOT allow minors or any unqualified per-
tire inflation, weight of the attachment tool, and
sonnel to operate or be near the machine unless
abrupt movement of any control lever. IF YOU
properly supervised.
ARE NOT CAREFUL WHILE OPERATING
THIS MACHINE, ANY OF THE ABOVE Ü DO NOT start the engine or operate any controls
FACTORS COULD CAUSE THE MACHINE unless properly seated in the operator’s seat!
TO TIP AND THROW YOU OUT OF THE
Ü DO NOT run the engine in an enclosed area with-
OPERATOR’S STATION, WHICH MAY
out providing proper ventilation for the exhaust.
CAUSE SERIOUS BODILY INJURY OR
Exhaust gases contain carbon monoxide, an odor-
DEATH!
less and deadly gas. Internal combustion engines
Ü ALWAYS wear the seat belt provided to prevent deplete the oxygen supply within enclosed spaces
being thrown from the machine. If you are in an and may create a serious hazard unless the oxygen
overturn: is replaced. This includes the atmosphere within
the cab when equipped.
- DO NOT jump!
Ü DO NOT leave the operator’s station with the
- Hold on tight and stay with the machine!
boom and attachment tool raised. ALWAYS
- Lean away from the fall! lower the boom and attachment tool to the
ground, shut off the engine and engage the park-
Ü ALWAYS keep hands, feet and arms inside of the ing brake before leaving the operator’s station.
operator’s station when operating the machine!
Ü NEVER travel with the boom above the carry
Ü ALWAYS use the recommended hand holds and position (attachment tool should be at minimum
steps with at least three points of support when
ground clearance.) Boom should be fully retract-
getting on and off the machine. Keep steps and
ed.
platform clean. Face the machine when climbing
up and down. Ü DO NOT drive too close to an excavation or
ditch. BE SURE that the surrounding ground has
Ü DO NOT depend on the backup alarm to clear adequate strength to support the weight of the
bystanders out of the path of the machine.
machine and the load it is carrying.
ALWAYS look in the direction of travel. Look to

PRINTED IN U.S.A. 11 50960025/CP0514

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

50960025/CP0514 12 PRINTED IN U.S.A.

 SAFETY
Note: Refer to the full text of the OSHA crane Servicing Safety Reminders
regulation (29 CFR Part 1926, Subpart CC) for
Ü ALWAYS be aware of and avoid pinch point areas
a detailed description of the regulatory on the machine, such as wheels-to-frame, cylin-
requirements. ders-to-frame, boom and attachment tool-to-
frame.
Ü DO NOT exceed the rated capacity of the tele- Ü NEVER attempt to by-pass the keyswitch to start
scopic handler as equipped for handling suspend- the engine. ONLY use the jump-starting proce-
ed loads. The weight of the rigging must be dure detailed in the Service and Storage chapter.
included as part of the load.
Ü NEVER use your hands to search for hydraulic
Ü During transport, the length of the rigging fluid leaks. Use a piece of paper or cardboard.
between the attachment and load should be as Escaping fluid under pressure can be invisible and
short as possible to reduce booms height and can penetrate the skin, causing serious injury. If
movement. DO NOT raise the load more than 12 any fluid is injected into your skin, see a doctor at
inches (305 mm) above the ground, or raise the once. Injected fluid MUST be surgically removed
boom more than 45 degrees. by a doctor familiar with this type of injury or
Ü Only lift the load vertically – NEVER drag it hor- gangrene may result.
izontally. Ü ALWAYS wear safety glasses with side shields
Ü Use multiple pickup points on the load when pos- when striking metal against metal. In addition, it
sible. Use taglines to restrain the load from is recommended that a softer (chip-resistant)
swinging and rotating. material be used to cushion the blow. Failure to
heed could lead to serious injury to the eyes or
Ü Start, travel, turn and stop SLOWLY to prevent other parts of the body.
the load from swinging. DO NOT exceed walking
speed. Ü DO NOT refill the fuel tank when the engine is
hot. Allow engine to cool down before refilling to
Ü Inspect rigging before use. Rigging must be in prevent hot engine parts from igniting the fuel if
good condition and in the U.S. comply with it should spill or splash.
OSHA regulation §1910.184, “Slings,” or
§1926.251, “Rigging equipment for material han- Ü DO NOT smoke while filling the fuel tank, work-
dling.” ing on the fuel or hydraulic systems, or working
around the battery.
Ü Rigging equipment attached to the forks must be
secured such that it cannot move either sideways Ü DO NOT fill the fuel tank completely. Allow
or fore and aft. The load center must not exceed room for expansion. Maintain control of the fuel
24 inches (610 mm). filler nozzle when filling the tank. Use the correct
fuel grade for the operating season.
Ü DO NOT lift the load with anyone on the load,
rigging or lift equipment, and NEVER lift the Ü Static electricity can produce dangerous sparks at
load over personnel. the fuel-filling nozzle. Do not wear polyester, or
polyester-blend clothing while fueling. Before
Ü Beware of the wind, which can cause suspended fueling, touch the metal surface of the machine
loads to swing, even with taglines. away from the fuel fill to dissipate any built-up
Ü DO NOT attempt to use frame-leveling to com- static electricity. Do not re-enter the machine but
pensate for load swing. stay near the fuel filling point during refueling to
minimize the build-up of static electricity. Do not
use cell phones while fueling. Make sure the stat-

PRINTED IN U.S.A. 13 50960025/CP0514

 SAFETY
ic line is connected from the machine to the fuel Ü All attachment tools MUST be marked to identi-
truck before fueling begins. fy the attachment tool and the total capacity with
the attachment tool at maximum elevation with
Ü Ultra-Low Sulfur Diesel (ULSD) poses a greater
the load laterally centered.
static ignition hazard than earlier diesel formula-
tions. Avoid death or serious injury from fire or Ü ALWAYS be sure all nameplates, warnings and
explosion; consult with your fuel or fuel system instruction markings are in place and legible.
supplier to ensure the entire fuel delivery system Local government regulations may require specif-
is in compliance with fueling standards for prop- ic decals, which are the responsibility of the
er grounding and bonding practices. owner to provide.
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
coolant will be extremely HOT and under pres- standards. It is intended to offer protection to the
sure. ALWAYS wait for the engine to cool before operator from falling objects and in case of an
attempting to relieve pressure and remove the overturn, but it cannot protect against every pos-
radiator cap. Failure to heed this warning could sible hazard. Therefore it should not be consid-
result in severe burns. ered a substitute for good judgment and safe prac-
Ü DO NOT loosen or disconnect any hydraulic tices in operating the machine. If the ROPS /
lines, hoses or fittings without first relieving FOPS structure is damaged, it must be replaced to
hydraulic circuit pressure. Also, be careful not to restore the protection it provides.
touch any hydraulic components that have been in Ü This machine is equipped with a horn and backup
recent operation because they can be extremely alarm. The user must determine if operating con-
hot and can burn you! ditions require the machine to be equipped with
Ü Avoid lubrication or mechanical adjustments with additional devices (mirrors, rotating beacon, etc.)
the machine in motion or the engine running. If and be responsible for providing and maintaining
the engine must be running to make certain such devices.
adjustments, place the transmission in neutral,
apply the parking brake, place the equipment in a Personnel Work Platform (PWP) System
safe position, securely block the tires and use
extreme caution.
Ü To ensure continued safe operation, replace dam-
WARNING
aged or worn-out parts with genuine Manitou ser- The machine must not be used to lift or carry
vice parts before using this equipment. personnel, or be fitted with any form of per-
sonnel work platform unless fitted with the
Modifications, Nameplates, Markings and optional PWP System.
Capacities
If fitted with the PWP System, the Mandatory
Ü Modifications and additions that affect capacity Work Platform Safety Rules must be followed
or safe operation must never be performed with-
at all times while lifting personnel.
out the manufacturer’s prior written approval.
Where such authorization is granted, any applica-
ble markings are to be changed accordingly.

50960025/CP0514 14 PRINTED IN U.S.A.

 SAFETY
The Mandatory Work Platform Safety Rules must be 11. Be sure that any required restraining means (rail-
adhered to at all times while elevating personnel. ings, chains, harnesses, etc.) are in place and
These rules are based on ANSI/ITSDF Standard properly used.
B56.6-2005, “Safety Standard for Rough Terrain
12. Before lifting personnel, shift the transmission
Forklift Trucks.” (A copy of this and related standards
into Neutral, apply the parking brake, and activate
can be obtained from the Industrial Truck Standards
the PWP System mode switch.
Development Foundation, 1750 K Street NW, Suite
460, Washington, DC 20009; or downloaded from: 13. Before lifting personnel, the area should be
www.itsdf.org.) The rules apply to the owner, operator marked to warn others of work by elevated per-
and the personnel in the work platform. sonnel.
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 16, “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 mov-
riage or forks, and the carriage securely attached ing the forklift. Do not drive the forklift with per-
to the boom. The forks must not protrude beyond sonnel on the platform.
the floor of the work platform.
18. Elevated personnel must always be alerted before
3. The carriage and forks must be secured to prevent raising or lowering the platform.
them from pivoting upward.
19. A trained operator must be in position to operate
4. If the machine is equipped with a rotating or the forklift and boom controls at all times.
swinging carriage, the rotation or swing must be
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-
al-handling capacity of the forklift.
5. Personnel on the platform must be provided pro-
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
lanyard attached to the platform or boom when
6. If overhead hazards exist for platform personnel, working from an elevated work platform, in
overhead protection must be provided. accordance with OSHA regulations. Use of rail-
7. Be sure that the lifting mechanism is operating ings, planks, ladders, etc. on platform for the pur-
smoothly throughout its entire range, both empty pose of achieving additional reach or height is
and loaded, and that any lift-limiting devices and 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.

PRINTED IN U.S.A. 15 50960025/CP0514

 SAFETY
24. The platform must be fully lowered for personnel
to enter and exit. Personnel must not climb on Electrical
any part of the forklift in attempting to enter and Connection
exit.
25. Any harness, body belt, lanyard, or deceleration PWP
device that has sustained permanent deformation Remote
Shutdown
or is otherwise damaged must be replaced. Switch
26. Modifications to the platform that are detrimental
to its safe use are prohibited.
Remote Shutdown Switch
with Coiled Wire Connector

WARNING
Use ONLY an approved work platform for ele-
vating personnel.
NEVER move the machine with the work plat-
form in a raised position or with personnel on
board. PWP
Remote
NEVER tilt the platform forward, rearward, or Shutdown
Switch
to the side with personnel on board.
ALWAYS engage the PWP System and follow
Wireless Remote Shutdown Switch on MT10055
the Mandatory Work Platform Safety Rules
when elevating personnel. Wireless Remote Battery Replacement
1. Remove the four screws from the cover of the
wireless remote.
2. Open the cover to gain access to the batteries.
Work Platform 3. Remove the batteries from their holders.
Switch
4. Install the replacement batteries in the holder tak-
ing care to position the battery terminals as shown
in the diagram at the bottom of the battery holder.
5. Replace the cover and install the screws to secure
the cover in place.
Work Platform Design Requirements
(Per ANSI/ITSDF B56.6-2005, Sec. 8.24)
1. A platform floor having a slip-resistant surface
located not more than 8 inches (200 mm) above
the normal load-supporting surface of the forks.

50960025/CP0514 16 PRINTED IN U.S.A.

 SAFETY
2. Floor dimensions, which shall not exceed two have an attachment point provided overhead for
times the load center distance of 24 inches (610 freedom of movement, and its length is to limit
mm) listed on the forklift nameplate, measured free-fall to 5 feet (1500 mm) measured from the
parallel to the longitudinal center plane of the point of attachment to the operator. The complete
forklift, nor have a width greater than the overall system shall be capable of withstanding three
width of the forklift (measured across the load- consecutive drop tests to simulate a 250 lb. (113
bearing tires) plus 10 inches (250 mm) on either kg) person falling 6 feet (1800 mm) without
side. Minimum space for each person on the plat- allowing the test weight to fall free to the ground.
form shall not be less than 18 inches (450 mm) in A deceleration device may be included.
either direction.
NOTE: Fall protection should comply with applic-
3. A 4 inch (100 mm) minimum height toe plate, able U.S. OSHA regulations: 1910.67 (c)(2)(v) (for
which may be omitted at the access opening. General Industry) or 1926.453 (b)(2)(v) (for
Construction).
4. An overhead protective device, when requested
by the user. 10. Lanyards, when provided, shall be arranged so as
5. Protection for personnel in their normal working not to cause a tripping hazard.
position on the platform from moving parts of the 11. Body harnesses, when provided, should have a
forklift that may present a hazard. width of at least 1.75 inches (44 mm).
6. Information prominently indicated on the plat- 12. Structural safety factor - all load-supporting struc-
form: tural elements of the work platform shall have a
a. maximum work load including personnel and structural safety factor of not less than 2-to-1
equipment, based on the minimum yield strength of the mate-
rials used.
b. weight of empty platform.
7. Means so that the platform can only be centered
laterally on the forklift, and retained against the
vertical face of the forks, carriage or lifting mach-
anism.
8. A means to securely attach the platform to the lift-
ing mechanism, and to prevent the platform from
inadvertantly pivoting.
9. Restraining means such as a guardrail or a means
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 inch-
es (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
means shall be capable of withstanding a concen-
trated horizontal force of 200 lb. (890 N) applied
at the point of least resistance without permanent
deformation. A body harness and lanyard is to

PRINTED IN U.S.A. 17 50960025/CP0514

 SAFETY

808037
808031

808033

808026

808029

808027 808030
808038

50380987

808033

50960025/CP0514 18 PRINTED IN U.S.A.

 SAFETY
808031

808038

808037
RED

808027

808033
808030 808029

50380987

PRINTED IN U.S.A. 19 50960025/CP0514

 SAFETY

51200535

808034

808033 808036

808033

808033

808033

808032 808031

808035

808035

50960025/CP0514 20 PRINTED IN U.S.A.

 SAFETY
808031 51200535

808032

808036

808033

808034

808035

PRINTED IN U.S.A. 21 50960025/CP0514

 SAFETY
PWP Safety Decals

808041
808040
808039

808039
808042

808041

808039

808040
808042

50960025/CP0514 22 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 Company
Read and thoroughly understand all safety
approved accessory or referral attachment
decals on the Telescopic Handler BEFORE
tool. Manitou Americas cannot be responsible
operating it. DO NOT operate the machine
for safety if the machine is used with an unap-
unless all factory-installed guards and shields
proved accessory or attachment tool.
are properly secured in place.

Steering Wheel Instrument and

Switch Panel
Speed and Travel
Direction Lever Frame Level
Indicator
Boom Angle
Indicator
Tri-Function
Joystick

Load Zone
Key Switch Charts
Start Button
Frame Level and
Attachment Joystick
Horn Button

Frame Level
Brake Pedal Control
Throttle Pedal
Outrigger
Boom Control Switches
Joystick
Auxiliary
Hydraulics
Control

Operator’s Compartment and Indicators/Controls Locations

PRINTED IN U.S.A. 23 50960025/CP0514

DASH PANEL AREA INSTRUMENT AND SWITCH PANEL
Located to the right of the steering wheel, this panel
contains the instrument gauges, indicator lamps and
function switches.

A1
A2

B C

Ignition Switch, Start and Horn Button

A1 - Key Switch OFF: When the key is vertical in the
keyswitch, power from the battery is disconnect-
ed to the control and instrument panel electrical
circuits. Also, this is the only position in which Instrument and Switch Panel
the key can be inserted and removed.
Instrumentation
A2 - Key Switch ON: When the key is turned one
position clockwise from the vertical (OFF) posi-
tion, power from the battery is supplied to all con- A F
trol and instrument panel electrical circuits. All I
E
indicator lamps in the instrument panel, exhaust
filter gauge and switch and the engine emergency
override switch will illuminate momentarily as a
lamp check. B
H D
NOTE: If the engine requires repeated attempts
to start, the key MUST be returned to the OFF G C
position between starting attempts to prevent bat-
tery run down.
B - Start Button: With key switch in ON position,
press the button to activate the starter. Release it
as soon as the engine starts. A - Multi-Function Display Screen: This screen dis-
plays the following functions:
C - Horn Button: With the key switch ON, press the
horn button to activate warning sound. • fuel level at all times,
• engine coolant temperature,
Load Zone Charts: A series of flip charts show lift
• engine oil pressure,
height and reach limits relative to the load weight
being handled with various attachment tools. • voltmeter
• hourmeter
• 250 hour maintenance reminder
• error fault codes
B - Scroll Button: Pressing this button changes the
function displayed in the gauge display panel.
A1 - Fuel Level Gauge: The fuel level is displayed at
all times in the lower portion of the display. It indicates
the amount of fuel remaining in the fuel tank.

50960025/CP0514 24 PRINTED IN U.S.A.

A2 - Engine Coolant Temperature: Press button “B” IMPORTANT: If this lamp comes on during nor-
until “TEMP” is displayed. It indicates the temperature mal operation, a problem may exist in the trans-
of the engine coolant. Under normal conditions, this mission oil system. Stop the machine immediate-
should indicate approximately 185°F (85°C). ly and investigate the cause of the problem!
A3 - Engine Oil Pressure: Press button “B” until F - Engine Pre-heat Indicator Lamp: When lighted
“OIL” is displayed. This indicates the engine lubricat- this lamp indicates that the cold weather starting aid is
ing oil pressure. in use.
A4 - Voltmeter: Press button “B” until “VOLTS” is G - Alternator Lamp: This lamp indicates the condi-
displayed. This indicates the voltage output from the tion of the electrical charging system. During normal
alternator. operation, this lamp should be off. If the charge rate is
A5 - Hourmeter: Press button “B” until “HRS” is dis- too high or too low, this lamp will come on.
played. It indicates the total operating time of the H - Coolant Temperature Lamp: This lamp indicates
machine and should be used for keeping the mainte- if the temperature of the engine coolant is too high.
nance log.
IMPORTANT: If this lamp comes on during nor-
A6 - Maintenance Reminder: After every 250 hours mal operation with the engine running, STOP the
a reminder will display: “ROUTINE MAINTENACE engine as soon as possible and check the engine
IS REQUIRED ⎯ CHECK OPERATOR’S MANU- cooling system.
AL.” Perform the required maintenance, and then clear
the message by pressing and holding button “B” until I - Engine Oil Pressure Lamp: This lamp indicates
the message is cleared. whether the engine lubricating oil pressure is suffi-
cient. During normal operation, with the engine run-
NOTE: The maintenance reminder message ning, this lamp should be off. During starting and when
must display at least three minutes before it can the ignition is on but the engine is not running, this
be cleared by pressing and holding button “B”. lamp will be on.
A7 - Error Fault Code: Error codes and a short error IMPORTANT: If this lamp comes on during nor-
description are displayed in this screen. The error code mal operation, stop the engine immediately! After
will clear when the error is corrected. allowing the oil to drain down for a few minutes,
check the engine oil level. Maintain oil level at the
Indicator Lamps FULL mark on the dipstick.
C - Low Fuel Lamp: This lamp indicates a low fuel
situation. The fuel tank should be filled as soon as pos- Exhaust Filter Gauge Indicators and
sible. Switches
D - Brake Failure Lamp: This lamp indicates the con-
A3 B1
dition of the service brake systems. The front and rear
brakes are on independent systems. If a loss of pressure
occurs in either system during normal operation with
the brake pedal depressed, this lamp will come on. A1 B2 B3 C

Failure in one of the brake systems does not affect the

operation of the other system. However, the MANDA-
TORY SAFETY SHUTDOWN PROCEDURE (p. 8) A2 B4

should be followed and any necessary repairs made

immediately. A - Exhaust Filter Cleaning Switch: This switch con-
E - Transmission Oil Temperature Lamp: This lamp trols the function of the exhaust filter. It has 3 positions
indicates whether or not the transmission oil is at the as follows:
proper temperature. During normal operation this lamp A1 Center position: In this position the exhaust fil-
should be off, indicating that the transmission oil sys- ter cleaning procedure is set to the automatic
tem is at the proper temperature. (AUTO) mode. Operating the engine in this cen-
ter AUTO Mode allows the ECU to perform intel-
ligent exhaust filter cleaning as required.

PRINTED IN U.S.A. 25 50960025/CP0514

A2 Bottom position: In this position the auto exhaust the operator should enable the auto exhaust filter
filter cleaning is disabled. clean setting or perform manual exhaust filter
cleaning.
A3 Top position: In this position the operator initi-
ates a manual exhaust filter cleaning operation. B4 - Exhaust Filter Warning Indicator: This
This process allows the system to clean the amber or red indicator works in combination with
exhaust filter when the operator previously dis- the Exhaust Filter Indicator (B3).
abled exhaust filter cleaning by pressing the bot-
• If this indicator is illuminated amber when the
tom of the switch. The top of the switch will need
Exhaust Filter Indicator (B3) is illuminated, the
to be pressed for at least three seconds to activate.
engine performance will be reduced by the ECU
The indicator in the switch will illuminate when
because the soot level of the exhaust filter is mod-
activated and be off when the exhaust filter clean-
erately high. If conditions are safe, the operator
ing is complete.
should enable the auto exhaust filter clean func-
B - Exhaust Filter Gauge: This gauge displays the tion. If conditions are not safe,the operator should
four indicators you will see through the operator initi- move the machine to a safe location and engage
ated or auto exhaust filter cleaning and disable the auto exhaust filter cleaning mode.
processes.
• If this indicator is illuminated red when the
NOTE: The indicators in the exhaust filter gauge Exhaust Filter Indicator (B3) is illuminated, the
will all illuminate when the keyswitch is put in the engine performance will be further reduced by the
“ON” position for a momentary lamp check. ECU because the soot level of the exhaust filter is
During normal operation all lamps will never all be extremely high. This combination will lead to a
illuminated at the same time. This image is only to “Service Only” soot condition, contact your
illustrate the indicators you may see during oper- authorized Manitou Americas dealer.
ation.
C - Engine Emergency Override Switch: The lamp
B1 - Exhaust Filter Cleaning Indicator: This in this switch will flash when there is a low oil pressure
indicator will illuminate when exhaust gas tem- WARNING or a high coolant temperature WARNING.
perature is at optimal regeneration temperature, The lamp in the switch will light continuously at the
elevated idle is active, or exhaust filter cleaning is low oil pressure SHUTDOWN set-point or the high
in process. coolant temperature SHUTDOWN set-point.
When this indicator is illuminated, the machine Pressing and holding the bottom of the shutdown over-
can be operated as normal unless the operator ride switch will override an engine shutdown signal
determines the machine is not in a safe location caused by low engine oil pressure or high engine
for high exhaust temperatures and disables auto coolant temperature.
cleaning.
The switch must be pressed within 30 seconds to pre-
B2 - Auto Cleaning Disabled Indicator: This vent undesired shutdown of engine. The switch can be
indicator will illuminate when the operator has overridden for 30 seconds at a time to move the
disabled the auto exhaust filter cleaning function machine to a safe location and to lower the boom to the
from the exhaust filter cleaning switch (A). This ground. If the engine shuts down, the ignition switch
icon will remain illuminated until the operator re- must be turned off and then back on before the engine
engages automatic exhaust cleaning from the can be restarted.
exhaust filter cleaning switch (A). Disabling the
NOTE: Holding the switch continously “ON” will
auto mode is not recommended for any situation
not reset the 30-second timer.
unless it is safety related or if the fuel tank lacks
the recommended 1/4 tank of fuel to complete the
cleaning process.
Switch Panel
The switch panel contains three rows of switches for
B3 - Exhaust Filter Indicator: This indicator the operation of standard and optional equipment on
will illuminate when the exhaust filter is in need the telescopic handler.
of cleaning because the soot level of the exhaust
filter is slightly high and the operator has disabled
auto exhaust filter cleaning. If conditions are safe,

50960025/CP0514 26 PRINTED IN U.S.A.

Top Row Switches NOTE: This lamp will flash on and off, indicating
Switches have graphic symbols to indicate function that the system is not yet fully functional, until the
and effect. The following descriptions start with the brakes are held on for three or more seconds.
first switch on the left. D - Parking Brake: When the machine is parked, this
switch should be pressed to actuate the parking brake
mechanism in the front axle.

WARNING
UNATTENDED MACHINE HAZARD
A B C D
Activate parking brake switch and lower
NOTE: Some switches are optional and may not attachment tool to ground before leaving
be on machine. machine. An unattended machine can move or
roll and cause death or serious injury to oper-
A - Steering Mode: This 3-position switch is used to ator or bystanders.
select among the three steering modes. The upper posi-
tion engages the 4-wheel-steer mode. This mode pro- Periodically check the parking brake opera-
vides all-wheel steering, used for making tighter turns, tion to maintain adequate holding power.
usually on a jobsite. The center position engages the 2- Always be sure the parking brake switch is off
wheel-steer mode. This mode provides front-wheel when resuming machine operation.
steering only, used for higher speed travel. The lower
position engages the crab-steer mode. This mode is Middle Row Switches
used when a small amount of side shift is needed for
picking or placing a load. Switches have graphic symbols to indicate function
and effect. The following descriptions start with the
NOTE: The rear wheels are not self-centering. first switch on the left.
Make sure all wheels are in a straight-ahead posi-
tion before changing the steering mode.
Any of the steering modes can be used in forward and
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 E F G H
faster engine acceleration and more power to the
hydraulic system, without power to the drive axles,
NOTE: Some switches are optional and may not
while the service brake pedal is pressed.
be on machine.
In the “OFF” position, the clutch mechanism of the
transmission remains engaged when the brakes are E - Head Lights/Work Lights: Pressing the top of the
applied. In the “ON” position, the clutch mechanism is switch will illuminate the lights mounted on the top of
disengaged when the brakes are applied. the operator’s station and the red tail lights, for use in
forward travel operations. Pressing the bottom of the
Normal brake force will hold the machine in position switch will illuminate the lights at the end of the boom
while accelerating the engine to power hydraulic con- in addition to the lights on the operator’s station, for
trol functions during load placement. additional lighting in working operations.
C - Personnel Work Platform: This is a red switch F - Turn Signal: This switch is used to indicate the
used to activate the Personnel Work Platform (PWP) direction of a turn with the tail lights. Depress the right
System. When activated, an amber lamp in the switch arrow for a right turn; depress the left arrow for a left
will be on. turn. Return the switch to the center position after the
turn is completed.

PRINTED IN U.S.A. 27 50960025/CP0514

G - Hazard: This switch can be activated to make the Fan Speed: This knob is located below the tempera-
tail lights flash on and off in case the machine is stalled ture control knob. Rotating the knob clockwise will
or temporarily stopped in a traffic area on the road or increase the fan speed for increased air circulation.
jobsite.
Heater A/C Controls
H - Strobe Light: When a stobe light is installed on
the machine, activating this switch will produce a Fan Speed
strobe light on and off flashing, for working in condi- Knob
tions that may obscure view of the machine.

Bottom Row Switches

Switches have graphic symbols to indicate function
and effect. The following descriptions start with the
first switch on the left.

Temperature
Control Knob

Fan Speed: This is the upper knob located to the left

of the steering wheel. The fan is in the off position
I1 I2 J K
when the knob is rotated completely to the left.
Rotating the knob clockwise will switch the fan on and
NOTE: Some switches are optional and may not increase the fan speed for increased air circulation.
be on machine.
Temperature Control: This knob is located below the
I1 and I2 - Wiper/Washer: The windshield and top fan speed knob. It is used to adjust the temperature out-
window of the operator’s station are each equipped put of the heater A/C unit. Turning the knob clockwise
with a wiper and washer mechanism. Switch “I1”oper- from the midpoint position will increase the tempera-
ates the wiper and washer on the windshield; switch ture output of the cab heater. Turning the knob counter-
“I2” operates the wiper and washer on the top window. clockwise from the midpoint position will switch the
A/C unit on and decrease the temperature output of the
J- K - Blank: cab A/C.
Heater Controls Travel Lever

Temperature
Located on the left side of the steering wheel column,
Control Knob this lever is used to change travel direction (forward or
reverse) and speed range.
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).

Fan Speed Position “F” (Forward)

Knob
Position “N” (Neutral)
Position “R” (Reverse)
Temperature Control: This is the upper knob located
to the left of the steering wheel. This knob is used to
adjust the temperature output of the heater. Turning the
knob clockwise will increase the temperature output of
the cab heater.

50960025/CP0514 28 PRINTED IN U.S.A.

Speed Range - MT6642 and MT8044: Twisting the Seat Positioning: The seat is mounted on rails for for-
lever end clockwise or counter-clockwise will change ward and rearward reposi-
the transmission speed between low, medium and trav- tioning, for comfort and to
A
el ranges. accommodate the opera-
tor’s size. A spring-loaded
Position “3” (Travel Range)
latch handle “A” under the
Position “2” (Medium Range)
front of the seat actuates
Position “1” (Low Range)
the adjustment mecha-
Speed Range - MT10044, MT10055 and MT12042: nism.
Twisting the lever end clockwise or counter-clockwise
Suspension Seat Option:
will change the transmission speed between low and
In addition to the “A” A
travel ranges.
latch handle for forward B

Position “4” (Travel Range) and rearward adjustment,

Position “3” (Upper Range) this seat has a knob “B”
Position “2” (Medium Range) under the front of the seat
Position “1” (Low Range) to adjust the suspension.
Turn the knob to the right
IMPORTANT: Care should be taken when down-
for a softer ride, and to the left for a firmer ride.
shifting or changing direction, because damage to
the transmission can occur if shifting is forced or Seat Belt: This machine has a retractable seat belt.
attempted at too high a speed. Allow engine Grasp the belt on the left side of the seat, pull the belt
speed to slow before any downshift or directional over your lap, and insert the belt into the buckle on the
change is attempted. right side of the seat until you hear it lock in place.

Steering
Seat Belt
Turn the steering wheel to the right or left to turn the
machine in that direction. The power steering system is
designed to provide low effort steering without shock
reaction from the tires to the steering wheel.
FLOOR AND SEAT AREA
Throttle Pedal: This pedal, operated by the right foot, RIGHT SIDE PANEL
controls the engine speed to match power require-
ments. Pushing down on the pedal increases engine These controls and indicators are used to position the
speed; letting up on the pedal decreases engine speed. frame, boom, attachment and outriggers. Graphic sym-
bols on the side panel indicate the control actions and
Service Brake Pedal: Pressing this pedal activates effects.
inboard hydraulic wet-disc-type brakes on all four
wheels. Separate front and rear brake systems allow This machine is equipped with one of two types of
bringing the machine to a safe stop if either system boom and attachment joystick control configurations,
loses pressure. either a two-joystick configuration, or a single tri-func-
tion joystick.

Throttle Pedal

Brake Pedal

PRINTED IN U.S.A. 29 50960025/CP0514

 Frame Level and Boom Control Auxilliary
WARNING Attachment Joystick Joystick Hydraulics
Control
Use extreme caution when raising or extend-
ing the boom. The Telescopic Handler MUST
be level. Loaded or empty, this machine can
tip if not level.
ALWAYS place the transmission in neutral, set
Outrigger
the parking brake and keep the service brakes Switches
fully applied before raising or extending the
boom. Two-Joystick Configuration
To tilt the attachment tool up, move the joystick handle
NEVER exceed the specified lifting and
rearward. To tilt the attachment tool down, move the
extending capacities of this machine, or seri-
joystick handle forward.
ous machine damage or personal injury may
result. Refer to the load charts at the opera- After the attachment tool is set to a desired angle, that
tor’s station or this manual. angle will be maintained as the boom is raised and low-
ered, extended and retracted, until a new angle is set.
If a boom circuit hose fails with the boom up,
with or without a load, shut down the machine
following the MANDATORY SAFETY SHUT-
DOWN PROCEDURE (page 9). DO NOT
WARNING
attempt repairs. Call your Manitou Americas DO NOT level the frame with the boom raised
dealer for assistance. or extended. Only level the frame while
The truss boom and winch attachment tools stopped and with the boom fully retracted and
should ONLY be used to lift and place loads the attachment raised just enough to clear the
when the machine is in a stationary position. ground.
Transporting suspended loads must ALWAYS
be done slowly and cautiously, with the boom
Boom Control Joystick: This machine has a
and load as low as possible. Use taglines to
hydraulic-type boom with telescopic sections. The sec-
restrict loads from swinging, to avoid over-
tions extend by means of a hydraulic cylinder and a
turn.
chain system inside the boom, sequenced for uniform
NEVER use winch for lifting or moving of per- extension of each section.
sonnel. NEVER exceed the maximum rated To extend the boom, move the joystick handle to the
capacity of the winch (3000 lbs./1360 kg) or right; to retract the boom, move the joystick handle to
exceed the load chart rating for winch appli- the left. To raise the boom, move the joystick handle
cations. rearward; to lower the boom, move the joystick handle
DO NOT tilt the truss boom back more than forward.
45° from horizontal. DO NOT attempt to use Outrigger Switches: The outriggers are used to pro-
the optional rotating carriage as a load level- vide greater stability in specific applications. Press the
ing function. ALWAYS level the frame prior to left switch forward to lower the left outrigger. Press the
raising a load. right switch forward to lower the right outrigger. Press
both switched rearward to raise the outriggers.
Two-Joystick Configuation
Level the frame before lowering the outriggers. Lower
Frame Level/Attachment Tilt Joystick: The machine the outriggers until the front tires just start to raise.
may be tilted slowly as much as 10° to the left or right
to level the frame and boom in relation to the ground.
Move the joystick handle to the left to tilt to the left;
move the joystick handle to the right to tilt to the right.

50960025/CP0514 30 PRINTED IN U.S.A.

 the function speed of both the attachment tilt and aux-
WARNING iliary hydraulics.
To extend the boom, move the joystick right; to retract
For maximum machine stability, never lower the boom, move the joystick to the left. To raise the
the outriggers so that the tires come com- boom, move the joystick rearward; to lower the boom,
pletely off the ground. move the joystick forward.
Do not use outriggers on soft or uneven sur- To tilt the attachment tool up, depress and hold the
faces. Be sure the surface can support the lower yellow button on the left side of the joystick han-
machine and load. dle. To tilt the attachment tool down, depress and hold
the upper yellow button on the left side of the joystick
Be sure NO persons or equipment are where
handle.
the outrigger pads will be positioned.
To operate the auxiliary attachment hydraulics, depress
DO NOT travel with the outriggers extended
and hold either the upper or lower blue button on the
under any circumstances.
right side of the joystick handle. The upper blue button
Adequate clearance is required for the outrig- will cause the reverse effect of the lower blue button.
gers in the retracted position when traveling
through doorways or narrow pathways. Depressing and holding the trigger on the front side of
the joystick handle will increase the speed of the
DO NOT attempt to use outriggers as a attachment tilt and auxiliary hydraulic functions.
hydraulic jack for maintenance or frame level-
ing or other similar uses. NOTE: The joystick handle does not need to be
Failure to heed could result in death or seri- moved to operate the tilt or auxiliary hydraulic
ous injury. functions.
Speed Control Knobs: The tri-function joystick incor-
Auxiliary Hydraulics Control: This two-position porates a manually adjusted speed control. Speed
lever is for attachment tools that require additional adjustment is accomplished by manual adjustment of
hydraulics. the pilot-pressure apply valves located on the top rear
of the hydraulic reservoir under the access cover on the
Tri-Function Joystick Configuation front hood section.

Boom, Attachment If the machine is equipped with auxiliary hydraulics,

and Auxilliary Frame Level Outrigger there will be two pilot-pressure apply valves, each hav-
Hydraulic Joystick Control Switches ing two speed-control knobs. The right pilot valve con-
trols the auxiliary hydraulics, and the left pilot valve
controls the attachment tilt function. On the attachment
tilt pilot valve, the left knob controls the attachment
tilt-back speed, and the right knob controls the attach-
ment tilt-forward speed. On the auxiliary hydraulic
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.
Single Tri-Function Joystick Configuration NOTE: There is a locking knob located forward of
the adjusting knob, which must be loosened
Tri-Function Joystick: This joystick handle is before the adjusting knob can be turned. After
equipped with two yellow buttons and two blue but- adjustment has been made, tighten the locking
tons on the upper rear of the handle, and a trigger knob to maintain the selected speed.
switch on the front of the handle. The yellow buttons
operate the attachment tilt. The blue buttons operate
the auxiliary hydraulics. The trigger switch increases

PRINTED IN U.S.A. 31 50960025/CP0514

 Attachment and Auxilliary Hydraulics Pilot-Pressure Apply Valves
AUXILIARY HYDRAULICS ATTACHMENT TILT
PILOT-PRESSURE APPLY PILOT-PRESSURE APPLY
LOCKING VALVE VALVE
KNOBS
LOCKING
KNOBS

AUXILIARY
L71378
HYDRAULICS SPEED
DECAL ATTACHMENT TILT ATTACHMENT TILT
CONTROL KNOBS FRONT L71378
REARWARD SPEED FORWARD SPEED DECAL
CONTROL KNOB CONTROL KNOB

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 Frame Level
Indicator
the frame and boom in relation to the ground.

Boom Angle Indicator: Mounted on the left side of

WARNING the outer boom, the movement of a ball indicates the
angle of boom elevation relative to the ground.
DO NOT level the frame with the boom raised
or extended. Only level the frame while
stopped and with the boom fully retracted and Boom Angle
the attachment raised just enough to clear the Indicator
ground.

Outrigger Switches: The outriggers are used to pro-

vide greater stability in specific applications. Press the SERVICE AND SAFETY FEATURES
left switch forward to lower the left outrigger. Press the
right switch forward to lower the right outrigger. Press Transmission Oil Level: Dipstick is located below the
both switches rearward to raise the outriggers. cover on the front section of the main hood.
Level the frame before lowering the outriggers. Lower Hydraulic Pressure Test Ports: A gauge can be
the outriggers until the front tires just start to raise. attached to these ports to check main hydraulic valve,
joystick and steering pressures.
FUNCTION INDICATORS
Frame Level Indicator: Located in front of the oper-
ator on the ROPS upper cross tube, the position of the
ball indicates when the frame is level relative to a slop-
ing ground surface.

50960025/CP0514 32 PRINTED IN U.S.A.

 Transmission
Dipstick

Hydraulic Oil Level

Sight Gauge
Hydraulic Oil
Hydraulic Fill Cap
Test Ports

Air Cleaner Restriction Indicator: Located in the

Engine Oil Level: Dipstick is located on the right side rubber elbow connector at the rear of the air cleaner, it
of the middle section of the main hood. The dipstick indicates when the air cleaner needs service. If the
can also be used as the oill fill. clear portion of the indicator is red, the air cleaner
should be checked for a clogged filter element.

Engine Oil
Dipstick/Fill

Air Filter
Coolant Level: Coolant can be checked and added Restriction
through the radiator cap located under the top rear Indicator
opening on the main hood.
Radiator Backup Alarm: Located inside the rear frame cover, it
Cap produces a loud warning sound when the machine is in
reverse.
Backup Alarm

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

Hydraulic Reservoir Oil Level and Fill Cap: The ner of the fuel tank, this mirror provides the operator
sight gauge on the side of the reservoir indicates the with a view toward the rear of the machine.
level of the hydraulic oil. The fill cap is accessible by Battery Compartment: The battery compartment is
removing the cover of the front hood section. below the tool box at the rear of the fuel tank. Remove
the bottom panel of the tool box to check the elec-
trolyte level. Remove the access panel on the side of
the battery compartment to remove the battery.

PRINTED IN U.S.A. 33 50960025/CP0514

 6 5
Electrolyte
Access F
3
4

1
A

2
E
B

Removal
Access

C D

Windshield Washer Fluid Reservoir: Located out- FUSES:

side the right front of the operator station as shown.
The fluid level is visible through the reservoir. 1. 15 AMP fuse: Ignition Switch, Horn, Brake Lights,
and Clutch Cutout
Windshield Washer 2. 20 AMP fuse: Transmission, Park Brake, PWP,
Fluid Reservoir
Steer Mode, and Backup Alarm
3. 15 AMP fuse: Lights, Ether, and Outriggers
4. 25 AMP fuse: Heater and Gauges
5. 25 AMP fuse: Top Wiper Motor
6. 25 AMP fuse: Front Wiper Motor
RELAYS:
A. 20/40 AMP change-over relay: Ignition
B. 20/40 AMP change-over relay: Ignition
Fuse and Relay Compartment: This compartment is C. 20 AMP relay: Front Wiper
located under the load chart panel. Remove the four
D. 20 AMP relay: Park Brake
screws to gain access to the fuses and relays.
E. 20 AMP relay: Lights
F. 20 AMP relay: Top Wiper
ATTACHMENT TOOLS
Manitou Americas offers a versatile range of attach-
ment tools to meet various lifting and material-han-
Fuse and dling applications. Contact your Manitou Americas
Relay Access
dealer for specifications and ordering information.

Fuses and Relays Functions: Refer to the illustration ACCESSORIES

and following description for the fuse and relay func- Manitou Americas offers a range of special accessories
tions. for this machine. Contact your Manitou Americas deal-
er for specifications and ordering information.
NOTE: All accessories are field-installed unless
otherwise noted. Information and parts for
installing accessories will be provided by the
Manitou Americas or Manitou Americas
Telescopic Handler dealers.

50960025/CP0514 34 PRINTED IN U.S.A.

 Chapter 6
OPERATION AND ADJUSTMENTS
GENERAL INFORMATION During the first 20 hours, avoid prolonged periods of
engine idling or sustained maximum load operation. If
engine will idle longer that 5 minutes, stop the engine.
CAUTION Consult the Lubrication chapter for the type and grade
BEFORE starting the engine and operating the of oil to use. Refer to the Service and Storage chapter
Telescopic Handler, review and comply with for the proper service intervals.
ALL safety recommendations in the SAFETY
chapter of this manual. Know how to STOP the PRE-START WALK-AROUND INSPEC-
machine before starting it. Also, BE SURE to TION
fasten and properly adjust the seatbelt.
It is the operator’s responsibility to perform a pre-start
inspect of the machine before the start of each work-
ENGINE BREAK-IN day. Every pre-start inspection must include more than
simply checking the fuel and oil levels. It is a good
A new engine does not require extensive “break-in.” practice to personally inspect any machine you are
However, for the first 100 hours of operation, follow assigned to use, even though it has already been put
these guidelines: Operate the engine at various condi- into service by other personnel.
tions during the initial 100 hours with at least 15% of
the time under heavy loads to achieve adequate engine The pre-start inspection is designed to discover if the
break-in. Check the oil level frequently and replenish machine has incurred any damage or is in need of rou-
as necessary with the oil specified in the engine manu- tine service.
al. Any needed repairs are to be made by a qualified ser-
John Deere engines use a “break-in” oil for the first vice technician.
100 hours of operation. After the first 100 hours of Refer to the illustration and checklist on the next two
operation, change the oil and replace the oil filter. pages for the “Pre-Start Walk-Around Inspection.”
If the engine has too much operating time at idle, con-
stant speeds, or light load usage, or if make-up oil is
required during the first 100 hour period, a longer
break-in period may be needed without changing the
break-in oil until 500 hours.

PRINTED IN U.S.A. 35 50960025/CP0514

 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.

5
7
1

15

2 3
16

17

9 10
8
11
12 13 14

31

32
29
19 28 27

18

20

23 24 22 25 26
30
21

50960025/CP0514 36 PRINTED IN U.S.A.

 Pre-Start Walk-Around Inspection Checklist
Note the condition of safety decals during the walk-around o14. Stabilizer Switch: Properly secured; no visible dam-
inspection. Replace missing or illegible safety decals. age; no loose or disconnected wires.
o1. Attachment Tool: Check for broken, missing or o15. Boom Pivot Assembly: Properly secured; no visible
damaged parts. When using a personnel work plat- damage or excessive wear; properly lubricated.
form, check to see if the platform meets ANSI/ITSDF
o16. Boom Hydraulic Hoses: No visible damage or exte-
standards and that it is secured to the forks and fork rior wear; no evidence of leaking.
carriage. When using forks, check for welds, cracks
or misalignment. Replace the forks in sets when the o17. Rear Light Assembly: Properly secured; no visible
condition of the forks is questionable. damage; no loose or disconnected wires; no malfunc-
tions.
IMPORTANT: DO NOT use forks that have been
repaired by welding. o18. Hydraulic Control Valve Assembly: No loose or
missing parts; no evidence of leaking; no damaged or
o2. Attachment Tool Mount: No loose or missing parts; leaking hoses.
no visible damage.
o19. Exhaust System: No loose or missing parts; no visi-
o3. Attachment Tool Mounting Pins: No visible dam- ble damage; no obstructions to the outlet.
age; pin fit is secure and properly lubricated.
o20. Hydraulic Cooler: No loose or missing parts; no vis-
o4. Boom Chain: No loose or missing parts; no visible ible damage; no evidence of leaking; cleanliness;
damage; sheave pin fit is secure and properly lubri-
cated. o21. Engine Compartment:
o5. Boom Sections and Wear Pads: No loose or missing o Engine oil level, add if needed;
parts; no visible damage or excessive wear. o Coolant level, add if needed;
NOTE: Wear pads that measure 3/8” (9.5 mm) thick or o No evidence of engine oil or coolant leaks;
less need to be replaced. o Belts and hoses in good condition, properly secured
and adjusted
o6. Outriggers (when equipped): Properly secured;
pads in downward position; no visible damage; no o22. Boom Hose Guards: Properly secured; no visible
loose or missing parts; no leaking from the cylinder. damage.
o7. Boom Angle Indicator: Properly secured; no visible o23. Engine Air Filter: No loose or missing parts; no vis-
damage; bubble is visible. ible damage; no obstructions to the evacuator; pre-
cleaner free from dirt; restriction indicator proper
o8. Tire and Wheel Assemblies: Properly secured; no reading.
loose or missing lug nuts; no visible tire damage (cuts
or abrasions); proper inflation. o24. Battery Compartment: Proper electrolyte level; no
loose or damaged cables; no visible damage or corro-
o9. Front and Rear Axles: No loose or missing parts; no sion.
visible damage; tie rod end studs locked; no evidence
of leaking; properly lubricated. o25. Fuel Tank: No visible damage; no evidence of leak-
ing; level of fuel; breather cap secure and working.
o10. Operator Compartment:
o26. Mirror Assembly: No loose or missing parts; no vis-
o Seat belt undamaged; operates properly; mounting ible damage; properly adjusted.
hardware secure.
o27. Hydraulic Oil Reservoir: No visible damage; no
o Switches and levers undamage;
evidence of leaking; recommended oil level; breather
o no loose or missing parts; cap secure and working.
o load charts properly secured and legible;
o28. Cowling and Latches: All cowling, doors and latch-
o levers and switches operate properly; control mark- es in working condition; properly secure; no loose or
ings legible; missing parts; all components operate properly.
o frame level indicator secured and undamaged, bub-
o29. Frame Tilt Cylinder: Properly secured; no evidence
ble is visible.
of leaking; properly lubricated.
o11. Lift Cylinder: Properly secured; no visible damage;
no evidence of leaking from the cylinder; properly o30. Frame: No visible damage; no cracked welds; no
lubricated. loose or missing parts.

o12. Rear Axle Stabilizer Cylinder: Properly secured; no o31. Tilt and Auxiliary Hydraulic Hoses: No visible
visible damage; no evidence of leaking from the damage or excessive wear; no evidence of leaking.
cylinder; properly lubricated. o32. Attachment Tilt Cylinder: Properly secured; no vis-
ible damage; no evidence of leaking from the cylin-
o13. Slave Cylinder: Properly secured; no visible dam-
age; no evidence of leaking from the cylinder; prop- der; properly lubricated.
erly lubricated. Date: _________________Initials: _______________

PRINTED IN U.S.A. 37 50960025/CP0514

BEFORE STARTING ENGINE 6. Check that indicators are in normal condition.

Before mounting the operator’s compartment, walk 7. Check 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 COLD STARTING PROCEDURES
you are going to start up. Wait until everyone is clear
of the machine before starting it up. The engine is equipped with glow plugs for starting the
engine in temperatures down to 0°F (-18°C) and a
Before starting the engine and running the machine, block heater for starting the engine in temperatures
refer to the Indicators and Controls chapter and below 0°F (-18°C).
become familiar with the various operating controls,
indicators and safety features.

STARTING THE ENGINE

WARNING
DO NOT use starting fluid on engines
WARNING equipped with glow plugs. Ether starting fluid
is highly flammable and may explode, causing
ALWAYS fasten the seat belt BEFORE starting serious injury.
the engine. Leave the parking brake applied
until the engine is running and you are ready
The following procedure is recommended for starting
to operate the machine.
the engine in temperatures 0°F - 32°F (-18°C - 0°C):
The following procedure is recommended for starting 1. Follow steps 1 - 3 as listed in Starting The Engine.
the engine in temperatures 32°F (0°C) and above:
2. Turn the key switch to the “ON” position to acti-
1. Grasp the handholds and step up into the opera- vate the glow plugs and wait until the Engine
tor’s compartment. Preheater Indicator light turns off. Then press the
start button to start the engine. If the start button
2. Adjust the seat and fasten the seatbelt.
is released before the engine starts, turn the key
3. Check that all controls are in their “neutral” posi- switch “OFF” and repeat the procedure.
tions, except the parking brake switch, which
NOTE: The glow plugs operate automatically
should be in the “ON” position.
through the ECU. The Engine Preheater Indicator
4. Turn the key switch to the “ON” position and light should always illuminate when the switch is
press the start button. If the button is released turned ON. In warm weather, the light illuminates
before the engine starts, turn the key switch to the briefly as a light check. In cold weather, the light
“OFF” position, and allow the starter to stop remains on during the automatic operation of the
before attempting to start again. glow plugs. Operating time depends on the tem-
perature. Do not crank the engine until the indica-
IMPORTANT: Crank the starter until the engine
tor light turns off.
starts. If the engine fails to start within 30 sec-
onds, return the key to the “OFF” position, wait 3. Follow steps 5 -7 as listed in “Starting The
two minutes, and try again to start the engine. Engine”.
Cranking the engine for longer than 30 seconds
will result in premature failure of the starter. The following procedure is recommended for starting
the engine in temperatures below 0°F (-18°C):
5. After the engine starts, operate the engine at or
below 1200 rpm with no load for 1-2 minutes to 1. Follow steps 1 - 3 as listed in Starting The Engine.
allow the engine time to warm-up properly before 2. Plug the engine block heater in at least one hour
operating the controls. before attmpting to start the engine.
NOTE: When the parking brake switch is pressed 3. Turn the key switch to the “ON” position to acti-
into the “OFF” position, the parking brake will vate the glow plugs and wait until the Engine
remain applied until the travel lever is placed into Preheater Indicator light turns off. Then press the
either “Forward” or “Reverse.” start button to start the engine. If the start button

50960025/CP0514 38 PRINTED IN U.S.A.

 is released before the engine starts, turn the key Place the travel lever in Forward or Reverse and select
switch “OFF” and repeat the procedure. a speed range. Switch off the parking brake and move
ahead slowly, while testing the steering and brakes.
4. Follow steps 5 -7 as listed in “Starting The
Stop and operate all boom, attachment tool functions
Engine”.
and frame leveling controls, checking for smooth
Refer to the engine operator manual for additional cold response.
starting procedures.
Apply the service brakes, stop the machine and move
If the battery becomes discharged and has insufficient the travel lever to the opposite direction.
power to start the engine, jumper cables can be used
for starting assistance. Refer to the jump starting Shifting to the next higher gear may be done at any
instructions in the Service and Storage chapter of this engine speed while the machine is in motion.
manual for safe jump starting procedures. DO NOT overspeed the engine when down-shifting.
Allow the machine to slow down before shifting to the
STOPPING next lower gear.
The following procedure is the recommended ENGINE SHUTDOWN PROTECTION
sequence for stopping the machine:
The engine is equipped with a WARNING and SHUT-
1. Bring the machine to a stop on a level surface.
DOWN feature to warn of low engine oil pressure and
Avoid parking on a slope, but if necessary park
high engine coolant temperature. If the problem is not
across the slope and block the wheels.
corrected, the engine power will be reduced automati-
2. Fully retract the boom and lower the attachment cally, or the engine will shut down.
to the ground.
Engine Oil Pressure
3. Idle the engine for at least 2 minutes for gradual
cooling. There are two low oil pressure protection features:
Low Oil Pressure WARNING, and Low Oil Pressure
IMPORTANT: If and Exhaust Filter Cleaning has SHUTDOWN.
just been performed, increase the engine idle time
to 4 minutes. At the Low Oil Pressure WARNING set-point, the
warning lamp in the engine override switch and the
4. Place controls in neutral. Apply the parking brake. amber lamp in the exhaust filter gauge will flash and a
5. Turn the ignition switch key to the “OFF” posi- slow engine power derate will begin. But if the oil
tion. Remove the key. pressure rises above the Low Oil Pressure WARNING
set-point, power will slowly increase until the engine is
6. Unfasten the seatbelt, and grasp the handholds back to full power. The lamp in the switch and exhaust
while climbing out of the operator’s compart- filter gauge will continue to flash until the power has
ment. returned to normal, even if the fault condition has been
corrected and the recovery is in process.
FIRST TIME OPERATION
At the Low Oil Pressure SHUTDOWN set-point, the
Make sure the engine is warm, and then go through the lamp in the engine override switch and the amber lamp
following procedures: in the exhaust filter gauge will light continously, and a
fast engine power derate will begin. If the oil pressure
CAUTION does not rise above the SHUTDOWN set-point within
30 seconds, the engine will shut down. However, if the
Be sure the area used for test-running is clear oil pressure rises above the Low Oil Pressure SHUT-
of spectators and obstructions. Initially, oper- DOWN set-point within 30 seconds, then the power
ate the machine with an empty attachment derate speed will revert to the Low Oil Pressure
tool. WARNING speed of reaction.

PRINTED IN U.S.A. 39 50960025/CP0514

Engine Coolant Temperature To avoid unnecessary buildup of diesel particles or
soot in the exhaust filter system;
There are two coolant temperature protection features:
High Coolant Temperature WARNING, and High 1. Utilize the Automatic (AUTO) Exhaust Filter
Coolant Temperature SHUTDOWN. Cleaning mode.
At the High Coolant Temperature WARNING set- 2. Avoid unnecessary idling.
point, the warning lamp in the engine override switch
and the amber lamp in the exhaust filter gauge will 3. Use the proper engine oil. See Lubrication chap-
flash and a slow engine power derate will begin. But if ter of this manual or the engine maual for proper
the coolant temperature drops below the High Coolant engine oil specifications.
Temperature WARNING set-point, the power will 4. Use only ultra low sulfur diesel (ULSD) fuel. See
increase slowly until the engine is back to full power. Lubrication chapter of this maual or the engine
The lamp in the switch and exhaust filter gauge will manual for fuel requirements.
continue to flash until the power has returned to normal
Even with proper maintenance, ash and soot will build
even if the fault condition has been corrected and the
up in the exhaust filter after several thousand hours of
recovery is in process.
operation and require service. This service will need to
At the High Coolant Temperature SHUTDOWN set- be performed by a authorized Manitou Americas deal-
point, the lamp in the engine override switch and the er.
amber lamp in the exhaust filter gauge will light conti-
nously, and a fast engine power derate will begin. If the Automatic (AUTO) Exhaust Filter Cleaning
coolant temperature does not drop below the SHUT- Operating the engine in AUTO Mode allows the ECU
DOWN set-point within 30 seconds, the engine will to perform intelligent exhaust cleaning as required.
shut down. However, if the coolant temperature drops The Exhaust Filter Cleaning Indicator will illuminate
below the High Coolant Temperature SHUTDOWN when the system is actively performing an exhaust fil-
set-point within 30 seconds, then the power derate ter cleaning. When the exhaust filter cleaning process
speed will revert to the High Coolant Temperature has completed its cycle, the cleaning indicator will turn
WARNING speed of reaction. off.
EXHAUST FILTER CLEANING SYSTEM The machine can be operated as normal during the auto
exhaust filter cleaning process unless the operator
The engine is equipped with an exhaust filter in place determines the machine is not in a safe location for
of a muffler. This filter is located to the front of the high exhaust temperatures and disables the auto clean-
engine under the engine cover. This exhaust filter ing process.
reduces carbon monoxide, hydrocarbons, and particu-
late matter from the exhaust stream. Trapped particles To enable the auto exhaust filter cleaning mode, the
are eventually oxidized through a process known as exhaust filter cleaning rocker switch should be in the
regeneration or exhaust filter cleaning. center position.
IMPORTANT: It is recommended that the exhaust
Under normal machine operation and with the system
filter cleaning be in the Auto mode at all times.
in AUTO mode, the exhaust filter requires minimal
Auto mode should only be disabled when the
operator interaction.
machine is not in a safe location during the
Engine Exhaust exhaust filter cleaning process.
Filter
If the machine is not able to be moved to a safe loca-
tion, the operator should temporarily disable auto
exhaust filter cleaning. If the machine is located in a
safe location, the auto mode should always be enabled.

Manual/Parked Exhaust Filter Cleaning

Manual/Parked exhaust filter cleaning is initiated by
the operator. This process allows the system to clean
the exhaust filter when the operator previously needed
to disable the auto exhaust cleaning process because of

50960025/CP0514 40 PRINTED IN U.S.A.

specific conditions. During this process the engine cleaning process can be canceled at any time during the
speed will be controlled by the ECU. The machine process.
must remain parked during this process.
Avoid disabling the cleaning process unless absolutely
necessary. Repeated disabling or ignoring prompts to
WARNING perform a manual/parked cleaning procedure will
cause additional engine power limitations and can
During auto or manual exhaust filter cleaning eventually lead to dealer required service.
operations, the engine will run at elevated idle Utilize AUTO Exhaust Filter Cleaning mode to avoid
and hot temperatures for approximately 30 additional service.
minutes. Exhaust gases and exhaust filter
components reach temperatures hot enough Disable Exhaust Filter Cleaning
to burn people, ignite, or melt common mate-
Disabling the exhaust filter cleaning request is not rec-
rials.
ommended. Disable the automatic exhaust filter clean-
Servicing the machine or attachments during ing only when necessary. Whenever possible, cleaning
exhaust filter cleaning can result in serious should be allowed and the exhaust filter cleaning
personal injury. Avoid exposure and skin con- switch should be left in the AUTO Mode. When left in
tact with hot exhaust gases and components. auto mode, soot buildup in the exhaust filter system
will be at a minimum.
If the machine is note in a safe location for ele-
vated temperatures, move the machine to a To disable exhaust filter cleaning, press the bottom of
safe location and check for adequate fuel level the exhaust filter cleaning rocker switch. The Auto
before beginning the exhaust filter cleaning Cleaning Disabled Indicator located in the exhaust fil-
process. ter gauge will be illuminated.

Exhaust Filter Cleaning Precautions

NOTE: It is not necessary to perform a
When the AUTO Exhaust Filter Cleaning is disabled,
manual/parked exhaust cleaning unless a previ-
the sytem has 3 levels of notification to advise the
ous auto cleaning process was cancelled and the
operator to perform the exhaust filter cleaning. The 3
indicator in the exhaust filter gauge is illuminated.
levels are as follows;
Cleaning times will vary depending upon several spe- 1. The Exhaust Filter Indicator
cific criteria. The average standard cleaning time can will illuminate, indicating the
range from 20 - 50 minute or longer. the soot level in the filter is
To enable manual/parked exhaust filter cleaning; slightly high. If conditions
are safe, the operator should
1. Park the machine in a safe location and check that enable auto exhaust filter
the machine has a recommended 1/4 tank of fuel cleaning or perform a manual
to complete the process. exhaust filter cleaning.
2. Reduce engine speed to low idle and apply the 2. The Exhaust Filter Indicator
parking brake. and the Amber Alert
3. Press the top of the exhaust filter cleaning switch Indicator in the exhaust fil-
for approximately 3 seconds until the indicator in ter gauge will illuminate. Amber
the switch illuminates. The cleaning indicator in The engine performace will
the exhaust filter gauge will also illuminate. be reduced by the ECU
because the soot level in the
The indicators will go off when the exhaust filter exhaust filter is moderately high.
cleaning process is completed. If the machine is not If conditions are safe, the operator should enable
going to be returned to service immediately after the auto exhaust filter cleaning. If conditions are not
cleaning process, allow the engine and the exhaust fil- safe, the operator should move the machine to a
ter time to return to normal operating temperature safe location and either enable the auto exhaust
before stopping the engine. The manual/parked filter filter cleaning or perform a manual exhaust filter
cleaning.

PRINTED IN U.S.A. 41 50960025/CP0514

3. The Exhaust Filter Indicator 3. Slowly extend the Quick-attach System and lower
and the Red Alert Indicator the hooks under the attachment tool hookup bar.
in the exhaust filter gauge
Red
will illuminate. The ECU
will further reduce engine
performance. Continuing to
operate the machine at this
level will set a “Service Only” soot
condition where the engine cannot clean the
exhaust filter itself. In this condition, perform a
Manual/Parked Exhaust Filter Cleaning. A
Attachment
“Service Only” exhaust cleaning time can range Quick-attach System Tilted
Tool Forward for Hookup
from 3 - 4 hours.
IMPORTANT: Be sure the machine is parked in a 4. Tilt the Quick-attach System back so that the lock
safe place and has an adequate amount of fuel to plate engages the attachment tool. This secures
complete a 3 - 4 hour exhaust filter cleaning. the attachment tool to the Quick-Attach system.

PARKING BRAKE
NOTE: The parking brake mechanism within the Attachment Tool
Shown Locked to
front axle is not designed for, and not intended to Quick-attach
be used as, the primary means of stopping move- System
ment of the machine. Hydraulic braking provided
through the service brakes within the axles is the
primary means for stopping movement. The axle-
by-axle split brake system is the secondary
means of stopping movement.
The proper sequence for correct machine operation is Quick-attach System Attaching Detail
to always engage the parking brake switch before shut- 5. For an attachment tool with auxiliary hydraulics,
ting off the engine; and to disengage the parking brake connect the hoses to the quick-disconnect connec-
ONLY after the engine is running. In an EMER- tors on the boom nose.
GENCY, if it becomes necessary to STOP movement,
activate the parking brake switch to “ON.” Detaching Procedure
CHANGING ATTACHMENT TOOLS To detach attachment tool, proceed as follows:

The Telescopic Handler boom nose will accept Quick- 1. Raise the boom slightly and extend it two to three
attach System Manitou Americas attachment tools. The feet (600 to 900 mm) for better visibility. Lower
Quick-attach System has a quick-release hookup and the boom until the attachment tool is approxi-
locking mechanism for mounting framing-type or mately 12” (0.3 m) off the ground.
masonry-type attachment tools to the boom nose. 2. Tilt the carrier rearward as far as it will go. Once
the carrier is tilted back all the way, perform the
Attaching Procedure Mandatory Safety Shutdown Procedure (p. 9,
To pick up the attachment tool proceed as follows: Safety chapter).

1. Raise the boom slightly, extend it two to three feet 3. With the engine off, leave the operator’s station.
(600 to 900 mm) for better visibility, and tilt the Manually raise the lock spring and flip the lock
Quick-attach System forward. plate up and outward at least 180° so it is in posi-
tion to re-lock on the next attachment tool.
2. Align the Quick-attach System squarely with the
back of the attachment tool.

50960025/CP0514 42 PRINTED IN U.S.A.

 3. Visually inspect for leaks, broken or malfunction-
Attachment Tool ing parts. Be sure all caps, covers and safety
Shown Unlocked shields are in place.
for Release from
Quick-attach 4. Check tires for cuts, bulges, nails, correct pres-
System sure, loose wheel nuts, etc.
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.
Quick-attach System Detaching Detail
6. Check clearances of ramps, doorways and
4. Tilt the Quick-attach System forward to allow the
passageways. Check overhead clearances if you
attachment tool to roll out, then lower the boom
will travel and place loads near power or tele-
so the hook ears clear the hookup bar on the
phone lines.
attachment tool.
If the machine is found to be in need of repair or in any
NOTE: One side of the lock plate has a bright red way unsafe, or contributes to an unsafe condition, the
decal to indicate the unlocked position. matter must be reported immediately to the user’s des-
5. If the attachment tool has auxiliary hydraulics, ignated authority. The machine must NOT be operated
disconnect the hoses from the quick-disconnects until it has been restored to a safe operating condition.
on the boom nose.
6. Start the engine and tilt the Quick-attach System
forward, then slowly back the machine until the
WARNING
attachment tool is free from the boom nose. Exhaust fumes can kill. Ensure proper ventila-
tion when starting indoors or in enclosed
areas.
WARNING
Use proper handholds, NOT the steering
Modifications, alterations to, or use of attach- wheel or control levers when mounting and
ment tools NOT authorized by Manitou dismounting.
Americas (or the manufacturer) in writing can
NEVER operate the machine with safety
void warranty and cause machine damage
guards or covers removed.
and/or serious personal injury or death.
Over-inflated tires can explode and cause
injury or death. Tire repairs MUST be made
SELF-LEVELING
only by authorized personnel using proper
The machine is equipped with a hydraulic self-leveling tools and equipment.
feature. This feature is designed to keep the attachment
tool level while the boom is being raised. Operate the travel controls gradually and smoothly
when starting, stopping, turning and reversing direc-
GENERAL MACHINE OPERATION
tion.
Take time to check the Telescopic Handler to be sure
all systems are in good operating condition. Perform Grade and Slope Precautions
the following steps before starting the machine for the The Telescopic Handler complies with industry stabil-
first time each day: ity test requirements and is stable when properly oper-
ated. However, improper operation, faulty mainte-
1. Check the engine oil, coolant, transmission oil
nance, and poor housekeeping can contribute to a con-
and hydraulic oil levels.
dition of instability.
2. Be sure weekly lubrication has been done.

PRINTED IN U.S.A. 43 50960025/CP0514

The amount of forward and rearward tilt to be used is LEVEL, as indicated by the level indicator on the
governed by the application. Although use of maxi- ROPS/FOPS cross member. The attachment tool
mum rearward tilt is allowable under certain condi- MUST be maintained at the “carry” position with
tions, such as traveling with the load fully lowered, the the boom fully retracted, and attachment tool at
stability of the machine, as determined by the industry minimum ground clearance.
standard tests, does not encompass consideration for
When ascending or descending grades in excess of 5%
excessive tilt at high elevations, or the handling of off-
or 3°, the machine should be driven with the load
center loads.
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
On grades, ramps and inclines, use extreme caution
the load.
and avoid turning if possible. Normally travel straight
up and down the slope.
Grade Limits
NOTE: Grade limits are based on ANSI /ITSDF Traffic Flow Patterns
standard B56.6-2005.
Know and understand the traffic flow patterns of your
This 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°.
2. DO NOT travel up or down a grade or slope that
exceeds 22% or 12° while loaded.
3. DO NOT place or retrieve loads on a side hill with
a slope or grade that exceeds 12% or 7°.
Regardless of terrain or position of wheels, the
FRAME MUST BE LEVEL, as indicated by the
level indicator on the ROPS/FOPS cross member.
4. DO NOT travel across a side hill that exceeds
18% or 10° grade. Regardless of the terrain or
position of the wheels, the FRAME MUST BE

50960025/CP0514 44 PRINTED IN U.S.A.

 Safety Hand Signals Continued 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.

WARNING
When ramps must be used in transporting loads with Excessive speed can be hazardous. ALWAYS
the machine, the following are the minimum widths for exercise caution and good judgement while
safe travel: operating the machine.
Compacted dirt, gravel, etc. 12 ft. (3.6 m) ALWAYS maintain a safe distance from elec-
Woodboard, concrete, etc. 10 ft. (3.0 m) tric power lines and avoid contact with any
electrically charged conductor and gas line. It
Permanent aisles, roadways and passageways, floors
is not necessary to make direct contact with a
and ramps must be clearly defined or marked.
power line for power to ground through the
Permanent or temporary protrusion of loads, equip-
structure of the machine. Keep the boom and
ment, material and construction facilities into the usual
load at least 10 ft. (3 m) from all power lines.
operating area must be guarded, clearly and distinc-
Accidental contact with a power line or rup-
tively marked, or clearly visible.
ture of a gas line can result in electrocution or
Maintain a safe distance from the edge of ramps, plat- an explosion. Contact the “Call Before You
forms and other similar working surfaces. Dig” referral system number at 8-1-1 in the
U.S., or 888-258-0808 in the U.S. and Canada,
Controlled lighting of adequate intensity should be to locate any underground utility lines
provided in operating areas. Where operating condi- BEFORE starting to dig.
tions dictate, the operator/user is responsible for hav-
Keep all body parts inside the operator’s sta-
ing the machine equipped with lights.
tion while operating the machine. BE SURE of
Provisions must be made to prevent trucks, semi-trail- clearance for the attachment tool when turn-
ers and railroad cars from being moved during loading ing, working around buildings, etc.
and unloading. Wheel stops, parking brakes, or other
positive holding means must be used to prevent move-
ment during loading and unloading.

PRINTED IN U.S.A. 45 50960025/CP0514

Turning corners too fast can tip the machine, During placement, the operator should observe when
or cause a load to slide off the attachment. the boom extension mark number “4” on the boom is
Sudden slowing or stopping of the machine visible and stop further extension. The operator knows
may cause the load to drop off the attachment the maximum safe extension distance with the 4000 lb.
tool. load has been reached.
Be certain you can control both speed and
BOOM
direction before moving. Always place the EXTENSION
MARKERS
machine in neutral and set the parking brake
before raising or extending the boom. NEVER
drive the machine up to someone standing in
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

This 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 this page. The
Typical Load Zone Chart
scale on the left indicates height in feet above the
ground level. The scale on the bottom shows the dis-
tance in feet out from the front of the machine. The arc
lines noted by the numbers “1” through “5” correspond WARNING
with the boom extension marks on the operator side of
NEVER exceed the rated operating capacity of
the intermediate boom section.
the Telescopic Handler as shown on the load
The following example illustrates proper use of the zone charts.
load zone charts for the Telescopic Handler:

Example: The operator, using a standard carriage HANDLING NON-SUSPENDED LOADS

attachment tool without outriggers, wants to raise a
4000 lb. load 25 feet high, and can only get to within Picking Up the Load
15 feet of the load placement point. Can this be done Inspect the load. If it appears unstable, DO NOT
within the capacity of the machine? attempt to move it. DO NOT attempt lifting double-
tiered loads, or straddling side-by-side pallets with one
Analysis: See “Typical Load Zone Chart” above.
on each fork. NEVER add extra unauthorized counter-
Projecting up from the 15-foot reach mark on the hor- weights to this machine. Consider the additional
izontal axis to intersect a line through the 25-foot weight of any attachment tool as part of the picking
height mark on the vertical axis shows that a load up to load capacity of the machine.
4000 lb. can be placed in that zone.

50960025/CP0514 46 PRINTED IN U.S.A.

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

WARNING
WARNING
NEVER exceed the rated operating capacity of
NEVER travel with the boom above the carry the telehandler as shown on the load zone
position (attachment tool should be at mini- charts.
mum ground clearance). Boom should be fully
retracted.
Use lower gear when traveling down an
incline. NEVER coast with the transmission in
WARNING
neutral. Travel up and down grades slowly. Operating conditions can reduce the telehan-
DO NOT operate the machine on a slope or dler’s safe operating capacity. Exceeding the
capacity when raising or extending the boom
grade that exceeds 22% or 12o.
will cause the telehandler to tip forward.

NOTE: Refer to the standard carriage load chart

Load Elevation and Placement
when using the boom mounted hook.
For ground level load placement, be sure the area
under the load and around the machine is clear of Picking Up Suspended Load
equipment and personnel. Lower the load to the
ground, tilt the forks to the horizontal position, and 1. Rigging should be in good condition and rated for
then carefully back away to disengage the forks from the load being lifted.
the load.

PRINTED IN U.S.A. 47 50960025/CP0514

2. Rigging should comply with OSHA regulation Elevated Suspended Load Placement
§1910.184, “Slings,” or §1926.251, “Rigging
1. Bring the telehandler as close as possible to the
equipment for material handling.”
landing point.
3. Be sure the rigging equipment is clear of any part
2. Level the telehandler BEFORE raising the load.
of the machine or machine attachment before lift-
Use extreme caution for high placement. Be sure
ing the load.
personnel are clear of the load landing area.
4. Avoid lifting double-tiered or any unstable loads.
3. Set the parking brake, shift the transmission into
5. Only lift loads vertically and clear from any adja- neutral, hold the service brake pedal fully applied
cent obstacles. Never drag the load horizontally. and slowly raise the load.
6. Use multiple lift points and taglines to restrain the 4. As the load approaches the landing point, feather
load from swinging or rotating. the boom control at minimum speed until the load
is just above the landing point.
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
Carrying Suspended Load objects.
1. Rigging between the load and attachment should
be as short as possible to reduce boom height. 6. Once the load is stationary on the landing point
and the rigging is loose from the load, have the
2. Do not raise the load more than 12 inches (305
signal person disconnect the rigging from the
mm) above the ground or raise the boom more
load.
than 45 degrees.
7. Raise boom enough to clear the rigging from the
3. All telehandler movements should be performed
load. Slowly and carefully, reverse the telehandler
slowly and cautiously to prevent load swing.
till the rigging is clear of the load.
Avoid abrupt movement. Do not exceed walking
speed. 8. Lower the boom to travel height.
4. Use a signal person anytime the load restricts the Installation of a Personnel Work Platform
operators view or assistance is required. The sig-
(PWP)
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 The machine must not be used to lift or carry
1. Be sure the area under the load and around the personnel, or be fitted with any form of per-
telehandler is clear of equipment and personnel. sonnel work platform unless fitted with the
optional PWP System.
2. Lower the load to the ground till load is stationary
and the rigging is loose from the load. Have sig- If fitted with the PWP System, the Mandatory
nal person disconnect the rigging from the load. Work Platform Safety Rules (p. 15) must be
adhered to at all times while lifting personnel.
3. Raise boom enough to clear the rigging from the
load before backing the telehandler away from the
1. Center the forks on the carriage, spaced apart to
load.
match the distance required to engage the PWP.

50960025/CP0514 48 PRINTED IN U.S.A.

2. After the forks are fully engaged in the PWP,
secure the PWP to the forks. This can be accom- Electrical
plished by means of a retaining pin behind the Connection
heel of the forks, as shown.
PWP
Remote
Shutdown
Switch

Retaining Remote Shutdown Switch

Pin with Coiled Wire Connector
5. For machines with a 55-foot boom: The remote
shutdown switch is wireless-operated. Secure the
3. Secure the forks from pivoting upward in case the remote shutdown switch to the PWP using the
PWP is lowered onto an obstruction. This can be strap attached to the switch, as shown.
accomplished by using the chain supplied with
the PWP, to secure the lower portion of the PWP
to the bottom of the carriage, as shown below.

Chain
PWP
Remote
Shutdown
Switch

Wireless Remote Shutdown Switch

on 55’ Model
6. Secure the lanyard from the body harness to the
WARNING PWP or the boom. Each person in the PWP should
have a body harness with a lanyard attached to the
The PWP must meet ANSI/ITSDF B56.6-2005, PWP.
Section 8.24. (See page 16 in the Safety chap-
ter for PWP design requirements.) If the PWP Elevating Personnel
being used does not offer means to secure the This Telescopic Handler is primarily intended for use
PWP to the forks and to secure the forks from as a material handler. It should only be used to elevate
pivoting, as shown in steps 2 and 3, then an personnel if it is equipped with the (optional) PWP
alternate method must be used. System when there is no other practical option. If this
machine is to be used to elevate personnel, then use
4. For machines with a 42-foot or 44-foot boom: only an approved work platform, lift personnel only
Connect the coiled wire from the remote shut- with the PWP System activated, and follow the
down switch to the connector on the end of the “Mandatory Work Platform Safety Rules” (p. 15,
boom. Secure the remote shutdown switch to the Safety chapter).
PWP using the strap attached to the switch, as If this Telescopic Handler is equipped with a PWP
shown. System and is to be used for elevating personnel, the
system must be activated, by the "PWP System" mode
switch, which is located in the instrument and switch
panel. To activate the system, apply and hold the ser-

PRINTED IN U.S.A. 49 50960025/CP0514

vice brakes on for three or more seconds, and press the NOTE: If the lamp in the PWP system rocker
top of the PWP rocker switch. The system is activated switch is flashing, apply the service brakes until
when the lamp in the PWP rocker switch is on conti- the lamp goes off.
nously.
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 61 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-
l transmission is de-clutched into Neutral stand this is only permitted in case of an
l parking brake is applied emergency. Otherwise, the PWP System must
l rear axle stabilizer cylinder is locked 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 Stabilizer System
the result that the Telescopic Handler must be
level laterally (side-to-side) and longitudinally This is an additional safety function while elevating
(front-to-back) to within the factory preset limits loads for placement. At a pre-determined angle, the
before the boom control joystick will function stabilizer cylinder on the rear axle will lock up. When
l For 42-foot and 44-foot models, the remote shut- this happens, the parking brake is activated. The
down switch is activated, with the result that the machine will not be able to move until the boom is
switch must be connected and in the “on” position lowered below the pre-determined angle.
for the boom control joystick to function.
Depressing the switch will disengage the boom
control joystick, and stop all platform movement. WARNING
The remote shutdown switch box is supplied with
The machine becomes less stable as the load
a coiled electrical cable that must be connected to
is raised higher.
the outlet on the front of the innermost boom sec-
tion near the carriage. The switch must be acces- NEVER use frame leveling to position an ele-
sible by the platform personnel any time the plat- vated load. Always lower the load to the
form is to be moved. ground and reposition the machine.
l For 55-foot model, remote shutdown switch is If a hydraulic boom circuit hose should break
activated, meaning that the switch must be “on” with the boom up, shut down the machine. DO
for the boom control joystick to function. NOT attempt to bring down the boom or make
Pressing the red button will disengage the boom repairs. Call your Manitou Americas dealer
control joystick and stop all platform movement. immediately.
The remote shutdown switch box is a wireless
remote control, so there is no direct connection to As lift height increases, depth perception
the Telescopic Handler. The switch must be decreases. High elevation placement may
accessible to the platform personnel at all times require a signal person to guide the operator.
when the platform is to be moved. DO NOT ram the lift cylinders to the end of the
To de-activate the system, apply and hold the service stroke. The resulting jolt could spill the load.
brakes on for three or more seconds, and press the bot-
tom of the PWP System rocker switch. The system is
de-activated when the lamp in the PWP System rocker
switch is off.

50960025/CP0514 50 PRINTED IN U.S.A.

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
suspended loads must ALWAYS be done slow-
ly and cautiously, with the boom and load as
low as possible. Use taglines to restrict loads
from swinging, to avoid overturn.

ROAD TRAVEL
For short distance highway travel, attach a Slow-
Moving Vehicle (SMV) emblem (purchased locally) to
the rear of the Telescopic Handler. For highway opera- Ramp Placement
tion, obtain and install an amber flashing beacon.
2. The ramps MUST be firmly attached to the truck
NOTE: ALWAYS follow ALL state and local regu- or trailer bed with NO step between the bed and
lations regarding the operation of equipment on or the ramps.
across public highways. Whenever there is an 3. The incline of the ramps MUST be less than 15
appreciable distance between jobsites, or if degrees. For a four-foot high truck bed, ramp
driving on public highway is prohibited, transport length must be at least 16 feet (4.9 m) long.
the machine using a vehicle of appropriate size
and capacity. 4. Ramp width MUST be at least 1-1/2 times the tire
width.
TRANSPORTING BETWEEN JOBSITES
5. Block the front and rear of the tires on the truck
ALWAYS abide by the following recommended proce- or trailer. Engage the parking brake.
dures and guidelines when using ramps to load the 6. Position the machine with the boom facing
machine onto (and unload it from) a truck or trailer. toward the front of the truck or trailer so that it is
Failure to heed can result in damage to equipment and straight in line with the ramps.
serious personal injury or death!
7. Slowly (at the lowest engine speed possible) and
Tie-down eyes are provided for inserting chains carefully drive the machine up the ramps.
through to secure the machine during transport.
8. Secure the machine to the bed of the truck or trail-
er with tie-down chains/cables.

WARNING
NEVER adjust travel direction (even slightly)
while on the ramps. Instead, back off the
ramps, and then realign the machine with the
ramps.
Front Tie-Down Rear Tie-Down

Loading Machine Using Ramps

NOTE: A matched pair of ramps is required. WARNING
1. The ramps MUST be of sufficient strength to sup- NEVER transport the machine with the boom
port the machine. The use of strong steel ramps is raised or extended. BE SURE to secure the
recommended, as well as center supporting machine (including boom) to the truck or trail-
blocks. er bed using chain and binders or steel
cables, to prevent any movement while trans-
porting.

PRINTED IN U.S.A. 51 50960025/CP0514

Unloading Machine Using Ramps
NOTE: A matched pair of ramps is required.
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.
THEFT DETERRENTS
Manitou Americas has recorded all component part
numbers and serial numbers. Users should take as
many of the following actions as possible to discour-
age theft, to aid in the recovery of the machine in the
event it is stolen, and to reduce vandalism:

1. Remove keys from unattended machines.

2. Attach, secure, and lock all anti-vandalism and
anti-theft devices on the machine.
3. Lock doors of cabs when not in use.
4. Inspect the gates and fences of the equipment
storage yard. If possible, keep machines in well-
lighted areas. Ask the local law enforcement
agency to make frequent checks around the stor-
age and work sites, especially at night, during
weekends, and on holidays.
5. Report any theft to your dealer and insurance
company. Provide the model and all serial num-
bers. Request your dealer to forward this infor-
mation to Manitou Americas.

50960025/CP0514 52 PRINTED IN U.S.A.

 Chapter 7
LUBRICATION
GENERAL INFORMATION Engine Crankcase Oil
Ambient Temperature Grade*
WARNING -22°F - 104°F (-30°C - 40°C)
-40°F - 122°F (-40°C - 50°C)
SAE 5W-30
SAE 0W-40
NEVER lubricate or service this unit when any -13°F - 104°F (-25°C - 40°C) SAE 10W-30
part of the machine is in motion. ALWAYS -13°F - 122°F (-25°C - 50°C) SAE 10W-40
exercise the MANDATORY SAFETY SHUT- 5°F - 122°F (-15°C - 50°C) SAE 15W-40
DOWN PROCEDURE (p, 9, SAFETY chapter) *API Service Classification: CJ-4
before lubricating or servicing this equipment. *API Service Classification for first 100 hours on new or
rebuilt John Deere engines: CJ-4

NOTE: The Maintenance chapter (Chapter 10) in Capacity: 15.5 quarts (14.7 L)
this manual has provisions for recording the dates Diesel Fuel
and hourmeter readings after lubrication or other IMPORTANT: Use ONLY ultra low sulfur
service has been performed; use those spaces to diesel (ULSD) fuel with a maximum of 15
keep a log for maintaining a current service inter- PPM sulfur content specified to EN590 or ASTM
val record. Proper routine lubrication is an impor- D975.
tant factor in preventing excessive part wear and Fuel Tank Capacity: 47 gls. (178 L)
early failure.
Engine Coolant
LUBRICANTS IMPORTANT: Use a ethylene glycol based
The chart on this page lists the locations, temperature Extended Life Coolant and quality water mix-
ranges and recommended types of lubricants to be used ture suitable for heavy duty diesel engines. Coolant
when servicing this machine. Also refer to the separate should be a phosphate-free, silicate-free, nitrite-free
engine manual for additional information regarding and borate-free formula with corrosion inhibitors to
recommended engine lubricants, quantities required provide wet sleeve liner cavitation and corrosion pro-
and grades. tection of all cooling system metals.
Factory filled with (recommended): FINAL
NOTE: Refer to “Operator Services” in the CHARGE 50/50 PRE-DILUTED Global Extended
Service and Storage chapter of this manual for Life Coolant/Antifreeze.
detailed information regarding periodic checking
and replenishing of lubricants. Axle Gear Oil
MobilFluid® 424 (recommended)
CHS Cenex Qwiklift HTB or equivalent
Brake System Capacity:
MT10044XT, MT10055XT and MT12042XT
Uses hydraulic system oil.
Front Differential: 14.8 qts. (14.0 L)
Transmission Oil Front Planetary: 1.85 qts. each (1.75 L)
Rear Differential: 14.25 qts. (13.5 L)
Use Multi-ATF Dexron® III or equivalent
Rear Planetary: 1.90 qts. each (1.80 L)
Capacity: All Models 13.75 qts. (12.9 L)
Capacity:
Hydraulic System Reservoir MT6642XT and MT8044XT
Use Mobil DTE 15M, or an equivalent that Front and Rear Differential: 15.8 qts. (15.0 L)
contains anti-rust, anti-foam and anti-oxidation Front and Rear Planetary: 2.6 qts. each (2.5 L)
additives and conforms to ISO VG46/VG32. All Grease Fittings
Reservoir Capacity: 30 gallons (113.5 L)
Use No. 2 lithium-based grease

PRINTED IN U.S.A. 53 50960025/CP0514

 --- CHASSIS AREA ---
FILTER REFERENCE CHART
9. Brake pedal linkage
TYPE PART NUMBER
10. Wheel spindle pins (4 per axle)
Engine Oil 808000
11. Stabilizer cylinder pivot pins (3)
Engine Fuel Primary 50220174
12. Axle pivot pins (2 per axle)
Secondary 50220173
13. Drive shafts (3 per drive shaft)
Air Filter Primary 809825
14. Leveling cylinder pivot pins (2)
Secondary 809826
15. Base end lift cylinder pivot pins (2)
Crankcase Vent 50220168
16. Base end slave cylinder pivot pins (2)
Hydraulic Return 808005
--- OUTRIGGERS ---
Hydraulic Strainer 808006 Refer to the illustration below.
Transmission Oil 808004 17. Outrigger pad (2 per pad)
Cab Ventilation 51200000 18. Outrigger cylinder (2 per cylinder)
19. Outrigger leg pivot (1 per leg)

GREASING
Refer to the illustrations and listings for fitting loca-
tions. Wipe dirt from the fittings before greasing them
to prevent contamination. Replace any missing or dam-
18
aged fittings. To minimize dirt build-up, avoid exces-
sive greasing.

BASIC MACHINE GREASE FITTING

LOCATIONS 17

Every 50 Hours (or weekly)

19
Refer to the illustrations on the facing page for loca-
tions.
--- BOOM AREA ---
1. Boom-to-frame upright pivot pins (2)
2. Rod end slave cylinder pivot pins (2)
3. Rod end lift cylinder pins (2)
4. Extend cylinder pin
5. Chain sheaves pins, (2)
6. Dynattach-to-boom nose pivot pin
7. Tilt cylinder pivot pins (2)
8. Boom slide pads - as required, front and rear

50960025/CP0514 54 PRINTED IN U.S.A.

 5
5
1

4
8
8

6
7
16

15

12
14

11
10

13

Grease Fittings Locations

PRINTED IN U.S.A. 55 50960025/CP0514

 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 performimg 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. 9, 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
by (or under the direction of) an authorized Manitou
NOTE: All service routines, with the exception of 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
lubrication information. POWER TRAIN COMPONENTS
The engine and transmission are coupled directly to
NOTE: This Service and Storage chapter each other. All service routines related to the internal
describes procedures to follow for making routine components are precise and critical to proper power
maintenance checks, adjustments and replace- train operation. The axle differential and planetary
ments. Most of the procedures are also referred to ends are also sophisticated assemblies that require spe-
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
the owner’s prior authorization. Allow only trained HYDRAULIC SYSTEM COMPONENTS
personnel to service the machine. Valves, pumps, motors and cylinders are also sophisti-
cated assemblies which require special know-how and
Warranty repairs can only be done by an authorized tools for servicing. All cylinders are appropriately
Manitou Americas dealer. Dealers know what portions designed with particular strokes, diameters, checks and
of the machine are covered under the terms of the hose connection provisions unique to the machine
Manitou Americas Warranty and what portions are application requirements. A schematic (Maintenance
covered by other vendor warranties. chapter) can be used as a guide for service reference, as
required.

50960025/CP0514 56 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 they are not being activated,
and they are under extremely high pressure. OPERATOR SERVICES
Before removing one of these valves, you
ARE REQUIRED to call your Manitou Some of the operator-related services will require
Americas dealer or Manitou Americas Service access to components located inside the superstructure,
Department. Failure to do so may result in under shields, hoods and covers. The chart on this page
serious injury or death. 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
Exhaust Filter (front of engine) l
Air Cleaner (right side) 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. 57 50960025/CP0514

 Block the wheels. Remove the ignition key. Remove
WARNING only guards or covers necessary to 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 damaged or painted-over
Wear a face shield when disassembling
plates and decals that 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 WARNING
torch.
NEVER leave guards off or access doors open
When working beneath a raised machine, when the machine is unattended. Keep
always use blocks, jack-stands or other rigid bystanders away if access doors are open.
and stable supports. Wear appropriate protec-
tive clothing, gloves, and shoes. Keep feet,
After servicing, check the work performed, that no
clothing, hands and hair away from moving
parts are left over, etc. Install all guards and covers.
parts.
Always wear safety glasses or goggles for eye
Service Every 10 Hours or Daily
protection from electric arcs from shorts, flu-
ids under pressure, and flying debris or loose
material when the engine is running or tools
are used for grinding or pounding.
WARNING
NEVER weld on bucket, forks, boom, support
frame or ROPS/FOPS without the consent of Static electricity can produce dangerous
the manufacturer. These components may be sparks at the fuel-filling nozzle. Do not wear
made with metals that require special welding polyester, or polyester-blend clothing while
techniques, or with designs that do not allow fueling. Before fueling, touch the metal sur-
weld repairs. NEVER cut or weld on fuel lines face of the machine away from the fuel fill to
or tanks. dissipate any built-up static electricity. Do not
re-enter the machine but stay near the fuel fill-
If repair welding is ever required, BE SURE to
ing point during refueling to minimize the
attach the ground (-) cable from the welder as
build-up of static electricity. Do not use cell
close as possible to the area to be repaired.
phones while fueling. Make sure the static line
Also, remove battery positive (+) terminal con-
is connected from the machine to the fuel
nection before welding.
truck before fueling begins.

Choose a clean, level work area. Make sure you have Ultra-Low Sulfur Diesel (ULSD) poses a
sufficient room, clearances, and adequate ventilation. greater static ignition hazard than earlier
Clean the walking and working surfaces. Remove oil, diesel formulations. Avoid death or serious
grease and water to eliminate slippery areas. Utilize injury from fire or explosion; consult with your
sand or oil absorbing compound, as necessary, while fuel or fuel system supplier to ensure the
servicing the Telescopic Handler. entire fuel delivery system is in compliance
with fueling standards for proper grounding
Before starting inspection and repair, move the
and bonding practices.
machine onto a level surface, shut down engine, and
release all hydraulic pressure. Always block the boom
securely, or lower it to full ground contact. Place all
controls in neutral.

50960025/CP0514 58 PRINTED IN U.S.A.

CHECKING FUEL TANK LEVEL CHECKING ENGINE OIL LEVEL
The fuel level is shown by the fuel level gauge on the With the machine on level ground, and the engine
instrument panel. After operation each day, the fuel stopped for ten minutes or more, slide open the right
tank should be filled to prevent water from condensing side engine panel and remove the engine dipstick.
in the tank. To fill, remove the filler cap and add fuel. Wipe it clean, re-insert it and remove to obtain a read-
See the Lubrication chapter for the diesel fuel require- ing. If the oil level is below the crosshatch pattern on
ments. the dipstick, fill with the required amount of oil to
bring the level to within the crosshatch pattern. Oil lev-
CHECKING FUEL FILTERS els anywhere within the crosshatch are considered full.
See the Lubrication chapter for the type of oil to use.
E

C CHECKING COOLANT LEVEL

D Coolant
Fill Cap

Coolant Level
A
View Window

NOTE: The engine is equipped with a water-in-

fuel sensor at the primary fuel filter (D). An error
code will display in the multi-function display. With the machine on level ground, and the engine cool,
check the coolant level in the coolant surge tank locat-
Check the fuel filters (B) and (D) for water or debris. ed under the engine cover. Using a flashlight if needed,
If filter is fitted with a see-through bowl, drain as need- check the level through the viewing window as shown.
ed based on a daily visual inspection. The tank has a cold maximum and minimum level. The
IMPORTANT: Drain water into a suitable contain- level should be between the maximum and minimum
er and dispose of properly. level. If the coolant level is below the minimum level,
add a silicate-free, phosphate-free, borate-free and
a. Disconnect water sensor wire from drain plug (A) nitrite-free ethylene glycol based coolant mixed with
on fuel filter (D). deionized water suitable for heavy-duty diesel engines.
b. Loosen half turn to one turn drain plugs (A) at See the engine manual for additional information.
bottom of fuel filters or bowls. Coolant should be added by removing the cap on the
top of the surge tank. Replace the cap securely.
c. When fuel starts to drain out, tighten drain plugs
securely. NOTE: If the engine is operated with a loose
surge tank cap, the pressure bypass will not work
e. Reconnect water sensor wire. and the engine will run hot.
After draining water from the fuel filters, the filters
must be primed by bleeding all air from the fuel sys-
tem. Refer to the fuel bleeding procedure on page 61. WARNING
A drain plug is also provided in the bottom of the fuel DO NOT remove the surge tank cap when the
tank for removing condensation and other foreign engine is running hot or overheated. Coolant
materials. Open the plug and allow water and fuel to is extremely hot and under pressure and it can
drain into a container until only clear fuel is flowing burn your skin. Allow sufficient time for the
from the tank. radiator to cool BEFORE relieving the pres-
sure and removing the cap.

PRINTED IN U.S.A. 59 50960025/CP0514

CHECKING TRANSMISSION OIL LEVEL 2. Lubricate both the tire beads and rim
flanges with a soap solution. DO NOT use
The machine must be on level ground. With the engine oil or grease.
and transmission at operating temperature, parking
brake on, transmission in neutral and engine speed at 3. DO NOT place fingers on the tire bead or
low idle, remove the access cover to the transmission rim during inflation. Use a clip-on tire
and hydraulic pump. Remove the dipstick and check chuck with a remote hose and gauge,
the oil level. Add the required amount of oil to bring which allows standing clear of the tire
the level to the FULL mark. See the Lubrication chap- while inflating it.
ter for the type of oil to use. 4. NEVER inflate beyond 35 psi (240 kPa) to
seat the beads. If the beads have NOT
CHECKING HYDRAULIC OIL LEVEL seated by the time the pressure reaches
The machine must be on level ground with boom low- 35 psi (240 kPa), deflate the assembly,
ered and completely retracted. The fluid MUST be cool reposition the tire on the rim, relubricate
when checking the reservoir level, to reduce the possi- both parts and re-inflate. Inflation pres-
bility of overfilling the hydraulic system. sure beyond 35 psi (240 kPa) with unseat-
ed beads may break the bead or rim with
Visually check the level of the hydraulic oil through explosive force sufficient to cause death
the sight gauge located on the right side of the front or serious injury.
hood. If low, remove the access cover from the front
5. After seating the beads, adjust the infla-
hood to replenish the oil through the filler cap. See the
tion pressure to the recommended oper-
Lubrication chapter for the type of oil to use.
ating pressure listed.
IMPORTANT: Be careful when removing the 6. DO NOT weld, braze, or otherwise attempt
reservoir filler cap so that no dirt or other foreign to repair and use a damaged rim.
matter enters the hydraulic system. DO NOT
OVERFILL.
To ensure proper load carrying capability, original
CHECKING TIRE PRESSURES equipment tires comply with the specifications pub-
lished in the Tire and Rim Association Yearbook.
To ensure proper operating stability and extend tire Replacement tires MUST meet the same specifica-
life, proper and equal tire pressure should be main- tions. When replacing tires, be sure all tires are of the
tained in all four tires. same type, quality and load rating, and the same size as
Check tire pressures “cold.” Inflate as necessary per the original equipment. When removing tires, follow
the chart below: industry safety practices. Deflate completely prior to
removal. After assembly of the tire on the rim, use a
13.00 x 24 - 12 PR: 65 psi (450 kPa) safety cage or restraining device while inflating.
14.00 x 24 - 12 PR: 62 psi (430 kPa)
14.00 x 24 - 16 PR: 70 psi (480 kPa) CHECKING WHEEL NUT TORQUE
NOTE: If the tires have been filled with water or On new machines, or any time a wheel has been
calcium chloride for ballast, a calcium chloride tire removed, re-torque until 450 ft.-lbs. (610 Nm) is main-
pressure gauge MUST be used to check the tire tained.
pressure.
CHECKING INSTRUMENTS OPERATION

WARNING Allow the engine to warm up for 1-2 minutes or 2-4

minutes in below freezing temperatures before begin-
ning operation. Indicator lamps should be OFF and
Inflating or servicing tires can be dangerous.
gauges should register normal readings. Tilt the frame
Whenever possible, trained personnel should
from side to side with the frame leveling control and
service and mount tires. To avoid possible
note the angle indicator movement.
death or serious injury, follow the safety pre-
cautions below:
1. BE SURE the rim is clean and free of rust.

50960025/CP0514 60 PRINTED IN U.S.A.

CHECKING GENERAL MACHINE l The carriage tilt and auxiliary functions should
OPERATION AND CONDITION now be disabled. The joystick control should
continue to function normally for boom
Are any decals missing or damaged? Are all guards, raise/lower and extend/retract.
shields and covers in place? Do all controls function
smoothly and properly? Are there any abnormal vibra- Lockout Tests
tions or noises? Are any hose or fitting connections To test the transmission and joystick control lockout
leaking? Is the engine exhaust color normal? logic:

CHECKING PERSONNEL WORK PLAT- 1. Shift transmission into “F” (Forward) and
FORM (PWP) SYSTEM (if used) increase the engine speed slightly.
l The transmission should remain de-clutched,
allowing the engine to increase speed easily.
WARNING l Return the transmission selector to “N”
If the PWP System fails to operate properly (Neutral) after the check.
during any of the PWP System checks, DO 2. Have an assistant move the remote shutdown
NOT USE the machine until the cause has switch to “Dis-engaged.”
been corrected. Contact your dealer (or
l The joystick control should now be disabled, so
Manitou Americas) for service information and
parts. that boom raise/lower and extend/retract will no
longer function.
Machine Position l Have the assistant move the remote shutdown
switch to “Engaged” after the check.
The following must be performed before begining the
PWP System checking procedures: 3. Tilt the frame to the right slightly more than two
degrees.
1. Machine on level surface,
l The joystick control should now be disabled so
2. Boom fully lowered, that boom raise/lower and extend/retract no
longer function.
3. Frame level,
l Repeat the procedure with the frame tilted to
4. Transmission in “N” (Neutral), the left.
5. Parking brake switch “OFF,” l Return the frame to a level position after the
6. PWP System switch “OFF,” checks.

7. Remote switch plugged in and “ENGAGED.” De-activation Tests

To test the PWP System de-activation logic:
Activation Tests
1. Turn the key switch to “OFF” and wait for the
To test the PWP System activation logic:
engine to stop. Then turn the key switch back to
1. Start the engine and press the PWP rocker switch “ON.”
to “ON.”
l The PWP switch lamp and the parking brake
l The PWP System lamp in the switch should be switch lamp should both be illuminated.
flashing. 2. Turn the key switch to “OFF” and then turn the
2. Apply the service brakes. PWP rocker switch to “OFF.” Turn the key switch
back to “ON.”
l The PWP switch lamp should be illuminated
continuously after three seconds, indicating that l The PWP switch lamp should be flashing and
the PWP System has been activated. the parking brake switch lamp should be on
l The parking brake should engage, as indicated continuously.
by the lamp in the parking brake switch illumi-
nating.

PRINTED IN U.S.A. 61 50960025/CP0514

3. Start the engine and apply the service brakes.
Check Plug
l The PWP switch lamp and the parking brake
switch lamp should go off after approximately
three seconds of brake pedal application. Fill Plug
If PWP System fails to perform properly, troubleshoot
using the chart on page 71. Contact your dealer for ser-
vice information and parts.
Drain Plug
Service Every 50 Hours or Weekly Planetary
Hubs
LUBRICATE GREASE POINTS
NOTE: The planetary hubs can be checked with-
Refer to the Lubrication chapter of this manual for out jacking up the machine.
grease fitting locations and other related details.
The planetary hubs have one plug each used for filling
and draining. See illustration below. For checking the
100 Hours (New Machine Only) level and filling, position the wheel until the oil level
arrow is horizontal. Remove the plug. If oil does not
The following initial oil and filter changes should be run out, add oil until it overflows. Check the remaining
made at 100 hours on a new machine. Thereafter these hubs the same way. Refer to the oil specifications
changes should be made at the regular maintenance found in the Lubrication chapter of this manual.
schedule listed below. Refer to those schedules for the
necessary procedures.
Plug in fill and
Engine Oil and Filter (250 Hours) check position.
Transmission Oil and Filter (1000 Hours)
Hydraulic Return Filter Element (1000 Hours)
Torque the boom chains after the first 100 hours of
operation on new machines or anytime a chain has
been replaced. Thereafter the boom chains should be
inspected for wear and proper tension at the regular
service interval of 250 hours. Refer to the boom chain
torqueing procedure in the 250 hour service interval. CHANGING FUEL FILTERS

Service Every 250 Hours or Quarterly The frequency of filter replacement will be determined
by the cleanliness of available fuel, the care used in
storing fuel supplies and the operating conditions in
NOTE: Perform all other service requirements
which the machine is used.
up to this point, as well as the following:

CHECKING AXLE OIL LEVELS WARNING

Differential NEVER service the fuel system while smok-
NOTE: The Telescopic Handler should be on a ing, while near an open flame, or after the
level surface for this procedure. engine has been operated and is hot.

Remove the oil check plug. See illustration below. Oil 1. Thoroughly clean fuel filter assemblies and sur-
should flow from the hole. If low, remove the oil fill rounding areas.
plug and add oil until it flows from the check hole. 2. Disconnect water sensor wiring from the (E) fil-
Replace the plug, wait 10 to 15 minutes and repeat the ter.
fill procedure. Continue this process until the differen-
tial is full. See the Lubrication chapter for the proper 3. Loosen drain plugs (C) and drain fuel into a suit-
oil specification. Replace the check and fill plugs. able container.

50960025/CP0514 62 PRINTED IN U.S.A.

4. Firmly grasp the retaining ring (A) and rotate it Fuel Bleeding Procedure
clockwise 1/4 turn (when viewed from the top).
Remove the ring with filter element (B or E). When the fuel filter is removed and replaced, or if the
engine runs out of fuel, air must be bled from the sys-
A tem. Refer to the following procedure for proper bleed-
ing procedure.
A
1. To bleed the fuel system, turn the ignition key to
the “ON” position for 60 seconds.
E
2. Start engine and check for leaks.
B
If the engine will not start, repeat step 1.

C
WARNING
Escaping diesel fuel under pressure can have
sufficient force to penetrate the skin. Before
NOTE: Lifting up on retaining ring (A) as it is rotat-
applying pressure to the fuel system, BE
ed helps to get it past raised locators.
SURE all connections are tight and lines and
5. Inspect filter mounting base for cleanliness. Clean hoses are not damaged. Use a piece of wood
as required. or cardboard to search for suspected leaks. If
injured by escaping fuel, see a doctor familiar
NOTE: Raised locators on the fuel filter canister
with this type of injury at once or gangrene
must be indexed properly with slots in mounting
may result.
base for correct installation.
6. Install new filter elements onto mounting bases. Diesel Fuel Injectors
Be sure elements are properly indexed and firmly
Whenever faulty or plugged injectors are indicated, see
seated on bases. It may be necessary to rotate fil-
your authorized engine dealer.
ters for correct alignment.
Remove filter element from seperator bowl (D). Diesel Injection Pump Timing
Drain and clean the separator bowl. Dry with
Whenever injection pump timing, or other pump ser-
compressed air. Install bowl onto new element.
vice is indicated by abnormal engine operation, contact
Tighten securely.
your authorized engine dealer.
7. Align keys on filter element with slots in filter
base. NOTE: Only an authorized engine dealer can per-
8. Install retaining ring onto mounting base making form warranty service on the engine.
certain dust seal is in place on filter base. Hand- CHANGING ENGINE OIL AND FILTER
tighten ring counter-clockwise (about 1/3 turn)
until it snap into the detent. DO NOT overtighten Change the engine oil and filter using the following
retaining ring. procedure:
NOTE: The proper installation is indicated when a 1. With the engine warm, remove the crankcase
“click” is heard and a release of the retaining ring drain plug.
is felt.
IMPORTANT: DO NOT discharge oil onto ground.
9. Reconnect water sensor wiring on the filter (E). Catch and dispose of per local waste disposal
After fuel filter replacement, bleed the air out of the regulations.
fuel system by following the fuel bleeding procedure
below. 2. The engine oil filter should be changed at every
oil change interval. Using a suitable filter wrench,
remove and discard the filter.

PRINTED IN U.S.A. 63 50960025/CP0514

 Open
Crankcase Vent

Engine Oil
Filter
IMPORTANT: Filtration of oils is critical to proper
lubrication. Always change the filter with every oil CHECKING THE BATTERY
change. The battery furnished in the machine is a 12-volt, wet-
3. Apply a thin coat of cell battery.
clean engine oil to The top of the battery must always be kept clean. Clean
the new oil filter at the battery with a brush dipped in an alkaline solution
the inner (A) and (ammonia or baking soda and water). After the foam-
outer (B) seals and to ing has stopped, flush the top of the battery with clean
the filter threads. water. If the terminals and cable connection clamps are
4. Wipe both sealing corroded or have a buildup, disconnect the cables and
surfaces of the clean the terminals and clamps with the same alkaline
filter header (C, solution. Wash hands after handling the battery.
D) with a clean
cloth. Ensure
keys in the dust WARNING
seal (E) are
p r o p e r l y Explosive gas is produced while a battery is in
installed in the use or being charged. Keep flames or sparks
slots in the away from the battery area. Make sure battery
housing. Replace dust seal if damaged. is charged in a well-ventilated area.

5. Install and tighten oil filter by hand until firmly NEVER lay a metal object on top of a battery
against dust seal (E). DO NOT apply an extra 3/4 as a short circuit can result.
to 1-1/4 turn after gasket contact is made, as is
Battery acid is harmful on contact with skin or
done with standard filters.
fabrics. If acid spills, follow these first aid tips:
6. Clean and re-install the drain plug.
1. IMMEDIATELY remove any clothing on
7. Re-fill the crankcase with new oil. Follow specifi- which acid spilled.
cations in the Lubrication chapter for type and vis-
cosity of new oil. 2. If acid contacted the skin, rinse the affect-
ed area with running water for 10 to 15
8. After new oil has been added, run the engine at idle
minutes.
speed until the oil pressure lamp is off. Check for
leaks at the filter and drain plug. 3. If acid came in contact with the eyes, flood
CHECK OPEN CRANKCASE VENT the eyes with running water for 10 to 15
minutes. See a doctor at once. NEVER use
Check and replace as necessary any worn, cracked, any medication or eye drops unless pre-
leaking, or bulging hoses. Check clamps for good ten- scribed by the doctor.
sion on all hose ends.

50960025/CP0514 64 PRINTED IN U.S.A.

4. To neutralize acid spilled on the floor, use 2. Connect one end of the (red) positive (+) jumper
one of the following mixtures: cable to the positive (+) battery terminal on the
disabled machine first. DO NOT allow the posi-
a. 1 pound (0.5 kg) of baking soda in 4
tive (+) jumper cable clamps to touch any metal
quarts (4 liters) of water.
other than the positive (+) battery terminals.
b. 1 pint (0.4 liters) of household ammo- Connect the other end of the positive jumper
nia in 4 quarts (4 liters) of water. cable to the jumper battery positive (+) terminal.
Whenever battery is removed from the unit, 3. Connect one end of the (black) negative (-)
BE SURE to disconnect the negative (-) bat- jumper cable to the jumper battery negative (-)
tery terminal connection first. terminal.
4. Make the final negative (-) jumper cable connec-
Jump Starting tion to the disabled machine’s engine block or
If the battery becomes discharged or does not have frame (ground) ⎯ NOT to the disabled machines
enough power to start the engine, use jumper cables negative battery post. If making the connection to
and the following procedure to jump-start the engine. the engine, keep the jumper cable clamp away
from the battery, fuel lines, and moving parts.
IMPORTANT: BE SURE that the jumper battery is
NOTE: Twist the jumper cable clamps on the bat-
also a 12-volt D. C. battery, and the vehicle used
tery terminals to ensure a good electrical connec-
for jump starting has a negative-ground electrical
tion.
system.
5. Start the engine. If it does not start immediately,
start the jumper vehicles engine to avoid exces-
WARNING sive drain on the booster battery.
The ONLY safe method for jump-starting a dis- 6. After the machine has started and is running
charged battery is for TWO PEOPLE to per- smoothly, have the second person remove the
form the following procedure. The second per- jumper cables (negative (-) jumper cable first)
son is needed for removing the jumper cables from the jumper vehicle battery, and then from the
so that the operator does not have to leave the disabled machine, while ensuring NOT to short
operator’s compartment while the engine is the two cables together.
running. NEVER connect the jumper cables Allow sufficient time for the alternator to build up a
directly to the starter solenoid of either charge in the battery before operating the machine or
engine. DO NOT start the engine from any shutting off the engine.
position other than the operator’s seat, and
then ONLY after making sure all controls are in NOTE: If the battery frequently becomes dis-
“neutral.” charged, have the battery checked for possible
dead cell(s), or troubleshoot the electrical system
Closely follow the jump-start procedures, in
for possible short circuits or damaged wire insula-
the order listed, to avoid personal injury. In
tion.
addition, wear safety glasses to protect your
eyes, and avoid leaning over the batteries CHECKING AND TORQUING BOOM
while jump-starting.
LEAF CHAINS
DO NOT attempt to jump-start the machine if
the battery is frozen, because this may cause Inspect the leaf chains for proper tension. On the three-
it to rupture or explode. section boom, two of the chains are on the top front of
the boom. A third chain is accessible from inside the
rear of the boom (see three-section boom illustration).
1. Turn the key switches on both vehicles to “OFF.” Torque the two chains on the front of the three-section
Be sure that both vehicles are in “Neutral” and boom to 30 ft.-lbs. (40 Nm). Lubricate with 80W-90
NOT touching. oil.

PRINTED IN U.S.A. 65 50960025/CP0514

 Two Front Inspect the leaf chains for wear. Run the boom out
One Rear Boom Chains
Boom Chain
slowly to inspect. Conditions to look for include:
cracked or broken plates, protruding or turned pins,
and excessive wear. With a steel tape, measure 16 links
of the strand that flexes over the sheaves. If the section
measures 12.375” (314 mm) or more, the chain should
be replaced. DO NOT repair sections of a chain.
Replace the complete chain.
Inner
Intermediate Section Chain anchors and sheaves also require inspection, for
Outer Section
Section worn or broken fingers and worn flanges.

Three-Section Boom Chain Hookup Detail After any chain has been replaced, operate under
loaded conditions and re-check the torque. Adjust the
IMPORTANT: On the three-section boom, on new chains per the following procedure: Extend the boom
machines or when chains have been replaced, it to its maximum length, then retract the boom slowly
is necessary to retorque the front double chain until the chain slack allows the chain to rest on the top
assembly after one hundred (100) hours of oper- of the boom. Torque the two chains on the front of the
ation. Failure to do so may allow the chains to three-section boom to 30 ft.-lbs. (40 Nm) and the three
become slack, which can result in a chain jumping chains on the front of the four-section boom to 50 ft.-
off a sheave. If this occurs, it could result in lbs. (68 Nm). Lubricate with 80W-90 oil.
severe damage to the boom assembly.
CHECKING BOOM SLIDE PAD WEAR
On the four-section boom, three chains are on the top AND CLEARANCE
front of the boom. A fourth and fifth chains are acces-
sible from the rear of the boom (see four-section boom The boom is equipped with special nylon low-friction
illustration). slide pads between the telescopic sections (see
Two Front One Front “Typical Slide Pad Detail” illustration). These are pre-
One Rear Boom Chains Boom Chain greased and initially worn in at the factory. Normally
Boom Chain
greasing is not required, except for maintaining a light
film of grease on the pad tracking areas of the boom
sections. An exception would be if a boom section has
been replaced.
Rear Inner
Outer 1st Intermediate 2nd Intermediate Inner
Section Section Section Section Shim

Four-Section Boom Chain Hookup Detail Pad

Torque the three chains on the front of the four-section

boom to 50 ft.-lbs. (68 Nm). Lubricate with 80W-90
oil.
IMPORTANT: On the four-section boom, on new
machines or when chains have been replaced, it
is necessary to retorque the front-center single Front
chain and the front-outer double chains after one Outer
hundred (100) hours of operation. Failure to do so
may allow the chains to become slack, which can Typical Slide Pad Detail
result in a chain jumping off a sheave. If this
occurs, it could result in severe damage to the Visually check for loose pad bolts. The bolts are
boom assembly. torqued to 30 ft.-lbs. (40 Nm). If the bolts are re-
torqued at any time, Loctite® 271 (red) thread lock or
The retract chains on the 2nd intermediate boom and equivalent must be re-applied to the bolts.
the inner boom are pre-set at the factory and do not
require adjustment, unless they are replaced.

50960025/CP0514 66 PRINTED IN U.S.A.

If the boom starts to chatter under load, grease the slide 2. Remove the cover to gain access to the condenser
pads and wipe off the excess grease. Maintain a clear- (2).
ance of 1/16” between the top or side slide pads and the
3. Clean any large debris that may have collect on
boom. Shims can be added to achieve the proper clear-
the top side of the condenser.
ance. Loosen the bolts and insert shims until proper
clearance is obtained. 4. Clean the condenser use a jet of compressed air
aimed in the same direction as the air flow.
NOTE: When inserting shims in the side slide
pads, be sure to place equal shims on both sides NOTE: To aid in the cleaning process, carry out
of the boom for even distribution of clearance. this operation with the condenser fans running.

Re-apply Loctite® 271 (red) thread lock or equivalent 5. Re-install the top cover.
to the bolts and re-torque to 30 ft.-lbs. (40 Nm).
CLEAN/CHANGE CAB VENTILATION
Bottom slide pads should not be shimmed and should
be replaced when the thickness is worn down to 3/8” FILTER
(9.5 mm). NOTE: Clean or change the filter more often if
there is a noticeable decrease in air flow from the
air vents.
WARNING 1. Remove the four screws (1) from the filter pro-
Failure to maintain proper slide pad clearance tective cover located on the lower portion of the
and thickness could cause damage to the dash in front of the brake pedal.
boom, resulting in sudden boom failure.

CLEAN AIR CONDITIONING CON-

DENSER
NOTE: Clean the condenser more often if there is 1

a noticeable decrease in A/C performance.

IMPORTANT: Do not use a water jet or high-pres-
sure steam, because this could damage the fins.
1. Remove the six screws (1) from the top cover of 2. Remove the filter from the cover.
the condenser.
3. Clean the filter with a jet of compressed air.
4. Check the condition of the filter and replace it if
neccessary.
1
5. Install the filter in the protective cover, then re-
install the protective cover.

Top View of Condenser Assembly

PRINTED IN U.S.A. 67 50960025/CP0514

 Service Every 1000 Hours or Yearly CHANGING HYDRAULIC RETURN
FILTER ELEMENT
NOTE: Perform all other service requirements
up to this point, as well as the following: WARNING
CHANGING TRANSMISSION OIL AND When servicing the hydraulic system, lower
FILTER the boom to the ground.
Operate the machine long enough to warm the trans-
mission oil to 150°F-200°F (65°C-93°C). Shut off the
This element is a cartridge-type accessible from a
engine. Access to filter is from under the access cover
housing on top of the hydraulic reservoir. Initial
on the front hood section. Access to the drain plug is
replacement is after the first 100 hours. See illustra-
from underneath the machine. Proceed as follows:
tion. Remove the top cover of the housing. Remove the
1. Remove the drain plug and drain old oil. Replace element and discard. Insert the new element into the
the drain plug. housing and replace the cover.

Housing Top

Transmission
Drain Plug Filter Element

Filter Housing

IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal
regulations. Reservoir Filter Removal
2. Remove and discard the oil filter. Wipe the seal- CHANGING AIR FILTER ELEMENT(S)
ing surface on the transmission with a clean cloth.
Apply a thin coat of clean oil to the new oil filter The air cleaner assembly consists of an outer (primary)
gasket. Hand tighten. filter element and an inner (secondary) filter element.
An air filter restriction indicator for monitoring the
condition of the filter elements is located on the rubber
Transmission elbow on the rear of the air cleaner. If the air filter
Filter becomes restricted, this indicator turns red to warn the
operator that the air cleaner requires service. Push the
Transmission reset button located at the end of the restriction indica-
Dipstick and tor after installing a clean element.
Filler
Secondary
Element

3. Refill the transmission with new oil as listed in

the Lubrication chapter of this manual.
IMPORTANT: DO NOT OVERFILL! lf the oil level
is too high, oil foaming, excessively high oil tem- Primary End Cap and
perature and oil leakage at the seals could result. Element Dust Ejector
Mounting
4. Start and run the machine long enough for the oil Housing Band
to circulate and warm slightly. Recheck the level
with the dipstick. Dual-Element Air Cleaner Assembly

50960025/CP0514 68 PRINTED IN U.S.A.

NOTE: Before replacing the filter element(s), 3. Insert the element(s), making sure that they are
push the reset button on the indicator. Start the seated properly.
engine and run at full throttle. If the indicator does
4. Secure the end cap to the housing with the three
not turn red, do not replace the element(s).
latches.
The outer element should be replaced only when the 5. Check the hose connections and make sure they
restriction indicator turns red. The inner element are all clamped and tightened properly.
should be replaced every third time the outer element
is replaced, unless the outer element is damaged or the 6. Reset the restriction indicator by pressing the
inner element is visibly dirty. Along with a daily check reset button.
of the restriction indicator, check that the air cleaner
intake hose and clamps, and the mounting bracket CHANGING OPEN CRANKCASE FIL-
hardware are properly secure. TER ELEMENT
Unlatch the three latches on the air cleaner and remove Open
the end cap assembly. Clean out any dirt built up in the Crankcase Vent
end cap assembly.

Primary Element
1. Carefully pull the primary (outer) element out of
the housing. Never remove the secondary (inner)
element unless it is to be replaced.
2. Clean out any dirt built up in the housing. Leave
the secondary element installed during this step to
prevent debris from entering the engine intake
manifold.
3. Use a trouble light inside the primary element to Located near the final fuel filter, the open crankcase
inspect for bad spots, pinholes and ruptures. filter element should be replaced by:
Replace the primary element if any damage is
1. Removing the thread-on cap on the top of the can-
noted. The primary element must be replaced if it
ister.
is oil- or soot-laden.
2. Lift the element out of the canister and replace
NOTE: Cleaning the primary element is not rec-
with a new filter. The filter is notched on the top
ommend.
for correct positioning.
Secondary Element 3. Replace the thread-on cap. The cap will need to
be indexed to the filter element before it can be
NOTE: Replace the secondary element only if it is
threaded on. Hand tighten only.
visibly dirty or if the primary element has been
replaced three times. CHANGING AXLE DIFFERENTIAL AND
Before removing the secondary element from the hous- PLANETARY OIL
ing, clean out any dirt built up in the housing. Leave
the secondary element installed during this step to pre- Differentials
vent debris from entering the engine intake manifold. 1. Remove the three drain plugs and drain the used
Remove the secondary element. oil. Replace the drain plugs (see illustration).

Reinstallation IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal
1. Check the inside of the housing for any damage
regulations.
that may interfere with the elements.
2. Be sure that the element sealing surfaces are
clean.

PRINTED IN U.S.A. 69 50960025/CP0514

 Fill Plug Check Plug CHECKING EXHAUST SYSTEM
Examine the entire exhaust system for possible holes
and leaks. Re-tighten any loose clamps and make sure
the manifold outlet gasket is not leaking.

Service Every 2000 Hours or Two Years

Drain Plug
NOTE: Perform all other service requirements
2. Remove the fill/check plug. Fill the differential up to this point, as well as the following:
with fresh oil as specified in the Lubrication
chapter. When the oil flows from the check hole, CHECKING HYDRAULIC SYSTEM
replace the plug. Wait 10 to 15 minutes and repeat RELIEF PRESSURES
this process until the axle is full.
Pressure settings for relief valves are pre-set at the fac-
Repeat this procedure with the other axle. tory. Three test ports are provided under the front hood
access cover.
Axle Planetary Hubs
The hubs have one plug each used for draining and fill-
ing (see illustration). Test ports under
front hood
1. Position the wheel until the oil level arrow points access cover.
down. Remove the drain/fill plug and allow the
oil to drain. Replace the plug.

Before conducting any test port pressure checks, check

the engine speed. Engine speed must be 800 rpm at low
Plug in drain idle and 2500 to 2550 rpm at high idle.
position.
NOTE: Pressure checks should be made with
engine at low idle.

Steering Relief Pressure

IMPORTANT: DO NOT discharge oil onto ground.
Plug a 3000 psi (207 bar) oil-or liquid-filled gauge into
Catch and dispose of per local waste disposal
the test port labeled ”SP.” Cramp the steering fully to
regulations.
the right or left. The gauge should read 2500 psi (172
2. Re-position the hub so the oil level arrow is hori- bar).
zontal. Fill with fresh oil as specified in the
Lubrication chapter. When the oil runs out, install Joystick and Parking Brake Release
the drain/fill plug. Pressure
Repeat this procedure on the three remaining hubs. Plug a 1000 psi (70 bar) gauge into the port labeled
CHECKING ALTERNATOR AND FAN “JP.” With the engine running, the gauge should read
350 psi (24 bar).
BELT CONDITION
Refer to the engine manual for proper fan belt tension Main Relief Pressure
adjustment and replacement procedures. If the belt Plug a 3000 psi (207 bar) oil-or liquid-filled gauge into
shows wear or cuts, it should be replaced. Order a the test port labeled “MP.” Fully retract the boom over
replacement belt from your Manitou Americas dealer. the relief valve. The gauge should read 3000 psi (207
bar).

50960025/CP0514 70 PRINTED IN U.S.A.

CHANGING HYDRAULIC RESERVOIR
OIL AND STRAINER WARNING
Clean all dirt and debris from around the top of the NEVER use your hands to search for hydraulic
reservoir, especially around the access cover. Refer to fluid leaks. Escaping hydraulic oil under pres-
illustration and use the following procedure: sure can have sufficient force to penetrate the
skin. Before applying pressure to the
Element
hydraulic system, be sure all connections are
Fill Cap
Dipstick
tight and lines and hoses are not damaged.
Use a piece of wood or cardboard to search
Access for suspected leaks. If injured by escaping
Cover hydraulic oil, see a doctor familiar with this
type of injury at once or gangrene may result.

Gasket CHANGING RADIATOR COOLANT

Drain old coolant, flush the entire cooling system, test
thermostats and fill with recommended coolant.

TOP OF
RESERVOIR WARNING
Hydraulic Reservoir Sump Strainer Removal
Remove the radiator cap only when the engine
is cool, or painful burns could result.
1. Remove the drain plug and drain used oil. Wash
or blow off all particles collected on the magnetic
drain plug.
IMPORTANT: DO NOT discharge coolant onto
IMPORTANT: DO NOT discharge oil onto ground. ground. Catch and dispose of per local waste dis-
Catch and dispose of per local waste disposal posal regulations.
regulations.
Refer to the John Deere engine manual for detailed
2. Remove the access cover and wash the inlet coolant replacement instructions.
screen with clean solvent. Remove and wash the
sump filter strainer from the bottom inside of the IMPORTANT: Fill the cooling system with a low-
reservoir. If the strainer has any damage, holes, silicate ethylene glycol based coolant mixed with
etc., it should be replaced. quality water and supplemental coolant additives
(SCAs) suitable for heavy-duty diesel engines.
3. Flush out the bottom of the reservoir with clean See the engine manual for additional information.
hydraulic oil. Re-install all cleaned components
and install the access cover on the reservoir with NOTE: Check the engine temperature gauge
a new gasket. Clean the filter/breather cap. every minute or two after coolant has been
changed. Air pockets can form and it may be nec-
4. Fill the reservoir with fresh oil. Follow specifica-
essary to refill the cooling system after a short
tions in the Lubrication chapter of this manual.
period of use, as the air will naturally bleed out of
IMPORTANT: Hydraulic fluid and filters should be the system.
replaced any time contamination is present before
the normally scheduled change.

PRINTED IN U.S.A. 71 50960025/CP0514

 Service As Required During Storage
1. About once each month, connect the battery,
EXHAUST FILTER SERVICE check all fluid levels to make sure they are prop-
er, and start the engine.
The exhaust filter will provide several thousand hours
of maintenance free operation. At some point the IMPORTANT: If it is desired to operate the
exhaust filter will require professional service to hydraulic cylinders at this time, BE SURE to wipe
remove accumulated ash buildup. Adhering to the rec- the protective grease (and any adhering dirt) from
ommended engine oil and diesel fuel requirements will the cylinder rods prior to starting the engine. After
maximize the hours of operation before professional operating, BE SURE to recoat the cylinder rods
service is required. with grease if the machine is to be returned to
storage.
A diagnostic code will display in the multi-function
display screen to indicate when professional exhaust 2. Allow the engine to run until it warms up and then
filter service is required. This professional exhaust fil- move the machine a short distance to help relu-
ter service must be performed by an authorized bricate the internal parts. Run the engine until the
Manitou Americas dealer. battery is recharged and then shut it off.

STORAGE After Storage

If the Telescopic Handler will not be operated for a After removing the machine from storage and
period of three months or more, prepare and store it BEFORE operating it, perform the following:
using the following procedure: 1. Change engine oil and filter to remove condensa-
NOTE: If the storage area is outdoors or in a tion and other residues.
harsh environment, the storage procedure should 2. Wipe off grease from cylinder rods.
be followed if the Telescopic Handler is to be
stored for one month. 3. Lubricate ALL grease fittings.
4. Follow the start-up and warm-up procedures out-
Before Storage lined in the Operation and Adjustments chapter of
Perform the following prior to placing the machine in this manual.
storage:
1 Wash the entire machine.
2. Lubricate all grease fittings as described in the
Lubrication chapter of this manual.
3. Change engine oil as outlined in the Service and
Storage chapter of this manual.
4. Apply grease to all exposed hydraulic cylinder
rod areas.
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 freez-
ing, make sure the engine coolant is either com-
pletely drained from the radiator and engine block
or that the concentration of anti-freeze is adequate
to keep the coolant from freezing. Refer to the
separate engine manual provided for anti-freeze
recommendations and quantities.

50960025/CP0514 72 PRINTED IN U.S.A.

 PWP SYSTEM OPERATIONAL TROUBLESHOOTING
Problem Possible Cause Remedy

PWP System mode lamp flash-

es when switch is turned “ON.”

Parking brake does not engage

when the PWP System switch is
turned “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 mode lamp is
the PWP System switch is on continously.
turned “ON.”

Transmission does not remain

de-clutched when shifted into
“FORWARD or REVERSE”
when the PWP switch is “ON.”

Machine is not level. Level the machine.

Remote PWP System switch is Activate the remote PWP

de-activated. System switch.

Boom control functions do not Remote PWP System switch is Plug in and engage the remote
operate. not plugged into the connector at PWP System switch.
the end of the boom.

PWP System angle sensor is Contact your Manitou Americas

unplugged or faulty. dealer for assistance.

PWP System mode lamp flash-

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

PRINTED IN U.S.A. 73 50960025/CP0514

 Chapter 9
DECAL LOCATIONS
GENERAL INFORMATION DECAL KITS
51200582 MT6642XT Telescopic Handler with PWP
51200583 MT6642XT Telescopic Handler without PWP
CAUTION 51200584 MT8044XT Telescopic Handler with PWP
51200585 MT8044XT Telescopic Handler without PWP
ALWAYS read and follow the safety precau- 51200586 MT10044XT Telescopic Handler with PWP
tions on decals. Replace decals if they are 51200587 MT10044XT Telescopic Handler without PWP
damaged, or if the unit is repainted. If repaint-
51200588 MT10055XT Telescopic Handler with PWP
ing, BE SURE that all applicable decals are 51200589 MT10055XT Telescopic Handler without PWP
affixed in their proper locations.
51200590 MT12042XT Telescopic Handler with PWP
51200591 MT12042XT Telescopic Handler without PWP

NOTE: Decals may be purchased in kits or indi-

Decal locations information is provided to assist in the vidually.
proper selection and application of new decals, in the
event the original decals become damaged or the NOTE: Decal kits contain decals for both control
machine is repainted. configuations. Refer to the following reference
pages to determine the correct control decals for
For correct replacement of decals, compare the loca- the machine.
tion illustrations to the machine before starting to
refinish the unit. Check off each required decal using PAINT FINISH
the illustration reference number to find the part num-
ber, description and quantity in the list. Refer to the Use this list to order paint for refinishing:
appropriate illustrations for replacement locations. 808020 1 Gallon Red
808021 6 (12-oz. Spray Cans) Red
If there is a decal on a part that is being replaced, be 808043 1 Gallon Gun-Metal Gray
sure that the decal is applied to the replacement part. 808044 6 (12-oz. Spray Cans) Gun-Metal Gray

NEW DECAL APPLICATION

Before applying the new decals, surfaces must be free
from dirt, dust, grease and other foreign material. To
apply a solid-formed decal, remove the smaller portion
of the decal backing paper and apply this part of the
exposed adhesive backing to the clean surface while
maintaining proper position and alignment. Slowly
peel off the other portion of the backing paper while
applying hand pressure to smooth out decal surface. To
apply a die-cut decal, first remove the backing paper.
Then, properly orient and position the decal onto the
clean mounting surface. After the decal is firmly
applied and smoothly pressed down, remove the front
covering paper.

50960025/CP0514 74 PRINTED IN U.S.A.

 2

8 6
5 14 8 9

13
12
4 11
15

16

16

3 1 2
7

10

DECAL LOCATIONS - FRAME AND BOOM

REF. DESCRIPTION MT6642 MT8044 MT10044 MT10055 MT12042

NO.

01 DANGER - HANDS OUT 808036 808036 808036 808036 808036

02 WARNING - PINCH POINT 808033 808033 808033 808033 808033
03 WARNING - JUMP START 808034 808034 808034 808034 808034
04 MANITOU LOGO, SMALL 804768 804768 804768 804768 804768
05 QUICK-ATTACH DIAGRAM 808046 808046 808046 808046 808046

06 MANITOU LOGO, LARGE 806320 806320 806320 806320 806320

07 ANTI-FREEZE 808047 808047 808047 808047 808047
08 HALF ZONE MARKER (5 ea.) 808048 808048 808048 808048 808048
09 NO. “1” EXTENSION MARKER (1 ea.) 808049 808049 808049 808049 808049
NO. “2” EXTENSION MARKER (1 ea.) 808050 808050 808050 808050 808050

NO. “3” EXTENSION MARKER (1 ea.) 808051 808051 808051 808051 808051
NO. “4” EXTENSION MARKER (1 ea.) 808052 808052 808052 808052 808052
NO. “5” EXTENSION MARKER (1 ea.) 808053 808053 808053 808053 808053
10 COOLANT UNDER PRESSURE 808054 808054 808054 808054 808054
11 WARNING - NO RIDERS 808035 808035 808035 808035 808035

12 OPERATOR MANUAL WARNING 808032 808032 808032 808032 808032

13 DANGER-PERSONNEL INJURY (w/o PWP) 808031 808031 808031 808031 808031
14 CARRY LOAD LOW 808037 808037 808037 808037 808037
15 LUBE CHART 50380371 50380371 50380371 50380371 50380371
16 MODEL NUMBER - LEFT SIDE 805815 805816 50380373 50380033 50380374

PRINTED IN U.S.A. 75 50960025/CP0514

 7

4
2
3
2

10
11

DECAL LOCATIONS - FRAME AND BOOM

REF. DESCRIPTION MT6642 MT8044 MT10044 MT10055 MT12042

NO.

01 DANGER - HANDS OUT 51200535 51200535 51200535 51200535 51200535

02 WARNING - PINCH POINT 808033 808033 808033 808033 808033
03 MANISCOPIC, LARGE 806319 806319 806319 806319 806319
04 HYDRAULIC OIL FILL 808057 808057 808057 808057 808057
05 WARNING - NO RIDERS 808035 808035 808035 808035 808035

06 MANITOU LOGO, SMALL 103275 103275 103275 103275 103275

07 DANGER-PERSONNEL INJURY (w/o PWP) 808031 808031 808031 808031 808031
08 QUICK-ATTACH UNLOCKED 808038 808038 808038 808038 808038
09 DIESEL FUEL 50301416 50301416 50301416 50301416 50301416
10 MODEL NUMBER - RIGHT SIDE 805815 805816 50380373 50380033 50380374

11 WARNING - HOOK 50380987 50380987 50380987 50380987 50380987

50960025/CP0514 76 PRINTED IN U.S.A.

 6 7 8
9

2
14 11

1 5

Dual Joystick Control

12

13
3

10

Tri-function Joystick Control

DECAL LOCATIONS - OPERATOR STATION

REF. DESCRIPTION MT6642 MT8044 MT10044 MT10055 MT12042

NO.

01 TILT HAZZARD/GENERAL OPERATOR 808027 808027 808027 808027 808027

02 CARRY LOAD LOW 808026 808026 808026 808026 808026
03 F-N-R SHIFT 808059 808059 808059 808059 808059
04 MADE IN USA 808060 808060 808060 808060 808060
05 PARK BRAKE/SEAT BELT 808030 808030 808030 808030 808030

06a LOAD ZONE CHARTS Note a Note a Note a Note a Note a

07b ATTACHMENT TILT/FRAME LEVEL 808061 808061 808061 808061 808061
08b BOOM CONTROL 808062 808062 808062 808062 808062
09b AUXILIARY HYDRAULIC CONTROL (Optional) 808064 808064 808064 808064 808064
10 IGNITION/START/HORN 808065 808065 808065 808065 808065

11 HI VOLT./MOVING PARTS 808029 808029 808029 808029 808029

12c JOYSTICK CONTROL 51200536 51200536 51200536 51200536 51200536
13c FRAME LEVEL 809307 809307 809307 809307 809307
14 EXHAUST FILTER NOTICE 50380943 50380943 50380943 50380943 50380943

Note a: See Load Zone Charts section of this manual for individual load zone chart part numbers.
Note b: Used on machines equipped with Dual Joystick Control setup.
Note c: Used on machines equipped with Tri-function Joystick Control setup.

PRINTED IN U.S.A. 77 50960025/CP0514

 2 3

5 1
1

DECAL LOCATIONS - PWP EQUIPPED UNITS

REF. DESCRIPTION MT6642 MT8044 MT10044 MT10055 MT12042

NO.

01 PERSONNEL LIFT 808039 808039 808039 808039 808039

02 WORK PLATFORM RULES 808040 808040 808040 808040 808040
03 PERSONNEL LIFT SAFETY RULES 808041 808041 808041 808041 808041
04 PWP LOAD CHART 808014 808007 50380399 50380043 50380406
05 PWP SWITCH 808042 808042 808042 808042 808042

50960025/CP0514 78 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 intervals 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)

Checking Fuel Tank Level l

Checking Fuel Filter (Drain Water If Required) l
Checking Engine Oil Level l
Checking Radiator Coolant Level l
Checking Transmission Oil Level l
Checking Hydraulic Oil Level l
Checking Tire Pressures l
Checking Wheel Nut Torque l1,2
Checking Instruments Operation l
Checking General Machine Operation and Condition l
Checking Personnel Work Platform Safety System l
Lubricate Grease Points l
Changing Engine Oil and Filter l2
Changing Transmission Oil and Filter l2
Changing Hydraulic Oil Filter l2
Checking and Torquing Boom Leaf Chains l3 l
Checking Axle Oil Levels l
Changing Fuel Filter l
Changing Engine Oil and Filter l
1 - On new machines or when a wheel has been removed, until 450 ft.-lbs. (610 Nm) is maintained.
2 - Only new machines.
3 - On new machines or when a chain has been replaced. The two chains on the front of the three-section boom should
be torqued to 30 ft.-lbs. (40 Nm), and the three chains on the front of the four-section boom should be torqued to 50 ft.-
lbs. (68 Nm).

PRINTED IN U.S.A. 79 50960025/CP0514

 MAINTENANCE INTERVAL CHART (CONT.)

SERVICE PROCEDURE Every 250 Every 1000 Every 2000 Service As

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

Check Open Crankcase Vent l

Checking Battery l
Checking and Torqueing Boom Leaf Chains l
Checking Boom Slide Pads Wear and Clearance l
Clean Air Conditioning Condenser l
Clean/Change Cab Ventilation Filter l
Changing Transmission Oil and Filter l
Changing Hydraulic Return Filter Element l
Changing Air Filter Element l
Change Open Crankcase Filter Element l
Changing Axle Differential and Planetary Oil l
Checking Alternator and Fan Belt Condition l
Checking Exhaust System l
Checking Hydraulic System Relief Pressures l
Changing Hydraulic Reservoir Oil and Strainer l
Changing Radiator Coolant l
Exhaust Filter Service l

MAINTENANCE LOG
Date Hours Service Procedure

50960025/CP0514 80 PRINTED IN U.S.A.

 MAINTENANCE LOG
Date Hours Service Procedure

PRINTED IN U.S.A. 81 50960025/CP0514

 MAINTENANCE LOG
Date Hours Service Procedure

50960025/CP0514 82 PRINTED IN U.S.A.

 MAINTENANCE LOG
Date Hours Service Procedure

PRINTED IN U.S.A. 83 50960025/CP0514

 ENGINE DIAGNOSTIC TROUBLE CODES (DTCs)
Engine diagnostic trouble codes are displayed in the Always contact your servicing engine dealer for help
instrument display panel. in correcting the diagnostic trouble codes that are dis-
played for the engine.
Stored and active diagnostic trouble codes are dis-
played as a two-part code: Suspect Parameter Number The fault code listing in the following tables are in
(SPN) and Failure Mode Identifier (FMI), as shown on ascending order.
the tables on this and the following pages.
The first table list the many SPN codes. The second
The first part is a Suspect Parameter Number (SPN) table lists the FMI codes. To use the tables below, first
followed by a Failure Mode Identifier (FMI). To deter- write down the SPN and FMI codes displayed in the
mine the exact type of failure, both parts (SPN and multi-function display. Locate the SPN code and its
FMI) of the code are needed. associated definition in the SPN table, then locate the
associated FMI code and its associated definition in the
The SPN indentifies the system or the component that
FMI table.
has the failure; for example, SPN 000110 indicates a
failure in the engine coolant temperature circuit. NOTE: Not all of these codes are used on all
engine applications.
The FMI indentifies the type of failure that has
occurred; for example, FMI 03 indicates a value above NOTE: If corrective actions below do not solve the
normal. Combining SPN 000110 with FMI 03 means engine fault, contact your servicing engine dealer.
the engine coolant temperature input voltage is too
high.

SUSPECT PARAMETER NUMBER (SPN) CODES

SPN SPN Name SPN SPN Name
Code Code

000027 EGR Valve Position Signal 000174 Fuel Temperature Signal

000028 Digital Throttle Signal 000177 Transmission Oil Temperature Signal
000029 Secondary Analog Throttle Signal 000189 Engine Speed Derate
000051 Air Throttle Poaition Signal 000190 Engine Speed
000054 Throttle Signal 000191 Engine/Pump Speed
000091 Primary Analog Throttle Signal 000237 VIN Security Data
000094 Low Pressure Fuel Signal 000412 EGR TemperatureSignal
000096 Fuel Level 000611 Injector Drive #1
000097 Water-in-fuel Signal 000612 Injector Drive #2
000100 Engine Oil Pressure Signal 000620 Sensor Supply Voltage
000101 Crankcase Pressure Signal 000627 All Injector Circuits
000102 Manifold Air Pressure Signal 000628 ECU Programming
000103 Turbocharger Speed Signal 000629 ECU EEPROM
000105 Manifold Air Temperature Signal 000632 Fuel Shutoff Valve
000107 Air Filter Pressure Differential 000636 Camshaft Position Signal
000108 Barometric Pressure Signal 000637 Crankshaft Position Signal
000109 Engine Coolant Pressure Signal 000638 Rack Position
000110 Engine Coolant Temperature Signal 000639 CAN Bus
000111 Engine Coolant Level Alarm Switch 000640 External Engine Protection
000127 Transmission Oil Pressure Signal 000641 VGT Actuator
000157 Fuel Rail Pressure Signal 000644 Lead ECU Sync Circuit
000158 ECU Power Down 000647 Engine Fan Drive Circuit
000168 Unswitched Battery Voltage 000651 Injector #1

50960025/CP0514 84 PRINTED IN U.S.A.

 SPN SPN Name SPN SPN Name
Code Code

000652 Injector #2 002798 Injector High Voltage Supply #2

000653 Injector #3 003246 DPF Outlet Temperature
000654 Injector #4 003251 DPF Differential Pressure Signal
000676 Cold Start Relay Output Signal 003464 Air Throttle Actuator Drive Circuit
000729 Inlet Air Heater Signal 003471 Fuel Dosing Control Valve Signal
000833 Rack Position Sensor 003480 Fuel Dosing Inlet Pressure Signal
000834 Rack Actuator 003482 Fuel Dosing Shutoff Valve Signal
000898 Requested Engine Speed Signal 003509 Sensor Supply #1 Voltage
000970 External Shutdown Switch 003510 Sensor Supply #2 Voltage
000971 External Derate Switch 003511 Sensor Supply #3 Voltage
000974 Remote Throttle Signal 003512 Sensor Supply #4 Voltage
001075 Low Pressure Fuel Pump Data 003513 Sensor Supply #5 Voltage
001076 Fuel Injector Pump Control Valve 003514 Sensor Supply #6 Voltage
001077 Fuel Injector Pump Control Valve 003556 Fuel Dosing Nozzle
001078 Fuel Injector Pump Speed/Position Sensor 003587 Auto Ether Control Circuit
001079 Sensor Supply 1 Voltage 003597 Injector Power Supply Voltage
001080 Sensor Supply Voltage 003598 Injector Power Supply Voltage #2
001109 Engine Protection Approaching 003659 Spill Valve Circuit #1
001110 Engine Protection 003660 Spill Valve Circuit #2
001136 ECU Temperature Signal 003661 Spill Valve Circuit #3
001172 Intake Air Temperature 003662 Spill Valve Circuit #4
001176 Intake Air Pressure 003663 Spill Valve Circuit #5
001180 Calculated VGT Turbine Inlet Temperature 003664 Spill Valve Circuit #6
001209 Exhaust Manifold Pressure Signal 003711 DOC Inlet Temperature
001321 Engine Starter Control Circuit 003719 Calculated Soot Level
001347 Suction Control Valve Circuit 003720 Calculated Ash Level
001348 Fuel Pump Control Valve #2 003822 Rear EGR Valve Position Signal
001349 Redundant Fuel Rail Pressure Signal 003936 DPF Fault Occurrences
001485 Pump Power Relay 004077 Fuel Dosing Outlet Pressure Signal
001568 Torque Curve Selection 004490 Intake Air Humidity
001569 Engine Power Derate 004765 DOC Inlet Temperature
001638 Hydraulic Oil Temperature Signal 004766 DOC Outlet Temperature
001639 Fan Speed Signal 004795 DPF Missing
001762 Hydraulic Oil Pressure Signal 005018 DOC Fault Occurrences
002000 Incorrect ECU 005125 Sensor Supply #7 Voltage
002629 Fixed Turbo Comp Outlet Temp Signal 005126 Sensor Supply #8 Voltage
002630 Charge Air Cooler Outlet Temp Signal 005298 DOC Fault Occurrences
002659 EGR Flow Signal 005456 Fuel Dosing Inlet Temperature Signal
002790 Fixed Tubocharger Comp Outlet Temp 522458 Fuel Dosing Pump Data
002791 EGR Valve Drive Circuit 522494 Intake Air Sensor Communication
002795 VGT Calibration Version 522495 Exhaust Filter Temperature Module
002797 Injector High Voltage Supply #1 523379 Single Point Ground #7

PRINTED IN U.S.A. 85 50960025/CP0514

 FAILURE MODE IDENTIFIER (FMI) CODES

FMI FMI Name FMI FMI Name

Code Code

00 Extremely High 11 Activated

01 Extremely Low 12 Error
02 Invalid 13 Fault
03 Out Of Range High 14 Incorrect Message
04 Out Of Range Low 15 Slightly High
05 High Resistance 16 Moderately High
06 Low Resistance 17 Slightly Low
07 Mismatch 18 Moderately Low
08 Signal Missing 19 Communication Error
09 Loss Of Communication 31 Condition Exists
10 Change Abnormal

50960025/CP0514 86 PRINTED IN U.S.A.

 Hydraulic Schematic
for Two-Joystick Control without PWP

PRINTED IN U.S.A. 87 50960025/CP0913

 Hydraulic Schematic
for Two-Joystick Control with PWP

50960025/CP0913 88 PRINTED IN U.S.A.

 Hydraulic Schematic
for Tri-Function Joystick without PWP

PRINTED IN U.S.A. 89 50960025/CP0913

 Hydraulic Schematic
for Tri-Function Joystick with PWP

50960025/CP0913 90 PRINTED IN U.S.A.

 Electrical Schematic with Radio Remote

PRINTED IN U.S.A. 91 50960025/CP0913

 Electrical Schematic without Radio Remote

50960025/CP0913 92 PRINTED IN U.S.A.

 INTENTIONALLY BLANK

PRINTED IN U.S.A. 93 50960025/CP0514

 Load Zone Charts
MT6642XT
Decal 808019 Decal 808017
Standard Carriage 1.3-Cu.-Yd. Bucket

Decal 808018 Decal 808016

Rotating Carriage 12-Ft. Truss Boom

50960025/CP0514 94 PRINTED IN U.S.A.

 Load Zone Charts
MT6642XT
Decal 808015 Decal 50380927
5-Ft. Winch Boom 90° Swing Carriage

Decal 808014
PWP

PRINTED IN U.S.A. 95 50960025/CP0514

 Load Zone Charts
MT8044XT
Decal 808013 Decal 808011
Standard Carriage 1.3-Cu.-Yd. Bucket

Decal 808012 Decal 808010

Rotating Carriage 15-Ft. Truss Boom

50960025/CP0514 96 PRINTED IN U.S.A.

 Load Zone Charts
MT8044XT
Decal 808009 Decal 808008
5-Ft. Winch Boom 90° Swing Carriage

Decal 808007
PWP

PRINTED IN U.S.A. 97 50960025/CP0514

 Load Zone Charts
MT10044XT
Standard Carriage 1.3-Cu.-Yd. Bucket
Decal 50380393 Decal 50380397

Rotating Carriage 15-Ft. Truss Boom

Decal 50380398 Decal 50380400

50960025/CP0514 98 PRINTED IN U.S.A.

 Load Zone Charts
MT10044XT
Winch Boom 90° Swing Carriage
Decal 50380396 Decal 50380394

180° Swing Carriage Work Platform

Decal 50380395 Decal 50380399

PRINTED IN U.S.A. 99 50960025/CP0514

 Load Zone Charts
MT12042XT
Standard Carriage Rotate Carriage
Decal 50380401 Decal 50380403

90° Swing Carriage 1.3-Cu.-Yd. Bucket

Decal 50380402 Decal 50380404

50960025/CP0514 100 PRINTED IN U.S.A.

 Load Zone Charts
MT12042XT
Winch 15-Ft. Truss Boom
Decal 50380405 Decal 50380407

180° Swing Carriage Work Platform

Decal 50380408 Decal 50380406

PRINTED IN U.S.A. 101 50960025/CP0514

 Load Zone Charts
MT10055XT
Standard Carriage - Outriggers Up Standard Carriage - Outriggers Down
Decal 50380035 Decal 50380036

Rotate Carriage - Outriggers Up Rotate Carriage - Outriggers Down

Decal 50380037 Decal 50380038

50960025/CP0514 102 PRINTED IN U.S.A.

 Load Zone Charts
MT10055XT
Swing Carriage 1.3-Cu.-Yd. Bucket
Decal 50380039 Decal 50380042

Winch 15-Ft. Truss Boom

Decal 50380040 Decal 50380041

PRINTED IN U.S.A. 103 50960025/CP0514

 Load Zone Charts
MT10055XT
Work Platform
Decal 50380043

50960025/CP0514 104 PRINTED IN U.S.A.

 Torque Specifications
Use these torque values when tightening Manitou Americas 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. 105 50960025/CP0514

 Index
A Controls
Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Access To Components Chart . . . . . . . . . . . . . . . . . . . . . 57
Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Floor and Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Adjustments
Function Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Slide Pads Clearance . . . . . . . . . . . . . . . . . . . . . . . . .66
Crankcase Filter
Wheel Lug Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . .60
Changing Filter Element . . . . . . . . . . . . . . . . . . . . . . . .69
Air Conditioner
Check Open Crankcase Vent . . . . . . . . . . . . . . . . . . . .64
Clean Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Cylinders
Clean/Change Cab Ventilation Filter . . . . . . . . . . . . . .67
Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Air Filter
Restriction Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . .33 D
Change Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68 Dealer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Alternator Decal Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Belt Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70 Decals, applying new . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Indicator Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Dimensions - See Chapter 2
Anti-freeze - See Radiator
Attachment Tools E
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Electrical Components
Operating Methods - See Chapter 6 Characteristics - See Chapter 2
Axles Controls and Indicators - See Chapter 4
Description - See Chapter 2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54 Engine
See Service Cold Start Procedures . . . . . . . . . . . . . . . . . . . . . . . . .38
Axle Oil Description - See Chapter 2
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69 Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . .84
Check Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Oil Pressure Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .53 Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . .25
B Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Engine Oil
Battery Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Jump Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .53
Boom Travel Engine Shutdown Protection
Function Controls . . . . . . . . . . . . . . . . . . . . . . . . .30, 31 Engine Coolant Temperature . . . . . . . . . . . . . . . . . . . .40
Function Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Engine Oil Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65 Engine Emergency Override Switch . . . . . . . . . . . . . .26

C Engine Oil Filter, Replacing . . . . . . . . . . . . . . . . . . . . . . .63

Exhaust Filter Gauge Indicator and Switch . . . . . . . . . . . .25
Capacities - See Chapter 2
Checklists, delivery and pre-delivery . . . . . . . . . . . . . . .6, 7

50960025/CP0514 106 PRINTED IN U.S.A.

Exhaust Filter Cleaning System . . . . . . . . . . . . . . . . . . . .40 Hydraulic Maintenance
Automatic Exhaust Filter Cleaning . . . . . . . . . . . . . . . .40 Oil Filters, replacing . . . . . . . . . . . . . . . . . . . . . . . . . .68
Manual Exhaust Filter Cleaning . . . . . . . . . . . . . . . . . .40 Oil Sump Strainer, replacing . . . . . . . . . . . . . . . . . . . .71
Disable Exhaust Filter Cleaning . . . . . . . . . . . . . . . . . .41 Pressure Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Exhaust Filter Cleaning Precautions . . . . . . . . . . . . . .41 Hydraulic Pump, servicing . . . . . . . . . . . . . . . . . . . . . . . .56
Exhaust System, Check . . . . . . . . . . . . . . . . . . . . . . . . . .70 Hydraulic Valves, servicing . . . . . . . . . . . . . . . . . . . . . . . .56

F I
Fan Belt - See Alternator Belt Identification Reference . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Frame Level Control . . . . . . . . . . . . . . . . . . . . . . . . . .30, 32 Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Frame Level Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . .32 Indicator Symbols . . . . . . . . . . . . . . . . . .Inside Front Cover
Fuel - See Separate Engine Manual Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Fuel Filter
J
Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Joystick Pressure Setting . . . . . . . . . . . . . . . . . . . . . . . . .70
Check and Drain Water . . . . . . . . . . . . . . . . . . . . . . . .59
Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24 L
Fuel Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Fuse Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Fuse Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Lubrication,
G See also Service Intervals
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
General Load Handling
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Load Capacity and Reach . . . . . . . . . . . . . . . . . . . . . .46
General Machine Operation M
Grade and Slope Precautions . . . . . . . . . . . . . . . . . . .43
Main Relief pressure check . . . . . . . . . . . . . . . . . . . . . . .70
Grade Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Maintenance
Grease Fittings
Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Scheduled Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Types of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Mandatory SAFETY Shutdown Procedure . . . . . . . . . . .9
Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Mandatory Work Platform Safety Rules . . . . . . . . . . . .15
H O
Handling Non-Suspended Loads
Oils - See Lubrication
Picking Up the Load . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Operation
Carrying the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Load Elevation and Placement . . . . . . . . . . . . . . . . . .47
Stopping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Handling Suspended Loads
Symbols . . . . . . . . . . . . . . . . . . . . . . .Inside Front Cover
Picking Up Suspended Loads . . . . . . . . . . . . . . . . . . .47
Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Carrying Suspended Loads . . . . . . . . . . . . . . . . . . . . .48
Operator’s Manual, storing . . . . . . . . . . . . . . . . . . . . . . . . .2
Ground Level Suspended Load Placement . . . . . . . . .48
Operator Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Elevated Suspended Load Placement . . . . . . . . . . . . .48
Operator’s Station
Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Heater Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Heater - A/C Controls . . . . . . . . . . . . . . . . . . . . . . . . .28
Hydraulic Components, servicing . . . . . . . . . . . . . . . . . . .56
Outrigger Switches . . . . . . . . . . . . . . . . . . . . . . . . . . .30, 32
Hydraulic Oil
Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Recommended type . . . . . . . . . . . . . . . . . . . . . . . . . .53

PRINTED IN U.S.A. 107 50960025/CP0514

 P Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Side View Mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Park Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Park Brake Pressure Setting . . . . . . . . . . . . . . . . . . . . . . .70
Stabilizer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
Paint, refinish . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Steering - See Controls
Pump, Delivery Rates - See Chapter 2
Steering Relief Pressure Check . . . . . . . . . . . . . . . . . . . .70
Personnel Work Platform Safety Decals . . . . . . . . . . . . . .22
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Personnel Work Platform Safety Rules . . . . . . . . . . . . . . .15
Suspended Loads
Personnel Work Platform Switch . . . . . . . . . . . . . . . . . . . .27
Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Personnel Work Platform System . . . . . . . . . . . . . . . . . . .14
Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Personnel Work Platform Checking Procedure . . . . . . . . .61
Pre-Start Walk-Around Inspection . . . . . . . . . . . . . . . . . . .35 T
Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Tables
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Q Paint Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

Quickattach System Replacement Filters . . . . . . . . . . . . . . . . . . . . . . . . . . .54

Attach/Detach Mechanism . . . . . . . . . . . . . . . . . . . . . .42 Theft Deterrents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Tire Pressures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
R Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Radiator Traffic Flow Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Change Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Transmission
Check Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59 Description - See Chapter 2
Flushing and Refilling . . . . . . . . . . . . . . . . . . . . . . . . .71 Temperature Lamp . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Relay Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Transmission Oil
Relay Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34 Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Road Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Check Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .53
S Transporting
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9 Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 Unloading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Schematics Travel Speed - See Controls
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91 Troubleshooting, PWP . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Seat, operator’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 W
Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . Inside Rear Cover
Service and Safety Features . . . . . . . . . . . . . . . . . . . . . . .32 Water Trap - See Fuel Filter
Service Intervals Windshield Washer Fluid Reservoir . . . . . . . . . . . . . . . . .34
Daily . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58 Windshield Wiper Switch . . . . . . . . . . . . . . . . . . . . . . . . .28
Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62 Work Platform Design Requirements . . . . . . . . . . . . . . . .16
100 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
250 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
1000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
2000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
As required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

50960025/CP0514 108 PRINTED IN U.S.A.

 MANITOU AMERICA
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
dealer'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 war-
ranty except as specifically set forth herein.

PRINTED IN U.S.A. 109 50960025/CP0514

50960025CP0514 © 2014 Manitou Americas Inc. PRINTED IN U.S.A.
All Rights Reserved.