Gehl DL SERIES GEN:3 DL11-44 DL11-55 DL12-40 DL12-55 Telescopic Handler Operator's Manual 50960172 -

DL SERIES GEN:3 DL11-44 / 55 (SN 41901 and Up)

DL12-40 / 55 (SN 51601 and Up)

Telescopic Handler Operator’s Manual

50960172 Rev. E 02/21

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 thoroughly understand the contents of the operator’s manual.

Failure to follow safety, operating and maintenance instructions could result in serious 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 Group before starting or continuing operation. Colleuges

Table of Contents Chapter

Description

Page

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

1 2 3 4 5 6 7 8 9

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 Checklists . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13, 15 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 Indicators and Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Operation and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71 Service and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Engine Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104 Hydraulic Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112 Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115 Hose and Pipe Clamp Torque Recommendations . . . . . . . . . . . . . . . . . . .129 Standard Hardware Torque Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132

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MANITOU EQUIPMENT AMERICA, LLC WARRANTY Manitou Equipment America, LLC under the GEHL®, MUSTANG by MANITOU®, MANITOU®, brand warrants new MANITOU Group equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months or Two Thousand Hours (2000 h) from the Warranty Start Date which occur first.

MANITOU Group WARRANTY SERVICE INCLUDES: Genuine XPRT parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

MANITOU Group 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 Group 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 Group 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.

7. Liability for consequential damages as an unfavorable environment (chemicals, dust, salt, corrosion and erosion...)

8. Repairs completed outside MANITOU Group network and/or by personnel not trained by MANITOU Group.

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

This agreement has been prepared in multiple languages, including but not limited to, English, Spanish, and French (Canada). In the event of any inconsistency, the English version shall apply and be binding upon the parties.

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Chapter 1 INTRODUCTION The information in this Operator’s Manual was written to give the owner/operator assistance in preparing, adjusting, 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 Group 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 compliance with the “Mandatory Work Platform Safety Rules” (see SAFETY chapter).

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 operation 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 group dealer or Manitou Group 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 group dealership network stands ready to provide any assistance that may be required, including genuine Manitou group service parts. All parts should be obtained from or ordered through your Manitou group 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 next page, as a handy record for quick reference.

Please be aware that Manitou Group 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 Group, 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!

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Legal Notices

In any case, the following activities are strictly prohibited:

Software IP

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any extraction, reproduction, representation, reuse by making available to the public, diffusion, or transfer, whether permanent or temporary, on any support, and by any means and in any form whatsoever, of all or a qualitatively or quantitatively substantial part of the contents of the database,

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any extraction, reproduction, representation, reuse by making available to the public, diffusion, transfer, or repeated and systematic extraction of qualitatively or quantitatively insubstantial parts of the contents of the database when these operations clearly exceed the conditions of normal use of the database by the user of the machine for his or her own needs,

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any use of a means of circumventing technical measures for the protection of databases or the source code of the software embedded in the boxes, in accordance with Article L.331-5 of the Intellectual Property Code.

Any extraction, decompilation, modification, duplication, or distribution of onboard software is strictly prohibited. Manitou shall have no liability for and hereby disclaims all direct and indirect liability for the consequences resulting from the use of any prohibited onboard software. Contact MANITOU for any request to correct or adapt onboard software for the purposes of interoperability.

Data Privacy Manitou connected machines are equipped with boxes that collect technical data concerning the machines (such as geolocation, operating, and component data).

This data, which is organized, processed, and enriched

by Manitou's own algorithms and knowledge, constitutes a protected database in accordance with Article L.341-1 of the French Intellectual Property Code.

It is strictly forbidden to access all or part of this database or to use this data (whether or not intentional) without Manitou's express authorization. In the event that Manitou authorizes an individual to access all or part of this database, Manitou, as producer of this database, only grants the user a personal, non-exclusive, and non-transferrable right to use the database, and only via access to a computer platform hosted on a server owned or controlled by Manitou.

In the event that the above measures are absolutely essential to enable the use of the software, in accordance with its intended purpose, or to obtain the information necessary for interoperability with other independently created software, the user must first contact Manitou, which may, at its sole discretion, take necessary measures or provide access to only the information strictly necessary for interoperability.

Any violation of these prohibitions is likely to constitute an infringement for which Manitou may take legal action.

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Component Identification (Left Side)

H F

G

E K I

J D A

B

C

Item

Description

A

Description Dynattach® Quick-Attach

G

Side Panel and Controls

B

Storage Compartment Access Door

H

Boom Angle Indicator

C

Rear Lights and Backup Alarm Access

I

Dash Indicators and Controls

D

Stabilizing Cylinder

J

Tilt Cylinder

E

Operator's Seat

K

Attachment Tool

F

ROPS/FOPS

Item

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Component Identification (Right Side)

D E B C A

H G F

Item

Description

Item

Description

A

Slave Cylinder

E

Auxiliary Hydraulics

B

Lift Cylinder

F

Frame Leveling Cylinder

C

Engine Exhaust

G

Rear View Mirror

D

Telescopic Boom

H

Power Train Covers

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Machine Model and Serial Numbers

ROPS/FOPS Certification and Serial Number Tag

The machine model and serial numbers are stamped on a plate located inside the storage compartment to the rear of the operators compartment door as shown below.

The Cab ROPS/FOPS certification and serial number tag is located on the inside of the door post to the left of the seat.

ROPS/FOPS Serial Number:__________________________

NOTE: The machine serial number is also stamped on the top of the left frame rail directly in front of the cab.

Record the machine Model and Serial number below for future reference. Refer to these numbers when inquiring about parts or service from your Manitou group dealer.

Model No. ______________________________ Serial No. ______________________________

Machine Serial Plate

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Component Serial Numbers The engine, axle and transmission serial plates are shown below. The engine serial plate is located on the left side of the engine valve cover behind the turbo charger. The axle serial plate is located on the top of the axle. The transmission serial plate is located on the rear side of the case near the drain plug.

NOTE: The axle serial plates are not visible when installed in the machine.

Transmission Serial Number:__________________________

Engine Serial Number:__________________________

Front Axle Serial Number:__________________________ Rear Axle Serial Number:__________________________

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Indicator and Operation Symbols

Read Operator’s

Parking Brake

Brake Failure

Safety Alert

Turn Signals

Hazard Flasher

Ignition Off

Ignition ON

Engine Start

Voltmeter

Horn

Wiper/Washer

Fan

Hydraulic Oil Filter

Hydraulic Oil

Diesel Fuel

Fuel

Transmission

Engine Coolant

Engine Oil

Hourmeter

Beacon

Lights

Work Lights

Engine RPM

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

Frame Level Left

Frame Level Right

Check Engine

Stop Engine

Wait To Start

Diesel Exhaust

SCR Cleaning

High Exhaust

SCR Cleaning

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Chapter 2 SPECIFICATIONS Lifting Performance

Loader Performance

Maximum lift capacity: DL11-44: 4990 kg (11000 lbs.)

DL11-55: 4990 kg (11000 lbs.)

DL12-40: 5444 kg (12000 lbs.)

DL12-55 5444 kg (12000 lbs.)

Breakout force: DL11-44: DL12-40:

Maximum lift height: DL11-44: DL11-55: DL12-40: DL12-55

13.5 m (44.33’) 16.8 m (55.42’) 12.3 m (40.33’) 16.8 m (55.42’)

Capacity at maximum lift height: DL11-44: 3629 kg (8000 lbs.)

DL11-55 (Outriggers up): 2268 kg (5000 lbs.)

DL11-55 (Outriggers down): 2495 kg (5500 lbs.)

DL12-40: 4536 kg (10000 lbs.)

DL12-55 (Outriggers up): 2268 kg (5000 lbs.)

DL12-55 (Outriggers down): 2495 kg (5500 lbs.)

Forward reach at max. lift height: DL11-44: 1016 mm (3.33’) DL11-55: 2007 mm (6.58’) DL12-40: 610 mm (2.0’) DL12-55 2007 mm (6.58’) Maximum forward reach to load center: DL11-44: 9.2 m (30.5’) DL11-55: 12.2 m (40.75’) DL12-40: 8.0 m (26.33’) DL12-55: 12.2 m (40.75’) Maximum capacity at maximum reach: DL11-44: 908 kg (2000 lbs.)

DL11-55 (outriggers down): 908 kg (2000 lbs.)

DL12-40: 908 kg (2000 lbs.)

DL12-55 (outriggers down): 908 kg (2000 lbs.)

Reach below grade: DL11-44: DL11-55: DL12-40: DL12-55:

610 mm (2.0’) 864 mm (2.83’) 406 mm (1.33’) 864 mm (2.83’)

62.2 kN (14000 lbs.)

62.2 kN (14000 lbs.)

Maximum dump height: DL11-44: 13.1 m (42.92’) DL12-40: 11.9 m (39.0’) Maximum reach at max. dump height: DL11-44: 686 mm (2.25’) DL12-40: 356 mm (1.17’) Dump angle at maximum dump height: DL11-44, DL12-40: 24° Maximum loadover height: DL11-44: 13.5 m (44.17’) DL12-40: 12.3 m (40.25’) Dump height at 45° dump angle: DL11-44: 10.4 m (34.0’) DL12-40: 9.4 m (30.75’)

Width across tires: DL11, DL12 (14.00 x 24 tires):

2.45 m (96.5”)

Overall height: DL11-55, DL12-55:

2.6 m (8.50’)

Ground clearance: 400 mm (16”) Wheel base: 3.3 m (10.66’) Outside turn radius: 3.7 m (12.17’) Machine weight: DL11-44: DL11-55: DL12-40: DL12-55:

11521 kg (25400 lbs.)

12909 kg (28460 lbs.)

11475 kg (25300 lbs.)

14442 kg (31840 lbs.)

Instrumentation Gauges: Fuel level, engine coolant temperature, engine oil pressure, voltage meter and hourmeter

Rollback at ground level: 30° Total bucket rotation: 132° Parallel lift: Standard

Monitoring lights: Oil pressure, coolant temperature, alternator, low fuel, air filter restriction, hydraulic filter restriction, transmission temperature, accumulator charge pressure, glow plug

General Dimensions

Monitoring alarms: Low accumulator charge

Based on standard machine equipped with listed tires, 1.2 m (48”) masonry carriage and 1.2 m (48”) pallet forks.

Visual indicators: Boom angle, boom extension, frame angle

Recommended tire type: DL11-44, DL11-55, DL12-40: 14.00 x 24 - 12 PR Inflate to 430 kPa (62 psi) Optional tire: 14.00 x 24 - 16 PR Inflate to 480 kPa (70 psi) DL12-40: (optional)17.5 x 25 Solid Rubber DL12-55: 14.00 x 24 - 16 PR Foam Filled 14.00 x 24 - 16 PR G2 Lift Rigger Foam Filled 14.00 x 24 Solidair Solid Rubber 17.5 x 25 Solid Rubber

Optional Features: Rear Camera Rear Camera with Reverse Radar

Maximum reach at 45° dump angle: DL11-44: 4.3 m (14.25’) DL12-40: 3.6 m (11.83’)

Frame leveling: 10° left/10° right

Overall length, less forks: DL11-44: 6.3 m (20.58’) DL11-55: 6.4 m (20.75’) DL12-40: 5.9 m (19.33’) DL12-55: 6.4 m (20.75’)

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Steering System Steer valve: Fixed displacement rotary Displacement/Rev: 328 cc (20 cu. in.)

System pressure: 172 bar (2500 psi) Steer cylinders: 1 per axle Steer mode valve: 3-position, 4-way solenoid, dashmounted switch actuation.

Steer modes: 2-wheel, 4-wheel, crab Outside turn radius: 3.7 m (12.17’)

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Braking System

Axles (front and rear)

Operator’s Station

Service brakes: Oil-immersed wet-disc-type, hydraulic fluid type, manual foot pedal actuation.

Type: Dana Drive/steer, double reduction planetary, limited slip front axle, open differential rear axle, full-time four wheel drive Overall ratio: 23.25:1

Rollover Protective Structure (ROPS) ISO 3471-1994 Falling Object Protective Structure (FOPS) Meets ANSI/ITSDF B56.6-2016, Sec 8.16 ISO 3449-2005 Seatbelt: Meets SAE J386

Parking brake: Spring-applied, hydraulic-release disc-type in front axle.

Actuation is electric switch with engine running, automatic with engine shutdown.

Drive Train Transfer case: Durst with 1.063:1 ratio and Lord vibration damper

Electrical System

Engine

Type: 12-volt DC, negative ground Alternator: 135 amp Battery: two group 34 batteries with a minimum 800 cold cranking amps each Circuit protection: Fuse panel Backup alarm: 107 dB(A) Horn: 111 dB(A)

Turbocharged aspiration: Cummins QSF3.8 Tier 4 3.8 L (232 cu. in.) displacement, 89 kW (120 hp) @ 2500 rpm

Standard on all models: Brake lights, neutral start switch, master disconnect switch

Service Capacities Cooling System: 20.1 L (21.2 qts.), 50/50 mixture Anti-freeze protection: -37°C (-34°F) Pressure cap: 110 kPa (16 psi) Engine Oil Capacity: 14.7 L (15.5 qts.)

Fuel tank: 114 L (30 gls.)

DEF tank: 11.4 L (3 gls.)

Hydraulic tank and system: 236.6 L. (62.5 gls.)

Transmission and cooler: 21.6 L (22.8 qts.)

Transfer case: 2.8 L (3 qts.)

Front Axle: Differential: 13 L (13.75 qts.)

Hubs: 1.9 L each (2 qts.)

Rear Axle: Differential: 15 L (15.8 qts.)

Hubs: 1.9 L each (2 qts.)

Transmission Type: Dana Powershift T13000 Speeds: 4 fwd / 3 rev Torque converter: Single-stage, dual-phase Travel speeds, DL11, and DL12: 1st gear: 5.4 km/h (3.3 mph) 2nd gear: 10.2 km/h (6.3 mph) 3rd gear: 20.4 km/h mph (12.7) 4th gear: 36.7 km/h (22.8 mph)

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Hydraulic System Type: Open-center Pump: Dual-section gear type Displacement / revolution: Front: 29 cc (1.77 cu. in.)

Rear: 36 cc (2.19 cu. in.)

Flow @ 2500 RPM: Front: 72 L/min (19 gpm) Rear: 90 L/min (24 gpm) Main relief pressure: 207 bar (3000 psi) Aux. relief pressure: 172 bar (2500 psi) Main control valve: Parallel, 3-spool sectional, remote hydraulic actuation Frame level control valve: Solenoid type w/ remote switch actuation Auxiliary control valve: Parallel, 1-spool sectional, remote hydraulic actuation with joystick switch Hydraulic filter: Remote return type, 15-micron media, replaceable element.

Rated flow: 265 L/min (70 gpm) Rated pressure: 55 bar (800 psi) By-pass pressure (full flow): 310 kPa (45 psi) Hydraulic strainer: In-tank suction, 149-micron media, replaceable element.

Rated flow: 189 L/min (50 gpm) By-pass pressure: 20 kPa (3 psi)

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Chapter 3 CHECKLISTS I acknowledge that the pre-delivery procedures were performed on this unit as outlined above.

PRE-DELIVERY The following Checklist is an important reminder of the inspections that MUST be made before delivering the Telescopic Handler to the customer. Check off each item after the prescribed action is taken.

Dealership’s Name

Ö Check that: q NO parts of machine have been damaged in shipment.

Dealer Representative’s Name Date Checklist Filled Out

Check for such things as dents and loose or missing parts; correct or replace components as required. q Battery is securely mounted and not cracked. Cable connections are tight. Electrolyte at proper level. q Cylinders, hoses and fittings are not damaged, leaking or loosely secured. q Oil, fuel and air filters are not damaged, leaking or loosely secured. q All grease fittings have been properly lubricated and no fittings are missing; see Lubrication chapter of this manual. q Wheel nuts are torqued to 610 Nm (450 ft.-lbs.). q Tires are inflated to: 13.00 x 24 - 12 PR: 450 kPa (65 psi) cold.

14.00 x 24 - 12 PR: 430 kPa (62 psi) cold.

14.00 x 24 - 16 PR: 480 kPa (70 psi) cold. q Hydraulic system reservoir, engine crankcase, engine coolant, transfer case, transmission and axles are filled to the proper operating fluid levels. q All adjustments have been made to comply with the settings in this manual and in the separate engine manual. q All guards, shields and decals are in place and securely attached. q Model and serial number for this unit is recorded in space provided on this page and page 1.

Machine Model No.

Machine Serial No.

Engine Serial No.

DELIVERY Ö Check that: The following Checklist is a reminder of the important information that MUST be passed on to the customer at the time the unit is delivered. Check off each item as it is explained to the customer. q Review with the customer the contents of this manual and the AEM Safety Manual and for the following: q The Index at the back, for quickly locating topics; q The Safety, Indicators and Controls, and Operation and Adjustments chapters for information regarding safe use of the machine. q The Lubrication and Service and Storage chapters for information regarding proper maintenance of the machine.

Explain that regular lubrication and maintenance are required for continued safe operation and long life. q Give this Operator’s Manual and the AEM Safety Manual to the customer and instruct them to be sure to read and completely understand their contents before operating the unit. q Remind the customer of U.S. OSHA regulation 1910.178 (l), which specifies operator training requirements. q Explain that the customer MUST consult the engine manual (provided) for related specifications, operating adjustments and maintenance instructions. q Completely fill out the Owner’s Registration, including customer’s signature, and return it to the Company. q Explain that a copy of the warranty is included on the inside back cover of this Operator’s Manual.

Start the machine and test-run the unit while checking that proper operation is exhibited by all controls.

Ö Check that: q All indicators (lamps, switches, etc.) function properly. q All hand and foot controls operate properly. q The PWP System operates properly (if equipped). Refer to Service and Storage chapter for procedure to check the PWP System. q Boom, DynattachÒ or DynacarrierÒ with attachment tool and frame level control all function properly. q No hydraulic system leaks when under pressure. q Listen for abnormal noises or vibrations; if detected, determine their cause and repair as necessary.

Customer’s Signature

Date Delivered

(Dealer’s File Copy - Remove at Perforation)

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INTENTIONALLY BLANK (To be removed as Dealer’s file copy)

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Chapter 3 CHECKLISTS I acknowledge that the pre-delivery procedures were performed on this unit as outlined above.

PRE-DELIVERY The following Checklist is an important reminder of the inspections that MUST be made before delivering the Telescopic Handler to the customer. Check off each item after the prescribed action is taken.

Dealership’s Name

Ö Check that: q NO parts of machine have been damaged in shipment.

Dealer Representative’s Name Date Checklist Filled Out

Check for such things as dents and loose or missing parts; correct or replace components as required. q Battery is securely mounted and not cracked. Cable connections are tight. Electrolyte at proper level. q Cylinders, hoses and fittings are not damaged, leaking or loosely secured. q Oil, fuel and air filters are not damaged, leaking or loosely secured. q All grease fittings have been properly lubricated and no fittings are missing; see Lubrication chapter of this manual. q Wheel nuts are torqued to 610 Nm (450 ft.-lbs.). q Tires are inflated to: 13.00 x 24 - 12 PR: 450 kPa (65 psi) cold.

14.00 x 24 - 12 PR: 430 kPa (62 psi) cold.

14.00 x 24 - 16 PR: 480 kPa (70 psi) cold. q Hydraulic system reservoir, engine crankcase, engine coolant, transfer case, transmission and axles are filled to the proper operating fluid levels. q All adjustments have been made to comply with the settings in this manual and in the separate engine manual. q All guards, shields and decals are in place and securely attached. q Model and serial number for this unit is recorded in space provided on this page and page 1.

Machine Model No.

Machine Serial No.

Engine Serial No.

DELIVERY Ö Check that: The following Checklist is a reminder of the important information that MUST be passed on to the customer at the time the unit is delivered. Check off each item as it is explained to the customer. q Review with the customer the contents of this manual and the AEM Safety Manual and for the following: q The Index at the back, for quickly locating topics; q The Safety, Indicators and Controls, and Operation and Adjustments chapters for information regarding safe use of the machine. q The Lubrication and Service and Storage chapters for information regarding proper maintenance of the machine.

Explain that regular lubrication and maintenance are required for continued safe operation and long life. q Give this Operator’s Manual and the AEM Safety Manual to the customer and instruct them to be sure to read and completely understand their contents before operating the unit. q Remind the customer of U.S. OSHA regulation 1910.178 (l), which specifies operator training requirements. q Explain that the customer MUST consult the engine manual (provided) for related specifications, operating adjustments and maintenance instructions. q Completely fill out the Owner’s Registration, including customer’s signature, and return it to the Company. q Explain that a copy of the warranty is included on the inside back cover of this Operator’s Manual.

Start the machine and test-run the unit while checking that proper operation is exhibited by all controls.

Ö Check that: q All indicators (lamps, switches, etc.) function properly. q All hand and foot controls operate properly. q The PWP System operates properly (if equipped). Refer to Service and Storage chapter for procedure to check the PWP System. q Boom, DynattachÒ or DynacarrierÒ with attachment tool and frame level control all function properly. q No hydraulic system leaks when under pressure. q Listen for abnormal noises or vibrations; if detected, determine their cause and repair as necessary.

Customer’s Signature

Date Delivered

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Chapter 4

SAFETY The above Safety Alert Symbol means ATTENTION! ALWAYS BE ALERT! YOUR SAFETY IS INVOLVED! It stresses an attitude of safety awareness and can be found throughout this Operator’s Manual and on the machine itself.

Manitou Group ALWAYS takes the operator’s safety into consideration when designing its machinery, and guards exposed moving parts for his/her protection.

However, some areas cannot be guarded or shielded in order to assure proper operation. Further, this Operator’s Manual, the Safety Manual (also available in Spanish) and decals on the machine warn of additional hazards and should be read and observed closely.

Before operating this equipment, read and study the following safety information. In addition, be sure that everyone who operates or works with this equipment is familiar with these safety precautions.

It is the responsibility of the operator to read and understand the Operator’s Manual and other information provided, and use correct operating procedures.

Machines should be operated only by qualified operators.

DANGER

REMEMBER! It is the owner’s responsibility for communicating information on the safe use and proper maintenance of this machine! This includes providing understandable interpretation of these instructions for operators who are not fluent in reading English.

“DANGER” indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

MANDATORY SAFETY SHUTDOWN PROCEDURE

WARNING “WARNING” indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

BEFORE cleaning, adjusting, lubricating or servicing the unit:

CAUTION “CAUTION” indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. It may also alert to unsafe practices.

1.

Stop machine on a level surface. (AVOID parking on a slope, but if necessary, park across the slope and block the tires.)

2.

Fully retract the boom and lower the attachment tool to the ground. Idle engine for gradual cooling.

3.

Place controls in neutral and apply the parking brake.

4.

Shut off the engine and remove the key.

ONLY when you have taken these precautions can you be sure it is safe to proceed. Failure to follow the above procedure could lead to death or serious bodily injury.

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SAFETY Additional Safety Reminders

WARNING U.S. OSHA regulations require employers in general industry and the construction, shipyard and cargo-handling industries (excepting agricultural operations) to ensure that forklift operators are competent, as demonstrated by successful completion of a training course.

Ü

User/operator safety practices, as established by industry standards, are included in this Operator’s Manual and intended to promote safe operation of the machine. These guidelines do not, of course, preclude the use of good judgment, care and common sense that may be necessary for the particular jobsite conditions.

Ü

It is essential that operators be physically and mentally fit, free of mind-altering drugs and chemicals, and thoroughly trained in the safe operation of the machine. Such training should be presented completely to all new operators and not condensed for those claiming previous experience. Information on operator training is available from several sources, including the manufacturer.

Ü

Some illustrations used in this manual may show doors, guards and shields open or removed for illustration purposes ONLY. BE SURE that all doors, guards and shields are in their proper operating positions BEFORE starting the engine.

The training course must consist of a combination of formal instruction and practical training, including both forklift-related and workplace-related topics, and evaluation of the operator’s performance in the workplace.

All operator training and evaluation is to be conducted by persons who have the knowledge, training and experience to train and evaluate operators.

Before Operation Safety Reminders

WARNING ALWAYS maintain a safe distance from electric power lines and avoid contact with any electrically charged conductor or gas line. It is not necessary to make direct contact with a power line for power to ground through the structure of the machine. Keep the boom and load at least 3 m (10 ft.) from all power lines.

Accidental contact or rupture can result in electrocution or an explosion. Contact the “Call Before You Dig” referral system number at 8-1-1 in the U.S., or 1-888-258-0808 in the U.S. and Canada, to locate any underground utility lines BEFORE starting to dig.

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Ü

Perform a pre-start walk-around inspection before starting the engine at the beginning of each work shift. Contact with a running engine or moving parts during the pre-start inspection could cause death or serious injury. Refer to the pre-start walk-around inspection checklist in the “Operation and Adjustment” chapter.

Ü

Walk around the machine and warn all personnel who may be servicing the machine or who are in the machine’s path prior to starting. DO NOT start until all personnel are clearly away from the machine.

Ü

Check brakes, steering, and hydraulic system prior to starting operation. Operate all controls to ensure proper operation. Observe all gauges and indicators for proper operation. If any malfunctions are found, correct the cause prior to using the machine.

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SAFETY Ü

Ü

ALWAYS wear appropriate personal protective equipment for the job and working conditions.

Hard hats, goggles, protective shoes, gloves, reflector-type vests, respirators and ear protection are examples of types of equipment that may be required. DO NOT wear loose fitting clothing, long hair, jewelry or loose personal items while operating or servicing the machine.

Ü

ALWAYS keep hands, feet and arms inside of the operator’s station when operating the machine!

Ü

DO NOT depend on the backup alarm to clear bystanders out of the path of the machine.

ALWAYS look in the direction of travel. Look to the rear before backing.

Ü

DO NOT depend on reverse radar and rear camera systems as the only means of determining the rear of the machine is clear of obstructions and people. These systems are for supplementary use only. Always check mirrors and look in the direction of travel. Look to the rear before backing.

Ü

ALWAYS use the recommended handholds and steps with at least three points of support when getting on and off the machine. Keep steps and platform clean. Face the machine when climbing up and down.

Ü

DO NOT raise or drop a loaded fork or bucket suddenly. Abrupt movements under load can cause serious instability.

Ü

Study the load charts carefully. They show maximum capacity to be lifted and placed at specific outward and upward distances. ALWAYS be aware of load weights prior to attempting lift and placement.

Ü

DO NOT exceed the machine’s rated operating capacity for the type of attachment tool being used.

Ü

DO NOT use outriggers on soft or uneven surfaces. BE SURE the surface can support the machine and load.

Ü

DO NOT allow minors or any unqualified personnel to operate or be near the machine unless properly supervised.

Ü

DO NOT start the engine or operate any controls unless properly seated in the operator’s seat!

ALWAYS check the job site for terrain hazards, obstructions and people. Remove all objects that do not belong in or on the machine and its equipment.

Ü Manitou group telescopic handlers are designed and intended to be used only with Manitou Group attachments and approved attachments. To avoid possible personal injury, equipment damage and performance problems, use attachments that are approved for use on and within the operating capacity of the machine. Contact your dealer or Manitou Group for information on attachment approval and compatibility with specific machine models. Manitou Group cannot be responsible if the machine is used with a non-approved attachment.

Operation Safety Reminders Ü

Ü

Any or all of the following elements may affect the stability of the machine: terrain, engine speed, type of load being carried and placed, improper tire inflation, weight of the attachment tool, and abrupt movement of any control lever. IF YOU ARE NOT CAREFUL WHILE OPERATING THIS MACHINE, ANY OF THE ABOVE FACTORS COULD CAUSE THE MACHINE TO TIP, AND YOU COULD BE THROWN OUT OF THE OPERATOR’S STATION, WHICH COULD RESULT IN SERIOUS BODILY INJURY OR DEATH! ALWAYS wear the seat belt provided to prevent being thrown from the machine. If you are in an overturn: - DO NOT jump!

- Hold on tight and stay with the machine!

- Lean away from the fall!

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SAFETY Ü

DO NOT run the engine in an enclosed area without providing proper ventilation for the exhaust.

Exhaust gases contain carbon monoxide, an odorless and deadly gas. Internal combustion engines deplete the oxygen supply within enclosed spaces and may create a serious hazard unless the oxygen is replaced. This includes the atmosphere within the cab when equipped..

Ü

DO NOT leave the operator’s station with the boom and attachment tool raised. ALWAYS lower the boom and attachment tool to the ground, shut off the engine and engage the park brake BEFORE leaving the operator’s station.

Ü

NEVER travel with the boom above the carry position (attachment tool should be at minimum ground clearance.) Boom should be fully retracted.

Ü

Use front wheel steer for high speed travel.

Ü

Do not use the travel drive and/or extend or retract the boom to push or pull a load or object.

Ü

DO NOT drive too close to an excavation or ditch. BE SURE that the surrounding ground has adequate strength to support the weight of the machine and the load it is carrying.

Ü

DO NOT turn quickly while traveling on a slope or operate the machine beyond the grade and slope limits noted in the Operation and Adjustments chapter of this Operator’s Manual.

Ü

If necessary to park on a grade, park across the slope and block the tires.

Ü

NEVER allow riders on this machine. This is strictly a single-seat, NO passenger machine!

Ü

NEVER use as a lift for personnel unless the machine is equipped with the Personnel Work Platform (PWP) Safety System.

Ü

When road travel is required, know and use the signaling devices on the machine. Provide an escort and Slow-Moving Vehicle (SMV) emblem when required.

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Ü

Solid rubber tires are designed for intermittent service and limited running distances. The Working Day Average Speed should not exceed 3 mph at an average load of 75% of maximum capacity. Telehandlers equipped with solid rubber tires should not be used in applications requiring speeds over (15 mph), or continuous journeys over 1 mile when loaded at or above 50% of capacity. In the event an application requires vehicle speeds over 24.1km/h (15 mph), excessive roading, or driving extended distances while loaded, Manitou Group recommends the use of other approved tire options.

Suspended Load Safety Reminders The handling of suspended loads by means of a truss boom, winch, boom mounted lift hook, or other similar device can introduce dynamic forces affecting the stability of the machine that are not considered in the stability criteria of industry test standards. Grades and sudden starts, stops and turns can cause the load to swing and create a hazard. Refer to the following guidelines for handling suspended loads.

WARNING U.S. OSHA regulations effective November 8, 2010 (29 CFR Part 1926, Subpart CC - Cranes and Derricks in Construction) include requirements for employers that use powered industrial trucks ("forklifts") configured to hoist (by means of a winch or hook) and move suspended loads horizontally. In particular, this regulation applies to any rough-terrain forklift (e.g., "telescopic handler") equipped with a jib or truss boom with a hook (with or without a winch), or a hook assembly attached to the forks. [Note: This regulation is in addition to the OSHA regulation that requires specific forklift operator training: §1910.178(l).]

When a forklift / telescopic handler is configured and used for hoisting, the employer must ensure that:

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SAFETY 1. Forklift, lift equipment, and rigging have been inspected (each shift, month, and year) and are in good, safe condition and properly installed.

Ü

DO NOT exceed the rated capacity of the telescopic handler as equipped for handling suspended loads. The weight of the rigging must be included as part of the load.

2. An operator's manual and applicable load charts are on the forklift.

Ü

During transport, the length of the rigging between the attachment and load should be as short as possible to reduce booms height and movement. DO NOT raise the load more than 305 mm (12 inches) above the ground, or raise the boom more than 45 degrees.

Ü

Only lift the load vertically; NEVER drag it horizontally.

Ü

Use multiple pickup points on the load when possible. Use taglines to restrain the load from swinging and rotating.

Ü

Start, travel, turn, and stop SLOWLY to prevent the load from swinging. DO NOT exceed walking speed.

Ü

Inspect rigging before use. Rigging must be in good condition and in the U.S. comply with OSHA regulation §1910.184, “Slings,” or §1926.251, “Rigging equipment for material handling.”

Ü

Rigging equipment attached to the forks must be secured such that it cannot move either sideways or fore and aft. The load center must not exceed 24 inches (610 mm).

Ü

DO NOT lift the load with anyone on the load, rigging or lift equipment, and NEVER lift the load over personnel.

Ü

Beware of the wind, which can cause suspended loads to swing, even with taglines.

Ü

DO NOT attempt to use frame-leveling to compensate for load swing.

3. Work zone ground conditions can support the equipment and load. Any hazardous conditions in the work area have been identified, and the operator notified.

4. Equipment is being used within its rated capacity and in accordance with the manufacturer's instructions.

5. Operator and crew members have been trained in the safe use and operation of the equipment, including how to avoid electrocution.

6. During use, no part of the equipment, load line, or load will be within the minimum clearance distance specified by OSHA [3.0 m (10 feet), and more for lines rated over 50 kV] of any energized power line, and any taglines used are non-conductive.

7. In addition, for lift equipment with a rated capacity greater than 907 kg (2000 lbs.), the employer must ensure that: a.) An accessible fire extinguisher is on the forklift; b.) Monthly and annual inspections are performed and documented, and records retained (three months for monthly, one year for annual); c.) Before November 10, 2014, operators must have had the additional training and qualification / certification required

by OSHA regulations §1926.1427 and §1926.1430.

DL12-55 Tire Servicing Safety Reminder Ü

Note: Refer to the full text of the OSHA crane regulation (29 CFR Part 1926, Subpart CC) for a detailed description of the regulatory requirements.

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The DL12-55 telehandler requires foam filled or solid rubber tires for proper load capacity and stability. Never replace foam filled or solid rubber tires with pneumatic tires. Pneumatic tires will affect machine load capacity and stability.

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SAFETY minimize the build-up of static electricity. Do not use cell phones while fueling. Make sure the static line is connected from the machine to the fuel truck before fueling begins.

Servicing Safety Reminders Ü

ALWAYS be aware of and avoid pinch point areas on the machine, such as wheels-to-frame, cylinders-to-frame, and boom-attachment-tool-toframe.

Ü

NEVER attempt to by-pass the keyswitch to start the engine. ONLY use the jump-starting procedure detailed in the Service and Storage chapter.

Ü

NEVER use your hands to search for hydraulic fluid leaks. Instead use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed by a doctor familiar with this type of injury or gangrene may result.

Ü

ALWAYS wear safety glasses with side shields when striking metal against metal. In addition, it is also recommended that a softer (chip-resistant) material be used to cushion the blow. Failure to heed could lead to serious injury to the eyes or other parts of the body.

Ü

DO NOT refill the fuel tank when the engine is hot. Allow engine to cool down BEFORE refilling to prevent the hot engine from igniting the fuel if it should spill or splash.

Ü

DO NOT smoke while filling the fuel tank, while working on the fuel or hydraulic systems, or while working around the battery.

Ü

DO NOT fill the fuel tank completely. Allow room for expansion. Maintain control of the fuel filler nozzle when filling the tank. Use the correct fuel grade for the operating season.

Ü

Static electricity can produce dangerous sparks at the fuel-filling nozzle. Do not wear polyester, or polyester-blend clothing while fueling. Before fueling, touch the metal surface of the machine away from the fuel fill to dissipate any built-up static electricity. Do not re-enter the machine but stay near the fuel filling point during refueling to

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Ü

Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations. Avoid death or serious injury from fire or explosion; consult with your fuel or fuel system supplier to ensure the entire fuel delivery system is in compliance with fueling standards for proper grounding and bonding practices.

Ü

NEVER use fuel for cleaning purposes.

Ü

DO NOT remove the radiator cap after the engine has reached operating temperature or if it is overheated. At operating temperatures, the engine coolant will be extremely hot and under pressure.

ALWAYS wait for the engine to cool down before attempting to relieve pressure and remove the radiator cap. Failure to heed this warning could result in severe burns.

Ü

DO NOT loosen or disconnect any hydraulic lines, hoses or fittings without first relieving hydraulic circuit pressure. Also, be careful not to touch any hydraulic components that have been in recent operation, because they can be extremely hot and can burn you!

Ü

DO NOT use the boom to lift or support the machine for maintenance or service.

Ü

Avoid lubrication or mechanical adjustments with the machine in motion or the engine operating. If the engine must be in operation to make certain adjustments, place the transmission in neutral, apply the park brake, place the equipment in a safe position, securely block the tires and use extreme caution.

Ü

When washing the machine using water, do not direct the water onto any electrical connections, electrical components, or electronic components.

Water may cause malfunction or damage. Power washing or other high-pressure jets may cause physical damage.

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SAFETY Ü

Crystalline Silica Exposure

To ensure continued safe operation, replace damaged or worn-out parts with genuine Manitou Group service parts before using this equipment.

Modifications, Nameplates, Markings and Capacities Ü

Modifications and additions that affect capacity or safe operation shall not be performed without the manufacturer’s prior written approval. Where such authorization is granted, any applicable markings are to be changed accordingly.

Ü

All attachment tools MUST be marked to identify the attachment tool and the total capacity with attachment tool at maximum elevation with the load laterally centered.

Ü

ALWAYS be sure all nameplates, warnings and instruction markings are in place and legible.

Local government regulations may require specific decals, which then become the responsibility of the owner or user to provide.

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. Comply with all applicable rules and regulations for the workplace. Wear approved respiratory protection or use water spray or other means if there is no other way to control the dust.

Safety Guards and Warning Devices Ü

Ü

This machine is fitted with a Roll-Over Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) in accordance with industry standards. It is intended to offer protection to the operator from falling objects, and in case of an overturn, but it cannot protect against every possible hazard. Therefore it should not be considered a substitute for good judgment and safe practices in operating the machine. If the ROPS/FOPS structure is damaged, it must be replaced to restore the protection it provides.

A Silica rule “29 CFR 1929.1153" by the U.S. Occupational Safety and Health (OSHA) indicates a significant risk of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime. Refer to the rule for more information regarding exposure limits and hazard prevention.

Personnel Work Platform (PWP) System The Mandatory Work Platform Safety Rules must be followed to at all times while lifting personnel. These rules are based on ANSI/ITSDF Standard B56.6-2016, “Safety Standard for Rough Terrain Forklift Trucks.”

(A copy of this and related standards can be obtained from the Industrial Truck Standards Development Foundation, 1750 K Street NW, Suite 460, Washington DC 20009; or downloaded from: www.itsdf.org.) The rules apply to the owner, operator and personnel in the work platform.

This machine is equipped with a horn and backup alarm. The user must determine if operating conditions require that the machine be equipped with additional devices (mirrors, rotating beacon, etc.) and be responsible for providing and maintaining such devices.

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SAFETY 10. Be sure that the forklift has a firm footing.

WARNING

11. Be sure that any required restraining means (railings, chains, harnesses, etc.) are in place and properly used.

The machine must not be used to lift or carry personnel, or be fitted with any form of personnel work platform unless fitted with the optional PWP System.

12. Before lifting personnel, shift the transmission into Neutral, apply the parking brake, and activate the “PWP System” switch.

If fitted with the PWP System, the Mandatory Work Platform Safety Rules must be followed at all times while lifting personnel.

13. Before lifting personnel, the area should be marked to warn others of work by elevated personnel.

14. Be sure the path of platform travel is clear of hazards, such as scaffolds, electrical wires and overhead obstructions.

MANDATORY WORK PLATFORM SAFETY RULES 1.

The work platform must comply with ANSI/ITSDF Standard B56.6-2016, Sec. 8.24, “Platforms for Elevating Personnel.” (See page 16, “Work Platform Design Requirements.”)

15. The operator must keep hands and feet clear of controls that are not in use.

16. Personnel must be lifted and lowered smoothly and cautiously, and only at their request.

2.

The platform must be securely attached to the carriage or forks, and the carriage securely attached to the boom. The forks must not protrude beyond the floor of the work platform.

17. The platform must be lowered fully before moving the forklift. Do not drive the forklift with personnel on the platform.

3.

The carriage and forks must be secured to prevent them from pivoting upward.

18. Elevated personnel must always be alerted before raising or lowering the platform.

4.

If the machine is equipped with a rotating or swinging carriage, the rotation or swing must be deactivated. (This occurs automatically when the “PWP System” is switched on.)

19. A trained operator must be in position to operate the forklift and boom controls at all times.

5.

20. The combined weight of the platform, personnel and load must not exceed one-third of the material handling capacity of the forklift.

Personnel on the platform must be provided protection from any moving parts on the forklift that may present a hazard.

6.

If overhead hazards exist for platform personnel, overhead protection must be provided.

7.

Be sure that the lifting mechanism is operating smoothly throughout its entire range, both empty and loaded, and that any lift-limiting devices and latches are functional.

8.

Be sure that the frame is level, to ensure a vertical lift.

9.

Be sure the platform is horizontal before lifting.

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21. Platform personnel must maintain firm footing on the platform floor. A harness is to be worn and a lanyard attached to the platform or boom when working from an elevated work platform, in accordance with OSHA regulations. Use of railings, planks, ladders, etc. on platform for the purpose of achieving additional reach or height is prohibited.

22. Workers on the platform must keep all parts of their bodies inside the work platform during raising and lowering.

23. Be sure that the personnel and equipment on the platform do not exceed the available space.

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SAFETY 24. The platform must be fully lowered for personnel to enter and exit. Personnel must not climb on any part of the forklift in attempting to enter and exit.

Electrical Connection

25. Any harness, body belt, lanyard, or deceleration device that has sustained permanent deformation or is otherwise damaged must be replaced.

PWP Remote Shutdown Switch

26. Modifications to the platform that are detrimental to its safe use are prohibited.

Remote Shutdown Switch With Coiled Wire Connector on DL12-40 and DL11-44 Models

WARNING Use ONLY an approved work platform for elevating personnel.

NEVER move the machine with the work platform in a raised position or with personnel on board.

NEVER tilt the platform forward, rearward, or to the side with personnel aboard.

PWP Remote Shutdown Switch

ALWAYS engage the PWP System and follow the Mandatory Work Platform Safety Rules when lifting personnel.

Wireless Remote Shutdown Switch on DL11-55 and DL12-55 Models

Wireless Remote Battery Replacement

Work Platform System Switch

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1.

Remove the four screws from the cover of the wireless remote.

2.

Open the cover to gain access to the batteries.

3.

Remove the batteries from their holders.

4.

Install the replacement batteries in the holder taking 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.

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SAFETY form when the movable sections are in the retracted and extended positions. Both capacities shall be clearly indicated on the personnel work platform nameplate. The rough terrain forklift truck information plate(s) or load capacity chart shall indicate the rated capacities for the personnel work platform with the movable sections in both extended and retracted.

Work Platform Design Requirements (Per ANSI/ITSDF B56.6-2016, Sec. 8.24) 1. A structural safety factor for the personnel work platform of not less than 2:1 for ductile materials (based on minimum yield strength) and 5:1 for non-ductile materials (based on minimum ultimate strength) used for all load supporting structural elements and personnel work platform attachment means.

7. A toe board with a minimum height from the platform floor of 150 mm (5.90 inches) shall be provided around the perimeter of the personnel work platform. At points of access to the personnel work platform the height of the toe boards may be reduced to 100 mm (3.94 inches). Toe boards may be attached to gates and removable guardrails.

2. The personnel work platform shall have a floor with a slip resistant and self-draining surface. Any opening in the floor or between the floor and the toe board shall be dimensioned so as to prevent the passage of a 15 mm. (59 inches) diameter sphere.

Trap doors in the floor of the personnel work platform are not permitted.

8. Means shall be provided to prevent a side tilt attachment from tilting laterally when the personnel work platform is installed. Personnel work platforms, whether fitted to the forks or a quick interchange device, shall not be equipped with a side tilt device.

3. If the distance from ground level to the floor of the personnel work platform exceeds 400 mm (15.75 inches), the personnel work platform shall be equipped with an access ladder. This distance shall be determined when the rough terrain forklift truck is on a level surface, and the personnel work platform is in the fully lowered position on the lifting means. The steps or rungs of the ladder, and the handholds or handrails of the ladder shall conform to the requirements of ISO 2867. The ladder shall align with the access opening to the personnel work platform.

9. Means shall be provided to: a. securely retain the personnel work platform against the vertical face of the forks or carriage (fork mounted), or b. securely attach the personnel work platform to the lifting mechanism (quick interchange mounted).

4. The personnel work platform shall not allow any portion of the fork tips with which the personnel work platform is intended to be used to protrude beyond any part of the personnel work platform.

10. The personnel work platform shall be provided with restraining means for personnel on the personnel work platform. Personnel work platforms equipped with movable sections shall meet the same restraining requirements. The restraining means shall consist of either a guardrail enclosing the entire perimeter of the personnel work platform, or a guardrail enclosing all but the side of the personnel work platform that faces the intended work area. A permanent guardrail or similar structure shall be provided on the side closest to the lifting mechanism. The lanyard anchorage points shall only be provided on the permanent part of the personnel work platform structure.

5. The minimum space required for each person allowed on the personnel work platform as stated on the personnel work platform nameplate shall not be less than 500 mm x 500 mm (19.68 x 19.68 inches).

6. Personnel work platforms may utilize movable sections to extend the length of the platform perpendicular to the longitudinal center plane of the truck. Personnel work platforms with movable sections may have a different capacity for the plat-

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SAFETY 11. Protection shall be provided from moving parts of the rough terrain forklift truck that present a hazard to personnel on the personnel work platform.

Safety Decals

12. All guardrails shall have a height from the personnel work platform floor of 1075 mm ± 75 mm (42.32 inches ± 5.95 inches) around its upper periphery. Midrails shall also be provided and shall be located not further than 550 mm (21.65 inches) from the guardrails and the toe board.

13. Gates which are hinged on the side shall open inward shall have a positive latch, even if they automatically return to the closed position.

Ü

The machine has decals that provide safety information and precautions. These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements can be obtained from your dealer.

Ü

Refer to the following pages for safety decal part numbers and locations.

New Decal Application Ü

Surfaces must be free of dirt, dust, grease, and foreign material before applying the decal.

Remove the smaller portion of the decal backing paper and apply the exposed adhesive to the clean surface, maintaining proper position and alignment. Peel the rest of the backing paper and apply hand pressure to smooth out the decal surface.

Refer to the following pages for proper decal locations.

Ü

If replacing a part that has a decal on it, ensure that the replacement part has the same decal.

14. Chains or ropes shall not be used for guardrails or access openings on the personnel work platform.

15. Each guardrail and midrail shall withstand a concentrated test load of 1000 N (225 pound-force) applied at any point in any direction without visible permanent deformation.

16. Anchorage(s) for the connection of a lanyard(s) shall be provided on the personnel work platform.

Anchorages shall be capable of withstanding the force of 16 kN (3600 lbs) for each person allowed by the rough terrain forklift truck manufacturer on the anchorage point without reaching ultimate strength. The strength requirement shall only apply to the anchorage(s) and their attachment to the personnel work platform. The number of anchorages shall equal or exceed the rated number of occupants as specified on the personnel work platform nameplate. More than one occupant may attach to a single anchorage if the anchorage is rated for more than one person. Anchorages shall be designed to accept the lanyard. Exposed edges or corners shall be relieved either with a radius of at least 02 inches0.5 mm. () or a 45° chamfer.

17. The personnel work platform manufacturer shall identify and mark each lanyard anchorage. The identification shall specify the maximum number of lanyards that can be attached at each location.

18. The personnel work platform manufacturer shall provide on the personnel work platform a weatherresistant compartment for storing manufacturer's manuals/instructions related to the personnel work platform.

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SAFETY L65926 L70307 L70306

101506

L65928

L65932

100359

50302800

50302796 105099

100359 L70238

L70238

105099

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SAFETY L70306

L70307

101506

L65926

50302796

50302800 L65932

L65928

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SAFETY L65927 L65926 50308585 DL12-55 Only

L65928

L65927

L65927

L65927

50380987

50308585 DL12-55 Only 072798

L65933 L70305

L65927

L65927 50308585 DL12-55 Only

50308585 DL12-55 Only

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SAFETY L65928

072798

50380987 L65927

L65926 50308585 DL12-55 Only

L70305

L65933

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SAFETY PWP Safety Decals L71555

102969

L71554

L71700

L71554

L71700

L71554

L71555 102969

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Chapter 5 INDICATORS AND CONTROLS GUARDS AND SHIELDS

CAUTION

Whenever possible and without affecting machine operation, guards and shields are used to protect potentially hazardous areas. In many places, decals are also provided to warn of potential hazards and to display special operating procedures.

Become familiar with and know how to use ALL safety devices and controls on the Telescopic Handler BEFORE operating it.

Know how to stop the machine operation BEFORE operating it. This Manitou Group machine is designed and intended to be used ONLY with a Manitou Group attachment tool, or a Manitou Group approved accessory or referral attachment tool. Manitou Group cannot be responsible for product safety if the machine is used with an unapproved attachment tool.

WARNING Read and thoroughly understand all safety decals on the Telescopic Handler BEFORE operating it. DO NOT operate the machine unless all factory-installed guards and shields are properly secured in place.

Boom Angle Indicator Rear Camera Monitor

Indicators and Gauges Panel

Right Bank Switches

Frame Level Indicator

Left Bank Switches

Load Zone Charts

Horn Button Multi-Function Joystick Console Tilt Lever

Steering Wheel

Frame Level Switch Brake Pedal

Throttle Pedal

Ignition Switch

Outrigger Switches (if equipped)

Operator Compartment Indicators and Controls Locations PRINTED IN U.S.A.

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Multi-Functional Display

DASH AND STEERING CONSOLE

Ignition Switch

Temperature Control

Ignition Switch, Temperature Control, 12-volt Power Port and Load Zone Charts Ignition Switch OFF: When the key is vertical in the ignition switch, power is disconnected from the battery to the control and instrument panel electrical circuits.

This is the only position in which the key can be inserted and removed.

A

B

C

D

E

F

G

Operation Gauges and Indicators This multi-functional panel displays the gauges for the fuel level, diesel exhaust fluid (DEF) level, engine oil pressure and coolant temperature.

Ignition Switch ON: When the key is turned one position clockwise from the vertical (OFF) position, power from the battery is supplied to all controls and multifunction display panel electrical circuits. All indicators lamps in the multi-function display will illuminate momentarily as a lamp check.

The fuel gauge includes a white indicator lamp with the percentage of fuel in the tank. If the fuel level is between 12% and 6%, the indicator will flash yellow. If the fuel level is below 6%, the indicator will flash red.

When the key is in this position, the engine wait to start indicator will stay on until the engine is pre-heated. In colder temperatures the wait to start indicator will stay lit for 3-30 seconds. When the wait to start indicator light goes out the engine can be started.

The DEF (Diesel Exhaust Fluid) gauge includes the letters DEF with a percentage of diesel exhaust fluid in the tank.

Start: Turn the ignition switch to this position to activate the starter. Release the ignition switch as soon as the engine starts.

The engine oil pressure gauge includes a white indicator that will flash red if the engine oil pressure is too low or too high.

NOTE: If the engine requires repeated attempts

The engine coolant temperature gauge includes a white indicator that will flash red if the engine coolant temperature is too high.

to start, the key MUST be returned to the OFF position between starting attempts to prevent battery run down and to reset the air intake heater.

Pressing the up or down arrow on the (D) button in the bottom center of the multi-functional panel will scroll through the:

WARNING

engine oil pressure,

Do not use starting fluid (ether) with an engine intake air heater system. An explosion can result, which can cause engine damage, injury or death.

coolant temperature, engine RPM and voltmeter lamps The hour meter is permanently displayed in the top center of the display area.

Temperature Control Knob: This knob is used to adjust the temperature inside the cab when the heater or air conditioner is in use.

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Button Function A - Display Brightness and Back: Press this button to make the display dimmer as indicated by the icon above the button.

This button is also the back button when navigating the main menu.

B - Display Brightness: Press this button to make the display brighter as indicated by the icon above the button.

C - Escape: Pressing this button will bring the display screen back to the operation gauges and indicators screen.

D - Scroll: This button is used to scroll through various user initiated functions.

NOTE: Press the (C) escape button any time to return to the operation gauges and icons screen.

E - OK: Press this button to display the main menu. It is also used to select an option from the main menu.

Fault Codes: Use the up or down scroll button to highlight the fault codes function, then press the OK button.

Press the up or down scroll button again to scroll through any additional fault codes.

NOTE: Press the escape button at any time to return to the operation gauges and icons screen.

F - Disable Auto Exhaust System Cleaning: Press this button to prevent an auto exhaust system cleaning.

This button should be used when high exhaust temperature presents a hazard. Pressing the button again will allow auto cleaning.

Press the left or right scroll button to switch the display to history or inactive fault codes. Press the (A) back button to return to the main menu.

NOTE: This button will reset to the off position when the ignition switch is turned “OFF” and then back “ON”.

G - Exhaust System Cleaning: Press this button to display three requirements needed to perform a stationary exhaust system cleaning. Pressing the down scroll arrow will display instructions on the procedure to perform a stationary exhaust system cleaning.

This button is also used to initiate a stationary exhaust filter cleaning.

MCU I/O Status: Use the up and down scroll button to highlight the MCU I/O function, then press the OK button. Use the up or down scroll button to select the inputs or outputs. Press the (A) back button to return to the main menu.

Multi-Function Display Main Menu Options Press the (E) OK button to display the main menu. Use the (D) scroll button up or down arrows to select a menu function.

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Engine Information: Use the up and down scroll button to highlight the Engine Information function, then press the OK button. This screen will display various engine related information. Press the (A) back button to return to the main menu.

Revisions: Use the up and down scroll button to highlight the Revisions function, then press the OK button.

This will display the part number and revision of the multi-function display panel and the MCU. Press the (A) back button to return to the main menu.

Maintenance: Use the up and down scroll button to highlight the Mainteneance function, then press the OK button. The 250 hour mantenance reminder can be disable by pressing the (G) button below 250hr box.

This will change the 250hr in the box to OFF. The routine maintenance reminder can be re-activated any time by following the same procedure and pressing the (G) button so that the box reads 250hr. Press the escape button to return to the operation gauges and icons screen.

Change Units: Use the up and down scroll button to highlight the Change Units function, then press the OK button. Press the up or down scroll button to switch between SAE and Metric units. Press the (A) back button to return to the main menu.

Idle Options: For high elevation operation, an alternate 1400 RPM low idle setting is available for sluggish or low power conditions at low idle.

Use the up and down scroll button to highlight the Idle Options function, then press the OK button. Press the (G) button to select the alternate 1400 RPM low idle setting. Press the (F) button to select the 1100 RPM default setting. Press the (A) back button to return to the main menu.

Exhaust Filter, Indicator Lamps

and

Service

Travel Direction and Speed Range Indicator: Located in the upper center of the display panel, the selected travel direction will be lighted and the selected travel speed will be displayed to the right of the direction indicator.

Icon Description: Use the up and down scroll button to highlight the Icon Description function, then press the OK button. Use the up or down button to scroll through the icon description pages. Press the (A) back button to return to the main menu.

50960172/E0221

Engine

Wait-to-Start Indicator Lamp: When lighted this lamp indicates that the intake air heater needs to warm the intake air prior to starting the engine.

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Alternator Lamp: This red lamp indicates the condition of the electrical charging system. During normal operation, this lamp should be off. If the alternator charge rate is too low, this lamp will come on.

High Exhaust System Temperature Lamp: This amber lamp will illuminate due to higher than normal exhaust temperature during an exhaust system cleaning. The operator should ensure the exhaust outlet is not directed at any flammable or combustible surfaces.

Diesel Exhaust Fluid (DEF) Lamp: This amber lamp will illuminate when the DEF level is low, and flashes when the DEF level falls below a very low level. Refill the DEF tank.

Exhaust System Cleaning Stop Lamp: This amber lamp will illuminate when the SCR system cleaning button (F) has been pressed to prevent an exhaust cleaning event.

Brake Failure Lamp: This red lamp indicates the condition 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. Failure in one of the brake systems does not affect the operation of the other system.

However, the MANDATORY SAFETY SHUTDOWN PROCEDURE (p. 15) should be followed and any necessary repairs made immediately.

Exhaust System Cleaning Lamp: This amber lamp will illuminate when the exhaust system is unable to complete an automatic Exhaust System Cleaning. The lamp will flash when a stationary exhaust system cleaning is initiated by pressing exhaust filter cleaning button.

Routine Maintenance Reminder: After every 250 hours of operation, the routine maintenance reminder shown below will display in the multi-functional panel when the ignition key is turned to the ON position. The reminder will display for 15 seconds then return to the normal operation screen.

Transmission Oil Temperature Lamp: This red lamp indicates whether or not the transmission oil is at the proper temperature. During normal operation this lamp should be off, indicating that the transmission oil system is at the proper temperature.

IMPORTANT: If this lamp comes on during normal operation, a problem may exist in the transmission oil system. Stop the machine immediately and investigate the cause of the problem!

Hydraulic Filter Lamp: This amber lamp will illuminate to indicate a restriction in the hydraulic return filter element.

Refer to the Service and Storage chapter to determine the required maintenance for the hours on the machine.

Once the maintenance has been performed, the routine maintenance reminder can be cleared by navigating to the maintenance menu. Once you select the maintenance menu, clear the message by pressing and holding the OK button for 3 seconds.

Check Engine Lamp: This amber lamp will illuminate when there is an engine or exhaust filter related error.

Stop Engine Lamp: This red lamp will illuminate when an engine or exhaust filter condition exists that could cause engine or exhaust filter damage. Shut down the engine as soon as it is safe to do so.

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D - Fan Speed: This switch increases and decreases circulation of heated or cooled air throughout the operator’s station interior.

Right Bank Switches

A

B

C1

C2

D

E

E - Heater/AC or Heater: This switch will be either the Heater switch shown or the Heater/AC switch.

Pressing the top of the Heater or Heater/AC switch activates the cab heater. Pressing the bottom of the Heater switch turns off the heater. Pressing the bottom of the Heater/AC switch activates the cab air conditioner. Return the Heater/AC switch to the center position to turn the heater and air conditioner off.

F

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

F - Parking Brake: When the machine is shut off, this switch should be depressed to activate the park brake mechanism in the front axle.

A - Engine Emergency Override Switch: The lamp in this switch will flash when there is a low oil pressure WARNING or a high coolant temperature WARNING. The lamp in the switch will light continuously at the low oil pressure SHUTDOWN set-point or the high coolant temperature SHUTDOWN set-point.

Left Bank Switches

Pressing and holding the bottom of the engine emergency override switch will override an engine shutdown signal caused by low engine oil pressure or high engine coolant temperature.

A

C

D

E

F

G

Left Bank Switches

This switch must be pressed within 30 seconds to prevent undesired shutdown of engine. The switch can be overridden for 30 seconds at a time to move the machine to a safe location and to lower the boom to the ground. If the engine shuts down, the ignition switch must be turned off and then back on before the engine can be restarted.

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

A - Steer Select: Use “2-wheel mode” for higher speed travel. Use “4-wheel mode” for making tighter turns, usually on jobsite. Use “crab mode” when a small amount of side shift is needed for picking or placing loads.

NOTE: Holding the switch continuously “ON” will not reset the 30-second timer.

B - Clutch Cutout: When activated, this switch allows faster engine acceleration and power to the hydraulics system without power to the drive axles while the service brake pedal is depressed.

NOTE: The rear wheels are not self-centering.

Use the axle alignment switch to determine when the rear wheels are tracking straight. To obtain the proper steer function selected and better machine tracking, make sure all wheels are in a straightahead position before changing the steer mode.

In the OFF position, the clutch mechanism in the transmission remains engaged when applying the brakes. In the ON position, the clutch mechanism is disengaged while applying the brakes.

Any of the steering position modes can be used in forward or reverse travel. The operator should learn to anticipate changes in machine movement if the steering selector mode is changed.

NOTE: Normal brake force will hold the machine in position while accelerating the engine to power the hydraulic control functions during load placement.

B - Axle Align: Allows the operator to check for straight tracking of the rear wheels. When activated, a green lamp lights on the switch to indicate straight tracking.

C1 and C2 - Wiper/Washer: The windshield and top window of the operator’s station are each equipped with a wiper and washer mechanism. Switch “C1” operates the wiper and washer on the windshield; switch “C2” operates the wiper and washer on the top window.

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B

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C - Head Lights/Work Lights: Pressing the top of the switch will illuminate the lights mounted on the top of the operator’s station and the red tail lights, for use in forward travel operations. Pressing the bottom of the switch will illuminate the lights at the end of the boom in addition to the lights on the operator’s station, for additional lighting in working operations.

B - Steering: The power steering motor is designed to give low-effort steering with no shock reaction from the axle wheels to the steering wheel. Turn the steering wheel to the right or left to turn the machine in the direction of wheel turn action.

C - Horn Button: With the keyswitch on, press the center of the steering wheel to activate the horn.

D - Hazard: This switch can be activated to make the tail lights flash on and off if the machine is stalled or temporarily stopped in a traffic area on the road or jobsite.

RIGHT SIDE PANEL These controls and indicators are used to position the frame, boom, and attachment. Graphic symbols on the side panel illustrate the control actions.

E - Turn Signal Option: This switch is used to indicate the direction of a turn. Depress the right arrow for right turn; depress the left arrow for a left turn.

A - Load Zone Charts: A series of flip charts show lift height and reach limits relative to the load weight being handled with various attachment tools.

F - Beacon: When a beacon is installed on the machine, activating this switch will produce a strobelight on and off flashing, for working in conditions that may obscure view of the machine.

G - Personnel Work Platform: This switch is used to activate the Personnel Work Platform (PWP) Safety System. It is a red switch located in the farthest right slot of the left side switch bank. When activated, an amber lamp lights on the switch.

A

B

B - 12-Volt Accessory Power Port: Use this power port to power small electrical devices.

E

D

C - Frame Leveling Switch: This switch is located on the right side panel behind the multiC function joystick. The machine may be tilted slowly 10° to the left or right to level the frame and boom in relation to the ground.

NOTE: This lamp will flash on and off, indicating that the (PWP) system is not fully functional, until the brakes are held on for three or more seconds.

Adjustable Steering Console B

NOTE: The frame leveling speed will be reduced when the parking brake is activated.

C

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

A

A - Position Adjust: This console can be adjusted so the steering wheel is placed in a comfortable operating position. Loosen the quick release handle on the left side of the console and re-position the steering wheel.

Tighten the quick release handle to lock in place.

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D - Outrigger Switches: The outriggers are used to provide greater stability for specific applications. Press the left switch forward to lower the left outrigger. Press the right switch forward to lower the right outrigger. To raise the outriggers, press both switches rearward.

E - Boom Raise/Lower and Extend/Retract: This machine has a hydraulic-type telescopic boom. The boom sections extends by means of a hydraulic cylinder inside or on top of the boom.

To extend the boom, move the joystick handle (F) to the right; to retract the boom, move the joystick handle (F) to the left. To raise the boom, move the joystick handle (F) rearward; to lower the boom, move the joystick handle (F) forward.

Level the frame before lowering the outriggers. Lower the outriggers until the front tires just start to raise.

WARNING

WARNING

For maximum machine stability, never lower the outriggers so that the tires come completely off the ground.

Use extreme caution when raising or extending the boom. The Telescopic Handler MUST be level. Loaded or empty, the machine can tip over if it is not level.

Do not use outriggers on soft or uneven surfaces. Be sure the surface can support the machine and load.

ALWAYS place the transmission in neutral, apply the parking brake and keep the service brakes fully applied before raising or extending the boom.

Be sure NO persons or equipment are located where the outrigger pads will be positioned.

DO NOT travel with the outriggers extended.

NEVER exceed the specified lift and reach capacities of the machine, or serious machine damage and personal injury may result. Refer to the load charts at the operator’s station or this manual.

Adequate clearance is required for the retracted outriggers when traveling through doorways or along narrow pathways.

DO NOT attempt to use the outriggers as a hydraulic jack for maintenance, or to level frame, or for other similar uses.

If a boom circuit hose fails with the boom up, with or without a load, shut down the machine following the MANDATORY SAFETY SHUTDOWN PROCEDURE. DO NOT attempt repairs.

Instead, call your Manitou Group dealer for assistance.

Failure to heed could result in death or serious injury.

E - Multi-Function Joystick: The multi-function joystick controls the boom raise/lower and extend/retract functions. Buttons on the joystick control the attachment tilt, auxiliary hydraulics, travel direction and travel speed.

F

H

I

J

F - Attachment Tilt: To tilt the attachment tool back, move switch (F) downward; to tilt the attachment tool forward, move switch (F) upward. When the operator tilts the attachment tool to a desired angle, that angle will be maintained as the boom is raised and lowered, extended and retracted, until a new angle is set.

WARNING

G

The truss boom and winch attachment tools should ONLY be used to lift and place loads when the machine is in a stationary position.

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

E

E - Multi-Function Joystick Operation

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NEVER use winch for lifting or moving personnel. NEVER exceed the maximum rated capacity of the winch 1360 kg (3000 lbs.) or exceed the load chart rating for winch applications.

FUNCTION INDICATORS Frame Angle Indicator: Located in front of the operator on the ROPS upper crossmember. Position of the ball shows when the frame is level relative to a sloping ground surface.

DO NOT tilt the truss boom back more than 45o from horizontal. DO NOT attempt to use the optional rotating carriage as a load leveling function. ALWAYS level the frame prior to raising a load.

Frame Angle Indicator

Boom Angle Indicator: Mounted on the left side of the outer boom, the position of the ball in the Boom Angle Indicator, shows the angle of the boom relative to the ground surface.

G - Auxiliary Hydraulics: Move switch (G) on the front of the joystick handle (E) to the left or right to operate the auxiliary hydraulics required on some attachment tools.

Boom Angle Indicator

H - Travel Direction Switch: The travel direction switch (H) controls forward/reverse travel direction. l Press the top of the switch (H) to engage forward travel. l Press the bottom of switch (H) to engage reverse travel.

FLOOR AND SEAT

l The center position of switch (H) will place the machine in neutral.

Throttle Pedal: This pedal, operated by the right foot, controls the engine speed to match power requirements. Pushing down on the pedal increases the RPM, letting up on the pedal decreases RPM.

NOTE: The selected travel direction is shown in the multi-function display.

NOTE: The switch (H) MUST be in the center (Neutral) position before the starter will engage to start the engine.

Service Brake Pedal: Pressing this pedal activates the internal braking mechanism in both the front and rear axle.

IMPORTANT: Care should be taken when downshifting or changing direction, because damage to the transmission can occur if shifting is forced or attempted at too high a speed. Allow engine speed to slow before any downshift or directional change is attempted.

Service Brake Pedal

Throttle Pedal

NOTE: The backup alarm automatically sounds when the (H) switch is in the reverse position and the park brake is not applied.

I - Decrease Travel Speed: Press the (I) button once to change travel speed to the next lower speed.

J - Increase Travel Speed: Press the (J) button once to change travel speed to the next higher speed.

NOTE: The selected speed range is shown in the multi-function display located to the right of the travel direction indicators.

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Seat Positioning: The seat is mounted on rails for forward and rearward repositioning, for comfort and to accommodate the operator’s size. A spring-loaded latch handle “A” under the front of the seat actuates the adjustment mechanism.

SERVICE AND SAFETY FEATURES The following indicators are for fluid level and pressure checks.

Hydraulic Test Ports: Two test ports are located under the center cover near the transmission dipstick. Use these ports for installing a test gauge to check hydraulic main and steering relief system pressures and also the joystick relief pressure.

Suspension Seat Option: In addition to the “A” latch handle for forward and rearward adjustment, this seat has a knob “B” under the front of the seat to adjust the suspension. Turn the knob to the right for a softer ride, and to the left for a firmer ride.

Transmission Oil Level and Fill Cap: The combination dipstick/fill tube is located under the center drive train cover as shown below.

A A

Steering and Main Relief Pressure Test Port B

Joystick Relief Pressure Test Port

Seat Belt: This machine has a retractable seat belt.

Grasp the belt on the left side of the seat pulling the belt over your lap and insert the belt into the buckle on the right side of the seat until you hear it lock in place.

Transmission Oil Level and Fill

Hydraulic Reservoir Oil Level and Fill Cap: The hydraulic oil level dipstick is located on the rear wall of the power train compartment forward of the hydraulic cooler. The hydraulic oil fill cap is located to the rear of the hydraulic cooler. See illustration on the next page.

Seat Belt

Coolant Level: A coolant level sight glass is located on the rear of the radiator. The level should be checked when the engine is cold. Add coolant if it is not visible in the sight glass. Add coolant though the radiator cap until it is visible in the sight glass. See illustration on the next page.

DEF Fluid Fill: The DEF level is shown on the Gauge displayed in the multi-functional panel. Add DEF fluid in the location shown on next page.

Diesel Fuel: The diesel fuel level is shown on the gauge displayed in the multi-functional panel. Add diesel fuel in the location shown on next page.

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Hydraulic Oil Level Dipstick

Engine Oil Fill

Radiator Cap

Coolant Level Sight Glass

Hydraulic Oil Fill

Engine Oil Dipstick

Windshield Washer Reservoir

Battery Disconnect Switch

Side Rear View Mirror: This mirror is located on top of the frame leveling cylinder mount. It provides the operator with a view of the area on the right side and behind the machine.

Diesel Fuel Fill Cap

Locking Power Train Covers: To tilt back the midframe access cover and the power train cover, pull out the lock mechanism handle and tilt up. Two gascharged springs help tilt back each cover, and keep them raised.

DEF Fill Cap

Storage Compartment Fuse and Relay Box: This box is located on the front inside wall of the storage compartment behind the operator’s compartment. A decal provides a quick reference guide for troubleshooting electrical functions.

Backup Alarm and Light: Located inside the rear frame cover, the backup alarm produces a loud warning sound and the backup light comes on when the park brake is off, and the machine is in reverse.

Backup Alarm Backup Light

Engine Oil Level: The dipstick is located on the right side of the engine.

Fuse/Relay Reference Decal

Battery Disconnect Switch: The battery can be disconnected from the electrical system by turning the disconnect switch key to the OFF position.

Fuse/Relay Box

Windshield Washer Reservoir: Located under the engine cover to the front of the engine compartment, the fluid level is visible through the reservoir. Remove the cap to fill with windshield washer fluid.

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21. 5 Amp - Instrument Panel

Storage Compartment Fuse and Relay Functions: The cover of the fuse box has a diagram indicating the position of the fuses and relays inside the box. Remove the cover to gain access to the fuses and relays. Refer to the illustration and following descriptions for the fuse and relay functions.

22. 5 Amp - Reverse Camera 23. 20 Amp - Spare 24. 10 Amp - Stabilizing Cylinder, Park Brake 25. 10 Amp - Frame Level, Steer Select 26. 10 Amp - Ignition-Engine Run Signal 27. 20 Amp - MCU, Reverse Relay 28. Open

RELAYS: E1. Ignition E2. Backup Lights and Alarm Fuse/Relay Box with Cover Installed

E3. Park Brake

Fuse/Relay Box with Cover Removed

E4. Top Wiper

FUSES:

E5. Heat-A/C Select

1.

Open

E6. Open

2.

Open

E7. Tilt / Auxiliary Select

3.

Open

E8. Canopy Lights

4.

Open

E9. Front Wiper

5.

Open

E10. Fan High Speed

6.

10 Amp - Auxiliary Power

7.

5 Amp - Auxiliary (Radio Battery)

8.

10 Amp - Beacon

9.

10 Amp - Canopy Lights, Tail Lights

Engine Compartment Fuse and Relay Box: This fuse and relay box is located directly to the rear of the air cleaner assembly. Remove the cover to access the relays and fuses. The cover has a decal indicating the fuse and relay functions.

NOTE: To remove the fuse/relay box cover, pull the yellow retainer on each end of the box up untill it clicks, then press the tab on each corner in toward the body of the box untill it clicks, the cover can now be removed.

10. 10 Amp - Turn Signals, Hazard Lights 11. 10 Amp - Boom Lights, Rear Lights 12. 10 Amp - Horn, Brake Lights 13. 10 Amp - Ignition Switch

To install the cover, place the cover on the box, firmly press each end down untill it clicks, then push the yellow retainers down untill they click.

14. Open 15. Open 16. 10 Amp - Auxiliary (Radio Ignition) 17. 10 Amp - Front Wiper/Washer 18. 10 Amp - Top Wiper/Washer 19. 30 Amp - Heat and A/C Fan 20. 10 Amp - Outriggers, Transmission Declutch, Axle Alignment switch

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Engine Fuse/Relay Box with Cover Installed

44

Engine Fuse/Relay Box with Cover Removed

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OPTIONAL FEATURES

Engine Compartment Fuse and Relay Functions: Refer to the illustration and following description for the fuse and relay functions.

F1

F6

F4

This system consists of the rearview camera (1) mounted at the rear of the machine and the viewing monitor (2) mounted on the left side of the dash. This system provides a visual view of the area directly behind the machine.

F5

F2 F3

Rear Camera System

K7

F7 1 F8

K6 2

K4 K3

K1

K5

Refer to the "Operation and Adjustments" chapter for more information on the rear camera system.

K2

Reverse Radar System This system consists of the preview sentry (3) mounted at the rear of the machine and the radar display (4) mounted on the left side of the viewing monitor (2).

The reverse radar system can be added to the rear camera system for an audible indication of objects to the rear of the machine.

FUSES: F1. 30 AMP: ECM Power F2. 5 AMP: Ignition

3

F3. 5 : Telematic F4. 15 AMP: Supply Module

4

2

F5. 15 AMP: Line Heat F6. 5 AMP: After Treatment Relay

Refer to the "Operation and Adjustments" chapter for more information on the reverse radar system.

F7. 10 AMP: After Treatment Power (DRT, SCR, DEF)

WARNING

F8. 15 AMP: Fuel Fan

RELAYS:

Always use mirrors and look to the rear of the machine before and during backing. Clear any people or obstruction from your path before backing. Rear camera and reverse radar systems are for supplementary use only.

K1. DEF Supply Module K2. Start Inhibit K3. DEF Line Heat #1 K4. DEF Line Heat #2 K5. DEF Line Heat #3 K6. After Treatment Power (DRT, SCR, DEF) K7. Fuel Cooler Fan

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ATTACHMENT TOOLS Manitou Group offers a range of attachment tools to meet various lifting and material handling applications.

Contact your Manitou Group dealer for specifications and ordering information.

ACCESSORIES Manitou Group also offers a range of special accessories for this machine. Contact your Manitou Group dealer for specifications and ordering information.

NOTE: All accessories are field-installed unless otherwise noted. Information and parts for installing accessories are provided by your Manitou Group Telescopic Handler dealer or Manitou Group.

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Chapter 6 OPERATION AND ADJUSTMENTS 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.

GENERAL INFORMATION

CAUTION

Consult the Lubrication chapter for the type and grade of oil to use. Refer to the Service and Storage chapter for the proper service intervals.

BEFORE starting the engine and operating the Telescopic Handler, review and comply with ALL safety recommendations in the SAFETY chapter of this manual. Know how to STOP the machine before starting it. Also, BE SURE to fasten and properly adjust the seatbelt.

PRE-START WALK-AROUND INSPECTION It is the operator’s responsibility to perform a pre-start inspect of the machine before the start of each workday. Every pre-start inspection must include more than simply checking the fuel and oil levels. It is a good practice to personally inspect any machine you are assigned to use, even though it has already been put into service by other personnel.

ENGINE BREAK-IN A new engine does not require extensive “break-in.”

However, for the first 100 hours of operation, follow these guidelines: Operate the engine at various conditions during the initial 100 hours with at least 15% of the time under heavy loads to achieve adequate engine break-in. Check the oil level frequently and replenish as necessary with the oil specified in the engine manual.

The pre-start inspection is designed to discover if the machine has incurred any damage or is in need of routine service.

Any needed repairs are to be made by a qualified service technician.

Cummins engines do not use special “break-in” oil.

Use the engine oils specified for the ambient temperature listed in the Lubrication chapter. After the first 100 hours of operation, change the oil and replace the oil filter.

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Refer to the illustration and checklist on the next two pages for the “Pre-Start Walk-Around Inspection.”

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Pre-Start Walk-Around Inspection Illustration Any needed repairs or service noted during the inspection must be performed by a qualified service technician before operating the machine.

PRE-START WALK-AROUND INSPECTION PROCEDURE Refer to the following illustration and checklist to perform the inspection. Begin with item 1 at the left front of the machine and walk toward the rear of the machine on the left side and around the back and toward the front on the right side of the machine.

The illustration and checklist page can be copied for future pre-start walk-around inspections.

4

5

7

1 3

17

2 6

18

19

11 10

12

13

15

14

16

9

8

30

24 21

27

26

31 28

33

20

25 32

23 22

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Pre-Start Walk-Around Inspection Checklist o15. Slave Cylinder: Properly secured; no visible damage; no evidence of leaking from the cylinder; properly lubricated.

Note the condition of safety decals during the walk-around inspection. Replace missing or illegible safety decals. o1.

Attachment Tool: Check for broken, missing or damaged parts. When using a personnel work platform, check to see if the platform meets ANSI/ITSDF standards and that it is secured to the forks and fork carriage.

When using forks, check for welds, cracks or misalignment. Replace the forks in sets when the condition of the forks is questionable.

o16. Stabilizer Switch and Rod: Properly secured; no visible damage; no loose or disconnected wires. o17. Boom Pivot Assembly: Properly secured; no visible damage or excessive wear; properly lubricated. o18. Boom Hydraulic Hoses: No visible damage or exterior wear; no evidence of leaking.

IMPORTANT: DO NOT use forks that have been repaired by welding.

o19. Rear Light Assembly: Properly secured; no visible damage; no loose or disconnected wires; no malfunctions.

o2.

Attachment Tool Mount: No loose or missing parts; no visible damage.

o3.

Attachment Tool Mounting Pins: No visible damage; pin fit is secure and properly lubricated.

o20. Hydraulic Control Valve Assembly: No loose or missing parts; no evidence of leaking; no damaged or leaking hoses.

o4.

Boom Chain: No loose or missing parts; no visible damage; sheave pin fit is secure and lubricated.

o21. Exhaust System: No loose or missing parts; no visible damage; no obstructions to the outlet.

o5.

Boom Sections and Wear Pads: No loose or missing parts; no visible damage or excessive wear.

o22. Hydraulic Cooler: No loose or missing parts; no visible damage; no evidence of leaking; cleanliness.

NOTE: Wear pads that measure 9.5 mm (3/8”) thick or less need to be replaced. o6.

Outriggers (when equipped): Properly secured; pads in downward position; no visible damage; no loose or missing parts; no leaking from the cylinder.

o7.

Boom Angle Indicator: Properly secured; no visible damage; bubble is visible.

o8.

Tire and Wheel Assemblies: Properly secured; no loose or missing lug nuts; no visible tire damage (cuts or abrasions); proper inflation.

o9.

Front and Rear Axles: No loose or missing parts; no visible damage; tie rod end studs locked; no evidence of leaking; properly lubricated.

o23. Engine Compartment: o Engine oil level, add if needed; o Coolant level, add if needed; o No evidence of engine oil or coolant leaks; o Fuel breather cap secure and working; o Hydraulic oil level; breather cap secure and working; o Battery proper electrolyte level; no loose or damaged cables; no visible damage or corrosion; o Belts and hoses in good condition, properly secured and adjusted. o24. Boom Hose Guards: Properly secured; no visible damage. o25. Engine Air Filter (under engine cover): No loose or missing parts; no visible damage; no obstructions to the evacuator; pre-cleaner free from dirt.

o10. Fuel Tank: No visible damage; no evidence of leaking. o11. Operator Compartment: o Seat belt undamaged; operates properly; mounting hardware secure. o Switches and levers undamage; o no loose or missing parts; o load charts properly secured and legible; o levers and switches operate properly; control markings legible; o frame level indicator secured and undamaged, bubble is visible. o12. Hydraulic Oil Reservoir: No visible damage; no evidence of leaking.

o30. Tilt and Auxiliary Hydraulic Hoses: No visible damage or excessive wear; no evidence of leaking.

o13. Lift Cylinder: Properly secured; no visible damage; no evidence of leaking from the cylinder; properly lubricated.

o31. Attachment Tilt Cylinder: Properly secured; no visible damage; no evidence of leaking from the cylinder; properly lubricated.

o14. Rear Axle Stabilizer Cylinder: Properly secured; no visible damage; no evidence of leaking from the cylinder; properly lubricated.

o32. DEF Fluid Tank: No visible damage; fill cap secure.

o26. Mirror Assembly: No loose or missing parts; no visible damage; properly adjusted. o27. Cowling and Latches: All cowling, doors and latches in working condition; properly secure; no loose or missing parts; all components operate properly. o28. Frame Tilt Cylinder: Properly secured; no evidence of leaking; properly lubricated. o29. Frame: No visible damage; no cracked welds; no loose or missing parts.

o33. Boom Mounted Hook (if applicable): Properly secured to boom, no sign of damage to hook or mounting hardware.

Date: _________________Initials: _______________

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IMPORTANT: The engine is equipped with a starting motor protection feature. If the engine fails to start within 60 seconds, the engine starter will stop operating and the wait-to-start lamp will flash for 2 minutes allowing the starter to cool. DO NOT turn the ignition switch to “OFF” until the wait-to-start lamp stops flashing. When the waitto-start lamp stops flashing turn the ignition key to “OFF” then back “ON”, when the wait-to-start lamp goes out, the engine can be started.

BEFORE STARTING ENGINE Before mounting the operator’s compartment, walk completely around the machine to be sure no one is under, on, or close to it. Let others in the area know you are going to start up. Wait until everyone is clear of the machine before starting it up.

Before starting the engine and running the machine, refer to the Indicators and Controls chapter and familiarize yourself with the various operating controls, indicators and safety features.

6. After the engine starts, allow 3 to 5 minutes before operating the machine with a load.

STARTING THE ENGINE

7. Check that indicators are in their normal operating conditions.

WARNING

8. Verify that there are no fuel, oil or engine coolant leaks, and no abnormal noises or vibrations.

ALWAYS fasten the seat belt BEFORE starting the engine. Leave the park brake applied until the engine is running and you are ready to operate the machine.

COLD STARTING PROCEDURES The engine is equipped with a intake air heater for starting the engine in temperatures down to -18°C (0°F) and a block heater for starting the engine in temperatures below -18°C (0°F).

The following procedure is recommended for starting the engine: 1.

Grasp the handholds and step up into the operator’s compartment.

2.

Adjust the seat and fasten the seatbelt.

3.

Check that all controls are in their “neutral” positions, except the parking brake switch, which should be in the “ON” position.

WARNING DO NOT use starting fluid on engines equipped with an intake air heater. Starting fluid is highly flammable and may explode, causing serious injury.

4. Turn the key switch clockwise one position to the “ON” position. When the wait-to-start indicator lamp in the multi-function display goes out, the engine can be started.

The following procedure is recommended for starting the engine in temperatures below -18°C (0°F):

NOTE: The lower the ambient temperature the longer the wait-to-start indicator lamp will remain illuminated. Wait for the indicator lamp to go out before attempting to start the engine.

1.

Plug the engine block heater in at least one hour before attempting to start the engine.

2.

Follow the steps 1 - 8 listed in “Starting The Engine”.

If the battery becomes discharged and has insufficient power to start the engine, jumper cables can be used for starting assistance. Refer to the jump starting instructions in the Service and Storage chapter of this manual for safe jump starting procedures.

5. Turn the key switch clockwise until the engine starter activates. Release the key switch when the engine starts. If the key switch is released before the engine starts, turn the key switch to the “OFF” position and wait one minute before attempting to start again.

STOPPING The following procedure is the recommended sequence for stopping the machine: 1.

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Bring the machine to a stop on a level surface.

Avoid parking on a slope, but if necessary park across the slope and block the wheels.

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2.

Fully retract the boom and lower the attachment to the ground.

3.

Idle the engine for at least 3 minutes for gradual cooling.

Engine Warning lamp. The red Engine Stop lamp flashes when out-of-range conditions continue to worsen. The operator must shut down the engine as soon as it is safe to do so.

EXHAUST FILTER CLEANING SYSTEM

IMPORTANT: If an Exhaust Filter Cleaning has just been performed, increase the engine idle time to 5 minutes.

4.

Place controls in neutral. Apply the parking brake.

5.

Turn the ignition switch key to the “OFF” position. Remove the key.

6.

Unfasten the seatbelt, and grasp the handholds while climbing out of the operator’s compartment.

The engine is equipped with a Selective Catalytic Reduction (SCR) system in place of a muffler. The SCR is located on the top center of the frame to the rear of the center transmission access cover. The SCR uses diesel exhaust fluid (DEF) to reduce the nitrogen oxide emissions from the exhaust into nitrogen and water.

Under normal machine operation and with the system in AUTO mode, the SCR system requires minimal operator interaction.

FIRST TIME OPERATION

To avoid unnecessary buildup of diesel particles or soot in the exhaust filter system;

CAUTION Be sure the area being used for test-running is clear of spectators and obstructions. Initially, operate the machine with an empty attachment tool.

Make sure the engine is warm and then go through the following procedures: Place the travel lever in a speed range and in Forward or Reverse. Turn off the parking brake switch and move slowly, while testing the steering and brakes.

Stop and operate all boom functions and frame leveling controls, checking for smooth responses.

Utilize the Automatic (AUTO) Exhaust Filter Cleaning mode.

2.

Avoid unnecessary idling.

3.

Use the proper engine oil. See Lubrication chapter of this manual or the engine manual for proper engine oil specifications.

4.

Use only ultra low sulfur diesel (ULSD) fuel. See Lubrication chapter of this manual or the engine manual for fuel requirements.

Automatic (AUTO) Exhaust Filter Cleaning Operating the engine in AUTO Mode allows the ECU to perform intelligent exhaust cleaning as required.

The High Exhaust System Temperature (HEST) Lamp will illuminate when the system is actively performing an exhaust filter cleaning. When the exhaust filter cleaning process has completed its cycle, the (HEST) indicator will turn off.

Apply the service brakes, and move the travel lever to the opposite direction (forward or reverse).

Shifting to the next higher gear may be done at any engine speed while the machine is in motion.

The machine can be operated as normal during the auto exhaust filter cleaning process unless the operator determines the machine is not in a safe location for high exhaust temperatures and disables the auto cleaning process.

DO NOT overspeed the engine when down shifting.

Allow the machine to slow down before shifting to the next lower gear.

ENGINE PROTECTION

To disable the auto exhaust filter cleaning mode, press the Disable Auto Exhaust Filter Cleaning button.

The engine is equipped with an engine protection system. The system monitors critical engine temperatures and pressures, and logs diagnostic faults when an over or under normal condition occurs. If an out-of-range condition exists and the engine derate action is to be initiated, the operator is alerted by the amber Check

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1.

IMPORTANT: It is recommended that the exhaust filter cleaning be in the Auto mode at all times.

Auto mode should only be disabled when the machine is not in a safe location for high exhaust temperatures.

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If the machine is not able to be moved to a safe location, 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.

complete the process.

2.

Apply the park brake, and place the transmission in neutral.

3.

With the engine running at idle, press the Exhaust System Cleaning button. The engine speed may increase, the High Exhaust System Temperature (HEST) Lamp may illuminate and the Exhaust System Cleaning Lamp will flash.

4.

Monitor the machine and surrounding areas for safety. If the machine needs to be used or moved before the exhaust cleaning is completed, stop the stationary cleaning by pressing the Disable Exhaust System Cleaning button.

5.

When the Exhaust System Cleaning is complete, the engine will return to idle speed and the (HEST) and Exhaust System Cleaning Lamp will turn off.

Stationary Exhaust Filter Cleaning Stationary exhaust filter cleaning is initiated by the operator. This process allows the system to clean the SCR when the operator previously needed to disable the auto exhaust cleaning process because of specific conditions.

When a stationary exhaust cleaning is initiated by pressing the Exhaust Filter Cleaning button, the Exhaust System Cleaning Lamp will flash indicating the exhaust cleaning is in process. During this process the engine speed will be controlled by the ECU. The machine must remain parked during this process.

If the machine is not going to be returned to service immediately after the cleaning process, allow the engine and the exhaust filter time to return to normal operating temperature before stopping the engine. The stationary exhaust filter cleaning process can be canceled at any time during the process.

WARNING During auto or manual exhaust filter cleaning operations, the engine will run at elevated idle and hot temperatures for approximately 30 minutes. Exhaust gases and exhaust components reach temperatures hot enough to burn people, ignite, or melt common materials.

Avoid disabling the cleaning process unless absolutely necessary. Repeated disabling or ignoring prompts to perform a stationary cleaning procedure will cause additional engine power limitations.

Servicing the machine or attachments during exhaust filter cleaning can result in serious personal injury. Avoid exposure and skin contact with hot exhaust gases and components.

Utilize AUTO Exhaust Filter Cleaning mode to avoid additional service.

Disable Exhaust Filter Cleaning

If the machine is not in a safe location for elevated temperatures, move the machine to a safe location and check for adequate fuel level before beginning the exhaust filter cleaning process.

This indicator lamp will be illuminated when the Disable Exhaust Filter Cleaning button has been pressed. When illuminated, an automatic or stationary exhaust system cleaning can not occur. Disabling the exhaust system cleaning is not recommended. Disable the automatic exhaust system cleaning only when high exhaust temperature presents a hazard. Whenever possible, cleaning should be allowed and the exhaust system cleaning button should be left in the AUTO Mode.

When left in auto mode, soot buildup in the exhaust filter system will be at a minimum.

NOTE: It is not necessary to perform a stationary exhaust cleaning unless a previous auto cleaning process was cancelled and the Exhaust System Cleaning indicator is illuminated.

Cleaning times will vary depending upon several specific criteria. The average standard cleaning time can range from 20 - 50 minutes or longer.

To enable a stationary exhaust system cleaning; 1.

Park the machine in a safe location away from any combustible surface, and check that the machine has a recommended 1/4 tank of fuel to

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Exhaust Filter Cleaning Precautions

PARKING BRAKE

When the AUTO Exhaust Filter Cleaning is disabled, the system has 2 levels of notification to advise the operator to perform the exhaust filter cleaning. The 2 levels are as follows;

NOTE: The parking brake mechanism within the front axle is not designed for, and not intended to be used as, the primary means of stopping movement of the machine. Hydraulic braking provided through the service brakes within the axle is the primary means for stopping movement.

1.

2.

The Exhaust System Cleaning Lamp will illuminate, indicating that the exhaust system needs to be cleaned at the next opportunity. If conditions are safe, the operator should enable auto exhaust filter cleaning or perform a manual exhaust filter cleaning.

The proper sequence for correct machine operation is to always engage the parking brake switch before shutting off the engine, and to disengage the brake ONLY after the engine is running. In an emergency however, if it becomes necessary to stop movement, activate the parking brake switch to “ON.”

If an Exhaust System Cleaning is not performed in a timely manner after the Exhaust Cleaning Lamp is illuminated, the Check Engine Lamp will illuminate, and engine power will be significantly reduced. If conditions are safe, the operator should enable auto exhaust filter cleaning. If conditions are not safe, the operator should move the machine to a safe location and perform a stationary exhaust filter cleaning.

CHANGING ATTACHMENT TOOLS The Telescopic Handler boom nose will accept two types of Manitou Group attachment devices: 1.)

DynattachÒ quick-attach system, which has a quickrelease hookup and locking mechanism for mounting framing and masonry type attachment tools to the boom nose, and 2.) DynacarrierÒ quick-attach system, which has a quick-release locking mechanism that uses a single lock lever control for attaching and detaching material-handling type attachment tools.

Diesel Exhaust Fluid (DEF) Precautions

DynattachÒ System Attaching Procedure

An illuminated DEF lamp indicates the DEF level is low. The DEF lamp flashes when the DEF level falls to 10%. Fill the DEF tank completely with DEF in order to correct any fault conditions.

To pick up an attachment tool, proceed as follows:

When the DEF lamp is flashing and the Check Engine Lamp is illuminated, the DEF level has fallen to 2.5% and is critically low. If the DEF tank is not filled with DEF immediately, power will be reduced.

1.

Raise the boom slightly and extend it 600 to 900 mm (2 or 3 feet) for better visibility. Tilt the tool carrier forward.

2.

Align the tool carrier squarely with the back of the attachment tool.

3.

Slowly extend the tool carrier and lower the hooks under the attachment tool hookup bar.

When the DEF lamp is flashing and the Stop Engine Lamp is illuminated, the DEF level has fallen to 0% and the gauge reads zero. If the DEF tank is not filled with DEF immediately, power will be further reduced or limited to idle.

NOTE: It is recommended that the DEF tank be filled in order to correct any fault conditions. DO NOT overfill DEF tank especially in freezing temperatures.

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Attachment Tool

53

Dynattach® System Tilted Forward for Pick up

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4.

4.

Tilt the tool carrier back so that the lock plate engages the attachment tool. This secures the attachment tool to the Dynattach System. Verify the attachment tool is properly secured by tilting the tool sufficiently forward such that it does not hinge away from the tool carrier.

Tilt the tool carrier forward to allow the attachment tool to roll out, then lower the boom so that the hook ears clear the hookup bar on the attachment tool.

NOTE: One side of the lock plate has a bright red decal to indicate the unlocked position.

Attachment Tool Shown Locked to Quick-attach System

5.

If the attachment tool has auxiliary hydraulics, disconnect the hoses from the quick-disconnects on the boom nose.

6.

Start the engine and roll the tool carrier forward.

Slowly back the machine until the attachment tool is free from the boom nose.

Attaching Manual DynacarrierÒ Quickattach System To pick up a bucket or material handling carriage tool, proceed as follows:

Quick-attach System Attaching Detail 5.

For an attachment tool with auxiliary hydraulics, connect hoses to the quick-connect connectors on the boom nose.

1.

Rotate the lock lever completely to the left (counter-clockwise, as viewed from the operator’s station) to fully retract the lock pins.

2.

Raise the boom slightly and extend it 600 to 900 mm (2 or 3 feet) for better visibility. Tilt the tool carrier forward.

3.

Align the tool carrier squarely with the back of the attachment tool.

DynattachÒ System Detaching Procedure To detach the attachment tool, proceed as follows: 1.

Raise the boom slightly and extend it 600 to 900 mm (2 or 3 feet) for better visibility. Lower the boom until the attachment tool is approximately 300 mm (12”) off the ground.

2.

Roll back the carrier as far as it will go. When the carrier is rolled back completely, perform the MANDATORY SAFETY SHUTDOWN PROCEDURE (Safety chapter, p. 15).

3.

With the engine off, leave the operator’s station and manually raise the lock spring and flip the lock plate up and outward at least 180° so that it is in position to re-lock onto the next attachment tool.

Lock Lever in Unlocked Position

Dynacarrier® Quick-attach System

Attachment Tool Shown Unlocked for Release from Quick-attach System

Quick-attach System Detaching Detail

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4.

Slowly extend the tool carrier and tilt it forward until the support pins on each side are in-line with and slightly below the hookup ears on the back side of the attachment tool.

5.

Slowly drive the machine forward, and, at the same time, roll the tool carrier back to engage the hookup ears on the attachment tool. Also, establish proper alignment of the carrier lock pins to the attachment tool.

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6.

7.

Stop forward travel when the hookup ears are engaged, but continue to roll the tool carrier back to pick the attachment tool off the ground. When the tool carrier is rolled back completely, perform the MANDATORY SAFETY SHUTDOWN PROCEDURE (Safety chapter, p.15).

5.

With the engine off, leave the operator’s station, and swing the lock lever completely to the right (clockwise, as viewed from the operator’s station) to fully engage the lock pins.

1.

Start the engine and tilt the tool carrier forward.

Slowly back the machine until the attachment tool is free from the boom carrier.

Attaching Hydraulic-Actuated DynacarrierÒ Quick-attach System With the engine off, leave the operator’s station, and turn the circuit selector handle on the end of the boom 1/4 turn counter-clockwise to the Attachment Lock Pins position.

WARNING Circuit Selector Handle

To prevent unexpected and undesired attachment tool release from the boom carrier, be sure to properly secure the quick-release lock pins by rotating the lock lever all the way to the right or inside.

Modifications, alterations to, or use of attachment tools not authorized by Manitou Group can void the warranty and cause machine damage, and may result in serious personal injury or death.

8.

For an attachment tool with auxiliary hydraulics, connect the hoses to the quick-connect connectors on the boom nose.

2.

Raise the boom slightly and extend it 600 to 900 mm (2 or 3 feet) for better visibility and tilt the tool carrier forward.

3.

Align the tool carrier squarely with the back of the attachment tool.

4.

Slowly extend the tool carrier and tilt it forward until the support pins on each side are in-line with and slightly below the hookup ears on the back side of the attachment tool.

5.

Slowly drive the machine forward, and, at the same time:

Detaching Manual DynacarrierÒ Quickattach System To detach the attachment tool, proceed as follows: 1.

2.

3.

4.

Raise the boom slightly and extend it 600 to 900 mm (2 or 3 feet) for better visibility. Lower the boom until the attachment tool is approximately 300 mm (12”) off the ground.

a. On machines with a four-button joystick, press and hold the lower blue auxiliary hydraulic button to retract the attachment lock pins.

Roll back the tool carrier as far as it will go. When the tool carrier is rolled back completely, perform the MANDATORY SAFETY SHUTDOWN PROCEDURE (Safety chapter, p. 15).

b. On machines with a two-button joystick, press and hold the blue button on the joystick handle and then move the handle rearward to retract the attachment lock pins.

With the engine off, leave the operator’s station, and rotate the lock lever completely to the left (counter-clockwise, as viewed from the operator’s station) to fully retract the lock pins.

Roll the tool carrier back to engage the hookup ears on the attachment tool.

6.

If the attachment tool has auxiliary hydraulics, disconnect the hoses from the quick-connects on the boom nose.

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55

Stop forward travel when the hookup ears are engaged, but continue to roll the tool carrier back to pick the attachment tool off the ground. When the tool carrier is rolled back completely:

50960172/E0221

a. On machines with a four-button joystick, release the lower blue auxiliary hydraulic button and press the upper blue auxiliary hydraulic button to engage the attachment lock pins.

a. On machines with a four-button joystick, press and hold the lower blue auxiliary hydraulic button to retract the attachment lock pins, tilt the tool carrier forward.

b. On machines with a two-button joystick, press and hold the blue button on the joystick handle and then move the handle forward to engage the attachment lock pins.

b. On machines with a two-button joystick, press and hold the blue button on the joystick handle and then move the handle rearward to retract the attachment lock pins, tilt the tool carrier forward.

Perform the MANDATORY SAFETY SHUTDOWN PROCEDURE (Safety chapter, p. 15).

7.

4.

With the engine off, leave the operator’s station, and turn the circuit selector handle on the end of the boom 1/4 turn clockwise to the Auxiliary Couplers position.

SELF-LEVELING The machine has a hydraulic self-leveling feature. This feature is designed to keep the attachment tool level while the boom is being raised.

WARNING

MACHINE OPERATION WITH SOLID RUBBER TIRES

To prevent unexpected and undesired attachment tool release from the Dynacarrier® Quick-attach, be sure to turn the Circuit Selector Handle to the Auxiliary Couplers position after the lock pins are engaged to the attachment tool.

Solid rubber tires are designed for intermittent service and limited running distances. The Working Day Average Speed should not exceed 5 km/h (3 mph) at an average load of 75% of maximum capacity.

Telehandlers equipped with solid rubber tires should not be used in applications requiring speeds over 24.1 km/h (15 mph), or continuous journeys over 1 mile when loaded at or above 50% of capacity. In the event an application requires vehicle speeds over 24.1 km/h (15 mph), excessive roading, or driving extended distances while loaded, Manitou Group recommends the use of other approved tire options.

Modifications, alterations to, or use of attachment tools not authorized by Manitou Group can void the warranty and cause machine damage, and may result in serious personal injury or death.

8.

For an attachment tool with auxiliary hydraulics, connect the hoses to the quick-connect connectors on the boom nose.

WARNING

Detaching Hydraulic-Actuated DynacarrierÒ Quick-attach System

The DL12-55 telehandler must be equipped with foam filled or solid rubber tires for proper load capacity and stability.

To detach the attachment tool, proceed as follows: 1.

With the engine off, leave the operator’s station, and, if the attachment tool has auxiliary hydraulics, disconnect the hoses from the quickconnects on the boom nose .

2.

Turn the circuit selector handle on the end of the boom 1/4 turn counter-clockwise to the Attachment Lock Pins position.

3.

Use of pneumatic tires will not provide published rated capacity or stability as shown on the load chart and may contribute to a tip over resulting in death, serious injury or property damage.

GENERAL MACHINE OPERATION

While sitting in the operator’s seat, start the engine and raise the boom slightly and extend it 600 to 900 mm (2 or 3 feet) for better visibility.

Lower the boom until the attachment tool is approximately 300 mm (12”) off the ground.

50960172/E0221

Slowly back the machine until the attachment tool is free from the tool carrier. With the joystick to the neutral position, release the blue button.

Check the Telescopic Handler to be sure all systems are in good operating condition. Perform the following steps before starting the machine for the first time each day.

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Grade and Slope Precautions

WARNING

The Telescopic Handler complies with industry stability tests requirements and is stable when properly operated. However, improper operation, faulty maintenance, or poor housekeeping may contribute to a condition of instability and defeat the purpose of the standard.

Exhaust fumes can kill. Ensure proper ventilation when starting indoors or in enclosed areas.

Use proper grab handles, NOT the steering wheel or control levers as handholds when mounting or dismounting.

The amount of forward and rearward tilt to be used is governed by the application. Although use of maximum rearward tilt is allowable under certain conditions, such as traveling with the load fully lowered, the stability of the machine, as determined by the industry standard tests, does not encompass consideration for excessive tilt at high elevations, or the handling of offcenter loads.

NEVER operate the machine with safety guards or covers removed.

Over-inflated tires can explode and cause injury or death. Tire repairs MUST be made only by authorized personnel using proper tools and equipment.

1.

Check the engine oil, coolant, transmission oil and hydraulic oil levels.

2.

Make sure weekly lubrication has been done.

3.

Visually inspect for leaks, broken or malfunctioning parts. Make sure all caps, covers and safety shields are in place.

Handle only loads within the capacity limits of the machine, and that are stable and safely arranged. When attachments are used, extra care should be taken in securing, manipulating, positioning and transporting the load.

Grade Limits

Check tires for cuts, bulges, nails, correct pressure, loose wheel nuts, etc.

NOTE: Grade limits are based on ANSI/ITSDF

5.

Inspect the work area. Make sure you know where you will make load pickups, lifts, and turns. Look over the terrain of the jobsite for holes, obstacles, slippery surfaces, soft or deep mud.

6.

Check clearances of ramps, doorways and passage ways. Check overhead clearances if you will travel and place loads near power or telephone lines or other obstructions.

7.

When traveling unloaded, tilt forks back and elevate boom as low as possible to obtain visibility around the machine.

The telescopic handler meets or exceeds the safety standard (ANSI/ITSDF B56.6-2016) stability limits for rough-terrain forklifts. The stability tipping limits cover specific, controlled test conditions, which are extremes, and which are not intended to be achieved during normal worksite operations. The following specifications are provided only as information to the operator, and must not be used as a guideline for operating the Telescopic Handler. For safe operation, always follow the instructions and warnings provided in this manual.

4.

standard B56.6-2016.

WARNING

If the machine is found to be in need of repair or in any way unsafe, or contributes to an unsafe condition, the matter shall be reported immediately to the user’s designated authority. The machine must NOT be operated until it has been restored to a safe operating condition.

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

Operate the travel controls gradually and smoothly when starting, stopping, turning and reversing the directions.

1.

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DO NOT place or retrieve loads on a up or down slope or grade that exceeds 7% or 4o grade.

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2.

DO NOT travel up or down a grade or slope that exceeds 22% or 12o grade while loaded.

3.

DO NOT place or retrieve loads on a side hill with a slope or grade that exceeds 12% or 7o grade.

Regardless of the terrain or position of the wheels, the FRAME MUST BE LEVEL, as indicated by the frame angle indicator on the ROPS crossmember.

4.

DO NOT travel across a side hill that exceeds 18% or 10o grade. Regardless of the terrain or position of the wheels, the FRAME MUST BE LEVEL, as indicated by the frame angle indicator on the ROPS crossmember. The attachment tool MUST be maintained at the “carry” position, with the boom fully retracted, and attachment tool at minimum ground clearance.

When ascending or descending grades in excess of 5% or 3o, the machine should be driven with the load upgrade. An unloaded machine should be operated on all forward grades with the load handling attachment tool downgrade, tilted back if applicable, and raised only as far as necessary to clear the road surface. Avoid turning if possible and use extreme caution on grades, ramps or inclines. Normally travel straight up and down.

Traffic Flow Patterns For safety, know and understand the traffic flow patterns of your jobsite and the Telescopic Handler hand signals. Use signal persons and make sure you can see the signal person and acknowledge the signals given.

Refer to the safety hand signal illustrations.

The backup alarm automatically sounds when the travel lever is in Reverse. Care should be taken when down shifting or reversing because damage to the transmission can occur if shifting is forced or attempted while traveling.

Safety Hand Signals

When ramps must be used in transporting loads with the machine, the following shall be the minimum widths for safe travel: Compacted dirt, gravel, etc. - 3.6 m (12 ft.)

Woodboard, concrete, etc. - 3 m (10 ft.)

Permanent aisles, roadways, passageways, floors and ramps should be marked or defined in some fashion.

Permanent or temporary protrusion of loads, equipment, material and construction facilities into the usual operating area should be guarded, clearly and distinctively marked, or clearly visible.

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Maintain a safe distance from the edge of ramps, platforms and other similar working surfaces.

ALWAYS maintain a safe distance from electric power lines and avoid contact with any electrically charged conductor and gas line. It is not necessary to make direct contact with a power line for power to ground through the structure of the machine. Keep the boom and load at least 3 m (10 ft.) from all power lines.

Accidental contact with a power line or rupture of a gas line can result in electrocution or an explosion. Contact the “Call Before You Dig” referral system number at 8-1-1 in the U.S., or 888-258-0808 in the U.S. and Canada, to locate any underground utility lines BEFORE starting to dig.

Controlled lighting of adequate intensity should be provided in operating areas. Where operating conditions indicate, the operator/user is responsible for having the machine equipped with lights.

Provision should be made to prevent trucks, semi-trailers and railroad cars from being moved during loading and unloading. Wheel stops, parking brakes, or other positive means should be used to prevent movement during loading and unloading.

DO NOT move railroad cars or trailers with the Telescopic Handler.

Keep all body parts inside the operator’s station while operating the machine. BE SURE of clearance for the attachment tool when turning, working around buildings, etc.

Do not use the travel drive and/or extend or retract the boom to push or pull a load or object.

DO NOT use the boom and attachment for leverage to push the machine out of mud.

Turning corners too fast can tip the machine, or cause a load to tip off the attachment.

Sudden slowing or stopping of the machine may cause the load to fall off the attachment tool.

IMPORTANT: DO NOT lower boom at high engine speed when attachment tool is at maximum rearward tilt. Damage to slave cylinders may result.

Be certain you can control both speed and direction before moving. Always place the machine in neutral and set the parking brake before raising or extending the boom. NEVER drive the machine up to someone standing in front of the load.

GENERAL LOAD HANDLING NEVER attempt to work controls except from the operator’s seat. NEVER jerk or use fast movements.

Avoid sudden 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 control a small amount away from neutral. Then, after movement has started, the control can be eased to full movement. Use the same feathering technique to stop the motion.

NEVER leave the operator’s station without first lowering the attachment tool to the ground. Set the parking brake, place controls 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

WARNING

The machine has flip-charts in the operator’s station that provide, at a glance, the capacity limits at various positions of attachment tool extension and elevation. A set of the load zone charts is reproduced at the end of this manual for reference.

Excessive speed can be hazardous. ALWAYS exercise caution and good judgement while operating the machine.

The Mandatory Work Platform Safety Rules must be adhered to at all times while elevating personnel.

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A typical load zone chart is shown on this page. The scale on the left indicates height in feet above the ground level. The scale on the bottom shows the distance in feet from the front of the machine. The arc lines noted by the numbers “1” through “5” correspond with the position extension markers on the operator side of the intermediate boom section.

WARNING NEVER exceed the rated operating capacity of the Telescopic Handler as shown on the load zone charts.

HANDLING NON-SUSPENDED LOADS

The following example illustrates proper use of the load zone charts for the Telescopic Handler:

Picking Up the Load Inspect the load. If it appears unstable, DO NOT attempt to move it. DO NOT attempt lifting doubletiered loads, or straddling side-by-side pallets with one on each fork. NEVER add extra unauthorized counterweights to this machine. Consider the additional weight of any attachment tool as part of the picking load capacity of the machine.

HEIGHT ABOVE GROUND

BOOM EXTENSION MARKERS

WARNING Operating conditions such as slopes or soft ground can reduce the machines safe operating capacity. Exceeding the capacity when raising or extending the boom will cause the machine to tip forward.

Approach the load slowly and squarely with the machine straight and level. Adjust the space between forks, if necessary. Engage the load equally on both forks until the load touches the carriage backrest. Tilt the forks back to position the load for travel.

DISTANCE LOAD IS EXTENDED

Typical Load Zone Chart Carrying the Load

Example: The operator, using a standard carriage attachment tool without outriggers, wants to raise a 3000 lb. load 20 feet high, and can only get to within 15 feet of the load placement point. Can this be done within the capacity of the machine?

If the load obstructs your view, get someone to direct you. Maintain ground speeds consistent with ground conditions and that permit stopping in a safe manner.

Analysis: See “Typical Load Zone Chart”.

Projecting up from the 15-foot reach mark on the horizontal axis to intersect a line through the 20-foot height mark on the vertical axis shows that up to a 4000 lb. load can be placed in that zone.

During placement, the operator should observe when the arc reference number “4” on the boom is visible and stop. The operator knows the maximum safe extension distance with the 4000 lb. load has been reached.

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An optional boom mounted hook is available for handling suspended loads. Contact your Manitou Group dealer.

WARNING NEVER travel with the boom above the carry position (attachment tool should be at minimum ground clearance). Boom should be fully retracted.

Use lower gears when traveling down an incline. NEVER coast with the transmission in neutral. Travel up and down grades slowly.

Boom Mounted Hook

DO NOT operate the machine on a slope or grade that exceeds 22% or 12o.

Load Elevation and Placement For ground level load placement, be sure the area under the load and around the machine is clear of equipment and personnel. Lower the load to the ground, tilt the forks to the horizontal position, and then carefully back away to disengage the forks from the load.

NOTE: Refer to the standard carriage load chart when using the boom mounted hook.

WARNING NEVER exceed the rated operating capacity of the telehandler as shown on the load zone charts.

For elevated or overhead placement, bring the machine as close as possible to the landing point, and then: 1.

Level the machine BEFORE raising the load. Use extreme caution for high placement. Be sure personnel are clear of the area where the load or the machine could fall or tip.

2.

Set the parking brake, shift the transmission into neutral, hold the service brake pedal fully applied and slowly raise the load, maintaining a slight rearward tilt to cradle the load.

3.

As the load approaches the desired height, feather the boom control at minimum speed until the load is slightly higher than the landing point.

WARNING Operating conditions can reduce the telehandler’s safe operating capacity. Exceeding the capacity when raising or extending the boom will cause the telehandler to tip forward.

Picking Up Suspended Load 1.

Rigging should be in good condition and rated for the load being lifted.

2.

Rigging should comply with OSHA regulation §1910.184, “Slings,” or §1926.251, “Rigging equipment for material handling.”

3.

Be sure the rigging equipment is clear of any part of the machine or machine attachment before lifting the load.

HANDLING SUSPENDED LOADS

4.

Avoid lifting any double-tiered or unstable loads.

Determine the weight and apply proper rigging technique for the load being handled. Refer to the telehandler load chart to determine if the load can safely be handled.

5.

Only lift loads vertically and clear from any adjacent obstacles. Never drag the load horizontally.

6.

Use multiple lift points and taglines to restrain the load from swinging or rotating.

4.

Continuing the feathering technique, lower the load into place.

5.

Free the forks from the load by alternately retracting 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.

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is just above the landing point.

Carrying Suspended Load 5.

With the assistance of a signal person, continue the feathering technique to lower the load into

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

1.

Rigging between the load and attachment should be as short as possible to reduce boom height.

2.

Do not raise the load more than 305 mm (12 inches) above the ground or raise the boom more than 45 degrees.

3.

All telehandler movements should be performed slowly and cautiously to prevent load swing.

Avoid abrupt movement. Do not exceed walking speed.

4.

place.

Use a signal person anytime the load restricts the operators view or assistance is required. The signal person should remain in contact (verbally or visually) with the operator at all times until the load is placed.

Be sure the area under the load and around the telehandler is clear of equipment and personnel.

2.

Lower the load to the ground till load is stationary and the rigging is loose from the load. Have the signal person disconnect the rigging from the load.

3.

Once the load is stationary on the landing point and the rigging is loose from the load, have the signal person disconnect the rigging from the load.

7.

Raise the boom enough to clear the rigging from the load. Slowly and carefully, reverse the telehandler until the rigging is clear of the load.

8.

Lower the boom to travel height.

Installing a Personnel Work Platform

WARNING

Ground Level Suspended Load Placement 1.

6.

The machine must not be used to lift or carry personnel or be fitted with any form of personnel work platform unless fitted with the optional PWP System.

If fitted with the PWP System, the Mandatory Work Platform Safety Rules (p. 22) must be followed at all times while lifting personnel.

Raise the boom enough to clear the rigging from the load before backing the telehandler away from the load.

(PWP) 1.

Center the forks on the carriage, spaced apart to match the distance required to engage the PWP.

2.

After the forks are fully engaged in the PWP, secure the PWP to the forks. This can be accomplished by means of a retaining pin behind the heel of the forks as shown.

Elevated Suspended Load Placement 1.

Bring the telehandler as close as possible to the landing point.

2.

Level the telehandler BEFORE raising the load.

Use extreme caution for high placement. Be sure personnel are clear of the load landing area.

3.

Set the parking brake, shift the transmission into neutral, hold the service brake pedal fully applied, and slowly raise the load.

4.

As the load approaches the landing point, feather the boom control at minimum speed until the load

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Retaining Pin

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3.

Secure the forks from pivoting upward in case the PWP is lowered onto an obstruction. This can be 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.

PWP Remote Shutdown Switch

Chain

6.

WARNING

Wireless Remote Shutdown Switch on DL11-55 and DL12-55 Models Secure the lanyard from the body harness to the PWP (or the boom). Each person in the PWP must have a body harness with a lanyard attached to the PWP (or the boom).

Lifting Personnel

The PWP must meet ANSI/ITSDF B56.6-2016, Section 8.24. (See page 24 in the Safety chapter for PWP design requirements.) If the PWP being used does not offer means to secure the PWP to the forks and to secure the forks from pivoting, as shown in steps 2 and 3, then an alternate method must be used.

The Telescopic Handler is primarily intended for use as a material handler. It should only be used to lift personnel if it is equipped with the (optional) PWP System when there is no other practical option. If this machine is to be used to lift personnel, then use only an approved work platform, lift personnel only with the PWP System activated, and follow the “Mandatory Work Platform Safety Rules” (Safety chapter, p. 22).

4.

If the Telescopic Handler is equipped with a PWP System and is to be used for lifting personnel, the system must be activated, by the “PWP System” mode switch, which is located in the left switch bank. To activate the system, press the top of the PWP rocker switch, apply and hold the service brakes on for three or more seconds. The system is activated when the lamp in the PWP rocker switch is on continuously.

On the DL12-40 and DL11-44 models, connect the coiled wire from the remote shutdown switch to the connector on the end of the boom. Secure the remote shutdown switch to the PWP using the strap attached to the switch, as shown.

Electrical Connection

NOTE: If the light is flashing, apply the service brakes until the light stops flashing.

PWP Remote Shutdown Switch

WARNING ALWAYS check the PWP System for proper operation prior to use. (See page 75 for PWP System checking procedure.)

Remote Shutdown Switch with Coiled Wire Connector on DL12-40 and DL11-44 Models 5.

On the DL12-55 and DL11-55 models, the remote shutdown switch is wireless-operated. Secure the remote shutdown switch to the PWP using the strap attached to the switch, as shown.

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When the PWP System is active:

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transmission is de-clutched into Neutral,

l

parking brake is applied,

l

rear axle stabilizer cylinder is locked,

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frame leveling speed is reduced,

l

auxiliary hydraulic and carriage tilt and swing functions are disabled,

l

machine inclination sensor is activated, with the result that the Telescopic Handler must be level laterally (side-to-side) and longitudinally (front-to-back) to the factory pre-set limits before the boom control joystick will function, and

l

l

emergency. Otherwise, the PWP System must be used at all times when there are workers on the platform. This is the only exception!

Stabilizer System This is an additional safety function while elevating loads for placement. At a pre-determined boom angle, the stabilizer cylinder on the rear axle will lock up.

When this happens, the parking brake activates and the frame leveling function slows down. Other than moving the boom and slowly leveling the frame, the machine will not be able to move until the boom is lowered below the pre-determined angle.

For DL12-40 and DL11-44 models, remote shutdown switch is activated, meaning that the switch must be connected and in the “on” position for the boom control joystick to function. Pressing the red button will disengage the boom control joystick, and stop all platform movement. The remote shutdown switch box is supplied with a coiled electrical cable, which must be connected to the outlet on the front of the innermost boom section near the carriage. The switch must be accessible to the platform personnel at all times when the platform is to be moved.

WARNING The machine becomes less stable as the load is raised higher.

NEVER use frame leveling to position an elevated load. Always lower the load to the ground and reposition the machine.

For DL12-55 and DL11-55 models, remote shutdown switch is activated, meaning that the switch must be “on” for the boom control joystick to function. Pressing the red button will disengage the boom control joystick and stop all platform movement. The remote shutdown switch box is a wireless remote control, so there is no direct connection to the Telescopic Handler. The switch must be accessible to the platform personnel at all times when the platform is to be moved.

If a hydraulic boom circuit hose should break with the boom up, shut down the machine. DO NOT attempt to bring down the boom or make repairs. Call your Manitou Group dealer immediately.

As lift height increases, depth perception decreases. High elevation placement may require a signal person to guide the operator.

To de-activate the PWP system, apply the service brakes and press the bottom of the PWP System rocker switch. The system is de-activated when the lamp in the PWP System rocker switch is off.

DO NOT ram the lift cylinders to the end of the stroke. The resulting jolt could spill the load.

A jib or truss boom should ONLY be used to lift and place loads when the machine is stationary and the frame is level. Transporting suspended loads must ALWAYS be done slowly and cautiously, with the boom and load as low as possible. Use taglines to restrict loads from swinging, to avoid overturn.

NOTE: If the lamp in the PWP System rocker switch is flashing, apply the service brakes until the lamp goes off.

WARNING In an emergency, if the platform worker has activated the remote shut-off switch and then is not able to re-activate the switch, such as if the worker fainted, then the Telescopic Handler operator is permitted to turn off the PWP System to regain control of the boom functions, in order to lower the work platform and come to the aid of the worker. But, understand this is only permitted in case of an

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MATERIAL HANDLING BUCKET TOOL APPLICATION IMPORTANT: The DL11-55 and DL12-55 models are not intended for ground or material pile engagement. The bucket should be used for lightduty site cleanup only.

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Material Densities

Digging Loose Materials

The table shown lists densities for some common materials that could be carried in a Telescopic Handler bucket tool. The densities listed are average values and intended only as a guide.

Table of Common Materials & Densities Material

Density in (kg/m3)

Density in (lb/yd3)

Ashes Brick-common Cement Charcoal Clay

560-800 1795 1760 370 1280-1600

945-1350 3024 2970 621 2160-2700

Coal Concrete Cinders Coal-anthracite Coke

850-1010 1840 800 1505 480

1431-1701 3105 1350 2538 810

Earth-dry loam Earth-wet loam Granite Gravel-dry Gravel-wet

480 1040 1490-1780 1060 1440

810 1755 2511-2997 1782 2430

Gypsum-crushed Iron Ore Lime Limestone

1840 2320 960 1440

3105 3915 1620 2430

Manure-liquid Manure-solid Peat-solid Phosphate-granular Potash Quartz-granular

1040 720 755 1440 1090 1760

1755 1215 1269 2430 1836 2970

Salt-dry Salt-Rock-solid Sand-dry Sand-wet Sand-foundry

1600 2160 1730 2000 1520

2700 3645 2916 3375 2565

Shale-crushed Slag-crushed Snow Sulpha Taconite

1440 1120 240-800 1520 1715

2430 1890 405-1350 2565 2889

Digging Hard-Packed Materials

Loading Bucket

Carrying Load

Digging, Loading and Carrying Material IMPORTANT: ALWAYS fully retract the boom before driving into material.

NOTE: When attempting to fill the bucket while working with most hard-packed materials, it will usually be necessary to raise the boom while rolling back the bucket.

When the bucket is filled, back the machine away from the material and roll back the bucket before proceeding to the dumping area.

Digging and Loading Refer to the illustration on this page. Retract and lower the boom, then tilt the bucket’s cutting edge down into contact with the ground. Drive the bucket into the material. As the engine loads, roll the bucket back slowly and, at the same time, decrease travel speed.

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Dumping the Load onto a Pile

Leveling with a Bucket

Carry the loaded bucket as low as possible until reaching the pile. Slowly stop forward motion, then raise and extend the boom high enough so that the bucket clears the top of the pile. Then slowly move the machine ahead to position the bucket, and dump the material on top of the pile. Empty the bucket. Back the machine away while retracting and lowering the boom, and rolling back the bucket.

First, drive the machine to the outer edge of the area to be leveled. Then, with the boom retracted and down, tilt the bucket forward to place the bucket cutting edge at a 30- to 45-degree angle to the surface being leveled.

Next, drive the machine rearward while feathering the boom control joystick, dragging the dirt and, at the same time, leveling it.

Positioning Bucket for Scraping

Dumping the Load into a Truck Carry the loaded bucket low and approach the truck or trailer box, square with the side of the box. Stop as close to the side of the box as possible while still allowing clearance for raising and extending the boom.

Raise and extend the boom until the bucket clears the top of the box, and slowly position the bucket over the inside of the box. Then tilt the bucket forward. After the material is dumped, slowly back away from the box, and then retract and lower the boom while rolling back the bucket.

Scraping with Bucket

Dumping the Load over an Embankment Carry the loaded bucket as low as possible while slowly traveling toward the dumping area. Stop the machine at the position where the bucket extends halfway over the edge of the embankment. Then tilt the bucket forward, and raise and extend the boom to dump the material. After the material is dumped, slowly back away from the embankment while retracting and lowering the boom, and then rolling back the bucket.

Leveling with Bucket

Scraping and Leveling with Bucket

ROAD TRAVEL

WARNING

For short distance highway travel, attach a SlowMoving Vehicle (SMV) emblem (purchased locally) to the back of the Telescopic Handler. Activate the hazard lights on the machine. For highway operation, obtain and install an amber flashing beacon.

ALWAYS carry a loaded bucket as close to the ground as possible. For additional stability when operating on inclines, ALWAYS travel with bucket end of the machine toward the top of the incline.

NOTE: ALWAYS follow ALL state and local regulations regarding the operation of equipment on or across public highways. Whenever there is an appreciable distance between jobsites, or if driving on public highways is prohibited, transport the machine using a vehicle of appropriate size and capacity.

Scraping with a Bucket Refer to the illustration. For scraping, the machine should be operated in the forward direction. First, position the boom retracted and down. Next tilt the bucket cutting edge forward at a slight angle. Then travel slowly forward. With the bucket in this position, material can flow over the cutting edge and collect inside the bucket.

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TRANSPORTING BETWEEN JOBSITES When transporting the Telescopic Handler, know the overall height to allow for clearance of obstructions.

Remove or tape over the Slow-Moving Vehicle (SMV) emblem if it will be visible to traffic.

ALWAYS abide by the following recommended procedures and guidelines when using ramps to load the machine onto (or unload it from) a truck or trailer.

Failure to heed can result in damage to equipment and serious personal injury or death!

4.

Ramp width MUST be at least 1-1/2 times the tire width.

5.

Block the front and rear of the tires on the truck or trailer. Engage the parking brake.

6.

Position the machine (with the boom facing toward the front of the truck or trailer) so that it is straight in line with the ramps.

7.

Slowly (at the lowest engine speed possible) and carefully drive the machine up the ramps.

8.

Secure the machine to the bed of the truck or trailer. Tie-down slots are provided on the front and rear sides of the frame structure.

Tie-down holes are provided for inserting chains through to secure the machine while transporting.

WARNING Front Tie-Down

NEVER adjust travel direction (even slightly) while traveling on the ramps. Instead, back down off the ramps, and then realign the machine with the ramps.

Rear Tie-Down

Loading Machine Using Ramps

NOTE: A matched pair of ramps is required.

TRUCK BED AND TOP OF RAMP MUST BE EVEN

TIRE BLOCKING (FRONT AND BACK)

WARNING

MINIMUM RAMP LENGTH MUST BE 3.9 TIMES HEIGHT

STURDY CENTER SUPPORT

NEVER transport the machine with the boom raised or extended. BE SURE to secure the machine to the truck or trailer bed using chains and binders or steel cables, to prevent any movement while transporting.

Unloading Machine Using Ramps

LESS THAN 15°

NOTE: A matched pair of ramps is required.

Repeat steps 1 through 5 and proceed as follows to unload the machine:

Ramp Placement 1.

The ramps MUST be of sufficient strength to support the machine. The use of strong steel ramps is recommended, as well as center supporting blocks.

2.

The ramps MUST be firmly attached to the truck or trailer bed with NO step between the bed and the ramps.

3.

The incline of the ramps MUST be less than 15 degrees (ramp length MUST be at least 4.9 m (16 feet) long).

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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.

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The camera image is displayed on the monitor located on the left side of the dash.

REAR CAMERA and REVERSE RADAR SYSTEMS (Optional)

To adjust the monitor vertical viewing angle, loosen the four knobs located on both side of the monitor.

Tighten the four knobs after the monitor vertical viewing angle is adjusted. Prior to operating the machine, the operator should check the monitor to verify that the monitor is positioned at the optimum viewing angle for them.

These optional systems are available on the DL Series telehandler to aid operators in the operation of the telehandler.

WARNING The rear camera and reverse radar systems are offered as an option and are not required for machine operation. The Manitou Group DL Series telehandler features frame designs with through-frame operator sight lines to the rear of the machine.

These optional systems are offered as a supplement to aid operators. However, operators remain responsible for checking the travel path for obstructions or hazards before moving the telehandler in that path

IMPORTANT: Always keep the camera lens and monitor viewing surface clean for a bright and clear image.

Reverse Radar System The reverse radar system is an optional addition to the rear camera system. It consists of the preview sentry (3) mounted at the rear of the machine, and the radar display (4) mounted on the left side of the viewing monitor (2).

3

Rear Camera System The rear camera system consists of the camera (1) and the viewing monitor (2).

4

2

Reverse Radar Preview Sentry and Radar Display

1

The reverse radar system provides an audible and visual indication of objects to the rear of the machine.

2

Rear Camera and Monitor The rear camera system provides a view of the area directly behind the machine.

WARNING Always use mirrors and look to the rear of the machine before and during backing. Clear any people or obstruction from your path before backing. Rear camera and reverse radar systems are for supplementary use only.

The rear camera system is activated any time the machine is running or the ignition key is in the "ON" position.

NOTE: The travel selector switch does not need to be in "REVERSE" for the camera to be activated.

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Reverse Radar Operation

THEFT DETERRENTS Manitou Group has recorded all major component part numbers and serial numbers. Users should take as many of the following actions as possible to discourage theft, to aid in the recovery in the event that the machine 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 vehicle storage yard. If possible, keep machines in well-lighted areas. Ask the local law enforcement agency to make frequent checks around the storage 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 serial numbers.

Request that your dealer forward this information to Manitou.

Reverse Radar Visual Indication When the engine is running or the ignition key is in the "ON" position and the travel selector is in the reverse position, the following will occur: l

The reverse radar system will activate.

l

If an object is detected within the reverse radar system coverage area the audible alarm will sound.

l

A visual indicator will appear in the right side of the multi-function display.

IMPORTANT: The reverse radar system covers an area 4.57m (15') back and 3.05m (10') wide to the rear of the machine. l

If 5 bars are shown in the display, the detected object is less than 4.57m (15') behind the machine.

NOTE: Each bar shown on the multi-function display represents .91m (3') from the back of the machine. For example, if 3 bars are shown, the object is less than 2.75m (9') behind the machine.

If zero bars are shown, the reverse radar coverage area is clear of obstructions. l

The closer the obstruction is to the rear of the machine, the fewer bars will show in the multifunction display and the audible alarm will sound more frequently.

l

The operator should take steps to avoid the object, or perform the "Mandatory Safety Shutdown Procedure" and clear the obstruction from the travel path before proceding.

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INTENTIONALLY BLANK

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Chapter 7 LUBRICATION GENERAL INFORMATION

Hydraulic System Reservoir Use Mobil DTE 15M, or an equivalent that contains anti-rust, anti-foam and anti-oxidation additives and conforms to ISO VG46/VG32.

Capacity: 170 L (45 gls.)

WARNING NEVER lubricate or service this unit when any part of the machine is in motion. ALWAYS exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (SAFETY chapter, p. 15) before lubricating or servicing this equipment.

Engine Crankcase Oil Ambient Temperature -40°F - 32°F (-40°C - 0°C) 5°F - 131°F (-15°C - 55°C)

Grade* SAE 0W-30 SAE 5W-40

*API Service Classification: CJ-4 *API Service Classification for first 100 hours on new or rebuilt Cummins engines: CJ-4

NOTE: The MAINTENANCE chapter in this manual has provisions for recording the dates and hourmeter readings after lubrication or other service has been performed; use those spaces to keep a log for maintaining a current service interval record. Proper routine lubrication is an important factor in preventing excessive part wear and early failure.

Capacity: 14.7 L (15.5 qts.)

Diesel Fuel IMPORTANT: Use ONLY ultra low sulfur diesel (ULSD) fuel with a maximum of 15 PPM sulfur content specified to EN590 or ASTM D975. Fuel Tank Capacity: 114 L (30 gls.)

LUBRICANTS

Diesel Exhaust Fluid (DEF) Must meet ISO 22241-1 or DIN 70070 standards. DEF Tank Capacity: 11.4 L (3 gls.)

The chart on this page lists the locations, temperature ranges and types of recommended lubricants to be used when servicing the machine. Refer to the separate engine manual for additional information regarding recommended engine lubricant, fuel and coolant quantities and grades required.

Engine Coolant IMPORTANT: Use a ethylene glycol based Extended Life Coolant and quality water mixture suitable for heavy duty diesel engines.

Coolant should be a phosphate-free, silicate-free, nitrite-free and borate-free formula with corrosion inhibitors to provide wet sleeve liner cavitation and corrosion protection of all cooling system metals.

Factory filled with (recommended): FINAL CHARGE 50/50 PRE-DILUTED Global Extended Life Coolant/Antifreeze.

NOTE: Refer to Operator Services topic in the Service and Storage chapter of this manual for detailed information regarding periodic checking and replenishing of lubricants.

Transmission Oil Use Multi-ATF Dexron® III or equivalent Capacity: 12.9 Liters (13.75 qts.)

Axle Gear Oil MobilFluid® 424 (recommended) CHS Cenex Qwiklift HTB or equivalent Front Differential Capacity: 13 L (13.75 qts.)

Front Planetary Capacity: 1.9 L each (2 qts.)

Rear Differential Capacity: 15 L (15.8 qts.)

Rear Planetary Capacity: 1.9 L each (2 qts.)

Transfer Case Use SAE 40W motor oil.

Capacity: 2.8 L (3 qts.)

Brake System Uses hydraulic system oil.

All Grease Fittings Use No. 2 lithium-based grease

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13. For DynattachÒ System Only Carrier Pivot Pin (1 ea.)

FILTER REFERENCE CHART TYPE

PART NUMBER

Engine Oil

50220837

Engine Fuel

Primary 50220838

Air Filter

13

For DynacarrierÒ System Only Carrier Pivot Pin Attachment Tool Release Pins (3 ea.)

- Not shown

Water Separator 50309433

14. Boom Slide Pads (as necessary)

Primary 50220831

15. Wheel Spindle Pins (4 per axle)

Secondary 50220832 DEF Module Filter 50220851 Hydraulic Return

L99459

Hydraulic Strainer L69358 Transmission Oil

L99184

Cab Ventilation

101843 1

GREASING Refer to the illustration and listing on the next page for fitting locations. Wipe dirt from the fittings before greasing them to prevent contamination. Replace any missing or damaged fittings. To minimize dirt buildup, avoid excessive greasing.

2

BASIC MACHINE GREASE FITTING LOCATIONS Every 50 Hours (or weekly) Refer to the illustrations for locations.

1.

Tilt Cylinder Pins (2 ea.)

2.

Frame Leveling Cylinder Pins (2 ea.)

3.

Stabilizing Cylinder Pins (3 ea.)

4.

Lift Cylinder Pivot Pins (4 ea.)

5.

Slave Cylinder Pivot Pins (4 ea.)

6.

Boom Pivot Pins (2 ea.)

7.

Extend Cylinder Pivot Pin (1 ea. )

8.

Boom Sheave Pins (2 ea.)

9.

Axle Pivot Trunions (2 per axle.)

3 15

4

10. Outrigger Pad (2 per pad) 11. Outrigger Cylinder (2 per cylinder) 12. Outrigger Leg Pivot (1 per leg)

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6

5 9

8 13 7 12 11 Three-Section Boom

8

10

13

Four-Section Boom

7 8 14 14

Four-Section Boom

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Chapter 8 SERVICE AND STORAGE When a problem occurs, don’t overlook simple causes such as an empty fuel tank. Check for leaks and broken connections. Make note of any specific problem symptoms, noises, etc. and contact your local Manitou Group dealer.

GENERAL INFORMATION

WARNING BEFORE performing any service on the Telescopic Handler, unless expressly instructed to the contrary, exercise the MANDATORY SAFETY SHUTDOWN PROCEDURE (Safety chapter, p. 15). After service has been performed, BE SURE to restore all guards, shields and covers to their original positions BEFORE resuming machine operation.

IMPORTANT: Always dispose of waste lubricating oils, anti-freeze and hydraulic fluids according to local regulations or take them to a recycling center for disposal. DO NOT pour them onto the ground or into a drain.

DEALER SERVICES The following areas of internal components service replacement and operating adjustments should only be attempted by (or under the direction of) an authorized Manitou Group Telescopic Handler dealer.

NOTE: All service routines, with the exception of those described under the “Dealer Services” topic, are owner-operator responsibilities. All operator services described under the subtopics are also referred to on a decal located inside the small rear access door of the operator’s station.

Refer to the Lubrication chapter of this manual for lubrication information.

IMPORTANT: DO NOT service or repair major components, unless authorized to do so by your Manitou Group dealer. Any unauthorized repair will void the warranty.

Powertrain Components The engine and transmission are coupled together with a transfer case. All service routines related to the internal components are precise and critical to proper powertrain operation. The axle differential and planetary ends are also sophisticated assemblies that require special know-how and tools for servicing.

NOTE: This Service and Storage chapter details procedures to follow for making routine maintenance checks, adjustments and replacements.

The majority of the procedures are also referred to in the Maintenance chapter of this manual. For engine-related adjustments and servicing procedures, refer to the engine manual provided.

IMPORTANT: If any area of powertrain componentry is suspected of faulty operation, contact your Manitou Group dealer for further assistance.

PRECAUTIONS DO NOT perform any maintenance or repair without the owner’s prior authorization. Allow only trained personnel to service the machine.

Hydraulic System Components Valves, pumps, motors and cylinders are sophisticated assemblies, which require special know-how and tools for servicing. All cylinders are appropriately designed with particular strokes, diameters, checks and hose connection provisions unique to the machine application requirements. A hydraulic schematic (located at the back of this manual) can be used as a guide for service reference, as required.

Warranty repairs can only be done by a Manitou Group dealer. Dealers know what portions of the machine are covered under the terms of the Manitou Group Warranty and what portions are covered by other vendor warranties.

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Warranty repairs can only be done by a Manitou Group dealer.

WARNING

Electrical Components

Tilt, lift, extend, and leveling cylinders have counterbalance valves. These valves keep hydraulic fluid from entering or exiting the cylinders while not being used, and are under extremely high pressure. Before removing any of these valves, it is REQUIRED to call the Manitou Group Service Department. Failure to do so may result in serious injury or death.

An electrical system schematic is provided, which includes instrumentation, electrical components and switch connections. It is located at the back of this manual and can be used as a guide for service reference, as required.

OPERATOR SERVICES Some of the operator-related services will require access to components located inside the superstructure under shields, hoods and covers. The chart on this page notes 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 Group Telescopic Handler dealer.

ACCESS TO COMPONENTS CHART Component

Operator Station

Frame

Mid-Top Cover

Rt. Side Hood

l

Axle (underside)

l

Engine Transmission

l

Transfer Case

l

Drive Shafts

l

Solenoid Valves (rear & middle)

l

Main Control Valve (rear)

l

l

l

Engine Exhaust Filter (front) l

Air Cleaner (rear) Battery

l

Radiator

l

Brake Valve (dash area)

l

Travel Controls (dash area)

l

Boom Controls (right side)

l l

Hydraulic Test Ports (pump) Hourmeter

l

Electric Switches (dash area)

l

Electric Switches (right side)

l l

Hydraulic Pump Hydraulic Reservoir (underside)

l

Fuel Tank (underside)

l

Fuse Box (rear)

l l

Hydraulic Filter (underside)

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Block the tires. Turn off the master disconnect switch to shut off power from the battery, and remove the ignition key. Remove only guards or covers that provide needed access. Wipe away excess grease and oil.

WARNING DO NOT smoke or allow any open flames in the area while checking or servicing hydraulic, battery or fuel systems; all contain highly flammable liquids or explosive gases, which can cause an explosion or fire if ignited.

Excessively worn or damaged parts can fail and cause injury or death. Replace any cracked or damaged parts.

Care should be taken to assure that all replacement parts are interchangeable with original parts and of equal quality. Use only genuine Manitou Group parts for service.

Wear a face shield when disassembling spring-loaded components or working with battery acid. Wear a helmet or goggles with special lenses when welding or cutting with a torch.

Use care not to damage machined and polished surfaces. Clean or replace all plates and decals that are damaged or painted over and cannot be read.

When working beneath a raised machine, always use blocks, jack-stands or other rigid and stable supports. Wear appropriate protective clothing, gloves, and shoes. Keep feet, clothing, hands and hair away from moving parts.

WARNING NEVER leave guards off or access doors open when the machine is unattended. Keep bystanders away if access doors are open.

Always wear safety glasses or goggles for eye protection from electric arcs from shorts, fluids under pressure, and flying debris or loose material when the engine is running or tools are used for grinding or pounding.

After servicing, check the work performed, no parts left over, etc. Install all guards, covers, and turn on the master disconnect switch to activate battery power.

NEVER weld on bucket, forks, boom, support frame or ROPS/FOPS without the consent of the manufacturer. These components may be made with metals that require special welding techniques, or with designs that do not allow weld repairs. NEVER cut or weld on fuel lines or tanks.

Service Every 10 Hours or Daily

CHECK FUEL and DIESEL EXHAUST FLUID LEVELS The fuel and diesel exhaust Fuel Fill fluid level is shown on there respective level gauge on the instrument panel. After operation each day, the fuel tank should be filled to prevent water from condensing in the tank.

Diesel exhaust fluid should DEF Fill be added if it is low. Engine power will be reduced if the level is allowed to drop to low. See the Lubrication chapter for the diesel fuel and diesel exhaust fluid requirements.

If repair welding is ever required, BE SURE to attach the ground (-) cable from the welder as close as possible to the area to be repaired.

Disconnect the positive (+) and negative (-) cables from the battery. Disconnect the connectors to the Electronic Control Module (ECM).

Choose a clean, level work area. Be sure there is sufficient room, clearances, and adequate ventilation.

Clean the walking and working surfaces. Remove oil, grease and water to eliminate slippery areas. Use sand or oil absorbing compound, as necessary, while servicing the Telescopic Handler.

Before starting inspection and repair, move the 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.

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c.

Use your hand to open the drain valve. Turn the valve counterclockwise until water drains from the separator.

d.

When clear fuel flows from the separator, tighten the drain valve.

e.

Reconnect the water sensor wire.

WARNING Static electricity can produce dangerous sparks at the fuel-filling nozzle. Do not wear polyester, or polyester-blend clothing while fueling. Before fueling, touch the metal surface of the machine away from the fuel fill to dissipate any built-up static electricity. Do not re-enter the machine but 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 static line is connected from the machine to the fuel truck before fueling begins.

IMPORTANT: When closing the drain valve, do not overtighten the valve. Overtightening can damage the threads.

A drain plug is also provided in the bottom of the fuel tank for removing condensation and other foreign materials. Open the plug and allow water and fuel to drain into a container until only clear fuel is flowing from the tank.

Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations. Avoid death or serious injury from fire or explosion; consult with your fuel or fuel system supplier to ensure the entire fuel delivery system is in compliance with fueling standards for proper grounding and bonding practices.

CHECK ENGINE OIL LEVEL Engine Oil Fill

CHECK FUEL WATER SEPARATOR Priming Pump

Engine Oil Dipstick

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

Water Separator Fuel Filter

Drain Valve w/ Water Sensor

NOTE: The engine is equipped with a water-infuel sensor at the water separator fuel filter. An error code will display in the multi-function display if water is present in the water separator fuel filter.

CHECK TRANSMISSION OIL LEVEL

Drain water and sediment from the separator daily using the following procedure: IMPORTANT: Drain water into a suitable container and dispose of properly. a.

Shut off the engine.

b.

Disconnect the water sensor wire from the drain plug at the bottom of the water separator.

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Transmission Oil Level and Fill

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The machine must be on level ground and the boom raised to 20º and completely retracted. With the engine and transmission at operating temperature, parking brake on, transmission in neutral and the engine at low idle, open the center drivetrain cover and remove the dipstick and check the oil level. If the oil level is below the ADD mark, fill into the dipstick tube with the required amount of oil to bring the level to the FULL mark. See the Lubrication chapter for the type of oil to use.

CHECK HYDRAULIC OIL LEVEL Hydraulic Oil Level Dipstick

CHECK RADIATOR COOLANT LEVEL Hydraulic Oil Fill Radiator Cap

The machine must be on level ground and the boom lowered and completely retracted. With the engine stopped for ten minutes or more, raise the engine hood.

Remove the dipstick to check the hydraulic oil level. If the oil level is below the ADD mark, fill with the required amount of oil to bring the level to the FULL mark. See the Lubrication chapter for the type of oil to use.

Coolant Level Sight Glass

IMPORTANT: Be careful when removing the reservoir filler cap so that no dirt or other foreign matter enters the hydraulic system. DO NOT OVERFILL. With the machine on level ground, and the engine cool, check the radiator coolant level through the sight glass on the rear of the radiator. If the coolant is not visible in the sight glass, remove the radiator cap and add a silicate-free, phosphate-free, borate-free and nitrite-free ethylene glycol based coolant mixed with deionized water suitable for heavy-duty diesel engines. See the engine manual for additional information. Add coolant until it is visible in the sight glass. Do not overfill the radiator. Replace the radiator cap securely. See the Lubrication chapter for the type of coolant to use.

CHECK FOAM FILLED OR SOLID RUBBER TIRES Check these tires for deep cuts, abrasions or gouges in the wear surface and sidewalls that may affect the tires performance.

NOTE: The DL12-55 model telehandler requires the use of foam filled or solid rubber tires.

CHECK TIRE PRESSURES To ensure proper operating stability and extend tire life, proper and equal tire pressure should be maintained in all four tires.

WARNING DO NOT remove the radiator cap when the engine is running hot or overheated. Coolant is extremely hot and under pressure and it can burn your skin. Allow sufficient time for the radiator to cool BEFORE relieving the pressure and removing the radiator cap.

Check tire pressures “cold.” Inflate as necessary per the chart below: 13.00 x 24 - 12 PR: 450 kPa (65 psi) 14.00 x 24 - 12 PR: 430 kPa (62 psi) 14.00 x 24 - 16 PR: 480 kPa (70 psi) NOTE: If the tires have been filled with water or calcium chloride for ballast, a calcium chloride tire pressure gauge MUST be used to check the tire pressure.

NOTE: If the engine is operated with a loose radiator cap, the pressure bypass will not work and the engine will run hot.

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To ensure proper load carrying capability, original equipment tires comply with the specifications published in the Tire and Rim Association Yearbook.

Replacement tires MUST meet the same specifications. When replacing tires, be sure all tires are of the same type, quality and load rating, and the same size as the original equipment. When removing tires, follow industry safety practices. Deflate completely prior to removal. After assembly of the tire on the rim, use a safety cage or restraining device while inflating.

CHECK WHEEL NUT TORQUE On NEW machines, or anytime a wheel has been removed, re-torque wheel nuts until 610 Nm (450 ft.lbs.) is maintained.

CHECK INSTRUMENTS OPERATION Allow the engine to warm up for 1-2 minutes or 2-4 minutes in below freezing temperatures before beginning operation. Indicator lamps should be OFF and gauges should register normal readings. Tilt the frame from side to side with the frame leveling control and note the angle indicator movement.

WARNING Inflating or servicing tires can be dangerous.

Whenever possible, trained personnel should service and mount tires. To avoid possible death or serious injury, follow the safety precautions below: 1.

BE SURE the rim is clean and free of rust.

2.

Lubricate both the tire beads and rim flanges with a soap solution. DO NOT use oil or grease.

3.

4.

CHECK GENERAL MACHINE OPERATION AND CONDITION Are any decals missing or damaged? Are all guards, shields and covers in place? Do all controls function smoothly and properly? Are there any abnormal vibrations or noises? Are any hose or fitting connections leaking? Is the engine exhaust color normal?

CHECK TUBE

DO NOT place fingers on the tire bead or rim during inflation. Use a clip-on tire chuck with a remote hose and gauge, which allows standing clear of the tire while inflating it.

After seating the beads, adjust the inflation pressure to the recommended operating pressure listed.

6.

DO NOT weld, braze, or otherwise attempt to repair and use a damaged rim.

BREATHER

Inspect the bottom flexible end of the tube for sludge, debris, or ice in the tube.

If sludge debris or ice is found, clean the tube with detergent and warm water or solvent. Dry the tube with compressed air.

NEVER inflate beyond 240 kPa (35 psi) to seat the beads. If the beads have NOT seated by the time the pressure reaches 240 kPa (35 psi), deflate the assembly, reposition the tire on the rim, relubricate both parts and re-inflate. Inflation pressure beyond 240 kPa (35 psi) with unseated beads may break the bead or rim with explosive force sufficient to cause death or serious injury.

5.

CRANKCASE

Visually inspect the tube for cracks or damage, replace if necessary.

Crankcase Breather tube

CHECK DUST EJECTION VALVE Inspect the dust ejector for cuts and tears. Replace the valve if damage is found.

Dust Ejector

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Located under the engine cover to the front left on the engine air pre-cleaner, the dust ejector is a thin flexible rubber boot located at the bottom of the pre-cleaner. It is used to accumulate and remove dust ejected from the pre-cleaner.

2.

Purge the dust ejection valve of dust by squeezing the valve until it opens. This may have to be performed multiple time depending on severity of dust or debris in the valve. If dust will not purge from the valve by squeezing the valve, remove the valve and clean it out by hand.

CHECKING PERSONNEL WORK PLATFORM (PWP) SYSTEM (if used)

1.

Machine Position

2.

Before beginning the PWP System checking procedures, position the machine as follows:

2.

Boom fully lowered,

3.

Frame level,

4.

Transmission in “N” (Neutral),

5.

Parking brake switch “OFF,”

6.

PWP System switch “OFF,” l

3.

For DL12-40 and DL11-44 models: Remote shutdown switch plugged in and “Engaged.”

l

For DL11-55 and DL12-55 models: Remote shutdown switch “Engaged.”

l

The parking brake should engage, as indicated by the lamp in the parking brake switch illuminating.

l

The carriage tilt and auxiliary functions, which are controlled by the buttons on the joystick handle, should now be disabled. The hydraulic joystick should continue to function normally for boom raise/lower and extend/retract.

Shift the transmission into “F” (Forward) and increase the engine speed slightly. l

The transmission should remain de-clutched, allowing the engine to increase speed easily.

l

Return the transmission selector to “N” (Neutral) after the check.

Have an assistant move the remote shutdown switch to “Dis-engaged.” l

The hydraulic joystick should now be disabled, so that boom raise/lower and extend/retract will no longer function.

l

Have the assistant move the remote shutdown switch to “Engaged” after the check.

Tilt the frame to the right slightly more than two degrees. l

The hydraulic joystick should now be disabled, so that boom raise/lower and extend/retract no longer function.

l

Repeat the procedure with the frame tilted to the left.

l

Return the frame to a level position after the checks.

De-activation Tests

Activation Tests

To test the PWP System de-activation logic:

To test the PWP System activation logic: 1.

The PWP switch lamp should be illuminated continuously after three seconds, indicating that the PWP System has been activated.

To test the transmission and joystick control lockout logic:

If the PWP System fails to operate properly during any of the PWP System checks, DO NOT USE the machine until the cause has been corrected. Contact your dealer (or Manitou Group) for service information and parts.

Machine on level surface,

l

Lockout Tests

WARNING

1.

Apply the service brakes.

1.

Start the engine and press the PWP rocker switch “ON.”

Turn the keyswitch to “OFF” and wait for the engine to stop. Then turn the keyswitch back to “ON.”

l

l

The PWP System lamp in the switch should be flashing.

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The PWP switch lamp and the parking brake switch lamp should both be illuminated.

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2.

Turn the keyswitch “OFF” and then press the PWP rocker switch to “OFF.” Turn the keyswitch back to “ON.” l

3.

Service Every 250 Hours or Quarterly NOTE: Perform all other service requirements up to this point, as well as the following:

The PWP switch lamp should be flashing and the parking brake switch lamp should be on continuously.

CHECK AXLE OIL LEVELS

Start the engine and apply the service brakes. l

Differentials

The PWP switch lamp and the parking brake switch lamp should go off after approximately three seconds of brake pedal application.

NOTE: The Telescopic Handler should be on a level surface for this procedure.

If PWP System fails to perform properly, troubleshoot using the chart on page 92. Contact your dealer for service information and parts.

Differential Oil Check/Fill Plug

Service Every 50 Hours or Weekly

LUBRICATE GREASE POINTS Refer to the Lubrication chapter of this manual for weekly grease fitting locations and related details.

Remove the oil check/fill plug, (see illustration below).

Oil should flow out the hole. If low, fill until oil flows out the hole. When oil overflows, replace the plug, wait 10 to 15 minutes and repeat the check/fill procedure. Continue this process until the differential is full.

See the Lubrication chapter of this manual for the proper oil specification. Replace the oil level check/fill plug.

100 Hours (New Machines Only) The following initial oil and filter changes should be made at 100 hours on a new machine. Thereafter these changes should be made at the regular maintenance intervals. Refer to the maintenance schedules for the necessary procedures.

Engine Oil and Filter Transmission Oil and Filter Hydraulic Return Filter

Planetary Hubs NOTE: The planetary hubs can be checked without jacking up the machine.

(1000 Hours) (1000 Hours) (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 torquing procedure in the 250-hour service interval.

Planetary Oil Check/Fill Plug in Check/Fill Position

The planetary hubs have one plug each used for filling and draining (see illustration). For checking the level and filling, position the wheel until the plug is horizontal. Remove the check/fill plug. If oil does not run out, add oil until it overflows. Check the other hubs the same way. Refer to the oil specifications in the Lubrication chapter of this manual.

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CHECK TRANSFER CASE OIL LEVEL

One Rear Boom Chain

Two Front Boom Chains

One Front Boom Chain

Transfer Case Check Plug Outer Section

1st Intermediate Section

2nd Intermediate Section

Inner Section

Four-Section Boom Chain Hookup Detail Torque the three chains on the front of the four-section boom to 68 Nm (50 ft.-lbs.). Lubricate with 80W-90 oil.

Remove the oil level check plug. Oil should flow from the hole. If low, remove the breather cap located on the front side of the transfer case. Fill with the proper oil until oil flows from the check hole. Replace the check plug and the breather cap. Refer to the oil specifications in the Lubrication chapter of this manual.

IMPORTANT: On the four-section boom, on new machines or when chains have been replaced, it is necessary to retorque the front-center single chain and the front-outer double chains after one hundred (100) hours of operation. Failure to do so may allow the chains to become slack, which can result in a chain jumping off a sheave. If this occurs, it could result in severe damage to the boom assembly.

CHECK AND TORQUE BOOM LEAF CHAINS Inspect the leaf chains for proper tension. On the threesection 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).

One Rear Boom Chain

Outer Section

Intermediate Section

The retract chains on the 2nd intermediate boom and the inner boom are pre-set at the factory and do not require adjustment, unless they are replaced.

Two Front Boom Chains

Inspect the leaf chains for wear. Run the boom out 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 314 mm (12.375”) or more, the chain should be replaced. DO NOT repair sections of a chain.

Replace the complete chain.

Inner Section

Three-Section Boom Chain Hookup Detail

Chain anchors and sheaves also require inspection, for worn or broken fingers and worn flanges.

Torque the two chains on the front of the three-section boom to 40 Nm (30 ft.-lbs.). Lubricate with 80W-90 oil.

After any chain has been replaced, operate under loaded conditions and re-check the torque. Adjust the chains per the following procedure: Extend the boom to its maximum length, then retract the boom slowly until the chain slack allows the chain to rest on the top of the boom. Torque the two chains on the front of the three-section boom to 40 Nm (30 ft.-lbs.) and the three chains on the front of the four-section boom to 68 Nm (50 ft.-lbs.). Lubricate with 80W-90 oil.

IMPORTANT: On the three-section boom, on new machines or when chains have been replaced, it is necessary to retorque the front double chain assembly after one hundred (100) hours of operation. Failure to do so may allow the chains to become slack, which can result in a chain jumping off a sheave. If this occurs, it could result in severe damage to the boom assembly.

On the four-section boom, three chains are on the top front of the boom. A fourth and fifth chains are accessible from the rear of the boom (see four-section boom illustration).

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CHECK BOOM SLIDE PAD WEAR AND CLEARANCE

CHECK CHARGE-AIR-COOLER AND PIPING

The boom is equipped with special nylon low-friction slide pads between the telescopic sections (see illustration). These are pre-greased and initially worn-in at the factory. Normally greasing is not required, except for maintaining a light film of grease on the pad tracking areas of the boom sections. An exception is if a boom section has been replaced.

Inspect the charge-air-cooler for dirt and debris blocking the fins. Check for cracks, holes or other damage.

Inspect the charge-air-piping and hoses for leaks, holes, cracks, or loose connections. Verify the chargeair-piping hose clamps are torqued to 5.8 Nm (45 inlbs.).

Replace any damaged or worn parts.

Visually check for loose pad bolts. The bolts are torqued to 40 Nm 30 ft.-lbs.(). If the bolts are retorqued at any time, LoctiteÒ 271 (red) thread lock or equivalent must be re-applied to the bolts.

Service Every 500 Hours or 6 Months

CHECK THE BATTERIES AND CABLES

Rear Inner

The batteries furnished in the machine are 12-volt, wet-cell batteries.

Shim Pad

WARNING Explosive gas is produced while a battery is in use or being charged. Keep flames and sparks away from the battery. Make sure battery is charged in a well-ventilated area.

Front Outer

NEVER lay a metal object on top of a battery, because a short circuit can result.

Slide Pad Detail

Battery acid is harmful on contact with skin or fabrics. If acid spills, follow these first aid tips:

If the boom starts to chatter under load, grease the slide pads and wipe off the excess grease. Maintain a clearance of 1.6 mm (1/16”) between the top and side slide pads and the boom. Shims can be added to achieve the proper clearance. Loosen the bolts and insert shims until proper clearance is obtained.

1. IMMEDIATELY remove any clothing on which acid spills.

2. If acid contacts the skin, rinse the affected area with running water for 10 to 15 minutes.

NOTE: When inserting shims in the side slide pads, be sure to place equal shims on both sides of the boom for even distribution of clearance.

3. If acid comes in contact with the eyes, flood the eyes with running water for 10 to 15 minutes. See a doctor at once. NEVER use any medication or eye drops unless prescribed by the doctor.

Re-apply Loctite® 271 (red) thread lock or equivalent to the bolts and re-torque to 40 Nm (30 ft.-lbs.).

Bottom slide pads should not be shimmed and should be replaced when the thickness is worn down to 9.5 mm (3/8”).

4. To neutralize acid spilled on the floor, use one of the following mixtures: a. 0.5 kg (1 pound) of baking soda in 4 liters (4 quarts) of water.

WARNING Failure to maintain proper slide pad clearance and thickness could cause damage to the boom, resulting in sudden boom failure.

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b. 1 pint (0.4 liters) of household ammonia in 4 quarts (3.78 liters) of water.

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Whenever battery is removed from the unit, BE SURE to disconnect the negative (-) battery terminal connection cable first.

Closely follow the jump-start procedures, in the order listed, to avoid personal injury. In addition, wear safety glasses to protect your eyes, and avoid leaning over the batteries while jump-starting.

The top of the battery must always be kept clean. Clean the battery with a brush dipped in an alkaline solution (ammonia or baking soda and water). After the foaming has stopped, flush the top of the battery with clean water.

DO NOT attempt to jump-start the machine if the battery is frozen, because this may cause it to rupture or explode.

IMPORTANT: BE SURE that the jumper battery is also a 12-volt D. C. battery, and the vehicle used for jump starting has a negative ground electrical system.

Use an inductive charging and cranking system analyzer to load-test the state of charge of the battery. If the charge is low, use a battery charger to charge the battery. Replace the battery if it will not except a charge or will not maintain a charge.

If conventional batteries are used, remove the cell caps or covers and check the electrolyte level in each cell.

Fill each battery cell with water.

1.

Turn the keyswitches on both units to OFF. Be sure that both machines are in “Neutral” and NOT touching.

2.

Connect one end of the positive (+) jumper cable to the positive (+) battery terminal on the disabled machine first. DO NOT allow the jumper’s positive (+) cable clamps to touch any metal other than the positive (+) battery terminals. Connect the other end of the positive (+) jumper cable to the jumper battery positive (+) terminal.

3.

Connect one end of the negative (-) jumper cable to the jumper battery negative (-) terminal.

4.

Make the final negative (-) jumper cable connection to the disabled Telescopic Handler’s engine block or frame (ground) ¾ NOT to the discharged battery’s negative (-) post. If making the connection to the engine, keep the jumper clamp away from the battery, fuel lines, and moving parts.

Use a hydrometer to measure the specific gravity of each cell. If the specific gravity of any cell is below 1.200, the battery must be replaced.

If the terminals and cable connection clamps are corroded or have a buildup, disconnect the cables and clean the terminals and clamps with a battery brush or wire brush untill the terminal and connections are shiny.

Connect the cables and tighten the battery connections.

Coat the terminals with grease to prevent corrosion.

Wash hands after handling the battery.

Jump Starting If the battery becomes discharged or does not have enough power to start the engine, use jumper cables and the following procedure to jump-start the engine.

NOTE: Twist the jumper cable clamps on the battery terminals to ensure a good electrical connection.

WARNING The ONLY safe method for jump-starting a discharged battery is for TWO PEOPLE to perform the following procedure. The second person is needed for removing the jumper cables, so that the operator does not have to leave the operator’s compartment while the engine is running. NEVER connect the jumper cables directly to the starter solenoid of either engine. DO NOT start the engine from any position other than the operator’s seat, and then ONLY after being sure all controls are in neutral.

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5.

Proceed to start the machine. If it does not start immediately, start the jumper vehicle engine to avoid excessive drain on the booster battery.

6.

After the machine is started and running smoothly, have the second person remove the jumper cables (negative (-) jumper cable first) from the jumper vehicle battery, and then from the disabled machine while being careful not to short the two cables together.

Allow sufficient time for the alternator to buildup a charge in the battery before attempting to operate the machine or shutting off the engine.

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NOTE: If the battery frequently becomes discharged, have the battery checked for possible dead cells, or troubleshoot the electrical system for possible short circuits or damaged wire insulation.

To check the antifreeze concentration: 1.

Place a drop of coolant on the refractometer window and shut the lid.

2.

Look through the eyepiece and focus.

CHECK FAN BELT TENSIONER

3.

Record the freeze point protection for either ethylene glycol or propylene glycol coolants.

With the engine stopped, check the tensioner arm, pulley and stops for cracks. If any cracks are noticed, the tensioner must be replaced.

NOTE: Factory filled with an ethylene glycol based antifreeze.

With the belt installed, verify that neither tensioner arm stop is in contact with the spring casing stop. If either of the stops is touching:

Antifreeze is essential in every climate.

Verify that the correct belt is installed.

If the correct belt is installed, replace the belt.

The corrosion inhibitors also protect the cooling system components from corrosion and provide longer component life.

After replacing the belt, if the tensioner arm stops are still in contact with the casing stop, replace the tensioner.

CLEAN AIR DENSER

It broadens the operating temperature by lowering the coolant freezing point and raising its boiling point.

With the belt installed, check the location of the belt on the belt tensioner pulley. The belt should be centered on, or close to the middle of the pulley. Misaligned belts, either to far forward or backward, can cause belt wear, belt roll-off malfunctions, or increase uneven tensioner bushing wear. If belt is not centered on the tensioner pulley, the tensioner will likely need to be replaced.

CONDITIONING

CON-

NOTE: Clean the condenser more often if there is a noticeable decrease in A/C performance.

IMPORTANT: Do not use a water jet or high-pressure steam, because this could damage the fins.

Refer to the engine Operation and Maintenance Manual for additional information.

1.

Remove the six screws (1) from the top cover of the condenser.

2.

Remove the cover to gain access to the condenser (2).

CHECK COOLANT SYSTEM ANTIFREEZE 1

Check the antifreeze concentration. Use a mixture of 50 percent water and 50 percent ethylene glycol or propylene glycol-base antifreeze to protect the engine to -32° C (-25° F) year round.

An antifreeze refractometer provides a reliable, easy to read, and accurate measurement of freezing point protection and antifreeze concentration.

Refractometer

2

3.

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Clean any large debris that may have collect on the top side of the condenser.

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4.

Clean the condenser with a jet of compressed air aimed in the same direction as the air flow.

WARNING

NOTE: To aid in the cleaning process, carry out this operation with the condenser fans running.

5.

NEVER service the fuel system while smoking, while near an open flame, or if the engine is hot.

Re-install the top cover.

CLEAN/CHANGE CAB VENTILATION FILTER NOTE: Clean or change the filter more often if there is a noticeable decrease in air flow from the air vents.

Canister Type Fuel Filter

1.

The cab ventilation filter is located inside the storage compartment behind the operator’s compartment. Remove the bulb seal from around the filter housing in order to remove the filter.

2.

Remove the filter from the housing.

3.

Clean the filter with a jet of compressed air.

4.

Check the condition of the filter and replace it if necessary.

5.

Install the filter in the housing, then re-install the bulb seal.

1.

Thoroughly clean fuel filter assembly and surrounding areas.

2.

Use a 32 mm hex drive on the bottom of the filter canister to remove it.

3.

Remove and discard the filter element from the canister.

Remove and discard the oring on the filter canister.

4.

Install a new filter element making sure the tabs of the filter element are seated in the canister.

Service Every 1000 Hours or Yearly

NOTE: Perform all other service requirements up to this point, as well as the following:

CHANGE FUEL FILTER 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 which the machine is used.

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5.

6.

Use the clean side block-off plug packed with the filter to block the center of the filter before prefilling the filter with fuel. Pre-fill the filter making sure to pour fuel only in the outside portion of the filter as shown. Do not to pour fuel into the center of the filter as this will cause unfiltered fuel to enter the system.

1. The water separator with the priming pump is located under the engine cover in the area below the air cleaner.

2. Pump the primer by pushing the knob down. The knob will return to the out position automatically.

Pump the primer until resistance is felt. Priming could take 140 to 150 strokes for a dry filter or 20 to 60 strokes if the new filter was pre-filled.

Install the new o-ring seal on the filter canister.

Lubricate the o-ring seal with clean lubricating oil.

3. Crank the engine. If the engine does not start after 30 seconds, turn the key to the OFF position.

4. Repeat priming procedure steps 2 and 3 until the engine starts.

Block-off Plug

When the engine starts, it may run erratically with increased noise levels for a few minutes until air is purged from the fuel system.

NOTE: It is possible that Fault Code 157-18 can become active after fuel filter replacement, due to the air in the system. Run the engine until the air is purged from the system then clear the fault code.

7.

Remove the block-off plug from the center of the filter installed in Step 5. Install the filter on the filter head until it contacts the filter head. Then using a 32 mm hex drive tighten the canister to 32 Nm (24 ft-lb).

WARNING

Fuel Priming Procedure

Escaping diesel fuel under pressure can have sufficient force to penetrate the skin. Before applying pressure to the fuel system, BE SURE all connections are tight and lines and hoses are not damaged. Use a piece of wood or cardboard to search for suspected leaks. If injured by escaping fuel, see a doctor familiar with this type of injury at once or gangrene may result.

When the fuel filter is removed and replaced, or if the engine runs out of fuel, the fuel system must be primed. Refer to the following procedure for the proper fuel priming procedure.

CHANGE WATER SEPARATOR ELEMENT

IMPORTANT: Do not overtighten the canister as it could damage the filter element seal and threads.

8.

The fuel system must be primed after changing the fuel filter or if the fuel tank runs out of fuel.

Priming Pump

IMPORTANT: Catch and dispose of any drained or spilled fuel according to local waste disposal regulations.

1.

Thoroughly clean water separator assembly and surrounding area.

2.

Disconnect the water sensor wire from the bottom of the separator element.

3.

Loosen drain plug with water sensor wire at the bottom of the separator to drain the fuel from the separator element.

Water Separator Fuel Filter

Drain Valve w/ Water Sensor

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CHANGE ENGINE OIL AND FILTER

Priming Pump Bleed Screw

Water Separator Fuel Filter Drain Valve w/ Water Sensor

4.

Grasp the retaining ring and rotate it clockwise (when viewed from the top) 1/4 to 1/3 turn.

Remove the retaining ring along with the separator element.

5.

Remove the drain plug loosened in Step 3 from the water separator. Install the drain plug into the replacement water separator element.

Engine Oil Filter

Change the engine oil and filter using the following procedure:

NOTE: A raised locator on the water separator element must be indexed properly with the slot in the mounting base for correct installation.

6.

7.

9.

Loosen the bleed screw on the mounting base 11/2 to 2 turns. Pump the priming pump until fuel flows from the bleed screw. Tighten the bleed screw.

2.

Shut off the engine and remove the oil drain plug.

3.

Install the retaining ring over the element and onto the mounting base. Hand tighten the ring counter-clockwise (when viewed from the top) about 1/4 to 1/3 turn until the detent is felt. DO NOT overtighten the retaining ring.

Reconnect the water sensor wire to the bottom of the element.

Operate the engine until the water temperature reaches 60° C (140° F).

IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal regulations.

Install the new water separator element on the mounting base. Be sure the element is properly indexed to the mounting base.

8.

1.

The engine oil filter should be changed at every oil change interval. Using a 1/2” drive wrench on the bottom of the filter, remove and discard the filter.

IMPORTANT: Filtration of oils is critical to proper lubrication. Always change the filter with every oil change.

4. Be sure the old filter gasket is not stuck to the filter head. Remove it if necessary. Clean the gasket surface of the filter head.

5. Apply a thin coat of clean engine oil to the gasket surface of the new oil filter. Fill the new filter with clean engine oil.

Diesel Fuel System

6. Install the oil filter by hand until firmly against the filter head. Tighten the filter an extra 3/4 to 1 turn after gasket contacts the filter head.

Whenever faulty or plugged injectors or injection pump service is indicated by abnormal engine operation, see your authorized engine dealer.

7. Clean and check the oil drain plug threads and sealing surface. Re-install the drain plug. Torque to 24 Nm (212 in-lb).

NOTE: Only an authorized engine dealer can perform warranty service on the engine.

8. Re-fill the crankcase with new oil. Follow specifications in the Lubrication chapter for type and viscosity of new oil.

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9. After new oil has been added, run the engine at idle speed until the oil pressure lamp is off. Check for leaks at the filter and drain plug.

3.

10. Shut off the engine. Wait approximately 5 minutes to let the oil drain back to the oil pan. Check the oil level. Add oil as necessary to bring oil level to the high mark on the dipstick.

IMPORTANT: DO NOT OVERFILL! lf the oil level is too high, oil foaming, excessively high oil temperature and oil leakage at the seals could result.

4.

CHANGE TRANSMISSION OIL AND FILTER

Refill the transmission through the dipstick tube with new oil as shown in the Lubrication chapter of this manual.

Start and run the machine long enough for the oil to circulate and warm slightly. Recheck the level with the dipstick.

CHANGE HYDRAULIC RETURN FILTER ELEMENT

Operate the machine long enough to warm up the transmission oil to 65°C-93°C (150°F-200°F). Shut off the engine. Access to the drain plug is from underneath the machine. Open the center drivetrain cover to access the filter and oil fill location. Proceed as follows:

WARNING Lower the boom to the ground when servicing the hydraulic system.

Transmission Drain Plug

1.

Remove the drain plug and drain oil. Replace the drain plug.

IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal regulations.

2.

Hydraulic Return Filter

The hydraulic return filter element is a cartridge-type, accessible from underneath the chassis. Initial replacement is after the first 100 hours. Unscrew the filter cover and remove. Slide off the old element and discard. Insert the new element onto the housing and replace the cover.

Remove and discard the oil filter. Wipe the sealing surface on the transmission with a clean cloth.

Apply a thin coat of clean oil to the new oil filter gasket. Hand tighten.

IMPORTANT: The hydraulic return filter is equipped with a restriction sensor. If the dash indicator light comes on, the element should be replaced.

CHANGE AIR FILTER ELEMENT(S)

Transmission Dipstick and Filler

The air cleaner assembly consists of an primary filter element and a secondary filter element. Air filter restriction is indicated by the check engine lamp and an error code in the multi-functional display.

Transmission Oil Filter

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3.

Clean out any dirt build up in the housing. Leave the secondary element installed during this step to prevent debris from entering the engine intake manifold.

4.

Place a new primary element in the housing so the seal is toward the secondary element. Push it in the housing so all surfaces are seated inside the housing.

Pre-cleaner and Dust Ejector Secondary Element Primary Element

NOTE: Cleaning the primary element is not recommend.

5.

Housing

Secondary Element

End Cap

NOTE: Replace the secondary element ever other time the primary element is replaced or if it is visibly dirty.

The amber check engine lamp will flash for 30 seconds when the ignition switch is turned ON, and an error code will be displayed to indicate the air filter should be replaced.

Before removing the secondary element from the housing, clean out any dirt build up in the housing. Leave the secondary element installed during this step to prevent debris from entering the engine intake manifold.

Secondary element removal:

If the air filter is not replaced and the restriction becomes more severe, the amber check engine lamp will light and stay ON, and an additional error code will display resulting in possible engine power reduction.

The outer element should be replaced whenever indicated by the multi-functional display. The inner element should be replaced every other time the outer element is replaced, unless the outer element is damaged or the inner element is visibly dirty. Along with a daily check of the restriction indicator, check that the air cleaner intake hose and clamps, and the mounting bracket hardware are properly secure.

Unlatch the four latches on the air cleaner and remove the end cap assembly. Clean out any dirt built up in the end cap assembly.

Primary Element Replacement 1.

Unlatch the four latches on the air cleaner and remove the end cap assembly. Clean out any dirt built up in the end cap assembly.

2.

The primary element has built in handles, grasp the handles and remove the element from the housing. Never remove the secondary element unless it is to be replaced.

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Re-install the end cap assembly and latch the four latches.

91

1.

Remove the primary element following Steps 1 and 3 of the primary element replacement procedure.

2.

The secondary element is removed by pulling on the two plastic ring tabs on the face of the element.

3.

Push the new secondary element into the back of the housing so all surfaces are seated inside the housing. Apply pressure to all four corners to make sure the element is secure within the housing.

4.

Install the primary element following Steps 4 and 5 of the primary element replacement procedure.

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2.

CHANGE AXLE DIFFERENTIAL AND PLANETARY OIL Differential 1.

Re-position the hub so the drain/fill plug is horizontal. Fill with fresh oil as specified in the Lubrication chapter. Re-install the drain/fill plug.

Repeat this procedure on the other hubs.

Remove the drain plug and drain the oil. Replace the drain plug (see illustration).

Planetary Oil Drain/Fill Plug in Fill Position

Drain Plug

CHECK FAN BELT AND FAN HUB CONDITION

Differential Oil Check/Fill Plug

Remove the fan belt and check for wear , cuts or cracks If the belt shows wear or cuts, it should be replaced.

Order a replacement belt from your Manitou Group dealer.

IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal regulations.

2.

With fan belt removed, check the fan hub for wobble or excessive end clearance.

Remove the check/fill plug and fill the differential with oil as specified in the Lubrication chapter.

When the oil flows out the oil check/fill hole, replace the plug. Wait 10 to 15 minutes and repeat this process until the axle is full. Repeat the procedure with the other axle (see illustration).

CHECK 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.

Axle Planetary Hubs

CHECK RADIATOR PRESSURE CAP

The axle hubs have one plug each used for draining and filling (see illustrations).

1.

Make sure the radiator cap is a 1.1 bar (16 psi) pressure cap. Inspect the rubber seal for damage. Replace it if damage is visible. Inspect the radiator filler neck for cracks or other damage.

Position the wheel until the drain/fill plug points down. This will allow the oil to drain out.

Remove the drain/fill plug.

An incorrect or malfunctioning radiator cap can result in the loss of coolant and the engine running hot.

Planetary Oil Drain/Fill Plug in Drain Position

IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal regulations.

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CHANGING HYDRAULIC RESERVOIR OIL AND STRAINER

Service Every 2000 Hours or Two Years NOTE: Perform all other service requirements up to this point, as well as the following:

Clean all dirt and debris from around the area where the hydraulic system suction (large) hose connects to the wall of the reservoir.

CHECK HYDRAULIC SYSTEM RELIEF PRESSURES

1.

Pressure settings for relief valves are pre-set at the factory. Two test ports are provided for checking relief pressures. These test ports are located under the center cover near the transmission dipstick as shown

Remove the drain plug and drain oil. Wash or blow off any collected particles on the magnetic drain plug.

Suction Hose

Steering and Main Relief Pressure Test Port

Hydraulic Strainer

Joystick Relief Pressure Test Port

IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal regulations.

2.

Disconnect the suction hose and remove the sump strainer from inside the reservoir. Inspect the strainer. If it has any damage, holes, etc., it should be replaced. Otherwise, wash it clean with an industrial solvent, dry with a rag and coat with fresh hydraulic oil.

3.

Flush out the bottom of the tank with clean hydraulic oil. Re-install the drain plug and strainer and reconnect the suction hose.

Plug a 207 bar (3000 psi) oil or liquid-filled gauge onto the main/steering test port. Turn the steering full to the right or left. The gauge should read 172 bar (2500 psi).

4.

Fill the tank with fresh oil. Follow specifications in Lubrication chapter of this manual.

Checking Main Relief Pressure

IMPORTANT: Hydraulic fluid and filters should be replaced any time contamination is present before the normally scheduled change.

Before conducting any pressure checks, check the engine speed. Engine speed must be 1100 rpm at low idle, and 2500 rpm at high idle.

NOTE: Pressure checks should be made with engine at low idle.

Checking Steering Relief Pressure

With the gauge on the main/steering test port and the boom extended, retract the boom fully. The gauge should read 221 bar (3200 psi) for the DL11-55 and DL12-55 and 207 bar (3000 psi) on all other models.

WARNING NEVER use your hands to search for hydraulic fluid leaks. Escaping hydraulic oil under pressure can have sufficient force to penetrate the skin. Before applying pressure to the hydraulic system, be sure all connections are tight and lines and hoses are not damaged.

Use a piece of wood or cardboard to search

Checking Joystick Relief Pressure Plug a 70 bar (1000 psi) gauge onto the joystick test port. With the engine running, the gauge should read 24 bar (350 psi).

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4.

for suspected leaks. If injured by escaping hydraulic oil, see a doctor familiar with this type of injury immediately or gangrene may result.

Disconnect the EGR cooler coolant line to make sure coolant is drained from the EGR. This line is located on the left side of the engine as shown.

Depending on accessibility, the line can be disconnected on either end.

CHANGE RADIATOR COOLANT Drain old coolant, flush the entire cooling system and fill with recommended coolant.

Drain the Coolant IMPORTANT: DO NOT discharge coolant onto ground. Catch and dispose of per local waste disposal regulations.

EGR Cooler Coolant Line

WARNING Remove the radiator cap only when the engine is cool, or painful burns could result.

Follow this procedure to drain the coolant from the system: 1.

Remove the radiator cap.

2.

Drain the radiator by opening the drain valve at the bottom front of the radiator.

3.

Working from under the right side of the engine, remove the drain plug at the bottom of the water inlet. See the following images for plug location.

5.

Check for damaged hoses and loose or damaged hose clamps. Replace as required.

6.

Check the radiator for leaks, damage and buildup of dirt. Clean and replace as required.

Flush the Cooling System 7.

Close the radiator drain valve.

8.

Install the drain plug in the water inlet.

9.

Connect the EGR cooler coolant line.

10. Fill the cooling system with a mixture of sodium carbonate and water or a commercially available product such as RestoreÔ.

Water Inlet Drain Plug Located Behind Water Inlet

NOTE: Do not install the radiator cap.

11. Operate the engine for 5 minutes with the coolant temperature above 80°C (176°F).

Engine Oil Filter

12. Shut the engine off and let it cool before draining the cooling system following Steps 2 - 4.

13. Follow Steps 7 - 8, then fill the system with water.

14. Operate the engine for 5 minutes with the coolant temperature above 80°C (176°F).

Engine Oil Filter

15. Shut the engine off and let it cool before draining the cooling system following Steps 2 - 4.

Water Inlet Drain Plug Viewed From Bottom

Filling the Cooling System IMPORTANT: Fill the cooling system with a lowsilicate ethylene glycol based coolant mixed with quality water and supplemental coolant additives (SCAs) suitable for heavy-duty diesel engines.

See the Lubrication chapter for engine coolant recommendations.

Water Inlet Connection

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16. Follow Steps 7 - 9.

CHANGE TRANSFER CASE OIL

17. Open the cab heater valve if equipped.

Raise the engine hood for access.

18. Fill coolant to bottom of the radiator fill neck, (center of the sight glass).

19. Wait 2 to 3 minutess for air to vent from the system.

Transfer Case Check Plug

20. Repeat Steps 18 and 19 until the coolant level remains at the full level (center of the sight glass).

21. Start and run the engine 5 minutes to purge out remaining air. Heater should be on if equipped.

22. Turn off the engine, wait until coolant is below 50°C (122°F) to remove the radiator cap if installed.

1.

Remove the drain plug from underneath to drain oil.

IMPORTANT: DO NOT discharge oil onto ground.

Catch and dispose of per local waste disposal regulations.

23. Top off the coolant to bottom of the radiator fill neck (center of the sight glass).

24. Install the radiator cap and run the engine until it reaches a temperature of 80°C (176°F) and check for leaks.

2.

25. Check the coolant level several times the first day after filling to be sure the coolant is at the correct level. Then check coolant level daily.

Remove the breather cap on the front side of the transfer case. Fill with fresh oil until it flows from the check plug hole. Follow specifications in the Lubrication chapter of this manual.

Service Every 4000 Hours or Three Years

Refer to the Cummins engine Operation and Maintenance manual for additional coolant replacement instructions.

CHANGE DIESEL EXHAUST FLUID DOSING UNIT FILTER

NOTE: Check the engine temperature gauge every minute or two after coolant has been changed. Air pockets can form and it may be necessary to refill the cooling system after a short period of use, as the air will naturally bleed out of the system.

The DEF dosing unit is located under the center drivetrain cover. It can be accessed by raising the drivetrain cover. Remove the bolt-on access cover at the bottom of the dosing unit. The filter is located on the bottom of the dosing unit.

CHECK COOLANT HOSES AND CONNECTIONS Check all coolant hoses for cuts, cracks or collapsing.

Replace any damaged hoses.

NOTE: The silicone engine coolant hoses used on the machine will exhibit swelling due to the elasticity of the hose.

DEF Dosing Unit Filter Cap

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The aftertreatment DEF dosing unit filter consists of the following components:

DEF Dosing Unit Filter Removal NOTE: Do not disconnect the vehicle batteries until the DEF dosing system has completed the purge cycle. Before beginning to remove and/or disconnect any components, wait at least five minutes after the keyswitch is turned OFF for the aftertreatment DEF dosing system to purge the DEF from the system. The purge cycle is an automatic process and does not require intervention to occur. The aftertreatment DEF dosing unit will create an audible pumping noise during the purging process.

Turn the battery disconnect switch to OFF and remove the key, then follow these removal instructions:

1.

Aftertreatment dosing unit cap.

2.

Aftertreatment dosing unit filter equalizing element.

NOTE: There may be residual DEF in the filter housing. A collection container placed below the DEF filter cap is recommended.

3.

Aftertreatment dosing unit filter element.

1.

Inspect the area around the seal and vent of the aftertreatment DEF dosing unit filter cap for signs of leakage.

Unscrew the DEF filter cap (1). A 27 mm wrench can be used on the cap to aid in removal.

2.

Remove the aftertreatment DEF filter equalizing element (2).

3.

Remove the old aftertreatment DEF dosing unit filter element (3). A disposable service tool is included with the filter to aid in filter removal.

Use the appropriate end of the tool, depending on the color of the plastic on the filter. When inserting the tool, a "click" sound can be heard which indicates proper engagement with the filter.

DEF leaks leave a white deposit. If deposits are found, see the Clean and Inspect for Reuse section in this procedure.

WARNING Diesel exhaust fluid (DEF) contains urea. Do not get the substance in your eyes. In case of contact, immediately flush eyes with large amounts of water for a minimum of 15 minutes. Do not swallow. In the event the DEF is ingested, contact a physician immediately.

Reference the Materials Safety Data Sheet (MSDS) for additional information.

DEF Filter Removal Tool

WARNING The diesel exhaust fluid (DEF) line connecting the aftertreatment DEF dosing unit to the aftertreatment DEF dosing valve is under low pressure and should not be disconnected while the engine is running or before the system has completed the purge process after engine shutdown. Disconnecting the DEF line while under low pressure could cause DEF to spray.

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NOTE: If the filter element and equalizing element are removed from the aftertreatment DEF dosing unit, they must be discarded and replaced; regardless of condition.

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Clean and Inspect DEF Cap for Reuse 1.

Inspect the aftertreatment DEF dosing unit filter cap for cracks or holes that could create a DEF leak path.

2.

Check the condition of the threads on the aftertreatment DEF dosing unit cap.

3.

If the threads are damaged, replace the aftertreatment DEF dosing unit filter cap.

4.

Inspect the aftertreatment DEF dosing unit threads. This is especially important if the aftertreatment DEF dosing unit cap was damaged.

5.

If the aftertreatment DEF dosing unit threads are damaged, replace the entire aftertreatment DEF dosing unit.

NOTE: Never operate the vehicle with the DEF cap removed.

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 freezing, make sure the engine coolant is either completely drained from the radiator and engine block or that the amount of anti-freeze in it is adequate to keep the coolant from freezing. Refer to the engine manual for anti-freeze recommendations and quantities.

During Storage 1.

Clean the aftertreatment DEF dosing unit cap and threads on the dosing unit with warm water and a clean cloth.

About once each month, connect the battery and, before starting the engine, check all fluid levels to make sure they are at the proper level.

IMPORTANT: If it is desired to operate the hydraulic cylinders at this time, BE SURE to wipe the protective grease (and any adhering dirt) from the cylinder rods prior to starting the engine. After operating, if the machine is to be returned to storage, re-coat the cylinder rods with grease.

DEF Dosing Unit Filter Installation Slide the DEF filter equalizing element (2) into the DEF filter cartridge (3).

Insert the assembly into the aftertreatment DEF dosing unit.

2.

Install and tighten the cap (1). A 27 mm wrench can be used to install and tighten the filter cap. Torque the cap to: 20 Nm (177 in-lb).

STORING THE MACHINE

Start the engine and allow it to run until it warms up. Then move the machine a short distance to help relubricate the internal parts. Run the engine until the battery has a chance to recharge, and then shut it off.

If the Telescopic Handler will not be operated for a period of three months or more, prepare and store it using the following procedure:

After Storage

NOTE: If the storage area is outdoors or in a harsh environment, the storage procedure should be followed if the Telescopic Handler is to be stored for one month.

1.

Change engine oil and filter to remove any condensation and residues.

2.

Wipe off grease from cylinder rods.

3.

Lubricate ALL grease fittings.

4.

Follow the starting and warm-up procedures outlined in the Operation and Adjustments chapter of this manual.

After removing the machine from storage and BEFORE operating it, perform the following:

Before Storage Perform the following prior to placing the machine in storage: 1.

Wash the entire machine.

2.

Lubricate all grease fittings as described in the Lubrication chapter of this manual.

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PWP SYSTEM OPERATIONAL TROUBLESHOOTING Problem

Possible Cause

Remedy

PWP System is not activated.

With PWP System switch “ON,” apply service brakes for three seconds until PWP switch lamp is lit continuously.

Machine is not level.

Level the machine.

PWP System remote shutdown switch is disengaged.

Engage the PWP System remote shutdown switch.

DL12-40 and DL11-44 models: PWP System remote shutdown switch is not plugged into the connector at the end of the boom.

Plug in and engage the PWP System remote shutdown switch.

PWP System switch lamp flashes when switch is pressed to “ON.” Parking brake did not engage when PWP System switch was pressed to “ON.” Carriage tilt and auxiliary functions continue operating when the PWP System switch is pressed to “ON.” Transmission does not remain de-clutched when shifted into “Forward” or “Reverse” when the PWP switch is “ON.”

Boom control functions do not operate.

DL12-55 and DL11-55 models: Replace batteries and engage Low or dead batteries in PWP the PWP System remote shutSystem remote shutdown switch. down switch.

PWP System level unplugged or faulty.

sensor

Contact your Manitou Group dealer for assistance.

PWP System is not de-activated.

With engine running, apply service brakes for three seconds until PWP switch lamp goes off.

PWP System switch lamp flashes when switch is turned “OFF.” Parking brake switch lamp stays “ON” when PWP System switch is “OFF.”

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Chapter 9 MAINTENANCE This Maintenance Interval Chart was developed to match the Service and Storage chapter of this manual. Detailed information on each Service Procedure may be found in the Service and Storage chapter. A Maintenance Log follows the Maintenance Interval Chart for recording the service procedures performed. Recording the 10 Hour (or Daily) service intervals would be impractical and therefore is not recommended.

IMPORTANT: Under severe operating conditions, more frequent service than the recommended intervals may be required. Users must decide if the severity of their operation requires more frequent than normal service.

MAINTENANCE INTERVAL CHART SERVICE PROCEDURE

Every 10 Hours (or Daily)

Check Fuel and Diesel Exhaust Fluid Level

l

Check Fuel Water Separator

l

Check Engine Oil Level

l

Check Transmission Oil Level

l

Checking Radiator Coolant Level

l

Check Hydraulic Oil Level

l

Check Foam Filled or Solid Rubber Tires

l

Check Tire Pressures

l

Check Wheel Nut Torque

l1,2

Check Instruments Operation

l

Check General Machine Operation and Condition

l

Check Crankcase Breather Tube

l

Check Dust Ejection Valve

l

Check Personnel Work Platform Safety System

l

Every 50 Hours (or Weekly)

First 100 Hours

Every 250 Hours (or Quarterly)

l

Lubricate Grease Points Change Engine Oil and Filter

l2

Change Transmission Oil and Filter

l2

Change Hydraulic Oil Filter

l2

Check and Torque Boom Leaf Chains

l3

1 - On new machines or when a wheel has been removed, until 610 Nm (450 ft.-lbs.) 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 40 Nm (30 ft.-lbs.), and the three chains on the front of the four-section boom should be torqued to 68 Nm (50 ft.-lbs.).

PRINTED IN U.S.A.

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50960172/E0221

MAINTENANCE INTERVAL CHART (CONT.) SERVICE PROCEDURE

Every 250 Hours (or Quarterly)

Check Axle Oil Levels

l

Check Transfer Case Oil Level

l

Check and Torque Boom Leaf Chains

l

Check Boom Slide Pads Wear and Clearance

l

Check Charge-Air-Cooler and Piping

l

Every 500 Hours (or 6 Months

Check the Batteries and Cables

l

Check Fan Belt Tensioner

l

Check Coolant System Antifreeze

l

Clean Air Conditioning Condenser

l

Clean/Change Cab Ventilation Filter

l

Every 1000 Every 2000 Hours (or Hours (or Yearly) Two Years)

Change Fuel Filter

l

Change Water Separator Element

l

Change Engine Oil and Filter

l

Change Transmission Oil and Filter

l

Change Hydraulic Return Filter Element

l

Change Air Filter Elements

l

Change Axle Differential and Planetary Oil

l

Check Fan Belt and Fan Hub Condition

l

Check Exhaust System

l

Check Radiator Pressure Cap

l

Check Hydraulic System Relief Pressures

l

Change Hydraulic Reservoir Oil and Strainer

l

Change Radiator Coolant

l

Check Coolant Hoses and Connections

l

Change Transfer Case Oil

l

SERVICE EVERY 4000 HOURS (OR THREE YEARS) Change Diesel Exhaust Fluid Dosing Unit Filter

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PRINTED IN U.S.A.

MAINTENANCE LOG Date

PRINTED IN U.S.A.

Hours

Service Procedure

101

50960172/E0221

MAINTENANCE LOG Date

50960172/E0221

Hours

Service Procedure

102

PRINTED IN U.S.A.

MAINTENANCE LOG Date

PRINTED IN U.S.A.

Hours

Service Procedure

103

50960172/E0221

ENGINE DIAGNOSTIC TROUBLE CODES (DTCs) Engine diagnostic trouble codes are displayed in the instrument display panel.

Stored and active diagnostic trouble codes are displayed as a two-part code: Suspect Parameter Number (SPN) and Failure Mode Identifier (FMI), as shown on the tables on this and the following pages.

The first part is a Suspect Parameter Number (SPN) followed by a Failure Mode Identifier (FMI). To determine the exact type of failure, both parts (SPN and FMI) of the code are needed.

The SPN indentifies the system or the component that has the failure; for example, SPN 000110 indicates a failure in the engine coolant temperature circuit.

SPN

FMI

27 81 84 84 84 91 91 91 91 91 91 91 94 94 95 97 97 97 97 100 100 100 100 100 102 102 102 102 105 105 105 105 105 107 107 108

4 16 2 10 19 3 4 1 0 2 19 9 3 4 16 15 3 4 16 3 4 18 1 2 3 4 16 2 3 4 0 16 15 16 15 3

50960172/E0221

The FMI indentifies the type of failure that has occurred; for example, FMI 03 indicates a value above normal. Combining SPN 000110 with FMI 03 means the engine coolant temperature input voltage is too high.

Always contact your servicing engine dealer for help in correcting the diagnostic trouble codes that are displayed for the engine.

The fault codes listed in the following table are in ascending order.

NOTE: Not all of these codes are used on all engine applications.

ERROR DESCRIPTION EGR Valve Position Circuit - Voltage Below Normal Engine DPF - Above Normal Range - Moderately Severe "Wheel-Based Vehicle Speed - Date Erratic, Intermittent or Incorrect" Wheel-Based Vehicle Speed - Abnormal Rate of Change Wheel-Based Vehicle Speed - Betwork Receive Error Accelerator Pedal Position Sensor 1 Circuit - Voltage Above Normal Accelerator Pedal Position Sensor 1 Circuit - Voltage Below Normal Accelerator Pedal Position Sensor 1 Circuit - Below Normal Range - Most Severe Accelerator Pedal Position Sensor 1 Circuit - Above Normal Range - Most Severe "Accelerator Pedal Position Sensor 1 Circuit - Date Erratic, Intermittent or Incorrect" Accelerator Pedal Position Sensor 1 Circuit - Betwork Receive Error Accelerator Pedal Position Sensor 1 Circuit - Abnormal Update Rate Fuel Delivery Pressure Sensor Circuit - Voltage Above Normal Fuel Delivery Pressure Sensor Circuit - Voltage Below Normal Fuel Filter Differential Pressure - Above Normal Range - Moderately Severe Water in Fuel Indicator - Above Normal Range - Least Severe Water in Fuel Indicator - Voltage Above Normal Water in Fuel Indicator - Voltage Below Normal Water in Fuel Indicator - Above Normal Range - Moderately Severe Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage Above Normal Engine Oil Rifle Pressure 1 Sensor Circuit - Voltage Below Normal Engine Oil Rifle Pressure 1 Sensor Circuit - Below Normal Range - Moderately Severe Engine Oil Rifle Pressure 1 Sensor Circuit - Below Normal Range - Most Severe "Engine Oil Rifle Pressure 1 Sensor Circuit - Date Erratic, Intermittent or Incorrect" Intake Manifold 1 Pressure Sensor Circuit - Voltage Above Normal Intake Manifold 1 Pressure Sensor Circuit - Voltage Below Normal Intake Manifold 1 Pressure Sensor Circuit - Above Normal Range - Moderately Severe "Intake Manifold 1 Pressure Sensor Circuit - Date Erratic, Intermittent or Incorrect" Intake Manifold 1 Temperature Sensor Circuit - Voltage Above Normal Intake Manifold 1 Temperature Sensor Circuit - Voltage Below Normal Intake Manifold 1 Temperature Sensor Circuit - Above Normal Range - Most Severe Intake Manifold 1 Temperature Sensor Circuit - Above Normal Range - Moderately Severe Intake Manifold 1 Temperature Sensor Circuit - Above Normal Range - Least Severe Engine Air Filter Differential - Above Normal Range - Moderately Severe Engine Air Filter Differential - Above Normal Range - Least Severe Barometric Pressure Sensor Circuit - Voltage Above Normal

104

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SPN

FMI

108 110 110 110 110 110 110 111 111 111 111 111 111 157 157 157 157 157 168 168 168 171 171 171 190 190 190 191 191 191 191 237 411 411 411 412 412 412 412 441 441 441 442 442 558 558 558 563 563 611 612 625 629 629 630 633

4 3 4 16 0 31 31 3 4 18 1 17 9 0 3 4 16 18 18 16 17 3 4 9 0 2 2 16 18 9 19 13 2 3 4 3 4 15 16 14 3 4 3 4 2 13 19 9 31 2 2 9 12 12 12 31

PRINTED IN U.S.A.

ERROR DESCRIPTION Barometric Pressure Sensor Circuit - Voltage Below Normal Engine Coolant Temperature 1 Sensor Circuit - Voltage Above Normal Engine Coolant Temperature 1 Sensor Circuit - Voltage Below Normal Engine Coolant Temperature 1 Sensor Circuit - Above Normal Range - Moderately Severe Engine Coolant Temperature 1 Sensor Circuit - Above Normal Range - Most Severe Engine Coolant Temperature 1 Sensor Circuit - Condition Exists Engine Coolant Temperature 1 Sensor Circuit - Condition Exists Coolant Level Sensor 1 Circuit - Voltage Above Normal Coolant Level Sensor 1 Circuit - Voltage Below Normal Coolant Level Sensor 1 Circuit - Below Normal Range - Moderately Severe Coolant Level Sensor 1 Circuit - Below Normal Range - Most Severe Coolant Level Sensor 1 Circuit - Below Normal Range - Least Severe Coolant Level Sensor 1 Circuit - Abnormal Update Rate Injector Metering Rail 1 Pressure - Above Normal Range - Most Severe Injector Metering Rail 1 Pressure - Voltage Above Normal Injector Metering Rail 1 Pressure - Voltage Below Normal Injector Metering Rail 1 Pressure - Above Normal Range - Moderately Severe Injector Metering Rail 1 Pressure - Below Normal Range - Moderately Severe Battery 1 Voltage - Below Normal Range - Moderately Severe Battery 1 Voltage - Above Normal Range - Moderately Severe Battery 1 Voltage - Below Normal Range - Least Severe Ambient Air Temperature Sensor 1 Circuit - Voltage Above Normal Ambient Air Temperature Sensor 1 Circuit - Voltage Below Normal Ambient Air Temperature Sensor 1 Circuit - Abnormal Update Rate Engine Crankshaft Speed/Position - Above Normal Range - Most Severe "Engine Crankshaft Speed/Position - Date Erratic, Intermittent or Incorrect" "Engine Crankshaft Speed/Position - Date Erratic, Intermittent or Incorrect" Transmission Output Shaft Speed - Above Normal Range - Moderately Severe Transmission Output Shaft Speed - Below Normal Range - Moderately Severe Transmission Output Shaft Speed - Abnormal Update Rate Transmission Output Shaft Speed - Betwork Receive Error Vehicle Identification Number - Out of Calibration "Exhaust Gas Recirculation Differential Pressure - Date Erratic, Intermittent or Incorrect" Exhaust Gas Recirculation Differential Pressure - Voltage Above Normal Exhaust Gas Recirculation Differential Pressure - Voltage Below Normal Exhaust Gas Recirculation Differential Pressure - Voltage Above Normal Exhaust Gas Recirculation Differential Pressure - Voltage Below Normal Exhaust Gas Recirculation Differential Pressure - Above Normal Range - Least Severe Exhaust Gas Recirculation Differential Pressure - Above Normal Range - Moderately Severe Auxiliary Temperature Sensor Input 1 Circuit - Special Instructions Auxiliary Temperature Sensor Input 1 Circuit - Voltage Above Normal Auxiliary Temperature Sensor Input 1 Circuit - Voltage Below Normal Auxiliary Temperature Sensor Input 2 Circuit - Voltage Above Normal Auxiliary Temperature Sensor Input 2 Circuit - Voltage Below Normal "Accelerator Pedal Idle Validation Switch - Date Erratic, Intermittent or Incorrect" Accelerator Pedal Idle Validation Switch - Out of Calibration Accelerator Pedal Idle Validation Switch - Betwork Receive Error Anti-Lock Braking (ABS) Controller - Abnormal Update Rate Anti-Lock Braking (ABS) Controller - Condition Exists "Auxiliary Intermediate (PTO) Speed Switch Validation - Date Erratic, Intermittent or Incorrect" "Engine Magnetic Speed Lost Both Signals - Date Erratic, Intermittent or Incorrect" Proprietary Datalink Error - Abnormal Update Rate ECM Critical Internal Failure - Bad Intelligent Device ECM Critical Internal Failure - Bad Intelligent Device ECM Calibration Memory - Bad Intelligent Device Electronic Fuel Injection Control Valve Circuit - Condition Exists

105

50960172/E0221

SPN

FMI

ERROR DESCRIPTION

639 639 640 647 647 649 649 649 651 652 652 653 653 654 654 655 656 677 677 697 697 701 702 703 723 723 723 729 729 748 974 974 974 1073 1073 1081 1172 1172 1176 1176 1176 1194 1209 1209 1209 1231 1235 1267 1267 1323 1324 1325 1326 1347 1347 1347

9 13 14 4 3 3 4 5 5 5 7 5 7 5 7 5 5 3 4 3 4 14 3 3 7 2 2 3 4 9 3 4 19 4 3 9 3 4 3 4 2 13 3 4 2 2 2 3 4 31 31 31 31 4 3 7

J1939 Multiplexing Error - Abnormal Update Rate J1939 Multiplexing Error - Out of Calibration Auxiliary Commanded Dual Output Shutdown - Special Instructions Fan Control Circuit - Voltage Below Normal Fan Control Circuit - Voltage Above Normal Engine Exhaust Back Pressure Regulator Control Circuit - Voltage Above Normal Engine Exhaust Back Pressure Regulator Control Circuit - Voltage Below Normal Engine Exhaust Back Pressure Regulator Control Circuit - Current Below Normal Injector Solenoid Driver Cylinder 1 Circuit - Current Below Normal Injector Solenoid Driver Cylinder 2 Circuit - Current Below Normal Injector Solenoid Driver Cylinder 2 Circuit - Mechanical System Not Responding Injector Solenoid Driver Cylinder 3 Circuit - Current Below Normal Injector Solenoid Driver Cylinder 3 Circuit - Mechanical System Not Responding Injector Solenoid Driver Cylinder 4 Circuit - Current Below Normal Injector Solenoid Driver Cylinder 4 Circuit - Mechanical System Not Responding Injector Solenoid Driver Cylinder 5 Circuit - Current Below Normal Injector Solenoid Driver Cylinder 6 Circuit - Current Below Normal Starter Relay Driver Circuit - Voltage Above Normal Starter Relay Driver Circuit - Voltage Below Normal Auxiliary PWM Driver 1 Circuit - Voltage Above Normal Auxiliary PWM Driver 1 Circuit - Voltage Below Normal Auxiliary Input/Output 1 - Special Instructions Auxiliary Input/Output 2 - Voltage Above Normal Auxiliary Input/Output 3 - Voltage Above Normal Engine Camshaft Speed/Position Sensor - Mechanical System Not Responding "Engine Camshaft Speed/Position Sensor - Date Erratic, Intermittent or Incorrect" "Engine Camshaft Speed/Position Sensor - Date Erratic, Intermittent or Incorrect" Intake Air Heater 1 Circuit - Voltage Above Normal Intake Air Heater 1 Circuit - Voltage Below Normal Transmission Output Retarder - Abnormal Update Rate Remote Accelerator Pedal position Sensor - Voltage Above Normal Remote Accelerator Pedal position Sensor - Voltage Below Normal Remote Accelerator Pedal position Sensor - Betwork Receive Error Engine Brake Actuator Driver Output 2 Circuit - Voltage Below Normal Engine Brake Actuator Driver Output 2 Circuit - Voltage Above Normal Engine Wait to Start Lamp - Abnormal Update Rate Turbocharger 1 Compressor Intake Temperature - Voltage Above Normal Turbocharger 1 Compressor Intake Temperature - Voltage Below Normal Turbocharger 1 Compressor Intake Pressure - Voltage Above Normal Turbocharger 1 Compressor Intake Pressure - Voltage Below Normal "Turbocharger 1 Compressor Intake Pressure - Date Erratic, Intermittent or Incorrect" Anti-theft Encryption Seed - Out of Calibration Exhaust Gas Pressure Sensor 1 - Voltage Above Normal Exhaust Gas Pressure Sensor 1 - Voltage Below Normal "Exhaust Gas Pressure Sensor 1 - Date Erratic, Intermittent or Incorrect" "J1939 Network #2 - Date Erratic, Intermittent or Incorrect" "J1939 Network #3 - Date Erratic, Intermittent or Incorrect" Idle Shutdown Vehicle Accessories Relay Driver - Voltage Above Normal Idle Shutdown Vehicle Accessories Relay Driver - Voltage Below Normal Engine Misfire Cylinder 1 - Condition Exists Engine Misfire Cylinder 2 - Condition Exists Engine Misfire Cylinder 3 - Condition Exists Engine Misfire Cylinder 4 - Condition Exists Fuel Pump Pressurizing Assembly 1 Circuit - Voltage Below Normal Fuel Pump Pressurizing Assembly 1 Circuit - Voltage Above Normal Fuel Pump Pressurizing Assembly 1 Circuit - Mechanical System Not Responding

50960172/E0221

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PRINTED IN U.S.A.

SPN

FMI

1377 1378 1387 1387 1388 1388 1388 1569 1623 1623 1623 1632 1639 1639 1668 1675 1761 1761 1761 1761 1761 1761 1761 1761 2623 2623 2630 2630 2789 2791 2791 2791 2791 2791 2797 3031 3031 3031 3031 3031 3031 3216 3216 3216 3216 3216 3216 3216 3218 3226 3226 3226 3226 3226 3228 3246

2 31 3 4 14 3 4 31 9 19 13 14 0 1 2 31 4 3 1 17 18 13 11 10 3 4 3 4 15 13 15 5 6 7 13 4 3 2 9 13 11 4 2 9 13 10 16 20 2 4 9 10 13 20 2 3

PRINTED IN U.S.A.

ERROR DESCRIPTION "Multiple Unit Synchronization Switch - Date Erratic, Intermittent or Incorrect" Engine Oil Change Interval - Condition Exists Auxiliary Pressure Sensor Input 1 Circuit - Voltage Above Normal Auxiliary Pressure Sensor Input 1 Circuit - Voltage Below Normal Auxiliary Pressure Sensor Input 2 Circuit - Special Instructions Auxiliary Pressure Sensor Input 2 Circuit - Voltage Above Normal Auxiliary Pressure Sensor Input 2 Circuit - Voltage Below Normal Engine Protection Torque Derate - Condition Exists Tachograph Output Shaft Speed - Abnormal Update Rate Tachograph Output Shaft Speed - Betwork Receive Error Tachograph Output Shaft Speed - Out of Calibration Engine Torque Limit Feature - Special Instructions Fan Speed - Above Normal Range - Most Severe Fan Speed - Below Normal Range - Most Severe "J1939 Network #4 - Date Erratic, Intermittent or Incorrect" Engine Starter Mode Overcrank Protection - Condition Exists DEF Tank Level - Voltage Below Normal DEF Tank Level - Voltage Above Normal DEF Tank Level - Below Normal Range - Most Severe DEF Tank Level - Below Normal Range - Least Severe DEF Tank Level - Below Normal Range - Moderately Severe DEF Tank Level - Out of Calibration DEF Tank Level - Root Cause Not Known DEF Tank Level - Abnormal Rate of Change Accelerator Pedal Position Sensor 2 Circuit - Voltage Above Normal Accelerator Pedal Position Sensor 2 Circuit - Voltage Below Normal Engine Charge Air Cooler Outlet Temperature - Voltage Above Normal Engine Charge Air Cooler Outlet Temperature - Voltage Below Normal Turbocharger Turbine Intake Temperature - Above Normal Range - Least Severe EGR Valve Control Circuit - Out of Calibration EGR Valve Control Circuit - Above Normal Range - Least Severe EGR Valve Control Circuit - Current Below Normal EGR Valve Control Circuit - Current Above Normal EGR Valve Control Circuit - Mechanical System Not Responding Engine Injector Bank 1 Barcodes - Out of Calibration DEF Tank Temperature - Voltage Below Normal DEF Tank Temperature - Voltage Above Normal "DEF Tank Temperature - Date Erratic, Intermittent or Incorrect" DEF Tank Temperature - Abnormal Update Rate DEF Tank Temperature - Out of Calibration DEF Tank Temperature - Root Cause Not Known Intake NOx Sensor Circuit - Voltage Below Normal "Intake NOx Sensor Circuit - Date Erratic, Intermittent or Incorrect" Intake NOx Sensor Circuit - Abnormal Update Rate Intake NOx Sensor Circuit - Out of Calibration Intake NOx Sensor Circuit - Abnormal Rate of Change Intake NOx Sensor Circuit - Above Normal Range - Moderately Severe Intake NOx Sensor Circuit - Data Drifted High "Intake NOx Sensor Power Supply - Date Erratic, Intermittent or Incorrect" Outlet NOx Sensor - Voltage Below Normal Outlet NOx Sensor - Abnormal Update Rate Outlet NOx Sensor - Abnormal Rate of Change Outlet NOx Sensor - Out of Calibration Outlet NOx Sensor - Data Drifted High "Outlet NOx Sensor Power Supply - Date Erratic, Intermittent or Incorrect" DPF Outlet Temperature - Voltage Above Normal

107

50960172/E0221

SPN

FMI

ERROR DESCRIPTION

3249 3249 3361 3361 3361 3362 3363 3363 3363 3363 3363 3364 3364 3364 3364 3364 3364 3364 3364 3364 3364 3364 3364 3364 3509 3509 3510 3510 3511 3511 3512 3512 3513 3513 3514 3514 3515 3515 3515 3515 3521 3597 3597 3667 3667 3695 4094 4096 4185 4186 4187 4188 4223 4334 4334 4334

17 18 2 3 4 31 3 4 18 16 7 4 3 13 11 18 9 7 12 2 19 10 5 6 4 3 4 3 4 3 3 4 3 4 3 4 10 5 6 11 11 12 2 3 4 2 31 31 31 31 31 31 31 3 4 18

Exhaust Gas Temperature 2 - Below Normal Range - Least Severe Exhaust Gas Temperature 2 - Below Normal Range - Moderately Severe "DEF Dosing Unit Temperature - Date Erratic, Intermittent or Incorrect" DEF Dosing Unit Temperature - Voltage Above Normal DEF Dosing Unit Temperature - Voltage Below Normal DEF Dosing Unit Input Lines - Condition Exists DEF Tank Heater - Voltage Above Normal DEF Tank Heater - Voltage Below Normal DEF Tank Heater - Below Normal Range - Moderately Severe DEF Tank Heater - Above Normal Range - Moderately Severe DEF Tank Heater - Mechanical System Not Responding DEF Quality Sensor Circuit - Voltage Below Normal DEF Quality Sensor Circuit - Voltage Above Normal DEF Quality Sensor Circuit - Out of Calibration DEF Quality Sensor Circuit - Root Cause Not Known DEF Quality Sensor Circuit - Below Normal Range - Moderately Severe DEF Quality Sensor Circuit - Abnormal Update Rate DEF Quality Sensor Circuit - Mechanical System Not Responding DEF Quality Sensor Circuit - Bad Intelligent Device "DEF Quality Sensor Circuit - Date Erratic, Intermittent or Incorrect" DEF Quality Sensor Circuit - Betwork Receive Error DEF Quality Sensor Circuit - Abnormal Rate of Change DEF Quality Sensor Circuit - Current Below Normal DEF Quality Sensor Circuit - Current Above Normal Sensor Supply 1 Circuit - Voltage Below Normal Sensor Supply 1 Circuit - Voltage Above Normal Sensor Supply 2 Circuit - Voltage Below Normal Sensor Supply 2 Circuit - Voltage Above Normal Sensor Supply 3 Circuit - Voltage Below Normal Sensor Supply 3 Circuit - Voltage Above Normal Sensor Supply 4 Circuit - Voltage Above Normal Sensor Supply 4 Circuit - Voltage Below Normal Sensor Supply 5 Circuit - Voltage Above Normal Sensor Supply 5 Circuit - Voltage Below Normal Sensor Supply 6 Circuit - Voltage Above Normal Sensor Supply 6 Circuit - Voltage Below Normal DEF Temperature 2 Sensor - Abnormal Rate of Change DEF Temperature 2 Sensor - Current Below Normal DEF Temperature 2 Sensor - Current Above Normal DEF Temperature 2 Sensor - Root Cause Not Known DEF Property - Root Cause Not Known Injector Power Supply - Bad Intelligent Device "Injector Power Supply - Date Erratic, Intermittent or Incorrect" Engine Air Shutoff Circuit - Voltage Above Normal Engine Air Shutoff Circuit - Voltage Below Normal "Aftertreatment Regeneration Inhibit Switch - Date Erratic, Intermittent or Incorrect" NOx limits exceeded due to Insufficient Reagen Quality - Condition Exists DEF Tank Empty - Condition Exists Overspeed Shutdown Relay Driver - Condition Exists Low Oil Pressure (LOP) Shutdown Relay Driver - Condition Exists High Engine Temperature Shutdown Relay Driver - Condition Exists Pre-Low Oil Pressure Warning Relay Driver - Condition Exists Pre-High Engine Temperature Warning Relay Driver - Condition Exists DEF Pressure Sensor - Voltage Above Normal DEF Pressure Sensor - Voltage Below Normal DEF Pressure Sensor - Below Normal Range - Moderately Severe

50960172/E0221

108

PRINTED IN U.S.A.

SPN

FMI

4334 4334 4337 4340 4340 4340 4342 4342 4342 4344 4344 4344 4360 4360 4360 4360 4360 4360 4363 4363 4363 4363 4363 4364 4376 4376 4376 4792 4792 4794 5024 5031 5125 5125 5245 5246 5394 5394 5394 5484 5484 5491 5491 5571 5571 5571 5603 5603 5605 5625 5625 5626 5742 5742 5743 5743

16 2 10 3 4 5 3 4 5 3 4 5 3 4 2 15 0 16 3 4 2 0 16 18 3 4 7 7 14 31 10 10 3 4 31 0 5 7 2 3 4 3 4 7 0 15 9 31 31 3 4 13 9 12 9 12

PRINTED IN U.S.A.

ERROR DESCRIPTION DEF Pressure Sensor - Above Normal Range - Moderately Severe "DEF Pressure Sensor - Date Erratic, Intermittent or Incorrect" DEF Dosing Temperature Sensor - Abnormal Rate of Change DEF Line Heater 1 Circuit - Voltage Above Normal DEF Line Heater 1 Circuit - Voltage Below Normal DEF Line Heater 1 Circuit - Current Below Normal DEF Line Heater 2 Circuit - Voltage Above Normal DEF Line Heater 2 Circuit - Voltage Below Normal DEF Line Heater 2 Circuit - Current Below Normal DEF Line Heater 3 Circuit - Voltage Above Normal DEF Line Heater 3 Circuit - Voltage Below Normal DEF Line Heater 3 Circuit - Current Below Normal SCR Intake Temperature - Voltage Above Normal SCR Intake Temperature - Voltage Below Normal "SCR Intake Temperature - Date Erratic, Intermittent or Incorrect" SCR Intake Temperature - Above Normal Range - Least Severe SCR Intake Temperature - Above Normal Range - Most Severe SCR Intake Temperature - Above Normal Range - Moderately Severe SCR Outlet Temperature - Voltage Above Normal SCR Outlet Temperature - Voltage Below Normal "SCR Outlet Temperature - Date Erratic, Intermittent or Incorrect" SCR Outlet Temperature - Above Normal Range - Most Severe SCR Outlet Temperature - Above Normal Range - Moderately Severe SCR Catalyst Conversion Efficiency - Below Normal Range - Moderately Severe DEF Return Valve - Voltage Above Normal DEF Return Valve - Voltage Below Normal DEF Return Valve - Mechanical System Not Responding SCR Catalyst System - Mechanical System Not Responding SCR Catalyst System - Special Instructions SCR Catalyst System Missing - Condition Exists Intake NOx Sensor Heater - Abnormal Rate of Change Outlet NOx Sensor Heater - Abnormal Rate of Change Sensor Supply 7 Circuit - Voltage Above Normal Sensor Supply 7 Circuit - Voltage Below Normal SCR Operator Inducement Active - Condition Exists SCR Operator Inducement - Above Normal Range - Most Severe DEF Dosing Valve - Current Below Normal DEF Dosing Valve - Mechanical System Not Responding "DEF Dosing Valve - Date Erratic, Intermittent or Incorrect" Engine Fan Clutch 2 Control Circuit - Voltage Above Normal Engine Fan Clutch 2 Control Circuit - Voltage Below Normal DEF Line Heater Relay - Voltage Above Normal DEF Line Heater Relay - Voltage Below Normal High Pressure Common Rail Fuel Pressure Relief Valve-Mechanical System Not Responding High Pressure Common Rail Fuel Pressure Relief Valve-Above Normal Range - Most Severe High Pressure Common Rail Fuel Pressure Relief Valve - Above Normal Range-Least Severe Cruise Control Disable Command - Abnormal Update Rate Cruise Control Disable Command - Condition Exists Cruise Control Pause Command - Condition Exists Engine Exhaust Back Pressure Regulator Position - Voltage Above Normal Engine Exhaust Back Pressure Regulator Position - Voltage Below Normal Engine Exhaust Back Pressure Regulator - Out of Calibration DPF Temperature Sensor Module - Abnormal Update Rate DPF Temperature Sensor Module - Bad Intelligent Device SCR Temperature Sensor Module - Abnormal Update Rate SCR Temperature Sensor Module - Bad Intelligent Device

109

50960172/E0221

SPN

FMI

5743 5743 5743 5743 5745 5745 5745 5746 5746 5798 6655 6655 6881 6881 6918 6928 520784 520784 520784

3 4 16 11 3 4 18 3 4 10 3 4 9 13 31 31 3 4 5

50960172/E0221

ERROR DESCRIPTION SCR Temperature Sensor Module - Voltage Above Normal SCR Temperature Sensor Module - Voltage Below Normal SCR Temperature Sensor Module - Above Normal Range - Moderately Severe SCR Temperature Sensor Module - Root Cause Not Known DEF Dosing Unit Heater - Voltage Above Normal DEF Dosing Unit Heater - Voltage Below Normal DEF Dosing Unit Heater - Below Normal Range - Moderately Severe DEF Dosing Unit Heater Relay - Voltage Above Normal DEF Dosing Unit Heater Relay - Voltage Below Normal DEF Dosing Unit Heater Temperature - Abnormal Rate of Change Maintain ECU Power Lamp - Voltage Above Normal Maintain ECU Power Lamp - Voltage Below Normal SCR Operator Inducement Inducement Override Switch - Abnormal Update Rate SCR Operator Inducement Inducement Override Switch - Out of Calibration SCR System Cleaning Inhibited Due to Inhibit Switch - Condition Exists SCR System Cleaning Inhibited Due to System Timeout - Condition Exists Fan Blade Pitch Position Sensor Circuit - Voltage Above Normal Fan Blade Pitch Position Sensor Circuit - Voltage Below Normal Fan Blade Pitch Position Sensor Circuit - Current Below Normal

110

PRINTED IN U.S.A.

Hydraulic Schematic

3000 PSI

3900 PSI

3000 PSI

2500 PSI

3900 PSI

2500 PSI 2500 PSI

3900 PSI

2500 PSI

2500 PSI 3 PSI

100 PSI

350 PSI

3700 PSI 3700 PSI

40 PSI 3900 PSI

3700 PSI

3700 PSI 3000 PSI

160 PSI

PRINTED IN U.S.A.

111

50960172/E0221

3900 PSI

3900 PSI

Electrical Schematic (continued on next page)

50960172/E0221

112

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Electrical Schematic (continued from previous page)

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113

50960172/E0221

INTENTIONALLY BLANK

50960172/E0221

114

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Load Zone Charts DL11-44 Standard Carriage - Decal 50381092 Outriggers Down

Standard Carriage - Decal 105743 Outriggers Up

DL11 - 44

DL11-44 12-Ft. Truss Boom - Decal 105745

PRINTED IN U.S.A.

15-Ft. Truss Boom - Decal 105746

115

50960172/E0221

Load Zone Charts DL11-44 1.3-Cu.-Yd. Bucket - Decal 105747

2.5-Cu.-Yd. Bucket - Decal 105748

DL11-44 Winch - Decal 105749

50960172/E0221

Rotate Carriage - Decal 105744

116

PRINTED IN U.S.A.

Load Zone Charts DL11-44 90° Swing Carriage - Decal 105750

180° Swing Carriage - Decal 211019

DL11-44 PWP - Decal 105751

PRINTED IN U.S.A.

117

50960172/E0221

Load Zone Charts DL11-55 Standard Carriage - Decal 105711 Outriggers Up

Standard Carriage - Decal 105712 Outriggers Down

DL11-55 Rotate Carriage - Decal 105713 Outriggers Up

50960172/E0221

Rotate Carriage - Decal 105714 Outriggers Down

118

PRINTED IN U.S.A.

Load Zone Charts DL11-55 1.3-Cu.-Yd. Bucket - Decal 105715 Outriggers Up

1.3-Cu.-Yd. Bucket - Decal 105716 Outriggers Down

DL11-55 12-Ft. Truss Boom - Decal 105717 Outriggers Up

PRINTED IN U.S.A.

12-Ft. Truss Boom - Decal 105718 Outriggers Down

119

50960172/E0221

Load Zone Charts DL11-55 15-Ft. Truss Boom - Decal 105719 Outriggers Up

15-Ft. Truss Boom - Decal 105720 Outriggers Down

DL11-55 Winch - Decal 105721 Outriggers Up

50960172/E0221

Winch - Decal 105722 Outriggers Down

120

PRINTED IN U.S.A.

Load Zone Charts DL11-55 90° Swing Carriage - Decal 105723 Outriggers Up

90° Swing Carriage - Decal 105724 Outriggers Down

DL11-55 PWP - Decal 105725 Outriggers Up

PRINTED IN U.S.A.

PWP - Decal 105726 Outriggers Down

121

50960172/E0221

Load Zone Charts DL12-40 Standard Carriage - Decal 50381093 Outriggers Down

Standard Carriage - Decal L71093 Outriggers Up

DL12 - 40

DL12-40 12-Ft. Truss Boom - Decal L71149

50960172/E0221

15-Ft. Truss Boom - Decal L71150

122

PRINTED IN U.S.A.

Load Zone Charts DL12-40 1.3-Cu.-Yd. Bucket - Decal L71151

2.5-Cu.-Yd. Bucket - Decal L71152

DL12-40 Rotate Carriage - Decal 103168

Winch - Decal L71153

PRINTED IN U.S.A.

123

50960172/E0221

Load Zone Charts DL12-40 90° Swing Carriage - Decal L71154

180° Swing Carriage - Decal 211020

DL12-40 PWP - Decal L71736

50960172/E0221

124

PRINTED IN U.S.A.

Load Zone Charts DL12-55 Standard Carriage - Decal 50308578 Outriggers Up

Standard Carriage - Decal 50308579 Outriggers Down

DL12-55 Rotate Carriage - Decal 50308802 Outriggers Up

PRINTED IN U.S.A.

Rotate Carriage - Decal 50308803 Outriggers Down

125

50960172/E0221

Load Zone Charts DL12-55 1.3-Cu.-Yd. Bucket - Decal 50308805 Outriggers Up

1.3-Cu.-Yd. Bucket - Decal 50308806 Outriggers Down

DL12-55 12-Ft. Truss Boom - Decal 50308809 Outriggers Up

50960172/E0221

12-Ft. Truss Boom - Decal 50308810 Outriggers Down

126

PRINTED IN U.S.A.

Load Zone Charts DL12-55 15-Ft. Truss Boom - Decal 50308811 Outriggers Up

15-Ft. Truss Boom - Decal 50308812 Outriggers Down

DL12-55 Winch - Decal 50308813 Outriggers Up

PRINTED IN U.S.A.

Winch - Decal 50308814 Outriggers Down

127

50960172/E0221

Load Zone Charts DL12-55 90° Swing Carriage - Decal 50308815 Outriggers Up

90° Swing Carriage - Decal 50308816 Outriggers Down

DL12-55 PWP - Decal 50308817 Outriggers Up

50960172/E0221

PWP - Decal 50308818 Outriggers Down

128

PRINTED IN U.S.A.

Torque Recommendations For Hose and Pipe Clamps Mini

Power-Seal

AeroSeal

CT AeroSeal

Hi-Torque

Torque Value Nm. (lb.-in)

Torque Value Nm. (lb.-in)

Torque Value Nm. (lb.-in)

Torque Value Nm. (lb.-in)

Torque Value Nm. (lb.-in)

1.1 - 1.7 (10 - 15) except 305 SS

3.4 - 5.1 (30 - 45) Stainless

3.4 - 5.1 (30 - 45) Stainless

3.4 - 5.1 (30 - 45)

.8 - 1.2 (7.5 - 10.5) 305 SS

2.8 - 4.2 (25 - 37) Carbon

2.8 - 4.2 (25 - 37) Carbon

CT Heavy-Duty

T-Bolt w/ Spring

T-Bolt w/o Spring

V-Band

Torque Value Nm. (lb.-in)

Torque Value Nm. (lb.-in)

Torque Value Nm. (lb.-in)

Torque Value Nm. (lb.-in)

10.2 (90)

PRINTED IN U.S.A.

6.8 (60) 305 Screw

6.8 (60) 1/4” T-Bolt

6.8 (60) 1/4” T-Bolt

6.8 (60) 1/4” V-Band

16.9 (150) 5/16” T-Bolt

16.9 (150) 5/16” T-Bolt

20.3 (180) 5/16” V-Band

129

10.2 (90) 410 Screw

50960172/E0221

Hardware Torque Specifications Use these torque values when tightening hardware—excluding: lock nuts, thread-forming, self-tapping, and metal screws—unless otherwise specified.

NOTE: All torque values are in Nm (lb.-ft.), except those marked with asterisks (*), which are in (lb.-in.).

Unified National Thread

Grade 2 Dry

Oiled

Dry

Oiled

Dry

Oiled

8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16/24 3/8-16 3/8-24 7/16-14 7/16-20 1/2-13 1/2-20 9/16-12 9/16-18 5/8-11 5/8-18 3/4-10 3/4-16 7/8-9 7/8-14 1-8 1-14

2.14 (19*) 2.3 (20*) 3.1 (27*) 3.5 (31*) 7.5 (66*) 8.6 (76*) 15 (11) 16 (12) 27 (20) 31 (23) 43 (32) 49 (36) 47 (35) 54 (40) 75 (55) 81 (60) 102 (75) 115 (85) 176 (130) 203 (150) 169 (125) 190 (140) 258 (190) 285 (210)

1.58 (14*) 1.7 (15*) 2.3 (21*) 2.6 (23*) 5.6 (50*) 6.3 (56*) 12(9) 12 (9) 20 (15) 23 (17) 33 (24) 37 (27) 47 (35) 54 (40) 75 (55) 81 (60) 102 (75) 115 (85) 176 (130) 203 (150) 169 (125) 190 (140) 258 (190) 285 (210)

3.4 (30*) 3.5 (31*) 4.8 (43*) 5.5 (49*) 12 (9) 14 (10) 23 (17) 26 (19) 41 (30) 47 (35) 68 (50) 75 (55) 102 (75) 122 (90) 149 (110) 163 (120) 203 (150) 244 (180) 353 (260) 407 (300) 583 (430) 637 (470) 868 (640) 963 (710)

2.5 (22*) 2.6 (23*) 3.6 (32*) 4.1 (36*) 8.5 (75*) 9.7 (86*) 18 (13) 19 (14) 31 (23) 34 (25) 47 (35) 54 (40) 75 (55) 88 (65) 108 (80) 122 (90) 149 (110) 176 (130) 271 (200) 298 (220) 434 (320) 854 (630) 651 (480) 719 (530)

4.6 (41*) 4.8 (43*) 6.8 (60*) 7.7 (68*) 16 (12) 19 (14) 34 (25) 34 (25) 61 (45) 68 (50) 95 (70) 108 (80) 149 (110) 163 (120) 203 (150) 230 (170) 298 (220) 325 (240) 515 (380) 569 (420) 813 (600) 895 (660) 1220 (900) 1356 (1000)

3.5 (31*) 3.6 (32*) 5.1 (45*) 5.8 (51*) 12 (9) 14 (10) 24 (18) 27 (20) 47 (35) 47 (35) 75 (55) 81 (60) 108 (80) 122 (90) 149 (110) 176 (130) 230 (170) 244 (180) 379(280) 434 (320) 624 (460) 678 (500) 922 (680) 1003 (740)

Grade 5

Grade 8

* Value shown is in pound-force inch (lb.-in.)—inch pounds.

50960172/E0221

130

PRINTED IN U.S.A.

Hardware Torque Specifications Use these torque values when tightening hardware—excluding: lock nuts, thread-forming, self-tapping, and metal screws—unless otherwise specified.

Metric Coarse-Pitch Thread—(DRY) M5 M6 M8 M10 M12 M14 M16 M18 M20 M22 M24 M27 M30

All torque values are in Nm (lb.-ft.)

DIN 912, DIN 931, DIN 933, etc...

8.8

10.9

12.9

5.5 (4.1) 8 (6) 10 (7) 10 (7) 14 (10) 17 (13) 25 (18) 35 (26) 42 (31) 45 (33) 65 (48) 80 (59) 87 (64) 110 (81) 147 (108) 135 (100) 180 (133) 230 (170) 210 (155) 275 (203) 350 (258) 280 (207) 410 (302) 480 (354) 302 (410) 420 (570) 509 (690) 550 (406) 780 (575) 930 (686) 710 (524) 1000 (738) 1190 (878) 1040 (767) 1480 (1092) 1770 (1305) 1420 (1047) 2010 (1482) 2400 (1770)

Metric Coarse-Pitch Thread—(OILED) M6-1 M8-1.25 M10-1.5 M12-1.75 M14-2 M16-2

Metric Fine-Pitch Thread—(DRY) M8X1.0 M10X1.0 M10X1.25 M12X1.25 M12X1.5 M14X1.5 M16X1.5 M18X1.5 M20X1.5 M22X1.5 M24X2.0 M27X2.0 M30X2.0

PRINTED IN U.S.A.

DIN 7984 8.8

10.9

5 (4) 8.5 (6.3) 20 (15) 40 (30) 69 (51) 110 (81) 170 (125) 245 (181) 340 (251) 460 (339) 590 (435) 870 (642) 1200 (885)

7 (5 12 (9) 30 (22) 59 (44) 100 (74) 160 (118) 250 (184) 345 (254) 490 (361) 660 (487) 840 (620) 1250 (922) 1700 (1254)

All torque values are in Nm (lb.-ft.)

DIN 912, DIN 931, DIN 933, etc...

8.8

10.9

12.9

8 (6) 19 (14) 38 (28) 65 (48) 103 (77) 160 (118)

11 (8) 27 (20) 53 (39) 91 (68) 146 (108) 224 (166)

14 (10) 33 (24) 63 (47) 111 (82) 177 (131) 271 (200)

All torque values are in Nm (lb.-ft.)

DIN 912, DIN 931, DIN 933, etc...

8.8

10.9

12.9

25 (18) 37 (27) 43 (32) 50 (37) 75 (55) 88 (65) 49 (36) 71 (52) 83 (61) 87 (64) 130 (96) 150 (111) 83 (61) 125 (92) 145 (107) 135 (100) 200 (148) 235 (173) 210 (155) 310 (229) 360 (266) 315 (232) 450 (332) 530 (391) 440 (325) 630 (465) 730 (538) 590 (435) 840 (620) 980 (723) 740 (546) 1070 (789) 1250 (922) 1100 (811) 1550 (1143) 1800 (1328) 1500 (1106) 2150 (1586) 2500 (1844)

131

DIN 7984 8.8

10.9

22 (16) 43 (32) 42 (31) 75 (55) 72 (53) 120 (89) 180 (133) 270 (199) 375 (277) 500 (369) 630 (465) 920 (679) 1300 (959)

32 (24) 65 (48) 62 (46) 110 (81) 105 (77) 175 (129) 265 (195) 385 (284) 530 (391) 710 (524) 900 (664) 1300 (959) 1850 (1364)

50960172/E0221

Index A

C

Access to Components Chart . . . . . . . . . . . . . . . . . . . . . 76

Capacities - See Chapter 2

Accessories

Checklists, delivery and pre-delivery . . . . . . . . . . . . .13, 15

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Adjustments

Controls

Slide Pads Wear and Clearance . . . . . . . . . . . . . . . . .84

Adjustable Steer Console . . . . . . . . . . . . . . . . . . . . . .39

Air Conditioner

Dash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Clean Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

Right Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Clean/Change Cab Ventilation Filter . . . . . . . . . . . . . .87 Air Filter

Floor and Seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41 Cylinders

Changing Elements . . . . . . . . . . . . . . . . . . . . . . . . . . .90

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75

Check Dust Ejector Valve . . . . . . . . . . . . . . . . . . . . . . .80

D

Operator’s Station Heater/AC Controls . . . . . . . . . . . . . . . . . . . . . . . .34, 38

Dealer Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75 Decals, applying new . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Alternator Check Belt and Fan Hub . . . . . . . . . . . . . . . . . . . . . . .92

Dimensions - See Chapter 2

Indicator Lamp

Display Menu Options . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Dynattach System

Anti-freeze - See Radiator

Attach/Detach Mechanism . . . . . . . . . . . . . . . . . . . . . .53

Attachment Tools Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Dynacarrier System Attach/Detach Hydraulic Mechanism . . . . . . . . . . . . . .55

Operating Methods - See Chapter 6 . . . . . . . . . . . . . .47

Attach/Detach Manual Mechanism . . . . . . . . . . . . . . .54

Axles Alignment Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38 Description - See Chapter 2 . . . . . . . . . . . . . . . . . . . . .12

E Electrical Components

Greasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Characteristics - See Chapter 2

See also Maintenance Interval Chart . . . . . . . . . . . . . .99

Controls and Indicators - See Chapter 4

Axle Oil

Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92

Engine

Checking Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Cold Weather Start Procedures

Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .71

. . . . . . . . . . . . . . . . .50

Description - See Chapter 2

B

Diagnostic Trouble Codes . . . . . . . . . . . . . . . . . . . . .104

Backup Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Oil Pressure Lamp

Battery

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Battery Disconnect Switch Jump Starting Service

Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . .34

. . . . . . . . . . . . . . . . . . . . .43

Temperature Lamp

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

. . . . . . . . . . . . . . . . . . . . . . . . . . .34

. . . . . . . . . . . . . . . . . . . . . . . . . . .34

Engine Oil Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Boom Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Checking Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78

Function Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .71

Function Controls Service

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83

Engine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51 Engine Emergency Override Switch . . . . . . . . . . . . . .38

Bucket Attachment Tool - See Material Handling

Engine Oil Filter, replacing . . . . . . . . . . . . . . . . . . . . . . . .85

50960172/E0221

132

PRINTED IN U.S.A.

Exhaust Filter, Engine and Service Indicator Lamps . . . .36

Hand Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Exhaust Filter Cleaning System . . . . . . . . . . . . . . . . . . . .51

Hourmeter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Automatic Exhaust Filter Cleaning . . . . . . . . . . . . . . . .51

Hydraulic Components, servicing . . . . . . . . . . . . . . . . . . .75

Stationary Exhaust Filter Cleaning . . . . . . . . . . . . . . . .52

Hydraulic Oil

Disable Exhaust Filter Cleaning . . . . . . . . . . . . . . . . . .52

Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Exhaust Filter Cleaning Precautions . . . . . . . . . . . . . .53

Checking level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Diesel Exhaust Fluid (DEF) Precautions . . . . . . . . . . .53

Recommended type

Change Diesel Exhaust Fluid Dosing Unit Filter . . . . . . . .95

Hydraulic Maintenance

Exhaust System, Checking

. . . . . . . . . . . . . . . . . . . . . . .92

Oil Filters, replacing

. . . . . . . . . . . . . . . . . . . . . . . . . .71 . . . . . . . . . . . . . . . . . . . . . . . . . .90

Oil Sump Strainer, replacing . . . . . . . . . . . . . . . . . . . .93

F

Pressure, Checking . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Fan Belt - See Alternator Belt

Hydraulic Pump, servicing . . . . . . . . . . . . . . . . . . . . . . . .75

Frame Level Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Hydraulic Valves, servicing . . . . . . . . . . . . . . . . . . . . . . . .75

Frame Angle Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

I

Fuel - See Separate Engine Manual

Identification Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Fuel Filter Checking and Draining . . . . . . . . . . . . . . . . . . . . . . . . .78

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Replacing

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

Indicator and Operation Symbols . . . . . . . . . . . . . . . . . . . .9

Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Fuse Access Storage Compartment . . . . . . . . . . . . . . . . .43

J

Fuse Functions Storage Compartment . . . . . . . . . . . . . . .44 Fuse Access Engine Compartment . . . . . . . . . . . . . . . . . .44

Joystick Relief Pressure Check . . . . . . . . . . . . . . . . . . . . .93

L

Fuse Functions Engine Compartment . . . . . . . . . . . . . . . .45

Legal Notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

G

Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39 Load Zone Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

General Load Handling Load Capacity and Reach . . . . . . . . . . . . . . . . . . . . . .59

Lubrication See also Maintenance Interval Chart . . . . . . . . . . . . . .99

General Machine Operation

Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Grade and Slope Precautions . . . . . . . . . . . . . . . . . . .57

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Grade Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

M

Grease Fittings Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

Main Relief Pressure Check . . . . . . . . . . . . . . . . . . . . . . .93

Types of Grease . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Maintenance

Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

H Handling Non-Suspended Loads Picking Up the Load . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Recording . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101 Scheduled Intervals . . . . . . . . . . . . . . . . . . . . . . . . . . .99 Mandatory Safety Shutdown Procedure . . . . . . . . . . .17 Mandatory Work Platform Safety Rules . . . . . . . . . . . .24 Material Handling Applications

Carrying the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Digging and Loading . . . . . . . . . . . . . . . . . . . . . . . . . .65

Load Elevation and Placement . . . . . . . . . . . . . . . . . .61

Dumping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Handling Suspended Loads

Leveling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Picking Up Suspended Loads . . . . . . . . . . . . . . . . . . .61

Scraping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Carrying Suspended Loads . . . . . . . . . . . . . . . . . . . . .62 Ground Level Suspended Load Placement . . . . . . . . .62 Elevated Suspended Load Placement . . . . . . . . . . . . .62

PRINTED IN U.S.A.

133

50960172/E0221

O Oils - See Lubrication

S SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Operation

Additional Safety Reminders . . . . . . . . . . . . . . . . . . . .18

Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Before Operation Safety Reminders . . . . . . . . . . . . . .18

Stopping

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Operation Safety Reminders . . . . . . . . . . . . . . . . . . . .19

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Suspended Load Safety Reminders . . . . . . . . . . . . . .20

With Solid Rubber Tires . . . . . . . . . . . . . . . . . . . . . . . .56

DL12-55 Tire Servicing Safety Reminder . . . . . . . . . . .21

Operator Services

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Servicing Safety Reminders . . . . . . . . . . . . . . . . . . . . .21

Operator’s Manual, storing . . . . . . . . . . . . . . . . . . . . . . . . .3

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27, 28

Optional Features

Schematics

Rear Camera System . . . . . . . . . . . . . . . . . . . . . . . . . .45

Electrical

Reverse Radar System . . . . . . . . . . . . . . . . . . . . . . . .45

Hydraulic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111

Outriggers, control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Seat, operator’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

P Parking Brake Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42 Service and Safety Features . . . . . . . . . . . . . . . . . . . . . . .42 Service Intervals

Park Brake Pressure Setting . . . . . . . . . . . . . . . . . . . . . . .93

Daily

Personnel Work Platform Safety Decals . . . . . . . . . . . . . .32 Personnel Work Platform Switch . . . . . . . . . . . . . . . . . . . .39 Personnel Work Platform (PWP) System . . . . . . . . . . . . .23 Personnel Work Platform Checking Procedure . . . . . . . . .81 Pre-Start Walk-Around Inspection . . . . . . . . . . . . . . . . . . .47 Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49 Pump, delivery rates - See Chapter 2

R Radiator Checking coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79 Changing coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Flushing and Refilling . . . . . . . . . . . . . . . . . . . . . . . . .94

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Weekly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

Personnel Work Platform Safety Rules . . . . . . . . . . . . . . .24

Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

100 hours

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

250 hours

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

1000 hours

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87

2000 hours

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

4000 hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Shields . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33 Side Rear View Mirror

Stabilizing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64 Steering - See Controls Steering Relief Pressure Check . . . . . . . . . . . . . . . . . . . .93 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97 Suspended Loads Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

Rear Camera System . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Safety Reminders . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Relay Access Engine Compartment . . . . . . . . . . . . . . . . .44

T

Relay Functions Engine Compartment . . . . . . . . . . . . . . .45 Relay Access Storage Compartment . . . . . . . . . . . . . . . .43

. . . . . . . . . . . . . . . . . . . . . . . . . . .43

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Tables

Relay Functions Storage Compartment . . . . . . . . . . . . . .44

Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71

Replacement Filters Chart . . . . . . . . . . . . . . . . . . . . . . . .72

Material Densities . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Reverse Radar Operation . . . . . . . . . . . . . . . . . . . . . . . . .69

Theft Deterrents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Reverse Radar System . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Torque Specifications for Hardware . . . . . . . . . . . . . . . .130

Road Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66

Torque Specifications for Hose and Pipe Clamps . . . . . .129 Traffic Flow Patterns

. . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Transfer Case Oil Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95 Checking level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

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PRINTED IN U.S.A.

Transmission Description - See Chapter 2 Temperature Lamp

. . . . . . . . . . . . . . . . . . . . . . . . . . .34

Transmission Oil Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90 Checking level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78 Recommended Grades . . . . . . . . . . . . . . . . . . . . . . . .71 Transporting Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67 Unloading

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67

Troubleshooting, PWP . . . . . . . . . . . . . . . . . . . . . . . . . . . .98 Travel Speed - See Controls

W Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Water Trap - See Fuel Filter Wheel Lug Nuts Torque . . . . . . . . . . . . . . . . . . . . . . . . . .80 Windshield Wiper/Washer Switch

. . . . . . . . . . . . . . . . . .38

Wireless Remote Battery Replacement . . . . . . . . . . . . . .25 Work Platform Design Requirements . . . . . . . . . . . . . . . .26

PRINTED IN U.S.A.

135

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