OPERATOR'S MANUAL WITH MAINTENANCE MANUAL

Transcription

1 US (2017/03/28) OPERATOR'S MANUAL WITH MAINTENANCE MANUAL

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3 1st ISSUE 2017/02/09 UPDATED 2017/03/28 GENERAL UPDATE This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be used without express and formal authorization. All rights are reserved. These machine comply with: ANSI/SIA A92.20 CAN B.354.7

4 SECTIONS FOREWORD 1- SAFETY PRECAUTIONS 2- INSTRUCTIONS 3- MAINTENANCE

5 FOREWORD ABOUT THIS MANUAL This manual is a permanent part of this machine and should remain in the weather resistant storage compartment located in the platform at all times. MANITOU reserves the right to change its models ans their equipments without prior notification. Contact MANITOU for updated informations. This manual provide to operators all the informations relating to safety precautions, operating instructions, inspection and maintenance procedures to ensure the safety of use and the reliability of this machine. Study this operator's manual before operate this machine. PURPOSE OF THE MACHINE This machine is designed to transport and lift personnel with their tools and materials to an aerial work site. MANITOU has ensured that this machine is suitable for use under the standard operating conditions defined in this manual. TECHNICAL INFORMATION BULLETINS The safety of the machine and of the personnel is crucial for MANITOU. Technical information bulletins are writed to communicate important safety informations to dealers, machine owners and users. This machine must comply with all the related technical information bulletins. Contact MANITOU or your dealer to have information about the applicable bulletins for your machine. These technical information bulletins are send to machine owners so it is very important to register your machine and ensure that the informations are up to date and accurate. When transfering the machine ownership, update the informations to be sure that the technical information bulletins will be send to the new owner. CONTACTING THE MANUFACTURER It is necessary to contact MANITOU for : - Reporting an accident. - Updating the informations related to the current owner. - Questions regarding standards and regulations compliance. - Questions regarding the use or the safety of the machine. - Questions regarding special product applications or product modifications. MANITOU BF S.A. 430 rue de l Aubinière Ancenis - France Phone: +33 (0)

6 PRODUCT IDENTIFICATION The machine identification plate is riveted to the right of the turntable. 1- Model 2- Serial No. 3- Year of manufacture 4- MEWP classification 5- Unloaded mass (kg - lb) 6- Power (kw - HP) 7- Voltage (VDC) 8- Maximum work platform height (m - ft) 9- Rated load (kg - lb) 10- Maximum no of persons 11- Mass of equipment (kg - lb) 12- Manual forces (N - lbf) 13- Maximum chassis inclination ( ) 14- Maximum wind speed (m/s - mph) 15- External electrical voltage (V) MANITOU BF ANCENIS CEDE FRANCE MODEL MODELE Serial no. N de série Year of manufacture Année de fabrication MEWP classification Classification PEMP Unloaded mass Masse à vide kg lb Power Voltage Puissance Tension kw VDC HP Maximum work platform height Hauteur maxi plateforme de travail m ft ANSI A92.20 CSA B354.7 Rated load Charge nominale = Max. no of persons Nb de personnes maxi + Mass of equipment Masse de l équipement Manual forces Forces manuelles Maximum tilt Inclinaison maxi Maximum wind speed Vitesse maxi du vent External electric voltage Tension électrique externe MADE IN FRANCE N kg lb kg lb N lbf m/s mph V SAFETY ALERT SYMBOLS AND TETS SAFETY ALERT SYMBOL: USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY HAZARDS, OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO AVOID POSSIBLE INJURY OR DEATH. DANGER DANGER INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY. USED IN OPERATOR'S MANUAL: THE BACKGROUNG IS BLACK, THE SAFETY ALERT SYMBOL AND THE TET ARE YELLOW (GREY WHEN PRINTED IN GREYSCALE). USED IN DECALS: THE BACKGROUND IS RED, THE SAFETY ALERT SYMBOL AND THE TET ARE WHITE. WARNING WARNING INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN DEATH OR SERIOUS INJURY. USED IN OPERATOR'S MANUAL: THE BACKGROUNG IS BLACK, THE SAFETY ALERT SYMBOL AND THE TET ARE YELLOW (GREY WHEN PRINTED IN GREYSCALE). USED IN DECALS: THE BACKGROUND IS ORANGE, THE SAFETY ALERT SYMBOL AND THE TET ARE BLACK. CAUTION CAUTION INDICATES A HAZARDOUS SITUATION WHICH, IF NOT AVOIDED, COULD RESULT IN MINOR OR MODERATE INJURY. USED IN OPERATOR'S MANUAL: THE BACKGROUNG IS BLACK, THE SAFETY ALERT SYMBOL AND THE TET ARE YELLOW (GREY WHEN PRINTED IN GREYSCALE). USED IN DECALS: THE BACKGROUNG IS YELLOW, THE SAFETY ALERT SYMBOL AND THE TET ARE BLACK. NOTICE NOTICE INDICATES A PRACTICE NOT RELATED TO PHYSICAL INJURY WHICH, IF NOT AVOIDED, COULD RESULT IN MACHINE DAMAGES. USED IN OPERATOR'S MANUAL: THE BACKGROUNG IS BLACK, THE TET IS YELLOW (GREY WHEN PRINTED IN GREYSCALE). USED IN DECALS: THE BACKGROUND IS BLUE AND THE TET IS WHITE. INSTRUCTIONS INDICATES INSTRUCTIONS WHICH, IF NOT OBSERVED, COULD RESULT IN MACHINE DAMAGES. USED ONLY IN DECALS: THE BACKGROUND IS GREEN AND THE TET IS WHITE.

7 FAMILIARIZATION DANGER THE EMPLOYERS HAVE THE RESPONSIBILITY TO ENSURE THAT ANY OPERATORS ARE FAMILIARIZED WITH THIS MACHINE BEFORE OPERATING IT. WEATHER RESISTANT STORAGE COMPARTMENT LOCATION The weather resistant storage compartment is located in the platform, refer to "2- INSTRUCTIONS: COMPONENTS LOCATION". It must contains the following manuals: - Operator's manual. - Manual of responsibilities. MACHINE CHARACTERISTICS This machine is a MEWP (Mobile Elevating Work Platform) type 3b (self-propelled boom) with the following main characteristics: - Diesel fuel engine. - Hydrostatic transmission. - Four wheel drive. - Two front wheel steering. - Negative brakes on the four wheels. - Maximum platform height = 32 ft 6 in (9.9 m). - Maximum horizontal reach = 20 ft 3.5 in (6.2 m). Refer to "2- INSTRUCTIONS: CHARACTERISTICS" and to "2- INSTRUCTIONS: DIMENSIONS AND RANGE OF MOTION CHART" to have more information about the machine specifications. MACHINE CONTROLS This machine has specific controls to operate the following main functions from the ground and from the platform: - Drive and steer. - Brake. - Raise/lower the primary/secondary booms. - Extend/retract the telescope boom. - Rotate the turntable. - Rotate the platform. Refer to "2- INSTRUCTIONS: MACHINE CONTROLS" to have more information about the controls specifications. MACHINE SAFETY DEVICES This machine has specific safety devices that may restricts functions depending of the conditions: - Footswitch. - Primary boom switch. - Telescope boom switch. - Overload sensors. - Tilt sensor. Refer to "2- INSTRUCTIONS: MACHINE CONTROLS" and to "2- INSTRUCTIONS: OPERATING INSTRUCTIONS" to have more information about the safety devices specifications.

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9 1- SAFETY PRECAUTIONS 1-1

10 1- SAFETY PRECAUTIONS GENERAL FALL HAZARDS ELECTROCUTION HAZARDS TIP-OVER HAZARDS COLLISION AND CRUSHING HAZARDS POISONING HAZARDS INSPECTION AND MAINTENANCE HAZARDS BATTERY HAZARDS

11 GENERAL DANGER FAILURE TO OBEY INSTRUCTIONS, SAFETY PRECAUTIONS AND LISTED HAZARDS OF THIS MANUAL COULD RESULT IN MACHINE OR PROPERTY DAMAGE, PERSONAL INJURY OR DEATH. IF THERE ARE ANY QUESTIONS ABOUT SAFETY PRECAUTIONS AND RULES, PLEASE CONTACT MANITOU. ONLY USE THIS MACHINE FOR THE PURPOSE DESCRIBED IN THIS MANUAL. DO NOT OPERATE THIS MACHINE DURING LIGHTNING STORMS, THUNDERSTORMS, SNOW, ICE OR IN THE EVENT OF UNSAFE WEATHER CONDITIONS. MACHINE OPERATING TEMPERATURE RANGE: REFER TO "3-MAINTENANCE: LUBRICANTS, COOLANT AND FUEL". DO NOT USE THIS MACHINE IN EPLOSIVE ENVIRONMENT AND CLOSE TO SOURCES OF STRONG ELECTROMAGNETIC FIELDS. ONLY THE PROPERLY TRAINED AND AUTHORIZED PERSONNEL MUST BE PERMITTED TO OPERATE THIS MACHINE. DO NOT OPERATE THIS MACHINE WHEN ALONE, A GROUND OPERATOR MUST BE PRESENT AND MUST BE QUALIFIED AND PROPERLY TRAINED TO OPERATE THE MACHINE AND PERFORM THE RESCUE FUNCTIONS. BE FAMILIAR WITH THE RESCUE FUNCTIONS OF THIS MACHINE AS DESCRIBED IN THIS MANUAL. ALL COVER PANELS MUST REMAIN CLOSED AND SECURED DURING MACHINE OPERATION. DO NOT USE A FAULTY OR POORLY MAINTAINED MACHINE. DO NOT ALTER OR REPLACE MACHINE COMPONENTS THAT COULD AFFECT STABILITY. DO NOT DISABLE OR MODIFY ANY SAFETY DEVICES OR SWITCHES. DO NOT OPERATE THIS MACHINE WHILE UNDER INFLUENCE OF ALCOHOL, DRUGS OR MEDICATION. BEFORE OPERATING THIS MACHINE: - READ, UNDERSTAND AND OBEY ALL APPLICABLE LOCAL AND GOVERNMENTAL REGULATIONS, THE EMPLOYER S SAFETY RULES AND THE WORKSITE REGULATIONS. - READ, UNDERSTAND AND OBEY THE MANUAL OF RESPONSIBILITIES, THE OPERATOR S MANUAL AND THE SAFETY DECALS. - PERFORM THE WALK-AROUND INSPECTION, THE ROUTINE MAINTENANCE, THE FUNCTION TESTS AND THE WORKPLACE INSPECTION AS DESCRIBE IN SECTION "2- INSTRUCTIONS". FALL HAZARDS DANGER ALWAYS OPERATE THIS MACHINE WITH A PERSONAL FALL PROTECTION EQUIPMENT. OPERATORS MUST WEAR AN APPROPRIATE PROTECTION IN ACCORDANCE WITH GOVERNMENTAL REGULATIONS ATTACHED TO A LANYARD ANCHORAGE POINT. THE PERSONAL FALL PROTECTION EQUIPMENT MUST COMPLY WITH GOVERNMENTAL REGULATIONS AND MUST BE INSPECTED IN COMPLIANCE WITH THE APPLICABLE SAFETY RULES. DANGER ALWAYS ENTER AND EIT THE PLATFORM THROUGH THE SWING GATE. DO NOT ENTER AND EIT THE PLATFORM IF IT IS NOT FULLY LOWERED. ALWAYS USE TWO HANDS AND ONE FOOT OR TWO FEET AND ONE HAND DURING ENTRY AND EIT. MAKE SURE THAT THE SWING GATE IS PROPERLY CLOSED BEFORE OPERATING THE MACHINE. 1-3

12 DANGER ALWAYS KEEP YOUR FEET FIRMLY ON THE FLOOR OF THE PLATFORM. DO NOT SIT OR CLIMB ON THE PLATFORM GUARD RAILS. DO NOT LEAN OVER GUARDRAILS. DO NOT TRY TO ETEND THE PLATFORM HEIGHT BY USING LADDERS, STEPS, BOES OR SIMILAR ITEMS. DO NOT CLIMB OR WALK ON THE BOOMS. DANGER DO NOT CLIMB ON THE COVER PANELS OF THE MACHINE. CAUTION KEEP THE PLATFORM FLOOR AND YOUR SHOES CLEAN AND FREE OF OIL, MUD AND OTHER SLIPPERY SUBSTANCES. ELECTROCUTION HAZARDS DANGER THIS MACHINE IS NOT INSULATED AND DOES NOT PROVIDE PROTECTION FROM CONTACT OR PROIMITY TO ELECTRICAL CURRENT. DANGER CONSULT A QUALIFIED PERSON IF POWER LINES OR ANY ENERGIZED PARTS MAY CARRY MORE THAN 50 KV. MAINTAIN CLEARANCE AT LEAST 10 FT (3 M) AWAY FROM POWER LINES OR ANY ENERGIZED PARTS WITH ANY PART OF BODY, CONDUCTIVE OBJECT OR ANY PART OF MACHINE ECEPT WHERE THE APPLICABLE LOCAL AND GOVERNMENTAL REGULATIONS, THE EMPLOYER S SAFETY RULES OR THE WORKSITE REGULATIONS REGARDING THE REQUIRED DISTANCE ARE MORE STRICT. ALLOW FOR PLATFORM MOVEMENT AND ELECTRICAL LINE SWAY OR SAG. 1-4

13 DANGER PERSONNEL ON THE GROUND OR IN THE PLATFORM MUST NOT TOUCH THE MACHINE IF IT CONTACTS WITH ELECTRIC LINES OR ANY ENERGIZED PARTS UNTIL ELECTRIC LINES OR ENERGIZED PARTS ARE SHUT OFF. DO NOT USE THIS MACHINE AS A GROUND FOR WELDING. TIP-OVER HAZARDS DANGER DO NOT ECEED THE MAIMUM PLATFORM CAPACITY AS SPECIFIED ON THE TABLE BELOW. THE TOTAL MASS OF OCCUPANTS WITH THEIR TOOLS AND MATERIAL MUST NOT ECEED THE MAIMUM PLATFORM CAPACITY. MAIMUM PLATFORM CAPACITY MAIMUM OCCUPANTS 500 lbs (227 kg) 2 THE LOAD MUST BE UNIFORMLY DISTRIBUTED ON THE PLATFORM FLOOR. 500 lbs (227 kg) MA DANGER DO NOT ECEED THE MAIMUM SLOPE RATINGS OF THE MACHINE WHEN DRIVING. NOTE: REFER TO SECTION "2- INSTRUCTIONS". Maximum slope rating in transport position 1- Platform downhill (gradeability) 40% (21.8 ) 2- Platform uphill 40% (21.8 ) 3- Side slope 25% (14 ) DANGER ALWAYS RAISE THE BOOMS OF THIS MACHINE ON A FIRM AND LEVEL SURFACE. DO NOT DISABLE OR MODIFY THE TILT SENSOR. DO NOT USE THE TILT ALARM AS A LEVEL INDICATOR. THIS MACHINE IS EQUIPPED WITH A SYSTEM THAT RESTRICTS FUNCTIONS WHEN ATTEMPTING TO OPERATE ON A SEVERE SLOPE IN WORK POSITION. NOTE: REFER TO SECTION "2- INSTRUCTIONS". DANGER THE OPERATOR MUST BE FAMILIAR WITH THE GROUND BEFORE DRIVING THE MACHINE. DEPENDING ON THE GROUND CONDITIONS, ONLY THREE WHEELS COULD BE IN CONTACT WITH THE GROUND. BE ETREMELY CAREFULL WHEN DRIVING NEAR HOLES, DROP-OFFS AND BUMPS. ALWAYS ADAPT THE MACHINE SPEED REGARDING TO THE GROUND CONDITIONS. NOTE: REFER TO SECTION "2- INSTRUCTIONS". 1-5

14 DANGER DO NOT SET THE MACHINE IN WORK POSITION OR DRIVE THE MACHINE IN WORK POSITION WHILE ON A SOFT OR UNEVEN TERRAIN, ON OR NEAR A SLOPING SURFACE. ALWAYS CHECK THE ALLOWABLE LOAD CAPACITY BEFORE DRIVING THE MACHINE ON BRIDGES, FLOORS, LOADING RAMPS AND ANY POTENTIAL HAZARDOUS STRUCTURES. DANGER DO NOT USE THE MACHINE AS A CRANE OR A JACK. DO NOT USE THE MACHINE TO TOW OR DRAG MATERIALS OR OTHER MACHINES. DO NOT TIE THE PLATFORM TO A STRUCTURE. DO NOT ATTACH CABLES, WIRES OR SIMILAR ITEMS TO THE PLATFORM. DANGER DO NOT SET THE MACHINE IN WORK POSITION OR DRIVE THE MACHINE IN WORK POSITION IF THE WIND ECEED 28 MPH (45 KM/H), 12.5 M/S OR IF THERE ARE GUSTY WINDS. DOT NOT USE ACCESSORIES THAT COULD INCREASE THE WIND PROFILE OF THE MACHINE. > 28 mph (45 km/h) or >12.5 m/s DANGER DO NOT PUSH OR PULL ON STRUCTURES, OBJECTS OR SIMILAR ITEMS OFF THE PLATFORM. NOTE: MAIMUM ALLOWABLE MANUAL LATERAL FORCE = 90 LBS / 400 N. COLLISION AND CRUSHING HAZARDS DANGER OBEY ALL APPLICABLE LOCAL AND GOVERNMENTAL REGULATIONS, THE EMPLOYER S SAFETY RULES AND THE WORKSITE REGULATIONS REGARDING THE USE OF PERSONAL PROTECTIVE EQUIPMENTS LIKE HARD HAT AND GLOVES. 1-6

15 WARNING OCCUPANTS MUST KEEP ALL BODY PARTS INSIDE THE PLATFORM GUARD RAILING WHEN OPERATING THE MACHINE. ALWAYS HOLD ON THE GUARDRAILS WHEN OPERATING THE MACHINE. WARNING CHECK FOR OBSTRUCTIONS OVERHEAD, ON SIDES AND ON BOTTOM OF THE PLATFORM AT ALL TIMES WHEN OPERATING THE MACHINE. ALWAYS KEEP GROUND PERSONNEL AT LEAST 16.5 FT (5 M) AWAY FROM THE MACHINE. WARNING ALWAYS REFER TO THE COLOR-CODED DIRECTION ARROWS ON THE CHASSIS AND ON THE PLATFORM CONTROLS PANEL BEFORE DRIVING/STEERING THE MACHINE. WARNING BE AWARE OF LIMITED SIGHT DISTANCE AND BLIND SPOTS AT ALL TIMES WHEN DRIVING AND OPERATING THE MACHINE. WARNING THE OPERATOR MUST LIMIT TRAVEL SPEED ACCORDING TO THE CONDITION OF THE GROUND, VISIBILITY, TRAFFIC, SLOPES, LOCATION OF PERSONNEL AND ANY OTHER FACTORS WHICH MAY CAUSE COLLISION OR INJURY. KEEP IN MIND THAT BRAKING DISTANCES CAN BE DIFFERENT DEPENDING ON THE GROUND CONDITION. 1-7

16 POISONING HAZARDS WARNING THE ENGINE PRODUCES CARBONE MONOIDE, ALWAYS USE THIS MACHINE IN WELL-VENTILATED AREAS. INSPECTION AND MAINTENANCE HAZARDS DANGER POWER DOWN THE MACHINE BEFORE PERFORMING THE WALK-AROUND INSPECTION AND THE MAINTENANCE OPERATIONS. DO NOT SMOKE WHEN PERFORMING INSPECTIONS OR MAINTENANCE OPERATIONS. DO NOT EPOSE ELECTRICAL COMPONENTS TO HIGH PRESSURE WASHER. WARNING ALWAYS WEAR A HARD HAT, PROTECTIVE CLOTHING AND GLOVES TO INSPECT THE MACHINE. USE A PIECE OF PAPER OR A CARD-BOARD WHEN CHECKING HYDRAULIC OR AIR LEAKS. EVEN IF THE MACHINE IS SHUT OFF, HYDRAULIC PRESSURE COULD REMAIN IN THE SYSTEM. DO NOT TRY TO REPAIR OR TIGHTEN ANY HYDRAULIC HOSES OR FITTINGS BEFORE RELIEVE HYDRAULIC PRESSURE. WARNING ONLY QUALIFIED SERVICE TECHNICIANS ACCREDITED BY MANITOU SHOULD ACCESS TO THE MACHINE COMPONENTS PROTECTED BY COVER PANELS ECEPT FOR THE WALK-AROUND INSPECTION AND THE ROUTINE MAINTENANCE. AVOID CONTACT WITH HOT COMPONANTS AND FLUIDS. DANGER DO NOT FILL THE FUEL TANK OR HYDRAULIC TANK WHEN THE ENGINE IS RUNNING. ALWAYS REFUEL THE MACHINE IN WELL-VENTILATED AREAS. DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE WHEN REFUELING. DO NOT USE THE MACHINE AS A GROUND FOR WELDING. 1-8

17 BATTERY HAZARDS CAUTION BATTERIES CONTAIN FLUID THAT IS HIGHLY CORROSIVE. ALWAYS WEAR PROTECTIVE CLOTHING, GLOVES AND SAFETY EYEWEAR OR FACE SHIELD WHEN DURING MAINTENANCE. AVOID CONTACT WITH ANY BODY PARTS AND CLOTHING AT ALL TIMES. FLUSH ANY EPOSED AREA WITH CLEAN WATER AND SEEK ADVICE A HEALTHCARE PROFESSIONAL. WARNING ALWAYS DISCONNECT BATTERIES WHEN CHARGING. ALWAYS CHARGE THE BATTERIES IN WELL-VENTILATED AREAS. MAKE SURE THAT THE BATTERIES TERMINALS CAN NOT CONTACT METALLIC ITEMS. DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE NEAR BATTERIES DURING CHARGING OR MAINTENANCE. ALWAYS DISCONNECT BATTERIES BEFORE ANY WELDING JOB ON THE STRUCTURE. 1-9

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19 2- INSTRUCTIONS 2-1

20 2- INSTRUCTIONS INSPECTIONS 2-4 GENERAL WALK-AROUND INSPECTION AND ROUTINE MAINTENANCE INTRODUCTION PROCEDURE FUNCTION TESTS INTRODUCTION TEST THE GROUND CONTROLS AND THE ALARMS TEST THE PLATFORM CONTROLS AND THE ALARMS WORKPLACE INSPECTION INTRODUCTION PROCEDURE COMPONENTS LOCATION 2-14 DECALS LOCATION - USA 2-16 DECALS LOCATION - CANADA 2-18 SAFETY COMPONENTS 2-20 SWING GATE LANYARD ANCHORAGE POINTS TURNTABLE LOCK PIN MACHINE CONTROLS 2-22 GROUND CONTROLS PANEL AND GROUND SAFETY DEVICES PLATFORM CONTROLS PANEL AND PLATFORM SAFETY DEVICES LCD READOUT SCREEN PAGES STARTUP PAGE PREHEATING PAGE ENGINE START PAGE MENU PAGE EDIT A SUB MENU WORK PAGE FAULT PAGE FAULT CODE PAGE WARNING PAGE MENUS/SUB-MENUS OPERATING INSTRUCTIONS 2-39 GENERAL TRANSPORT/WORK POSITION OPERATE FROM THE GROUND START THE ENGINE STOP THE ENGINE POSITION THE PLATFORM EMERGENCY STOP

21 OPERATE FROM THE PLATFORM START THE ENGINE STOP THE ENGINE DRIVE AND STEER POSITION THE PLATFORM EMERGENCY STOP SIMULTANEOUS FUNCTIONS GROUND CONTROLS PANEL PLATFORM CONTROLS PANEL DRIVING ON A SLOPE MEASURE THE SLOPE GRADE LOCKED FUNCTIONS TRANSPORT POSITION WORK POSITION RESCUE FUNCTIONS IF THE ENGINE IS RUNNING PROPERLY IF THE ENGINE FAILS STANDARD EQUIPMENT BATTERY MASTER SWITCH DOUBLE 110 V ELECTRICAL OUTLET IN THE PLATFORM BLOCK HEATER OPTIONS HYDRAULIC OIL HEATER BATTERY HEATER V GENERATOR WORK LIGHT ANTI-CRUSHING "SAFEMANSYSTEM" PARKING AND STORAGE 2-51 GENERAL TRANSPORT AND LIFTING 2-52 GENERAL TRANSPORT INSTRUCTIONS LOAD AND UNLOAD THE MACHINE SET THE MACHINE POSITION TIE DOWN THE MACHINE TURNTABLE LOCK PIN FREE-WHEEL CONFIGURATION FOR WINCHING LIFTING INSTRUCTIONS PROCEDURE CHARACTERISTICS 2-58 DIMENSIONS AND RANGE OF MOTION CHART

22 INSPECTIONS GENERAL DANGER THE SECTION "1- SAFETY PRECAUTIONS" OF THIS MANUAL AND THE MANUAL OF RESPONSIBILITIES MUST HAVE BEEN READ AND FULLY UNDERSTOOD BY ANY OPERATOR THAT SHOULD USE THE MACHINE IN THE SAME WORK SHIFT. THE INSPECTIONS MUST BE PERFORMED PRIOR EACH WORK SHIFT BY ANY OPERATOR THAT SHOULD USE THE MACHINE. ALWAYS CHECK THE WEATHER CONDITIONS LIKE THE WIND SPEED OR AN IMMINENT STORM. DO NOT PERFORM THE MACHINE INSPECTIONS IN THE EVENT OF UNSAFE WEATHER CONDITIONS. REFER TO "COMPONENTS LOCATION" DURING THE INSPECTIONS TO HAVE INFORMATIONS ABOUT THE COMPONENTS LOCATION. WALK-AROUND INSPECTION AND ROUTINE MAINTENANCE INTRODUCTION DANGER THE WALK-AROUND INSPECTION AND THE ROUTINE MAINTENANCE ARE DESIGNED TO ENSURE THAT THE MACHINE IS IN GOOD CONDITION AND CAN BE OPERATED SAFELY. THE OPERATOR HAS THE RESPONSIBILITY TO PERFORM THE WALK-AROUND INSPECTION AND THE ROUTINE MAINTENANCE BEFORE OPERATING THIS MACHINE. THE MACHINE MUST BE TURNED OFF DURING THE WALK-AROUND INSPECTION. THE OPERATOR HAS THE AUTHORITY TO REMOVE THE MACHINE FROM SERVICE IF ANY PROBLEM IS DETECTED. DO NOT OPERATE THE MACHINE IF THERE ARE DAMAGES OR MALFUNCTIONS. IF DAMAGES OR MALFUNCTIONS ARE DISCOVERED, THE MACHINE MUST BE REPAIRED BY A QUALIFIED SERVICE TECHNICIAN, THE WALK-AROUND INSPECTION MUST BE DONE AGAIN AFTER REPAIRING. PROCEDURE The operator must perform a visual inspection of the machine: - Check that the operator manual and the manual of responsibilities are clean, complete and stored in the weather resistant storage compartment located in the platform. - Check the decals and be sure they are all present, clean and legible, refer to "DECALS LOCATION". - Check the levels: diesel fuel, engine oil, coolant, battery fluid and hydraulic oil, refer to section "3- MAINTENANCE". - Check the battery charge level, refer to "FUNCTION TESTS". - Check if there are no leaks: diesel fuel, engine oil, coolant, battery fluid, and hydraulic oil. - Check the good condition of hydraulic pumps, distributors, valves, motors, cylinders, hoses, fittings and all hydraulic components. - Check the good condition of wheels, tires, tie-rods, ring gear, spindles, pins, and all mechanical components. - Check the good condition of the platform: structure, floor, swing gate and lanyard anchorage points. - Check the good condition of covers panels, handles and latches. - Check the good condition of controls panels, batteries, cables, fuses, beacons, electric wires, connectors, foot switch, switches, push buttons, control handles and all electrical components. - Check if there are no excessive mechanical clearance or wear in the structure. - Check if there are no missing or loose pins, fasteners, nuts or bolts. - Check if there are no missing parts and no unauthorized parts or modifications. - Check the machine structure for dents or damages, welds or component cracks and for excessive corrosion. - Remember all the not visible areas that must be checked when performing the function tests. 2-4

23 FUNCTION TESTS INTRODUCTION DANGER THE WALK-AROUND INSPECTION AND THE ROUTINE MAINTENANCE MUST HAVE BEEN PROPERLY DONE BEFORE PERFORMING THE FUNCTION TESTS. THE FUNCTION TESTS ARE DESIGNED TO CHECK IF THERE ARE ANY MALFUNCTIONS BEFORE PUTTING THE MACHINE IN SERVICE. THE OPERATOR HAS THE RESPONSIBILITY TO PERFORM FUNCTION TESTS BEFORE OPERATING THIS MACHINE. PERFORM THE FUNCTION TESTS OUTDOOR IN A WELL-VENTILATED AREA, ON A FIRM AND LEVEL SURFACE, CLEAR OF ANY OBSTRUCTIONS AND DEBRIS. ALWAYS START THE TESTS BY THE GROUND CONTROLS. CHECK THE GOOD CONDITION OF THE COMPONENTS THAT WERE NOT VISIBLE DURING THE WALK-AROUND INSPECTION. THE OPERATOR HAS THE AUTHORITY TO REMOVE THE MACHINE FROM SERVICE IF ANY PROBLEM IS DETECTED. DO NOT OPERATE THE MACHINE IF THERE ARE DAMAGES OR MALFUNCTIONS. IF DAMAGES OR MALFUNCTIONS ARE DISCOVERED, THE MACHINE MUST BE REPAIRED BY A QUALIFIED SERVICE TECHNICIAN, THE WALK-AROUND INSPECTION, THE ROUTINE MAINTENANCE AND THE FUNCTION TESTS MUST BE DONE AGAIN AFTER REPAIRING. REFER TO "MACHINE CONTROLS" AND TO "OPERATING INSTRUCTIONS" TO HAVE MORE INFORMATIONS ABOUT THE MACHINE CONTROLS AND THE OPERATING INSTRUCTIONS. TEST THE GROUND CONTROLS AND THE ALARMS ENGINE START AND EMERGENCY STOP BUTTON The engine is not running. The machine is in transport position. The turntable and the platform are in neutral position. - Make sure that: The battery master switch is turned to the ON position. The ignition key switch is turned to the position. The emergency stop buttons of the ground controls panel and platform controls panel are pulled out (ON position). - Turn the ignition key switch to the position. Result: The preheating page should display on the LCD readout screen. The diesel fuel level and the battery charge level should display on the LCD readout screen. "Permanent amber beacon" option activated: the amber beacon should turn on. If the outside temperature is above 14 F (-10 C): - Wait for the end of preheating cycle and start the engine. - Push in the emergency stop button (OFF position). Result: The emergency stop button should operate properly. The engine should stop after at least 2 seconds. - Pull out the emergency stop button (ON position). Result: The preheating page should display on the LCD readout screen. If the outside temperature is below 14 F (-10 C): - Wait for the end of preheating cycle. Press the engine start mode push-button and release it. - Start the engine. Result: The engine should run at high idling speed. - Wait for 30 seconds. Raise the primary/secondary boom for 3 seconds. Result: The engine speed should change to low idling speed. - Fully lower the primary/secondary boom. - Push in the emergency stop button (OFF position). Result: The engine should stop after at least 2 seconds. 2-5

24 MACHINE FUNCTIONS CAUTION DURING THE TEST, ROTATE THE TURNTABLE A SMALL ANGLE TO AVOID INJURY. The engine is not running. The machine is in transport position. The turntable and the platform are in neutral position. - Start the engine. - Do not touch the platform/ground controls selection switch. Try to operate all functions one after the other. Result: No functions should operate. - Push and hold the platform/ground controls selection switch to the right. Operate all functions one after the other. Check that all mechanical stops and cut-out switches operate properly. Result: All functions should operate smoothly with precise control. All mechanical stops and cut-out switches should operate properly. "Permanent amber beacon" option deactivated: the amber beacon should turn on when operating each function. "Permanent amber beacon" option activated: the amber beacon should remain on when operating each function. "All motion alarm" option: the horn should sound intermittently when operating each function. - Set the machine in transport position. Set the turntable and the platform in neutral position. TILT ALARM The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. - Raise the primary/secondary boom for 10 seconds, extend the telescope boom for 4 seconds - Open the turntable right cover panel. Locate the tilt sensor. - Press down and hold the tilt sensor. Result: The buzzer should sound intermittently. The tilt sensor LED should turn off. The LCD readout screen should display a tilt warning page. - Release the tilt sensor. Result: The buzzer should stop. The tilt sensor LED should turn on. The LCD readout screen should not display the tilt warning page anymore. - Fully retract the telescope boom and fully lower the primary/secondary boom. OVERLOAD ALARM The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. - Put a 608 lbs (276 kg) mass in the platform. Result: The buzzer should sound continually. The LCD readout screen should display an overload warning page. The overload warning light of the platform controls panel should flash. - Remove 57 lbs (26 kg) from the 608 lbs (276 kg) mass to have a 550 lbs (250 kg) mass in the platform. Result: The buzzer should stop. The LCD readout screen should not display the overload warning page anymore. The overload warning light of the platform controls panel should stop. - Remove all the mass from the platform. RESCUE FUNCTIONS The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. - Raise the primary/secondary boom for 10 seconds and extend the telescope boom for 4 seconds. - Turn the ignition key switch to the position. Result: The engine should stop after at least 2 seconds. - Operate all functions by using the rescue functions. Result: All functions should operate by using the rescue functions. 2-6

25 TEST THE PLATFORM CONTROLS AND THE ALARMS ENGINE START AND EMERGENCY STOP BUTTON The engine is not running. - Start the engine from the ground controls panel. - Set the machine in transport position. Set the turntable and the platform in neutral position. Fully lower the jib boom. - Push in the emergency stop button (OFF position) of the ground controls panel. Result: The engine should stop after at least 2 seconds. - Pull out the emergency stop button (ON position) of the ground controls panel. - Enter the platform. Make sure that the gate is properly closed. Attach your lanyard to an anchorage point. - Push in the emergency stop button (OFF position). - Pull out the emergency stop button (ON position). Result: The emergency stop button should operate properly. The preheat indicator light should turn on. - Wait for the end of preheating cycle and start the engine. Result: The engine should start. - Push in the emergency stop button (OFF position). Result: The engine should stop after at least 2 seconds. HORN The engine is not running. The machine is in transport position. The turntable and the platform are in neutral position. - Pull out the emergency stop button (ON position). - Wait for the end of preheating cycle and start the engine. - Press the horn push-button. Result: The horn should sound. MACHINE FUNCTIONS AND FOOT SWITCH Note: do not drive and steer the machine during this test. CAUTION DURING THE TEST, TILT THE PLATFORM A SMALL ANGLE TO AVOID INJURY. The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. - Do not press down the foot switch. Try to operate all functions one after the other. Result: No functions should operate. - Press down the foot switch. - Operate all functions one after the other. Check that all mechanical stops and cut-out switches operate properly. Result: All functions should operate smoothly with precise control. All mechanical stops and cut-out switches should operate properly. "Permanent amber beacon" option deactivated: the amber beacon should turn on when operating each function. "Permanent amber beacon" option activated: the amber beacon should remain on when operating each function. "All motion alarm" option: the horn should sound intermittently when operating each function. - Set the machine in transport position. Set the turntable and the platform in neutral position. 2-7

26 DRIVING/BRAKING/STEERING FUNCTIONS AND SPEED SELECTION (TRANSPORT POSITION) The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. Note: "Permanent amber beacon" option deactivated: the amber beacon should turn on when driving and steering. "Permanent amber beacon" option activated: the amber beacon should remain on when driving and steering. "All motion alarm" option or "drive/steer alarm" option: the horn should sound intermittently when driving and steering. - Do not press the trigger of the drive/steer control handle. Do not press down the foot switch. Try to drive and steer. - Do not press the trigger of the drive/steer control handle. Press down and hold the foot switch. Try to drive and steer. - Press and hold the trigger of the drive/steer control handle. Do not press down the foot switch. Try to drive and steer. Result: Driving and steering functions should not operate. - Select the HARE speed (high speed). Slightly raise the jib boom for a better visibility. - Press and hold the trigger of the drive/steer control handle. Press down and hold the foot switch. - Drive the machine forward and reverse a short distance. - Drive the machine forward and test the brakes. Evaluate and remember the braking distance of the machine. - Drive the machine forward and test the steering. Result: Driving and steering functions should operate smoothly with precise control. The driving speed selection should operate proprely. The braking function should operate properly. - Select the TURTLE speed (slow speed). - Drive the machine forward and reverse a short distance. - Drive the machine forward and test the brakes. Evaluate and remember the braking distance of the machine. - Drive the machine forward and test the steering. Result: Driving and steering functions should operate smoothly with precise control. The driving speed selection should operate proprely. The braking function should operate properly. WORK POSITION SPEED The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is slightly raised. Note: "Permanent amber beacon" option deactivated: the amber beacon should turn on when driving and steering. "Permanent amber beacon" option activated: the amber beacon should remain on when driving and steering. "All motion alarm" option or "drive/steer alarm" option: the horn should sound intermittently when driving and steering. - Select the HARE speed (high speed). - Drive the machine forward a short distance. Evaluate and remember the speed of the machine. - Brake the machine. - Raise the primary/secondary boom for 3 seconds. - Drive the machine forward a short distance. Result: The driving speed should be "Work position" speed. - Fully lower the primary/secondary boom. - Drive the machine forward a short distance. Result: The driving speed should be HARE speed (high speed). - Extend the telescope boom for 2 seconds. - Drive the machine forward a short distance. Result: The driving speed should be "Work position" speed. - Fully retract the telescope boom. - Drive the machine forward a short distance. Result: The driving speed should be HARE speed (high speed). 2-8

27 DIFFERENTIAL LOCK The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is slightly raised. - Select the TURTLE speed (slow speed). - Fully steer to the right or to the left without driving. - Drive the machine forward a short distance. - Push the differential lock push-button and release it. Result: The right wheel or the left wheel should skid. The differential lock indicator light should turn on. - Push the differential lock push-button and release it. Result: The right wheel or the left wheel should no longer skid. The differential lock indicator light should turn off. - Brake the machine. - Push the differential lock push-button and release it. Result: The differential lock indicator light should turn on. - Wait for at least 2 seconds. Result: The differential lock indicator light should turn off. DRIVING WITH COLOR-CODED DIRECTION ARROWS AND DRIVING DIRECTION FUNCTION "DRIVE ENABLE" The engine is running. The TURTLE speed (low speed) is selected. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is slightly raised. - Rotate the turntable on the left or on the right until the angle of the turntable is greater than 90 relative to the neutral position. Result: The driving direction warning light "Drive Enable" should turn on. - Try to drive/steer. Result: The drive/steer functions should not operate. - Complete the turntable rotation on the left or on the right until stop. - Push and hold the driving direction push-button "Drive Enable". - Drive/steer the machine forward and reverse a short distance. Match the black/white arrows on the chassis and on the platform controls panel to drive in the desired direction. Result: The drive/steer functions should operate. The colors of the arrows should allow to drive and steer in the desired direction. - Rotate the turntable on the left or on the right until the angle of the turntable is less than 90 relative to the neutral position. Result: The driving direction warning light "Drive Enable" should turn off. - Set the turntable in neutral position. 2-9

28 DRIVING ON A SLOPE AND TILT ALARM The engine is running. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is slightly raised. - Select a slope between 20% (11.3 ) and 30% (16.7 ). - Select the RAMP speed (slow speed with full power). - Raise the jib boom to the horizontal. - Slowly drive the machine forward on the slope, facing it, platform downhill. Result: The driving speed selection should operate proprely. The tilt indicator warning should flash. The buzzer should sound intermittently. - Brake the machine on the slope. Result: The braking function should operate properly. The machine should stay in place on the slope for a minimum of 1 minute. - Try to raise the primary/secondary boom and to extend the telescope boom. Result: The functions should not operate. - Slowly drive reverse to set the machine off the slope on a level surface. Result: The tilt warning light should turn off. The buzzer should stop. - Raise the primary/secondary boom for 3 seconds and extend the telescope boom for 2 seconds. - Slowly drive the machine forward on the slope, facing it, platform downhill. Result: The machine should brake automatically. The tilt warning light should flash. The buzzer should sound intermittently. - Try to raise the primary/secondary boom, to extend the telescope boom, to raise/ lower the platform tilt level and to drive/steer. Result: The functions should not operate. - Fully retract the telescope boom and fully lower the primary/secondary boom. Result: The functions should operate. - Slowly drive reverse to set the machine off the slope on a level surface. Result: The tilt warning light should turn off. The buzzer should stop. - Fully lower the jib boom. - Push in the emergency stop button (OFF position) to stop the engine. - Pull out the emergency stop button (ON position). - Exit the platform. - Turn the ignition key switch to the position. Turn the battery master switch to the OFF position. 2-10

29 110 V GENERATOR (OPTION) The engine is not running. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is fully lowered. - Turn the battery master switch to the ON position. Turn the ignition key switch to the position. - Enter the platform. Make sure that the gate is properly closed. Attach your lanyard to an anchorage point. - Start the engine. - Press the generator push-button to start the 110 V generator. - Plug an electrical device (110 V/60 Hz, maximum 15 A) into one of the output of the double 110 V electrical outlet then into the other output of the double 110 V electrical outlet. Result: The electrical device should operate in both cases. - Press on the generator push-button to stop the 110 V generator. Result: The electrical device should not operate. - Push in the emergency stop button (OFF position) to stop the engine. - Exit the platform. - Turn the ignition key switch is to the position. Turn the battery master switch to the OFF position. ANTI-CRUSHING "SAFEMANSYSTEM" (OPTION) The engine is not running. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is fully lowered. - Turn the battery master switch to the ON position. Turn the ignition key switch to the position. Result: The buzzer should sound one time. The blue flashing beacon should flash several times and stop flashing. - Enter the platform. Make sure that the gate is properly closed. Attach your lanyard to an anchorage point. - Start the engine. - Raise the primary/secondary boom for 3 seconds and extend the telescope boom for 3 seconds. - Press and release the safety edge. Result: The horn should sound intermittently and the blue flashing beacon should flash. "Automatic telescope boom retractation" option: the telescope boom retracts automatically during less than 2 seconds. - Press the reset push-button. Result: The horn should stop sounding and the blue flashing beacon should stop flashing. - Fully retract the telescope boom and fully lower the primary/secondary boom. Result: The functions should operate properly. - Raise the primary/secondary boom for 3 seconds and extend the telescope boom for 3 seconds. - Press and hold the safety edge. Result: The horn should sound intermittently and the blue flashing beacon should flash. "Automatic telescope boom retractation" option: the telescope boom retracts automatically during less than 2 seconds. - Press on the reset push-button without release the safety edge. - Fully retract the telescope boom and fully lower the primary/secondary boom. Result: The functions should operate properly. The horn and the blue flashing beacon should continue to operate. - Release the safety edge. Result: The horn should stop sounding and the blue flashing beacon should stop flashing. - Push in the emergency stop button (OFF position) to stop the engine. - Exit the platform. - Turn the ignition key switch is to the position. Turn the battery master switch to the OFF position. 2-11

30 WORKPLACE INSPECTION INTRODUCTION DANGER THE WALK-AROUND INSPECTION, THE ROUTINE MAINTENANCE AND THE FUNCTION TESTS MUST HAVE BEEN PROPERLY DONE BEFORE PERFORMING THE WORKPLACE INSPECTION. THE WORKPLACE INSPECTION IS ESSENTIAL TO COLLECT A WIDE RANGE OF INFORMATIONS ABOUT THE WORKING AREA BEFORE OPERATING THE MACHINE. THE OPERATOR HAS THE RESPONSIBILITY TO DETECT AND REMEMBER ANY POSSIBLE HAZARDS TO AVOID THEM WHILE OPERATING THE MACHINE. PROCEDURE The operator must check and remember: - Weather conditions like the wind speed or an imminent storm. Do not operate the machine in the event of unsafe weather conditions. - Electric lines, cranes, building structures, trees and any possibly hazardous overhead obstructions. - Electrical components, building structures, fences and any possibly hazardous ground obstructions. - Holes, drop-offs, bumps, debris and any possibly hazardous ground conditions. - Slopes, slippery and uneven surfaces and any possibly hazardous surface conditions. - Travel of the ground personnel and of the other machines or vehicules and any possibly hazardous circulation conditions. - Bridges, gateways, ramps and any possibly hazardous structures that would not withstand with the mass of the machine. - Any other possibly hazardous locations. 2-12

31 2-13

32 COMPONENTS LOCATION

33 LEGEND 1- PLATFORM 2- SWING GATE 3- LANYARD ANCHORAGE POINTS 4- WEATHER RESISTANT STORAGE COMPARTMENT 5- PLATFORM CONTROLS PANEL AND COVER PANEL 6- BUZZER 7- FOOT SWITCH 8- JIB BOOM 9- TELESCOPE BOOM 10- PRIMARY BOOM 11- SECONDARY BOOM 12- TURNTABLE 13- RING GEAR 14- TURNTABLE LOCK PIN 15- TURNTABLE RIGHT COVER PANEL 16- GROUND CONTROLS PANEL 17- DIESEL FUEL TANK (UNDER COVER PANEL) 18- FUEL TANK CAP 19- TILT SENSOR (UNDER COVER PANEL) 20- HORN (UNDER COVER PANEL) 21- TURNTABLE LEFT COVER PANEL 22- RESCUE MANUAL PUMP + PUMP LEVER (UNDER COVER PANEL) 23- AMBER BEACON 24- BLUE FLASHING BEACON (OPTION: ANTI-CRUSHING "SAFEMANSYSTEM") 25- OIL SIGHT GAUGE 26- LEFT CHASSIS COVER PANEL 27- FUEL FILTER/VALVE 28- CHASSIS RIGHT COVER PANEL 29- CHASSIS REAR COVER PANEL 30- ENGINE (UNDER COVER PANEL) 31- AIR FILTER BO (UNDER COVER PANEL) 32- HYDROSTATIC PUMP (UNDER COVER PANEL) 33- FUSE BO (UNDER COVER PANEL) 34- COOLANT RADIATOR (UNDER COVER PANEL) 35- CHASSIS FRONT COVER PANEL 36- BATTERY MASTER SWITCH 37- BATTERY (UNDER COVER PANEL) 38- HYDRAULIC OIL TANK (UNDER COVER PANEL) 39- FRONT DRIVE/STEER WHEELS 40- REAR DRIVE WHEELS Front, rear, left and right are defined by: - The machine is in transport position, the turntable and the platform are in neutral position, refer to "TRANSPORT/WORK POSITION". - The operator is located in the platform and is looking in the direction of the front wheels. 2-15

34 DECALS LOCATION - USA

35 LEGEND ITEM NUMBER PART NUMBER QUANTITY DECAL DESCRIPTION LANYARD ANCHORAGE POINT LIFTING POINT TIE DOWN POINT WHEEL LOAD WHEEL SIZE AND TIGHTENING TORQUE DIESEL FUEL DANGER - EPLOSION HAZARD WARNING - EPOSED ROTATING FAN BLADES DANGER - ELECTROCUTION HAZARD DANGER - FALL HAZARD DANGER - TIP-OVER HAZARD DANGER - TIP-OVER HAZARD DANGER - IMPROPER USE HAZARD WARNING - EPLOSION / BURN HAZARD DANGER - TIP-OVER HAZARD WARNING - COLLISION HAZARD A- BRAKE RELEASED INSTRUCTIONS WARNING - COLLISION HAZARD / B- BRAKE RELEASED INSTRUCTIONS WARNING - COLLISION HAZARD WARNING - RESTRICTED ACCESS WARNING - CRUSH HAZARD WARNING - CRUSH HAZARD WARNING - DRIVE DIRECTION HAZARD WARNING - FOOT SWITCH WARNING - LIMIT SWITCHES DANGER - EPLOSION HAZARD DANGER - RUNAWAY HAZARD LIFTING TRANSPORT/TIE DOWN RESCUE CONTROLS INSTRUCTIONS FAULT CODES OPERATOR'S MANUAL LOCATION WARNING - COLLISION HAZARD NOTICE - HIGH PRESSURE WASHER CAUTION - BURN HAZARD WHITE ARROW BLACK ARROW BATTERY MASTER SWITCH V POWER (STANDARD EQUIPMENT: 110 V ELECTRICAL OUTLET IN THE PLATFORM) BLOCK HEATER HYDRAULIC OIL HEATER (OPTION: HYDRAULIC OIL HEATER) BATTERY HEATER (OPTION: BATTERY HEATER) V POWER (OPTION: 110 V GENERATOR) DANGER - ELECTROCUTION HAZARD (OPTION: 110 V GENERATOR) CAUTION - BURN HAZARD (OPTION: WORKLIGHT), LOCATION: REFER TO "OPTIONS" CALIFORNIA PROPOSITION 65 WARNING Note: grey shadings indicate that the decals are hidden (under cover panels). 2-17

36 DECALS LOCATION - CANADA

37 LEGEND ITEM NUMBER PART NUMBER QUANTITY DECAL DESCRIPTION LANYARD ANCHORAGE POINT LIFTING POINT TIE DOWN POINT WHEEL LOAD WHEEL SIZE AND TIGHTENING TORQUE DIESEL FUEL DANGER - EPLOSION HAZARD WARNING - EPOSED ROTATING FAN BLADES DANGER - ELECTROCUTION HAZARD DANGER - FALL HAZARD DANGER - TIP-OVER HAZARD DANGER - TIP-OVER HAZARD DANGER - IMPROPER USE HAZARD WARNING - EPLOSION / BURN HAZARD DANGER - TIP-OVER HAZARD WARNING - COLLISION HAZARD A- BRAKE RELEASED INSTRUCTIONS WARNING - COLLISION HAZARD / B- BRAKE RELEASED INSTRUCTIONS WARNING - COLLISION HAZARD WARNING - RESTRICTED ACCESS WARNING - CRUSH HAZARD WARNING - CRUSH HAZARD WARNING - DRIVE DIRECTION HAZARD WARNING - FOOT SWITCH WARNING - LIMIT SWITCHES DANGER - EPLOSION HAZARD DANGER - RUNAWAY HAZARD LIFTING TRANSPORT/TIE DOWN RESCUE CONTROLS INSTRUCTIONS FAULT CODES OPERATOR'S MANUAL LOCATION WARNING - COLLISION HAZARD NOTICE - HIGH PRESSURE WASHER CAUTION - BURN HAZARD WHITE ARROW BLACK ARROW BATTERY MASTER SWITCH V POWER (STANDARD EQUIPMENT: 110 V ELECTRICAL OUTLET IN THE PLATFORM) BLOCK HEATER HYDRAULIC OIL HEATER (OPTION: HYDRAULIC OIL HEATER) BATTERY HEATER (OPTION: BATTERY HEATER) V POWER (OPTION: 110 V GENERATOR) DANGER - ELECTROCUTION HAZARD (OPTION: 110 V GENERATOR) CAUTION - BURN HAZARD (OPTION: WORKLIGHT), LOCATION: REFER TO "OPTIONS" Note: grey shadings indicate that the decals are hidden (under cover panels). 2-19

38 SAFETY COMPONENTS Note: item numbers are the same as used in "COMPONENTS LOCATION". SWING GATE DANGER FALL HAZARD, REFER TO SECTION "1- SAFETY PRECAUTIONS". The swing gate 2 of the platform is equipped with a latch handle. 2 LANYARD ANCHORAGE POINTS DANGER FALL HAZARD, REFER TO SECTION "1- SAFETY PRECAUTIONS". The lanyard anchorage points are used to attached the personal fall protection equipment when operators are in the platform. The platform is equipped with two lanyard anchorage points 4. Only one operator is allowed per anchorage point. 4 4 TURNTABLE LOCK PIN Refer to "TRANSPORT AND LIFTING"

39 2-21

40 MACHINE CONTROLS GROUND CONTROLS PANEL AND GROUND SAFETY DEVICES Left and right are defined by: - The machine is in transport position, the turntable and the platform are in neutral position. Refer to "TRANSPORT/WORK POSITION". - The operator is located in the platform and is looking in the direction of the front wheels EMERGENCY STOP BUTTON IGNITION KEY SWITCH ENGINE START PUSH-BUTTON ENGINE START MODE PUSH-BUTTON PLATFORM/GROUND CONTROLS SELECTION SWITCH KEYPAD FOR MACHINE FUNCTIONS KEYPAD FOR LCD READOUT SCREEN LCD READOUT SCREEN TILT SENSOR HORN AMBER BEACON BLUE FLASHING BEACON (OPTION: ANTI-CRUSHING "SAFEMANSYSTEM")

41 PLATFORM CONTROLS PANEL AND PLATFORM SAFETY DEVICES Drive forward, drive reverse, left and right are defined by: - The machine is in transport position, the turntable and the platform are in neutral position. Refer to "TRANSPORT/WORK POSITION". - The operator is located in the platform and is looking in the direction of the front wheels FOOT SWITCH EMERGENCY STOP BUTTON PREHEAT INDICATOR LIGHT ENGINE START PUSH-BUTTON HORN PUSH-BUTTON PLATFORM ROTATION SWITCH JIB BOOM SWITCH PLATFORM TILT LEVEL SWITCH TELESCOPE BOOM SWITCH PRIMARY/SECONDARY BOOM AND TURNTABLE CONTROL HANDLE DRIVE/STEER CONTROL HANDLE DRIVING SPEED SELECTION SWITCH DIFFERENTIAL LOCK PUSH-BUTTON DIFFERENTIAL LOCK INDICATOR LIGHT DRIVING DIRECTION WARNING LIGHT "DRIVE ENABLE" DRIVING DIRECTION PUSH-BUTTON "DRIVE ENABLE" TILT ALARM WARNING LIGHT TILT PUSH-BUTTON FAULTS WARNING LIGHT LOW FUEL LEVEL WARNING LIGHT OVERLOAD WARNING LIGHT BUZZER GENERATOR PUSH-BUTTON (OPTION: 110 V GENERATOR) SAFETY EDGE (OPTION: ANTI-CRUSHING "SAFEMANSYSTEM") RESET PUSH-BUTTON (OPTION: ANTI-CRUSHING "SAFEMANSYSTEM")

42 1- EMERGENCY STOP BUTTON WARNING PUSH IN THE EMERGENCY STOP BUTTON TO STOP ALL THE FUNCTIONS AND TO CUT OFF THE ENGINE IN THE EVENT OF AN ANOMALY OR A DANGEROUS SITUATION. WHEN PUSHING IN THE EMERGENCY STOP BUTTON, THE FUNCTIONS CAN STOP ABRUPTLY. 1 The red mushroom shaped button has two position: - OFF position: pushed in. - ON position: pulled out. Note: this emergency stop button has priority at all times, even when functions are operated from the platform controls panel. 2- IGNITION KEY SWITCH The key switch has two positions: Power down and engine stop. The key can be removed. Power up and start of the engine preheating cycle. The key can not be removed. Note: the emergency stop button of the ground controls panel and of the platform controls panel must be in the ON position to power up the machine start the engine preheating cycle ENGINE START PUSH-BUTTON - Press and hold the push-button to start the engine. - Release it when the engine is started ENGINE START MODE PUSH-BUTTON - Press the push-button to switch SUN/SNOW POSITION: SUN POSITION by default for an outside temperature higher than 14 F (-10 C). SNOW POSITION for an outside temperature below 14 F (-10 C): Press the push-button and release it. Start the engine. The engine runs at high idle speed. Wait for 30 to 60 seconds depending on the outside temperature without operate any other function. Press the push-button or operate any function to restore the low idle speed PLATFORM/GROUND CONTROLS SELECTION SWITCH The switch has two positions: PLATFORM CONTROLS when released: To operate machine controls from the platform. GROUND CONTROLS: Push and hold the switch to the right to operate machine functions from the ground

43 6- KEYPAD FOR MACHINE FUNCTIONS - Push and hold the platform/ground controls selection switch to the right. Press and hold the relevant keys to operate the machine functions: A- RAISE THE JIB BOOM. B- LOWER THE JIB BOOM. C- ETEND THE TELESCOPE BOOM. D- RETRACT THE TELESCOPE BOOM. E- RAISE THE PRIMARY/SECONDARY BOOM. F- LOWER THE PRIMARY/SECONDARY BOOM. G- ROTATE THE TURNTABLE TO THE LEFT. H- ROTATE THE TURNTABLE TO THE RIGHT. I- RAISE THE PLATFORM TILT LEVEL. J- LOWER THE PLATFORM TILT LEVEL. 6 A B G C D E F H I J 7- KEYPAD FOR LCD READOUT SCREEN - Press the relevant keys to control the LCD readout screen pages: Press the ARROWS keys to navigate in the menu and the sub-menu pages. Press the MINUS/PLUS keys to change parameters in the sub-menu pages. Press the OK key to: Validate selections made by using the ARROWS or the MINUS/PLUS keys. Delete a fault display without solving it. The fault is no longer displayed and stored in the fault history. Press the MENU key to: Display the menu page. Exit a sub-menu and go back to the operating page. Press the EIT key to: Cancel a current validation. Go back to the previous level in the sub-menu pages. Press the FAULT key to display the fault code page. Note: refer to "LCD READOUT SCREEN PAGES" to see exemples of screen pages LCD READOUT SCREEN The LCD readout screen displays all startup steps, settings and provides access to specific sub-menus such as: Machine maintenance. Fault history. Hour counters (engine operating hours counter, daily operating hours counter...). Note: refer to "LCD READOUT SCREEN PAGES" to see exemples of screen pages

44 9- TILT SENSOR A green LED located on the tilt sensor indicates its operating status: - Green LED turned on: maximum chassis inclination is not reached. - Green LED turned off: maximum chassis inclination is reached HORN The horn sounds when the horn push-button is pressed. "All motion alarm" option: it sounds intermittently when functions are operated and when driving/steering the machine, refer to "MENUS/SUB-MENUS: OPTIONS: KLAON MODE". "Drive/steer alarm" option: it sounds intermittently when driving/steering the machine, refer to "MENUS/SUB-MENUS: OPTIONS: KLAON MODE". 10 Anti-crushing "SafeManSystem" option: it sounds intermittently when the anti-crushing system is in alarm mode, refer to "OPTIONS". 11- AMBER BEACON "Permanent amber beacon" option deactivated: the amber beacon turns on when functions are operated and when driving/steering the machine, refer to "MENUS/SUB- MENUS: OPTIONS: ALWAYS FLASH. LIGHT". 11 "Permanent amber beacon" option activated: the amber beacon turns on when the machine is powered up, refer to "MENUS/SUB-MENUS: OPTIONS: ALWAYS FLASH. LIGHT". 12- BLUE FLASHING BEACON (OPTION: ANTI-CRUSHING "SAFEMANSYSTEM") The blue flashing beacon turns on when the anti-crushing "SAFEMANSYSTEM" option is in alarm mode, refer to "OPTIONS"

45 13- FOOT SWITCH NOTICE DO NOT PRESS DOWN THE FOOT SWITCH WHEN STARTING THE ENGINE. IF DONE: - A FAULT PAGE IS DISPLAYED ON THE LCD READOUT SCREEN. - PUSH IN THE EMERGENCY STOP BUTTON AND PULL IT OUT. - START AGAIN THE MACHINE WITHOUT PRESSING DOWN THE FOOT SWITCH. - Press down and hold the foot switch to operate functions from the platform controls panel. Note: the functions could not operate if the foot switch is released EMERGENCY STOP BUTTON WARNING PUSH IN THE EMERGENCY STOP BUTTON TO STOP ALL THE FUNCTIONS AND TO CUT OFF THE ENGINE IN THE EVENT OF AN ANOMALY OR A DANGEROUS SITUATION. 13 WHEN PUSHING IN THE EMERGENCY STOP BUTTON, THE FUNCTIONS CAN STOP ABRUPTLY. The red mushroom shaped button has two position: - OFF position: pushed in. - ON position: pulled out. Note: the emergency stop button has priority at all times, except when the emergency stop button of the ground controls panel is in the OFF position. 15- PREHEAT INDICATOR LIGHT The indicator light turns on during the engine preheating cycle. It turns off when the preheating cycle is finish ENGINE START PUSH-BUTTON - Press and hold the push-button to start the engine. - Release it when the engine is started HORN PUSH-BUTTON - Press and hold the push-button to sound the horn. - Release it to stop sounding

46 18- PLATFORM ROTATION SWITCH - Press down and hold the foot switch. ROTATE THE PLATFORM TO THE LEFT - Push and hold the switch to the left. Release to stop. ROTATE THE PLATFORM TO THE RIGHT - Push and hold the switch to the right. Release to stop JIB BOOM SWITCH - Press down and hold the foot switch. RAISE THE JIB BOOM - Push and hold the switch forward. Release to stop. LOWER THE JIB BOOM - Pull and hold the switch backwards. Release to stop PLATFORM TILT LEVEL SWITCH - Press down and hold the foot switch. RAISE THE PLATFORM TILT LEVEL - Push and hold the switch forward. Release to stop. LOWER THE PLATFORM TILT LEVEL - Pull and hold the switch backwards. Release to stop TELESCOPE BOOM SWITCH - Press down and hold the foot switch. ETEND THE TELESCOPE BOOM - Push and hold the switch forward. Release to stop. RETRACT THE TELESCOPE BOOM - Pull and hold the switch backwards. Release to stop

47 22- PRIMARY/SECONDARY BOOM AND TURNTABLE CONTROL HANDLE NOTICE THE PROPORTIONAL CONTROL HANDLE MUST BE OPERATED SMOOTHLY AND WITHOUT JERKING. - Press down and hold the foot switch. 22 RAISE THE PRIMARY/SECONDARY BOOM - Push and hold the control handle forward. Release to stop. LOWER THE PRIMARY/SECONDARY BOOM - Pull and hold the control handle backward. Release to stop. ROTATE THE TURNTABLE TO THE LEFT - Push and hold the control handle to the left. Release to stop. ROTATE THE TURNTABLE TO THE RIGHT - Push and hold the control handle to the right. Release to stop. 23- DRIVE/STEER CONTROL HANDLE WARNING B C ALWAYS REFER TO THE COLOR-CODED DIRECTION ARROWS ON THE CHASSIS AND ON THE PLATFORM CONTROLS PANEL BEFORE DRIVING/STEERING THE MACHINE. A NOTICE THE PROPORTIONAL CONTROL HANDLE MUST BE OPERATED SMOOTHLY AND WITHOUT JERKING. - Press and hold the trigger A, press down and hold the footswitch to drive and steer the machine. The drive/steer functions could not operate if the trigger and/or the foot switch are released. DRIVE FORWARD - Push and hold the control handle forward. Release to brake. DRIVE REVERSE - Pull and hold the control handle backwards. Release to brake. BRAKE - Release the control handle to the neutral position to activate the brakes. The brakes are also activated when the trigger and/or the foot switch are released. STEER TO THE LEFT - Press and hold the push-button B. Release to stop steering. STEER TO THE RIGHT - Press and hold the push-button C. Release to stop steering. 24- DRIVING SPEED SELECTION SWITCH NOTICE THE DRIVING SPEED SELECTION OPERATES IN TRANSPORT POSITION ONLY, REFER TO "TRANSPORT/ WORK POSITION". ALWAYS BRAKE THE MACHINE BEFORE SELECTING THE DRIVING SPEED. 24 The switch has three positions: - TURTLE speed position to drive the machine at slow speed. - RAMP speed position to drive the machine at slow speed with full power. - HARE speed position to drive the machine at high speed. 2-29

48 25- DIFFERENTIAL LOCK PUSH-BUTTON NOTICE THE DIFFERENTIAL LOCK SHOULD BE ACTIVATED WHEN THE STEERING WHEELS ARE IN STRAIGHT-AHEAD POSITION. - Press the push-button to activate the differential lock and release it. - Press the push-button to deactivate the differential lock and release it. Note: the differential lock is automatically deactivated if the machine is stopped for more than 2 seconds. 25 Note: the differential lock is automatically activated when the machine is in work position. 26- DIFFERENTIAL LOCK INDICATOR LIGHT The indicator light turns on when the differential lock is activated. Note: the indicator light does not turn on when the differential lock is automatically activated (machine in work position) DRIVING DIRECTION WARNING LIGHT "DRIVE ENABLE" The indicator light turns on when the angle of the turntable is greater than 90 relative to the neutral position, the drive/steer functions are locked: - Refer to driving 'direction push-button "Drive Enable'". The indicator light is turned off when the angle of the turntable is less than 90 relative to the neutral position DRIVING DIRECTION PUSH-BUTTON "DRIVE ENABLE" WARNING ALWAYS REFER TO THE COLOR-CODED DIRECTION ARROWS ON THE CHASSIS AND ON THE PLATFORM CONTROLS PANEL BEFORE DRIVING AND STEERING THE MACHINE. - Press and hold the push-button to recover drive/steer functions when the driving direction warning light "Drive Enable" is turned on

49 29- TILT ALARM WARNING LIGHT The indicator light flashes and the buzzer sounds intermittently when the machine is on a severe slope. Some functions are locked, refer to "LOCKED FUNCTIONS". - To stop the tilt alarm: 1- Retract the telescope boom. 2- Lower the primary/secondary boom. 3- Move the machine on a level surface TILT PUSH-BUTTON DANGER THE MACHINE COULD TIP OVER WHEN THIS FUNCTION IS OPERATED. ONLY USE WITH ETREME CAUTION. - Press and hold the push-button to operate locked functions when the machine is on a severe slope and when the tilt alarm waning light flash FAULTS WARNING LIGHT The indicator light flashes and the buzzer sounds intermittently when a major machine fault is detected: - Power down the machine immediately. - Check the fault code displayed on the LCD readout screen. 31 Major machine faults: CAN communication Solenoid valve Overload sensor Engine oil pressure Engine oil pressure sensor Engine coolant temperature Very low fuel level Engine overspeed 32- LOW FUEL LEVEL WARNING LIGHT The indicator light flashes and the buzzer sounds when the diesel fuel level is low. There are 3 different alarm levels that indicates: - Level 1: 3 beeps every 10 minutes. - Level 2: 3 beeps every minute. - Level 3: 3 beeps every 10 seconds. It is no longer possible to raise the primary/ secondary boom, to raise the jib boom and to extend the telescope boom after the first 5 seconds. The fault warning light flashes OVERLOAD WARNING LIGHT The indicator light flashes and the buzzer sounds continuously when the load in the platform has reached the maximum capacity. All the machine functions are locked, refer to "LOCKED FUNCTIONS". - To stop the overload alarm: Remove the excessive load

50 34- BUZZER The buzzer sounds intermittently when the machine is on a severe slope, refer to "TILT ALARM WARNING LIGHT". It sounds continuously when the maximum platform capacity is reached, refer to "OVERLOAD ALARM WARNING LIGHT". It sounds when the diesel fuel is low, refer to "LOW FUEL LEVEL INDICATOR LIGHT". It sounds intermittently when functions can not be operated simultaneously, refer to "SIMULTANEOUS FUNCTIONS". Anti-crushing "SafeManSystem" option: it sounds intermittently when the anti-crushing system is in alarm mode, refer to "OPTIONS" GENERATOR PUSH-BUTTON (OPTION: 110 V GENERATOR) Refer to "OPTIONS" SAFETY EDGE (OPTION: ANTI-CRUSHING "SAFEMANSYSTEM") Refer to "OPTIONS" RESET PUSH-BUTTON (OPTION: ANTI-CRUSHING "SAFEMANSYSTEM") Refer to "OPTIONS"

51 LCD READOUT SCREEN PAGES STARTUP PAGE Once powered up, the startup page is displayed briefly, then the PREHEATING PAGE is displayed. Note: the current time is displayed at the top of each page. The serial number of the machine is displayed at the bottom of each page. PREHEATING PAGE The preheating page is displayed during the engine preheating cycle. The bar graph increases proportionally to the elapsed time of the preheating cycle. The preheating cycle is finish when the bar graph is full. A faults/warnings search is automatically performed: - If no faults/warnings are detected: the ENGINE START PAGE is displayed. - If a fault is detected: a FAULT PAGE is displayed. - If a warning is detected: a WARNING PAGE is displayed. Note: the battery voltage 1 and the diesel fuel level 2 is displayed at the PREHEATING PAGE, the ENGINE START PAGE, the WORK PAGE and the FAULT PAGE. 1 2 ENGINE START PAGE The engine can be started when OK is displayed. Accessing to the menu page is possible, refer to MENU PAGE. When the engine is started, the WORK PAGE is displayed. MENU PAGE - Press the MENU key to display the menu page. - Select a menu by pressing the ARROWS keys and confirm by pressing the OK key. - Select a sub-menu (if applicable) by pressing the MINUS/PLUS keys and confirm by pressing the OK key. - Go back to the WORK PAGE by pressing the MENU key. Note: refer to "MENUS/SUB-MENUS". 2-33

52 EDIT A SUB MENU - After selecting a menu, select the desired sub menu (if applicable) by using the ARROWS keys. - Press the MINUS/PLUS keys to change parameters. - Validate once by pressing the OK key. A confirmation message is displayed. - Press again OK key to confirm. - Go back to the previous page by pressing the EIT key. - Go back to the MENU PAGE by pressing the MENU key. Note: refer to "MENUS/SUB-MENUS". WORK PAGE NOTICE A WORK PAGE WITH THE WRENCH 1 DISPLAYED INDICATE THAT A MAINTENANCE OPERATION MUST BE DONE. THE MACHINE MUST BE STOPPED IMMEDIATELY AND MUST BE MAINTENED BY A QUALIFIED SERVICE TECHNICIAN. 1 The WORK PAGE with the platform illustration is displayed by default and the platform controls are activated. The WORK PAGE with the chassis/turntable illustration is displayed when the ground controls are activated. Refer to "GROUND CONTROLS PANEL AND GROUND SAFETY DEVICES". OR FAULT PAGE NOTICE DEPENDING ON THE FAULT, SOME FUNCTIONS COULD BE LOCKED. THE MACHINE MUST BE STOPPED AND MUST BE REPAIRED BY A QUALIFIED TECHNICIAN. A FAULT PAGE is displayed when a machine fault occurs. - Press the FAULT key to display the FAULT CODE PAGE. 2-34

53 FAULT CODE PAGE Press the OK key to delete the fault display without solving it. The fault is no longer displayed and stocked in the fault history. Note: the illustration shows a fault code exemple. WARNING PAGE A WARNING PAGE is displayed intermittently with the FAULT PAGE when a machine warning occurs. - Solve the problem to go back to the WORK PAGE. Note: the illustrations shows two differents warnings exemples. 2-35

54 MENUS/SUB-MENUS User Dealer/renter Icons Menus/sub-menus No access code required Settings Visualization adjustment Access code required Settings Visualization adjustment Code Options Language System parameters Maintenance Maintenance History Klaxon mode (1) Always flash. light (2) Locking telescop Drive in working mode Tilt in working mode Safe Man System Auto retract tel. (SMS) Reduce speed fast + bkwd Unbrake on steering move Easy manager English Deutsch Nederlands Francais Engine management Arm management Arm bumper Telescop management Telescop bumper Jib management Turret management Bskt levell mgmt Bskt rotation mgmt Steering management Generator Maint periods USB download Oil change at Oil filter at Air filter at Fuel filter at Hydraulic filter at Hydrostat filter at Lubrification at Mechanical check at (1): NONE = none, AVCT = drive/steer alarm, MVT = all motion alarm. (2): OFF = deactivated, ON = activated. 2-36

55 User Dealer/renter Icons Menus/sub-menus No access code required Settings Visualization adjustment Access code required Settings Visualization adjustment Contrast Screen settings Brightness Date and time Button tones Codification Program and equipment codes Machine selection Hour counters Rental Engine Day hours Power supply Fuses INTOR UC233 Input/output visualisation INANA UC233 HSCE UC233 OUTTOR UC233 OUTPWM UC233 Lifting arm Lowering arm Telescop extend Telescop retract Lifting jib Lowering jib Diagnostic Turret rotation Lifting basket tilt Lowering basket tilt Basket rotation Driving Steering Generator activation Engine starter Defaults history 2-37

56 User Dealer/renter Icons Menus/sub-menus No access code required Settings Visualization adjustment Access code required Settings Visualization adjustment Step engine speed test 1/5 Step engine speed test 2/5 Engine accel calibration Joysticks calibration Mvt start calibration Speed calibration Pressure setting Overload calibration Generator calibration Parameters setting Step engine speed test 3/5 Step engine speed test 4/5 Step engine speed test 5/5 Arm lifting down Retract telescop Jib lifting down Forward drive working mode Arm lifting up Arm lifting down Extend telescop Retract telescop Jib lifting up Jib lifting down Rotation turret Basket right rotation Basket left rotation Forward drive working mode Backward drive working mode Forward drive slow transport Backward drive slow transport Forward drive slope transport Backward drive slope transport Mach parametres restoration Mach parametres saving Raw factory prm restoration 2-38

57 OPERATING INSTRUCTIONS GENERAL DANGER THE SECTION "1- SAFETY PRECAUTIONS" OF THIS MANUAL AND THE MANUAL OF RESPONSIBILITIES MUST HAVE BEEN READ AND FULLY UNDERSTOOD. THE WALK-AROUND INSPECTION, THE ROUTINE MAINTENANCE, THE FUNCTION TESTS AND THE WORK PLACE INSPECTION MUST HAVE BEEN PROPERLY PERFORMED BEFORE OPERATING THE MACHINE ON THE WORK AREA, REFER TO "INSPECTIONS" DO NOT USE THIS MACHINE FOR ANY OTHER PURPOSE THAN TRANSPORTING AND LIFTING PERSONNEL WITH THEIR TOOLS AND MATERIALS TO AN AERIAL WORK SITE. THE OPERATOR HAS THE RESPONSIBILITY TO READ AND FULLY UNDERSTAND THE OPERATING INSTRUCTIONS. REFER TO "MACHINE CONTROLS" FOR DETAILLED INFORMATIONS ABOUT THE MACHINE CONTROLS. TRANSPORT/WORK POSITION TRANSPORT POSITION: The machine is in transport position when the primary/ secondary boom is fully lowered and when the telescope boom is fully retract. The jib boom can be raised or not, the turntable and the platform can be rotated or not. The turntable and platform are in neutral position when the primary/secondary boom and the platform are parallel to the machine chassis with the platform between the two rear wheels. Drive forward, drive reverse, front, rear, left and right are defined by: - The machine is in transport position, the turntable and the platform are in neutral position. - The operator is located in the platform and is looking in the direction of the front wheels. TURTLE speed, RAMP speed and HARE speed can be selected in transport position only, refer to the table below to have more informations. DRIVE FORWARD STEER RIGHT ROTATE TO THE RIGHT DRIVE REVERSE STEER LEFT ROTATE TO THE LEFT FRONT WHEELS REAR WHEELS TURTLE speed selected RAMP speed selected HARE speed selected Drive forward TURTLE speed activated RAMP speed activated HARE speed activated Drive reverse TURTLE speed activated RAMP speed activated RAMP speed activated Differential lock activated TURTLE speed activated RAMP speed activated RAMP speed activated WORK POSITION: The machine is considered in work position when the primary/secondary boom is not fully lowered or when the telescope boom is not fully retract. The jib boom can be raised or not, the turntable and the platform can be rotated or not. The "Work position" speed and the differential lock are automatically activated and when the machine is in work position. 2-39

58 OPERATE FROM THE GROUND Refer to "GROUND CONTROLS PANEL AND GROUND SAFETY DEVICES" to have more informations about the machine controls. START THE ENGINE Make sure that the battery master switch is turned to the ON position. Make sure that the emergency stop buttons of the ground controls panel and of the platform controls panel are pulled in (ON position). - Turn the ignition key switch to the position. - Wait for the end of the engine preheating cycle, refer to "LCD READOUT SCREEN PAGES". - Start the engine, refer to "ENGINE START PUSH-BUTTON" and refer to "ENGINE START MODE PUSH-BUTTON" if the outside temperature is below 14 F (-10 C). - If the engine fails to start, turn the ignition key switch to the position. Turn it to the position, wait for the end of the preheating cycle and try to start again the engine. Note: refer to the maintenance personnel if the engine fails to start after several tries. STOP THE ENGINE - Turn the ignition key switch to the position or push in the emergency stop button (OFF position). POSITION THE PLATFORM - Push and hold the platform/ground selection switch to the right. - Press and hold the relevant keys of the keypad for machine functions to operate functions. - Release the keys or the platform/ground selection switch to stop the activated functions. Note: perform combinations of keys to operate simultaneous functions, refer to "SIMULTANEOUS FUNCTIONS" on next page. EMERGENCY STOP - Push in the emergency stop button (OFF position). OPERATE FROM THE PLATFORM Refer to "PLATFORM CONTROLS AND PLATFORM SAFETY DEVICES" to have more informations about the machine controls. START THE ENGINE Make sure that the battery master switch is turned to the ON position. Make sure that the emergency stop buttons of the ground controls panel and of the platform controls panel are in the ON position. Make sure that the ignition key switch is turned to the position at the ground controls panel. - Wait for the end of the engine preheating cycle, refer to "PREHEATING INDICATOR LIGHT". - Start the engine, refer to "ENGINE START PUSH-BUTTON". Note: refer to "OPERATE FROM THE GROUND" if the outside temperature is below 14 F (-10 C). - If the engine fails to start, push in the emergency stop button, pull it out, wait for the end of the preheating cycle and try to start again the engine. Note: refer to the maintenance personnel if the engine fails to start after several tries. STOP THE ENGINE - Push in the emergency stop button (OFF position). DRIVE AND STEER - Move the driving speed selection switch to the desired speed position, refer to "DRIVING SPEED SELECTION SWITCH". - Press down and hold the foot switch, refer to "DRIVE/STEER CONTROL HANDLE" to drive, steer and brake. Note: perform combinations of switches and/or control handle to operate simultaneous functions, refer to "SIMULTANEOUS FUNCTIONS" on next page. 2-40

59 POSITION THE PLATFORM - Press down and hold the foot switch. - Press/push/pull and hold the relevant push-buttons/switches and/or the control handles to operate functions. - Release the push-buttons/switches and/or the control handles to stop the activated functions. Note: perform combinations of switches and/or control handles to operate simultaneous functions, refer to "SIMULTANEOUS FUNCTIONS". EMERGENCY STOP - Push in the emergency stop button (OFF position). SIMULTANEOUS FUNCTIONS Note: the buzzer sounds intermittently when functions can not be operated simultaneously. GROUND CONTROLS PANEL In transport/work position: a maximum of two functions can be operated simultaneously. PLATFORM CONTROLS PANEL Without driving and without steering in transport/work position: a maximum of three functions can be operated simultaneously. When driving without steering in transport/work position: a maximum of one other function can be operated simultaneously. When driving and steering in transport/work position: no other functions can be operated simultaneously. 2-41

60 DRIVING ON A SLOPE DANGER DO NOT ECEED THE MAIMUM SLOPE RATINGS OF THE MACHINE WHEN DRIVING. IF THE SLOPE GRADE ECEED THE MAIMUM SLOPE RATING, THE MACHINE MUST BE TRANSPORTED UP OR DOWN THE SLOPE, REFER TO "TRANSPORT INSTRUCTIONS" AND TO "LIFTING INSTRUCTIONS". Maximum slope rating in transport position 1- Platform downhill (gradeability) 40% (21.8 ) 2- Platform uphill 40% (21.8 ) 3- Side slope 25% (14 ) The gradeability is defined by: - The machine is in transport position with the platform downhill. - The turntable and the platform are in neutral position. Slope ratings are dependent of the ground conditions and an adequate traction. Always measure the slope grade before driving. Use a digital inclinometer or refer to "MESURE THE SLOPE GRADE". Always select the RAMP speed position. Always drive the machine facing the slope MEASURE THE SLOPE GRADE ITEMS NEEDED A: one straight wood stud at least 3 ft (36 in or 91 cm) B: one spirit level at least 12 in (30 cm) C: one tape measure PROCEDURE Measure the "L" lenght of the wood stud. Place and level the wood stud as shown on the illustration. A B L Measure the "H" height perpendiculary to the levelled wood stud. Divide H by L. H Multiply result by 100. EEMPLE L = 48 in (122 cm) H = 10 in (25 cm). Slope grade= (H/L)x100 = (10/48)x100 = 20.85% 2-42

61 LOCKED FUNCTIONS Some or all functions are locked when the load in the platform has reached the maximum platform capacity (OVERLOAD ALARM) or when the machine is on a severe slope (TILT ALARM), refer to the tables below: TRANSPORT POSITION GROUND CONTROLS PANEL RAISE THE PRIMARY/SECONDARY BOOM LOWER THE PRIMARY/SECONDARY BOOM ETEND THE TELESCOPE BOOM RETRACT THE TELESCOPE BOOM RAISE THE JIB BOOM RAISE THE JIB BOOM RAISE THE PLATFORM TILT LEVEL LOWER THE PLATFORM TILT LEVEL ROTATE THE TURNTABLE (LEFT/RIGHT) OVERLOAD ALARM LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED TILT ALARM PLATFORM CONTROLS PANEL OVERLOAD ALARM TILT ALARM RAISE THE PRIMARY/SECONDARY BOOM LOCKED LOCKED LOWER THE PRIMARY/SECONDARY BOOM LOCKED ETEND THE TELESCOPE BOOM LOCKED LOCKED RETRACT THE TELESCOPE BOOM LOCKED RAISE THE JIB BOOM LOCKED RAISE THE JIB BOOM LOCKED RAISE THE PLATFORM TILT LEVEL LOCKED LOWER THE PLATFORM TILT LEVEL LOCKED ROTATE THE TURNTABLE (LEFT/RIGHT) LOCKED ROTATE THE PLATFORM (LEFT/RIGHT) LOCKED DRIVE (FORWARD/REVERSE) LOCKED STEER (LEFT/RIGHT) LOCKED WORK POSITION GROUND CONTROLS PANEL RAISE THE PRIMARY/SECONDARY BOOM LOWER THE PRIMARY/SECONDARY BOOM ETEND THE TELESCOPE BOOM RETRACT THE TELESCOPE BOOM RAISE THE JIB BOOM RAISE THE JIB BOOM RAISE THE PLATFORM TILT LEVEL LOWER THE PLATFORM TILT LEVEL ROTATE THE TURNTABLE (LEFT/RIGHT) OVERLOAD ALARM LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED LOCKED TILT ALARM PLATFORM CONTROLS PANEL OVERLOAD ALARM TILT ALARM RAISE THE PRIMARY/SECONDARY BOOM LOCKED LOCKED LOWER THE PRIMARY/SECONDARY BOOM LOCKED ETEND THE TELESCOPE BOOM LOCKED LOCKED RETRACT THE TELESCOPE BOOM LOCKED RAISE THE JIB BOOM LOCKED RAISE THE JIB BOOM LOCKED RAISE THE PLATFORM TILT LEVEL LOCKED LOCKED LOWER THE PLATFORM TILT LEVEL LOCKED LOCKED ROTATE THE TURNTABLE (LEFT/RIGHT) LOCKED ROTATE THE PLATFORM (LEFT/RIGHT) LOCKED DRIVE (FORWARD/REVERSE) LOCKED LOCKED STEER (LEFT/RIGHT) LOCKED LOCKED 2-43

62 RESCUE FUNCTIONS IF THE ENGINE IS RUNNING PROPERLY DANGER OPERATE FUNCTIONS WITH ETREME PRECAUTION AND CHECK FOR OBSTRUCTIONS AT ALL TIMES. If the machine can no longer be operated from the platform, operate functions from the ground controls panel: - Push and hold the platform/ground selection switch 1 to the right. - Start the engine. - Press and hold the relevant keys of the keypad for machine functions to operate functions. - Release the keys or the platform/ground selection switch to stop the activated functions. 1 IF THE ENGINE FAILS DANGER THE TILT ALARM SYSTEM IS NO LONGER ACTIVATED AND THE MACHINE COULD TIP OVER. 2 OPERATE FUNCTIONS WITH ETREME PRECAUTION AND CHECK FOR OBSTRUCTIONS AT ALL TIMES. NOTICE 4 4 HANDLE THE VALVES KNOBS WITH CARE TO AVOID DAMAGES TO THE HYDRAULIC DISTRIBUTOR If the machine can no longer be operated from the platform and if the engine fails, push in the emergency stop button of the ground controls panel and use the manual rescue pump to operate functions: - Open the turntable left cover panel. - Grab the pump lever 2 and place it in the manual rescue pump 3. - Locate the hydraulic distributor 4 and the valves A to E. - Operate functions. Note: refer to the decal "RESCUE CONTROLS INSTRUCTIONS" in "DECALS LOCATION". A 4 B C E D 2-44

63 ROTATE THE TURNTABLE TO THE LEFT 1- Push the valve knob A, turn it clockwise until stop and release it Pump to rotate the turntable to the left, stop when desired position is reached. 3- Turn the valve knob A counterclockwise until stop and release it. ROTATE THE TURNTABLE TO THE RIGHT 1- Pull the valve knob A, turn it counterclockwise until stop and release it Pump to rotate the turntable to the right, stop when desired position is reached. 3- Turn the valve knob A clockwise until stop and release it. LOWER THE JIB BOOM 1- Push the valve knob B, turn it clockwise until stop and release it Pump to lower the jib boom, stop when desired position is reached. 3- Turn the valve knob B counterclockwise until stop and release it. RAISE THE JIB BOOM 1- Pull the valve knob B, turn it counterclockwise until stop and release it Pump to raise the jib boom, stop when desired position is reached. 3- Turn the valve knob B clockwise until stop and release it. LOWER THE PRIMARY/SECONDARY BOOM 1- Turn the valve knob C counterclockwise, push it and turn it clockwise until stop Pump to lower the primary/secondary boom, stop when desired position is reached. 3- Turn the valve knob C counterclockwise, release it and turn it clockwise until stop. RAISE THE PRIMARY/SECONDARY BOOM 1- Turn the valve knob C counterclockwise, pull it and turn it clockwise until stop Pump to raise the primary/secondary boom, stop when desired position is reached. 3- Turn the valve knob C counterclockwise, release it and turn it clockwise until stop. RETRACT THE TELESCOPE BOOM 1- Turn the valve knob D clockwise until stop. Turn the valve knob E counterclockwise until stop Pump to retract the telescope boom, stop when desired position is reached. 3- Turn the valve knob D counterclockwise until stop. Turn the valve knob E clockwise until stop. ETEND THE TELESCOPE BOOM 1- Turn the valve knob D clockwise until stop. Turn the valve knob E clockwise until stop Pump to extend the telescope boom, stop when desired position is reached. 3- Turn the valve knob D counterclockwise until stop. Make sure the valve knob E is turned clockwise until stop. 2-45

64 STANDARD EQUIPMENT BATTERY MASTER SWITCH The battery master switch is designed to power down/power up the machine: - OFF = 0 (power down): the handle is vertical. - ON = I (power up): the handle is horizontal. Note: refer to the decal "BATTERY MASTER SWITCH" on the front of the chassis. DOUBLE 110 V ELECTRICAL OUTLET IN THE PLATFORM DANGER ELECTROCUTION HAZARD: ONLY PLUG ELECTRICAL DEVICES THAT OPERATE AT 110 V/60 HZ, MAIMUM 15 A. DO NOT PLUG ETENSION CORDS, POWER STRIPS OR MULTI-OUTLET PLUGS. The 110 V electrical plug is located in the rear of the turntable. It is available in two versions: USA or CANADA. The double 110 V electrical outlet is located in the platform. - Plug the 110 V electrical plug into a 110V power source. - Plug the electrical device into one of the output of the double 110 V electrical outlet. Note: refer to the decals A "110 V" on the turntable and on the double 110 V electrical outlet. Note: the double 110 V electrical outlet supplies 110 V/60 Hz, maximum 15 A. A USA PLUG A CANADA PLUG A 2-46

65 BLOCK HEATER DANGER ELECTROCUTION HAZARD: THE HEATER OPERATES AT 110 V/60 HZ. NOTICE THE ENGINE MUST BE STOPPED WHEN THE HEATER IS PLUGGED. The block heater is designed to heat the engine block when the outside temperature is below 14 F (-10 C): - Open the chassis right cover panel. - Locate the 110 V electrical plug. - Plug it to a 110 V power source. - Wait for the desired heating time and unplug it. - Close the chassis right cover panel. Note: the heating time depends of the ambient temperature and other factors, adjust the heating time by observing the engine cranking condition. 2-47

66 OPTIONS HYDRAULIC OIL HEATER DANGER ELECTROCUTION HAZARD: THE HEATER OPERATES AT 110 V/60 HZ. NOTICE THE ENGINE MUST BE STOPPED WHEN THE HEATER IS PLUGGED. The hydraulic oil heater is designed to heat the hydraulic oil when the outside temperature is below 5 F (-15 C): - Open the chassis front cover panel. - Locate the 110 V electrical plug. - Plug it to a 110 V power source. - Wait for the desired heating time and unplug it. - Close the chassis front cover panel. Note: the heating time depends of the ambient temperature and other factors, adjust the heating time by observing the engine cranking condition. BATTERY HEATER DANGER ELECTROCUTION HAZARD: THE HEATER OPERATES AT 110 V/60 HZ. NOTICE THE ENGINE MUST BE STOPPED WHEN THE HEATER IS PLUGGED. The battery heater is designed to heat the battery when the outside temperature is below 14 F (-10 C): - Open the chassis front cover panel. - Locate the 110 V electrical plug. - Plug it to a 110 V power source. - Wait for the desired heating time and unplug it. - Close the chassis front cover panel. Note: the heating time depends of the ambient temperature and other factors, adjust the heating time by observing the engine cranking condition. 110 V GENERATOR DANGER ELECTROCUTION HAZARD: ONLY PLUG ELECTRICAL DEVICES THAT OPERATE AT 110 V/60 HZ, MAIMUM 15 A. DO NOT PLUG ETENSION CORDS, POWER STRIPS OR MULTI-OUTLET PLUGS. NOTICE WHEN STARTING THE GENERATOR, POWER SURGES COULD OCCURS. The engine must run to operate the 110 V generator. - Press the generator push-button 1 to start the 110 V generator. - Plug one electrical device into one of the output of the double 110 V electrical outlet located in the platform. - Press the generator push-button 1 to stop the 110 V generator. Note: refer to the decals A "110 V" on the double 110 V electrical outlet. Note: each output of the double 110 V electrical outlet supplies 110 V/60 Hz, maximum 15 A. 1 A 2-48

67 WORK LIGHT WARNING BURN HAZARD: DO NOT TOUCH THE WORK LIGHT WHEN SWITCHED ON. REFER TO THE DECAL A "CAUTION - BURN HAZARD". The work light mounted on the guard rail is equipped with a on/off switch 1. A 1 ANTI-CRUSHING "SAFEMANSYSTEM" DANGER OPERATE FUNCTIONS WITH ETREME PRECAUTION WHEN TRYING TO BE NO LONGER TRAPPED. WARNING IF THE BUZZER SOUNDS INTERMITTENTLY AND QUICKLY AND IF THE BLUE FLASHING BEACON 1 FLASHES QUICKLY: THE MACHINE CAN BE OPERATED BUT THE ANTI-CRUSHING SYSTEM "SAFEMANSYSTEM" IS DISABLED. REFER TO THE MAINTENANCE PERSONNEL. When the machine is powered up, the buzzer sounds one time and the blue flashing beacon 1 flashes several times. If the operator is trapped between the safety edge 2 and a structure: - All the functions are stopped. - The horn sounds intermittently and the blue flashing beacon 1 flashes. - "Automatic telescope boom retractation" option: the telescope boom retracts automatically during less than two seconds. If the operator is still trapped in the platform: - Press the reset push-button 3. - Operate functions to be no longer trapped. - When done, the horn stops sounding and the blue flashing beacon 1 stops flashing. If the operator is no longer trapped in the platform: - Press the reset push-button 3. - The functions are recovered. The horn stops sounding and the blue flashing beacon 1 stops flashing

68 2-50

69 PARKING AND STORAGE GENERAL DANGER THE MACHINE MUST BE PARKED IN A PROTECTED AREA ON A LEVEL SURFACE. MAKE SURE THAT THERE IS NO LOAD IN THE PLATFORM. THE MACHINE MUST BE SET IN TRANSPORT POSITION, THE JIB BOOM MUST BE FULLY LOWERED, THE TURNTABLE AND THE PLATFORM MUST BE SET IN NEUTRAL POSITION. IT IS RECOMMENDED TO CHOCK THE WHEELS. ALL THE COVER PANELS MUST BE CLOSED AND SECURED IF APPLICABLE. THE EMERGENCY STOP BUTTONS OF THE GROUND CONTROLS PANEL AND OF THE PLATFORM CONTROLS PANEL MUST BE IN THE OFF POSITION. THE BATTERY MASTER SWITCH MUST BE TURNED TO THE OFF POSITION. THE IGNITION KEY SWITCH MUST BE IN THE POSITION AND THE KEY MUST BE REMOVED. 2-51

70 TRANSPORT AND LIFTING GENERAL DANGER THE TRANSPORT AND LIFTING INSTRUCTIONS ARE ONLY RECOMMENDATIONS. DRIVERS HAVE THE RESPONSIBILITY TO ENSURE THAT THE MACHINE IS PROPERLY SECURED AND THAT THE TRANSPORT VEHICULE COMPLIES WITH THE APPLICABLE REGULATIONS OF THE DEPARTMENT OF TRANSPORTATION, THE APPLICABLE LOCAL REGULATIONS AND THEIR COMPANY POLICY. ONLY QUALIFIED AND TRAINED OPERATORS SHOULD DRIVE THE MACHINE ON OR OFF THE TRANSPORT VEHICULE. ONLY QUALIFIED RIGGERS SHOULD RIG THE MACHINE FOR LIFTING IN ACCORDANCE WITH THE APPLICABLE REGULATIONS. ONLY CERTIFIED CRANE OPERATORS SHOULD LIFT THE MACHINE IN ACCORDANCE WITH THE APPLICABLE CRANE REGULATIONS. MAKE SURE THAT THE TRANSPORT VEHICULE, THE LOADING RAMPS, THE CHAINS AND/OR THE STRAPS ARE STRONG ENOUGH TO WITHSTAND THE MACHINE MASS. SEE THE MACHINE IDENTIFICATION PLATE AND THE APPLICABLE DECAL, REFER TO "DECALS LOCATION". MAKE SURE THAT THE CRANE, THE CHAINS AND/OR THE STRAPS ARE STRONG ENOUGH TO WITHSTAND THE MACHINE MASS. SEE THE MACHINE IDENTIFICATION PLATE AND THE APPLICABLE DECAL, REFER TO "DECALS LOCATION". ALWAYS LOCK THE TURNTABLE ROTATION WHEN THE MACHINE IS TRANSPORTED ON A VEHICULE OR LIFTED, REFER TO "TURNTABLE LOCK PIN". THE SLOPE OF LOADING RAMPS MUST NOT ECEED THE MAIMUM SLOPE RATINGS, REFER TO "DRIVING ON A SLOPE". THE MACHINE MUST BE LOADED BY USING A WINCH OR A CRANE IF THE LOADING RAMPS ARE SLIPPERY OR IF THE SLOPE OF THE LOADING RAMPS ECEEDS THE SLOPE RATINGS OF THE MACHINE, REFER TO "FREE-WHEEL CONFIGURATION FOR WINCHING" AND TO "LIFTING INSTRUCTIONS". THE TRANSPORTATION BY CONTAINER MUST BE PERFORMED BY A QUALIFIED FREIGHT COMPANY THAT MUST ENSURE THAT THE LOADING, THE SECURING AND THE LIFTING OF THE MACHINE ARE PROPERLY DONE. TRANSPORT INSTRUCTIONS LOAD AND UNLOAD THE MACHINE DANGER THE TRANSPORT VEHICULE MUST BE PARKED ON A LEVEL SURFACE. THE WHEELS MUST BE CHOCKED TO AVOID ROLLING WHEN LOADING THE MACHINE. THE MACHINE MUST BE LOADED AND UNLOADED IN TRANSPORT POSITION WITH PLATFORM DOWNHILL. THE TURNTABLE AND THE PLATFORM MUST BE SET IN NEUTRAL POSITION. REFER TO "TRANSPORT/WORK POSITION". WARNING MAKE SURE THAT THE TURNTABLE ROTATION IS NOT LOCKED WHILE LOADING AND UNLOADING THE MACHINE ON THE TRANSPORT VEHICULE, REFER TO "TURNTABLE LOCK PIN". NOTICE THE JIB BOOM COULD BE SLIGHTLY ELEVATED TO PREVENT THE PLATFORM FROM HITTING THE GROUND OR THE LOADING RAMPS. DRIVE SMOOTHLY AND SLOWLY THE MACHINE AT RAMP SPEED. 2-52

71 SET THE MACHINE POSITION When transporting, the machine can be set in transport position or in stowed position: - Transport position: refer to "TRANSPORT/WORK POSITION". - Stowed position: Set the machine in transport position, refer to "TRANSPORT/WORK POSITION". Slightly raise the primary/secondary boom and slightly extend the telescope boom. Lower the platform tilt level. Make sure that the platform can not hit the vehicule floor. Lower the primary/secondary boom and retract the telescope boom to set the platform close to the vehicule ground and the machine chassis. - Set the machine from stowed position to transport position before unloading: Slightly raise the primary/secondary boom. Raise the platform tilt level until the platform is level. Make sure that the platform can not hit the vehicule floor. Fully lower the primary/secondary boom and fully retract the telescope boom. TRANSPORT POSITION STOWED POSITION 2-53

72 TIE DOWN THE MACHINE WARNING LOCK THE TURNTABLE ROTATION, REFER TO "TURNTABLE LOCK PIN". CHOCK THE WHEELS. LOCATE THE 6 TIE DOWN POINTS OF THE MACHINE, REFER TO THE DECALS "TIE DOWN POINT" IN "DECALS LOCATION". TIE DOWN THE MACHINE TO THE TRANSPORT VEHICULE WITH A MINIMUM OF 6 CHAINS. ADJUST THE RIGGING TO PREVENT DAMAGES. PUT A BLOCK OF WOOD OR FOAM BETWEEN THE PLATFORM AND THE VEHICULE GROUND. SECURE THE PLATFORM WITH A STRAP. DO NOT OVERTIGHTEN TO PREVENT DAMAGES. NOTE: THE ILLUSTRATION BELOW CONTAINS THE SAME INFORMATION AS THE DECAL "TRANSPORT/TIE DOWN", REFER TO "DECALS LOCATION". 5 ft 11 in (1800 mm) 18 ft 1 in (5500 mm) 14 ft 10 in (4500 mm) 6 ft 8 in (2015 mm) 8 ft 3 in (2500 mm) LOAD ON 1 WHEEL LOAD ON 2 WHEELS 2650 lbs (1200 kg) 5070 lbs (2300 kg) 2205 lbs (1000 kg) LOAD ON 1 WHEEL 4200 lbs (1900 kg) LOAD ON 2 WHEELS TOTAL MASS 9150 lbs (4150 kg) 2-54

73 TURNTABLE LOCK PIN TO LOCK THE TURNTABLE - Turn the lock pin counterclockwise and push it down into the chassis slot: 1A position: lock pin is engaged. TO UNLOCK THE TURNTABLE - Pull the lock pin and turn it clockwise: 1B position: lock pin is not engaged. 1A 1B FREE-WHEEL CONFIGURATION FOR WINCHING DANGER CHOCK THE WHEELS TO PREVENT THE MACHINE FROM ROLLING BEFORE RELEASING THE BRAKES. - Attach the winch to the tie points of the machine. - Release the brakes: Open the chassis right cover panel. Locate the hydrostatic pump 1 and the screw A between the two hoses. Loosen the screw A two turns counterclockwise by using an allen key. Close the chassis right cover panel. Locate the brakes release device 2 at the front of the machine. Push and hold the button B. Push and pull the pump button C several times to raise the pressure and release the brakes. When sufficient pressure is reached, the button B stays pushed in. The brakes are released. - Make sure that the path is clear of any obstructions. Remove the wheels blocks. - Pull the machine slowly by using the winch. - Chock the wheels when the machine is in the desired position. - Restore the brakes: Pull the B button. Open the chassis right cover panel. Tighten the screw A two turns clockwise by using an allen key. Close the chassis right cover panel. Remove the winch. A 1 B 2 C 2-55

74 LIFTING INSTRUCTIONS PROCEDURE WARNING SET THE MACHINE IN TRANSPORT POSITION. SET THE TURNTABLE AND THE PLATFORM IN NEUTRAL POSITION. FULLY LOWER THE JIB BOOM. LOCK THE TURNTABLE ROTATION, REFER TO "TURNTABLE LOCK PIN". LOCATE THE 4 LIFTING POINTS OF THE MACHINE, REFER TO THE DECALS "LIFTING POINT" IN "DECALS LOCATION". ATTACH THE RIGGING TO THE LIFTING POINTS. ADJUST THE RIGGING TO PREVENT DAMAGES AND TO KEEP THE MACHINE LEVEL. LIFT THE MACHINE. NOTE: THE ILLUSTRATION BELOW CONTAINS THE SAME INFORMATION AS THE DECAL "LIFTING", REFER TO "DECALS LOCATION". 5 ft (1520 mm) 5 ft 8 in (1720 mm) CG = Center of gravity 3 ft 8 in (1095 mm) Y 3 ft 3 in (985 mm) A 1 ft 11 in (560 mm) B 2 ft 8 in (800 mm) TOTAL MASS 9150 lbs (4150 kg) CG Y A B 2-56

75 2-57

76 CHARACTERISTICS LOAD SPECIFICATIONS TOL ± Platform - Indoor use capacity - wind 0 mph (0 km/h) lbs (kg) 500 (227) - - Outdoor use capacity - wind 28 mph (45 km/h) lbs (kg) 500 (227) - - Maximum occupants for indoor use Maximum occupants for outdoor use Unladen mass lbs (kg) 9150 (4150) 2% - Driving speed - "Work position" speed mph (km/h) 0.6 (1) 0.06 (0.1) - Driving speed 1 - TURTLE speed mph (km/h) 2 (3.2) 0.31 (0.5) - Driving speed 2 - RAMP speed mph (km/h) 2.4 (3.8) 0.12 (0.2) - Driving speed 3 - HARE speed mph (km/h) 3.2 (5.2) 0.12 (0.2) Wheels - Load on one front wheel - transport position lbs (kg) 2650 (1200) 2% - Load on one rear wheel - transport position lbs (kg) 2205 (1000) 2% - Maximum wheel load - work position lbs (kg) 3970 (1800) 2% - Contact area on the ground - hard / soft in² (cm²) 27.9 / 64.6 (180.1 / 417.1) 5% - Punching on the ground - hard / soft psi (dan/cm²) / 87 (15 / 6.5) 5% Level of sound power in the LwA environment db DIMENSIONS TOL ± Platform external dimensions (lenght x width) ft-in (mm) 4-11 (1500) x 3-3 (987) 1% Platform floor dimensions (lenght x width) ft-in (mm) 4-8 (1435) x 2-4 (710) 1% Platform rotation angle - right / left 70 / 66 1% Jib boom rotation angle - up / down 64 / 70 1% Turntable rotation angle 350 1% Other dimensions: refer to "DIMENSIONS AND RANGE OF MOTION CHART" ENGINE TOL ± Type KUBOTA D1105- E4B Fuel Diesel Number of cylinders 3 Size cu.in (cm3) 68.5 (1,123) - Unladen idling speed - factory setting rpm 1300 (1300) 20 Maximum engine running speed - factory setting rpm 3000 (1300) 40 Horsepower HP (kw) 24.8 (18.5) Maximum torque ft-lbf (Nm) 52.4 (71) - Unladen mass lbs (kg) 205 (93) 11 (5) Cooling type Water Fan type Suction TRANSMISSION TOL ± Type Wheel motor MSE02 - Cubic capacity cu.in (cm3) 24.3 (398) - - Maximum pressure psi (bar) (400) - - Theoretical tensile force lbf (dan) (1950) - - Reduction ratio 1 : 1 - Steering wheels - front / rear 2 / 0 - Drive wheels - front / rear 2 / 2 - Front and rear wheels - Differential Hydraulic flow divider - - Tires type CURED ON - - Wheels dimensions (O.D x width) in (mm) 28.3 x 9.6 (720 x 245) - BRAKE SYSTEM TOL ± Brake type Multidisc - Control type Negative with hydraulic control - Braked wheels - front / rear 2 / 2 - Brakes release (free-wheel mode) yes, manual - Brake torque ft-lbf (danm) (187.5) 5% 2-58

77 HYDRAULIC CIRCUIT TOL ± Main hydraulic pump - Type High pressure closed loop - - Cubic capacity cu.in (cm3) 1.2 (20.4) - - Flow rate - maximum unladen rpm gpm (L/min) 16.2 (61.2) - - Maximum service pressure psi (bar) (350) - Auxiliary hydraulic pump - Type Gears - - Cubic capacity cu.in (cm3) 0.85 (14) - - Flow rate - maximum unladen rpm gpm (L/min) 11.1 (42) - - Maximum service pressure psi (bar) (210) 72.5 (5) ELECTRIC CIRCUIT TOL ± Battery - C5 capacity Ah C20 capacity Ah Rated voltage V Type Startup 110 A - Alternator - Type Current A Voltage V 12 - Starter - Type Electric - - Power kw Voltage V 12 - RESCUE PUMP TOL ± - Type Manual - - Cubic capacity cu.in (cm3) 1.2 (20) - EQUIPMENT TOL ± Amber beacon Standard Hour meter Standard Diesel fuel level - proportional display Standard Low fuel level alarm Standard Low battery alarm Standard Tool box in the platform Standard User interface - diagnostic aid Standard Fuel tank cap with lock Standard Battery master switch Standard Double 110 V electrical outlet in the platform Standard Block heater Standard Driving direction "Drive Enable" Standard Permanent amber beacon Option All motion alarm Option Drive/steer alarm Option Hydraulic oil heater Option Battery heater Option 110 V generator Option Work light Option Anti-crushing "SafeManSystem" Option Automatic telescope boom retractation (anti-crushing "SafeManSystem") Option 2-59

78 DIMENSIONS AND RANGE OF MOTION CHART A ft-in (mm) 18 (5500) A1 ft-in (mm) 14-9 (4500) B ft-in (mm) 6-7 (2000) B1 ft-in (mm) 3-1 (950) C ft-in (mm) 6-7 (2015) C1 ft-in (mm) 8-2 (2495) D ft-in (mm) 5-11 (1800) E in (mm) 8 (200) E1 in (mm) 12.5 (320) F in (mm) 15.5 (395) G ft-in (mm) 5-8 (1715) G1 ft-in (mm) 13-6 (4115) H ft (mm) 3 (920) I in (mm) 7.5 (190) J ft-in (mm) 9-6 (2900) K (%) 36 (73) E D I H G1 G J A1 A C C1 K E1 F B B1 2-60

79 S4 = 13 ft 1.5 in (4 m) S5 = 16 ft 5 in (5 m) S6 = 19 ft 8 in (6 m) S7 = 24 ft (7.3 m) Dimension Description H1 6 ft 4.5 in 1940 mm Platform height for maximum horizontal reach D1 20 ft 3.5 in 6190 mm Maximum horizontal reach H2 32 ft 6 in 9900 mm Maximum platform height D2 10 ft 2 in 3100 mm Horizontal reach for maximum platform height H4 D4 17 ft 1.5 in 19 ft 1.5 in 5220 mm 5830 mm Horizontal reach and platform height for a building height of 13 ft 1.5 in (4 m) H5 D5 21 ft 8.5 in 17 ft 9 in 6620 mm 5410 mm Horizontal reach and platform height for a building height of 16 ft 5 in (5 m) H6 D6 25 ft 9 in 15 ft 6 in 7850 mm 4720 mm Horizontal reach and platform height for a building height of 19 ft 8.25 in (6 m) H7 28 ft 1 in 8565 mm D7 12 ft 11.5 in 3950 mm Horizontal reach and platform height for a building height of 24 ft (7.32 m) 0 3 ft (0.91 m) 6 ft (1.83 m) 9 ft (2.74 m) 12 ft (3.66 m) 15 ft (4.57 m) 18 ft (5.49 m) 21 ft (6.40 m) 24 ft (7.32 m) 39 ft (11.89 m) D2 36 ft (10.97 m) D7 33 ft (10.06 m) H2 30 ft (9.14 m) S7 H7 D5 27 ft (8.23 m) 24 ft (7.32 m) S5 H5 21 ft (6.40 m) 18 ft (5.49 m) 15 ft (4.57 m) D1 12 ft (3.66 m) 9 ft (2.74 m) 6 ft (1.83 m) H1 3 ft (0.91 m) 0 3 ft (0.91 m) 6 ft (1.83 m) 9 ft (2.74 m) ft (3.66 m) 15 ft (4.57 m) 18 ft (5.49 m) 21 ft (6.40 m) 0 24 ft (7.32 m)

80 CALIFORNIA PROPOSITION 65 WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Batteries posts, terminals and related accessories contain lead and lead compounds known to the State of California to cause cancer and reproductive harm. Batteries contain chemicals known to the State of California to cause cancer. 2-62

81 3- MAINTENANCE 3-1

82 3- MAINTENANCE GENERAL 3-3 PERIODIC MAINTENANCE 3-4 COMMISSIONING MAINTENANCE 3-5 MANDATORY MAINTENANCE 3-5 SCHEDULED MAINTENANCE 3-6 FILTER ELEMENTS AND BELTS 3-9 LUBRICANTS, COOLANT AND FUEL 3-10 ROUTINE MAINTENANCE 3-12 EVERY 50 OPERATING HOURS OR EVERY WEEK 3-14 EVERY 250 OPERATING HOURS OR EVERY 6 MONTHS 3-16 EVERY 500 OPERATING HOURS OR EVERY YEAR 3-22 EVERY 1000 OPERATING HOURS OR EVERY 2 YEARS 3-28 EVERY 2000 OPERATING HOURS OR EVERY 4 YEARS 3-32 OCCASIONAL MAINTENANCE

83 GENERAL INTRODUCTION DANGER THE SECTION "1- SAFETY PRECAUTIONS" OF THIS MANUAL AND THE MANUAL OF RESPONSIBILITIES MUST HAVE BEEN READ AND FULLY UNDERSTOOD. REFER TO SECTION "2- INSTRUCTIONS" TO HAVE INFORMATIONS ABOUT COMPONENTS LOCATION AND SPECIFIC INSTRUCTIONS. DURING ANY MAINTENANCE OPERATIONS, ECEPT WHEN SPECIFIC INSTRUCTIONS ARE GIVEN: - THE MACHINE MUST BE PARKED ON A LEVEL SURFACE. - THE WHEELS MUST BE CHOCKED. - THE MACHINE MUST BE IN TRANSPORT POSITION, THE TURNTABLE AND THE PLATFORM MUST BE IN NEUTRAL POSITION, REFER TO "TRANSPORT/ WORK POSITION". - THE JIB BOOM MUST BE FULLY LOWERED. - THE MACHINE MUST BE POWER DOWN: THE IGNITION KEY SWITCH MUST BE TURNED TO THE POSITION AND THE BATTERY MASTER SWITCH MUST BE TURNED TO THE OFF POSITION. AVOID CONTACT AT ALL TIMES WITH HOT COMPONENTS WHICH MAY CAUSE SEVERE BURNS. ORIGINAL MANITOU SPARE PARTS WARNING MACHINES MUST BE SERVICED BY USING GENUINE MANITOU PARTS. GENUINE REPLACEMENT PARTS ARE DISTRIBUTED ECLUSIVELY BY MANITOU AND ITS DEALER NETWORK. BY ALLOWING THE USE OF NON-GENUINE REPLACEMENT PARTS, COUNTERFEIT PARTS OR NON-APPROVED COMPONENTS, YOU RISK: - TO LOOSE THE BENEFIT OF THE CONTRACTUAL WARRANTY. - TO BE HELD LEGALLY RESPONSIBLE IN THE EVENT OF AN ACCIDENT. - TO CAUSE DAMAGES, MALFUNCTIONS OR TO REDUCE THE MACHINE SERVICE LIFE. The dealer network list is available on the Manitou web site: Only the Manitou network has detailed knowledge of the machine design and the best technical ability to provide maintenance. Through its network, Manitou provides the user: - Know-how and competence. - Warranty of high-quality work. - Original replacement parts. - Help with preventive maintenance. - Efficient help with diagnosis. - Improvements due to experience feedback. - Operator training. 3-3

84 PERIODIC MAINTENANCE WARNING THE ROUTINE MAINTENANCE MUST BE PERFORMED BY ANY OPERATOR THAT SHOULD USE THE MACHINE IN THE SAME WORK SHIFT. THE "EVERY 50 OPERATING HOURS OR EVERY WEEK" MAINTENANCE MUST BE PERFORMED BY QUALIFIED MAINTENANCE PERSONNEL EACH WEEK EVEN WHEN THE MACHINE HAS NOT BEEN OPERATED FOR 50 HOURS. ROUTINE MAINTENANCE - CHECK Diesel fuel level CHECK Engine oil level CHECK Coolant level CHECK Battery fluid level CHECK Hydraulic oil level EVERY 50 OPERATING HOURS OR EVERY WEEK - CHECK 110 V generator (option) CLEAN Engine and oil radiators CHECK/CLEAN Outer air filter element GREASE Steering pivots

85 COMMISSIONING MAINTENANCE WARNING THE COMMISSIONING MAINTENANCE MUST BE PERFORMED BY QUALIFIED SERVICE TECHNICIANS ACCREDITED BY MANITOU. THE COMMISSIONING MAINTENANCE MUST BE PERFORMED WHEN THE FIRST 50 OPERATING HOURS HAVE BEEN REACHED. FIRST 50 OPERATING HOURS - REPLACE Engine oil REPLACE Engine oil filter MANDATORY MAINTENANCE WARNING THE MANDATORY MAINTENANCE MUST BE PERFORMED BY QUALIFIED SERVICE TECHNICIANS ACCREDITED BY MANITOU. WHEN THE FIRST 6 OPERATING MONTHS HAVE BEEN REACHED AND WHEN THE FIRST 500 OPERATING HOURS HAVE NOT BEEN REACHED: - ONLY THE MANDATORY MAINTENANCE MUST BE PERFORMED. WHEN THE FIRST 500 OPERATING HOURS HAVE BEEN REACHED AND WHEN THE FIRST 6 OPERATING MONTHS HAVE NOT BEEN REACHED: - THE MANDATORY MAINTENANCE MUST BE PERFORMED. - THE "500 OPERATING HOURS" SCHEDULED MAINTENANCE MUST BE PERFORMED. FIRST 6 OPERATING MONTHS - CHECK 110 V generator (option) CLEAN Engine and oil radiators CHECK/CLEAN Outer air filter element GREASE Steering pivots CHECK Tightening torque of the wheel motors bolts CHECK Wheel nuts tightening torque CHECK Brakes CHECK Adjustment of the telescope boom CHECK Turntable motor oil level CHECK Manual rescue pump CHECK Boom limit switches CHECK Overload alarm CHECK/ADJUST Fan/alternator belt CHECK/CLEAN Fuel filter element GREASE Pins, hubs and cylinder bushings GREASE Turntable ring gear CHECK Tightening torque of the turntable ring gear bolts CHECK Tightening torque of the turntable motor bolts CHECK Hydraulic hoses CHECK Engine silent blocks * CHECK Engine speed * CHECK Valve clearances * CHECK Pressure of hydrostatic transmission system * CHECK Flow regulation of hydrostatic transmission * CHECK Speed of hydraulic movements * CHECK Condition of cylinders * CHECK Condition of the electrical wiring * * Consult your dealer. 3-5

86 SCHEDULED MAINTENANCE WARNING SCHEDULED MAINTENANCE MUST BE PERFORMED BY QUALIFIED SERVICE TECHNICIANS ACCREDITED BY MANITOU. MAINTENANCE SCHEDULE SCHEDULED MAINTENANCE OR TERM FIRST 50 HOURS 250 H 6 FIRST MONTHS 500 FIRST HOURS 500 H HOUR COUNTER MAINTENANCE DATE COMMISSIONING MAINTENANCE MANDATORY MAINTENANCE MANDATORY MAINTENANCE + OR 1 YEAR + TERM 750 H 1000 H OR 2 YEARS 1250 H 1500 H OR 3 YEARS SCHEDULED MAINTENANCE HOUR COUNTER MAINTENANCE DATE 1750 H TERM 2000 H OR 4 YEARS 2250 H 2500 H OR 5 YEARS 2750 H 3000 H OR 6 YEARS SCHEDULED MAINTENANCE HOUR COUNTER MAINTENANCE DATE TERM 3250 H 3500 H OR 7 YEARS 3750 H 4000 H OR 8 YEARS SCHEDULED MAINTENANCE HOUR COUNTER MAINTENANCE DATE 4250 H TERM 4500 H OR 9 YEARS 4750 H 5000 H OR 10 YEARS 5250 H 5500 H OR 11 YEARS SCHEDULED MAINTENANCE HOUR COUNTER MAINTENANCE DATE 3-6

87 EVERY 250 OPERATING HOURS OR EVERY 6 MONTHS - CHECK Tightening torque of the wheel motors bolts CHECK Wheel nuts tightening torque CHECK Brakes CHECK Adjustment of the telescope boom CHECK Turntable motor oil level CHECK Manual rescue pump CHECK Boom limit switches CHECK Overload alarm CHECK/ADJUST Fan/alternator belt CHECK/CLEAN Fuel filter element GREASE Pins, hubs and cylinder bushings GREASE Turntable ring gear EVERY 500 OPERATING HOURS OR EVERY YEAR - CHECK Tightening torque of the turntable ring gear bolts CHECK Tightening torque of the turntable motor bolts CHECK Hydraulic hoses REPLACE Engine oil REPLACE Engine oil filter REPLACE Fuel prefilter REPLACE Fuel filter element REPLACE Outer air filter element REPLACE Fan/alternator belt REPLACE Turntable motor oil REPLACE Pressure hydraulic filter element REPLACE Hydrostatic filter element EVERY 1000 OPERATING HOURS OR EVERY 2 YEARS - CHECK/CLEAN Fuel tank REPLACE Inner air filter element REPLACE Hydraulic oil CLEAN Filling filter and suction strainers CHECK Engine silent blocks * CHECK Engine speed * CHECK Valve clearances * CHECK Pressure of hydrostatic transmission system * CHECK Flow regulation of hydrostatic transmission * CHECK Speed of hydraulic movements * CHECK Condition of cylinders * CHECK Condition of the electrical wiring * * Consult your dealer. EVERY 2000 OPERATING HOURS OR EVERY 4 YEARS - REPLACE Coolant CHECK Fuel injectors * CHECK Engine and oil radiators * CHECK Water pump and thermostat * CHECK Alternator and starter * CHECK Turbocharger * CHECK Injection pump * CHECK Pressure of hydraulic systems * CHECK Flow regulation of hydraulic systems * CLEAN Hydraulic oil tank * * Consult your dealer. OCCASIONAL MAINTENANCE - REPLACE Wheels BLEED Fuel system

88 3-8

89 FILTER ELEMENTS AND BELTS EVERY 500 OPERATING HOURS OR EVERY YEAR ENGINE OIL FILTER Part number: OUTER AIR FILTER ELEMENT Part number: FAN/ALTERNATOR BELT Part number: FUEL FILTER ELEMENT Part number: FUEL PREFILTER Part number: PRESSURE HYDRAULIC FILTER ELEMENT Part number: HYDROSTATIC FILTER ELEMENT Part number: EVERY 1000 OPERATING HOURS OR 2 YEARS ADD THE FILTERS LISTED IN "EVERY 500 OPERATING HOURS OR EVERY YEAR" INNER AIR FILTER ELEMENT Part number: OTHER REPLACEMENT FILTERS FILLING FILTER Part number: SUCTION STRAINERS Part number:

90 LUBRICANTS, COOLANT AND FUEL GENERAL NOTICE USE A HIGH-QUALITY DIESEL FUEL TO OBTAIN OPTIMAL PERFORMANCE OF THE ENGINE: - (*) ASTM D975 ULTRA LOW SULFUR DIESEL FUEL (SULFUR CONTENT < 15 PPM). USE THE RECOMMENDED LUBRICANTS: - MANITOU OILS ARE PERFECTLY SUITED FOR OIL CHANGES. - NON-APPROVED OILS MAY BE NOT MISCIBLE. DIAGNOSTIC ANALYSIS OF OILS: - IF A SERVICE OR MAINTENANCE CONTRACT HAS BEEN ORGANIZED WITH THE DEALER, A DIAGNOSTIC ANALYSIS OF ENGINE OIL AND HYDRAULIC OIL MAY BE REQUESTED DEPENDING ON THE UTILIZATION RATE. RECOMMENDATIONS ENGINE OIL DESCRIPTION CAPACITY RECOMMENDATION -40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C 5.28 US qt (5.1 L) 10W30 MANITOU PREMIUM OIL 15W40 API CI4-40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C COOLANT 9.51 US qt (9 L) COOLANT -31 F (-35 C) -40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C FUEL 14 US gal (53 L) (*) DIESEL FUEL TRANSMISSION FRONT STEERING PIVOTS DESCRIPTION RECOMMENDATION -40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C MANITOU BLUE MULTI-PURPOSE LUBRICANT LIFTING STRUCTURE DESCRIPTION CAPACITY RECOMMENDATION -40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C GENERAL LUBRICATION TURNTABLE RING GEAR BEARINGS TURNTABLE RING GEAR TEETH TURNTABLE MOTOR GEAR TEETH TURNTABLE MOTOR 0.89 US qt (0.85 L) NLGI2 GRAPHITE GREASE NLGI2 GRAPHITE GREASE -40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C BLACK G ULTRA GREASE -40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C MANITOU MECHANICAL TRANSMISSION OIL SAE80W90 HYDRAULICS DESCRIPTION CAPACITY RECOMMENDATION -40 F -22 F -4 F 14 F 32 F 50 F 68 F 86 F 104 F 122 F -40 C -30 C -20 C -10 C 0 C 10 C 20 C 30 C 40 C 50 C ISO VG 100 HYDRAULIC OIL US gal ISO VG 68 MANITOU HYDRAULIC OIL ISO VG 46 (60 L) ISO VG 37 ISO VG

91 PACKAGING/PART NUMBERS OIL PACKAGING/PART NUMBER PRODUCT 1.06 US qt (1 L) 2.11 US qt (2 L) 5.28 US qt (5 L) 5.28 US gal (20 L) US gal (55 L) US gal (209 L) - MANITOU PREMIUM OIL 15W40 API CI MANITOU ISO VG 46 HYDRAULIC OIL MANITOU SAE80W90 MECHANICAL TRANSMISSION OIL GREASE PACKAGING/PART NUMBER PRODUCT 0.42 US qt (400 ml) 0.88 lbs (400 g) 2.20 lbs (1 kg) lbs (5 kg) lbs (20 kg) lbs (50 kg) - BLACK G ULTRA GREASE NLGI2 GRAPHITE GREASE MANITOU BLUE MULTI-PURPOSE LUBRICANT COOLANT PACKAGING/PART NUMBER PRODUCT 1.06 US qt (1 L) 2.11 US qt (2 L) 5.28 US qt (5 L) 5.28 US gal (20 L) US gal (55 L) US gal (210 L) - COOLANT -31 F (-35 C)

92 ROUTINE MAINTENANCE CHECK Diesel fuel level DANGER DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE WHEN ADDING DIESEL FUEL. - Open the turntable right cover panel. - Check the diesel fuel level in the see-through tank 1. - If the level is not correct: Remove the fuel tank cap 2. Add diesel fuel until the correct level is reached, refer to "LUBRICANTS, COOLANT AND FUEL". Put the fuel tank cap 2 back in place. - If the level is correct: Make sure that the fuel tank cap 2 is properly closed. - Power up the machine. - Check the diesel fuel level displayed on the LCD readout screen. - Power down the machine. - Close the turntable right cover panel. 1 2 CHECK Engine oil level - Remove the chassis rear cover panel. - Pull out the dipstick 1. Clean it with a clean cloth and put it back in place. - Pull out the dipstick 1. The level is correct when the engine oil level is between the two notches A and B. Put the dipstick back in place. - If the level is not correct: Remove the oil filler cap 2. Add engine oil, refer to "LUBRICANTS, COOLANT AND FUEL". Put the oil filler cap 2 back in place. Pull out the dipstick 1. Clean it with a clean cloth and put it back in place. Pull out the dipstick 1. The level is correct when the engine oil level is between the two notches A and B. Put the dipstick back in place. - If the level is correct: Make sure that the oil filler cap 2 is properly closed. 2 1 A 1 B CHECK 3-12 Coolant level CAUTION IF THE ENGINE HAS BEEN RUNNING A SHORT TIME AGO, WAIT FOR IT TO COOL DOWN. DO NOT REMOVE THE RADIATOR CAP UNTIL THE ENGINE HAS COMPLETELY COOLED DOWN. Note: the chassis rear cover panel is removed. - Remove the radiator cap 1. The level is correct when the coolant reaches the top of the filler hole. - If the level is not correct: Add coolant until the correct level is reached, refer to "LUBRICANTS, COOLANT AND FUEL". Put the radiator cap 1 back in place. Put the chassis rear cover panel back in place. - If the level is correct: Put the radiator cap 1 back in place. Put the chassis rear cover panel back in place. 1

93 CHECK Battery fluid level CAUTION BATTERIES CONTAIN FLUID THAT IS HIGHLY CORROSIVE. ALWAYS WEAR PROTECTIVE CLOTHING, GLOVES, AND SAFETY EYEWEAR OR FACE SHIELD DURING MAINTENANCE. 1 AVOID CONTACT WITH ANY BODY PARTS AND CLOTHING AT ALL TIMES. FLUSH ANY EPOSED AREA WITH CLEAN WATER AND SEEK ADVICE A HEALTHCARE PROFESSIONAL. MAKE SURE THAT BATTERIES TERMINALS CAN NOT CONTACT METALLIC ITEMS. NOTICE CLEAN AND DRY THE BATTERY CAPS BEFORE PUT THEM BACK IN PLACE. - Remove the chassis front cover panel. - Remove the battery caps 1. - The level is correct when the fluid is at distance of 3/8 in (10 mm) above the battery plates. - If the level is not correct: Add distilled water until the correct level is reached. Put the battery caps 1 back in place. - If the level is correct: Put the battery caps 1 back in place. CHECK Hydraulic oil level NOTICE THERE MAY BE A LEVEL DIFFERENCE FROM 3/8 IN TO 3/4 IN (10 TO 20 MM) BETWEEN A HOT AND A COLD OIL. IT IS RECOMMENDED TO CHECK AGAIN THE LEVEL WHEN THE HYDRAULIC OIL IS HOT. CLEAN THE OIL CAN BEFORE ADDING OIL IN THE HYDRAULIC TANK. USE A CLEAN FUNNEL TO ADD OIL IN THE HYDRAULIC TANK. Note: the chassis front cover panel is removed. - The level is correct when the hydraulic oil reaches the red point of the sight gauge 2. - If the level is not correct: Start the engine. Rotate the turntable 90 to the left or to the right. Stop the engine. Power down the machine. Remove the hydraulic oil tank cap 1. Add hydraulic oil until the correct level is reached, refer to "LUBRICANTS, COOLANT AND FUEL". Put the hydraulic oil tank cap 1 back in place. Put the chassis front cover panel back in place. Start the engine. Set the turntable in neutral position Stop the engine. Power down the machine. - If the level is correct: Make sure that the hydraulic oil tank cap 1 is properly closed. Put the chassis front cover panel back in place

94 EVERY 50 OPERATING HOURS OR EVERY WEEK CHECK 110 V generator (option) - Start the engine. Start the 110 V generator. - Locate and lift the rubber mat of the generator housing located on the left side of the turntable. - Locate the test button 1 on the 110 V generator and press on it: The reset switch 2 should release to the OFF position. - Push the reset switch 2 to the ON position. - Stop the 110 V generator. Stop the engine. Power down the machine. 1 2 CLEAN Engine and oil radiators NOTICE CLEAN THE RADIATOR MORE OFTEN WHEN THE MACHINE IS OPERATING IN A DUSTY ENVIRONMENT. - Remove the chassis rear cover panel. - Remove the ventilation grid 1 and clean it with a clean and slightly damp cloth. - Clean the radiator 2 with a hand brush to remove dust. - Clean the radiator 2 with compressed air from the inside to the outside. - Put the ventilation grid 1 back in place. - Put the chassis rear cover panel back in place

95 CHECK/CLEAN NOTICE Outer air filter element CLEAN/CHECK THE OUTER AIR FILTER ELEMENT MORE OFTEN WHEN THE MACHINE IS OPERATING IN A DUSTY ENVIRONMENT. NEVER OPERATE THE MACHINE WITHOUT THE OUTER AIR FILTER ELEMENT OR IF IT IS DAMAGED. IF ANY DOUBTS EIST ABOUT THE CONDITION OF THE OUTER AIR FILTER ELEMENT, REFER TO "REPLACE: OUTER AIR FILTER ELEMENT". NEVER OPERATE THE MACHINE WITHOUT THE INNER AIR FILTER ELEMENT OR IF IT IS DAMAGED. IF ANY DOUBTS EIST ABOUT THE CONDITION OF THE INNER AIR FILTER ELEMENT, REFER TO "REPLACE: INNER AIR FILTER ELEMENT". - Open the chassis right cover panel. - Clean the outside of the air filter box 1 with a clean and slightly damp cloth. - Remove the air filter box cover. - Remove the outer air filter element 2 with care to avoid dust spread. - Check the condition of the the inner air filter element 3 without removing it. - Clean the inside of the air filter box and of the cover with a clean and slightly damp cloth. - Check the condition of the air filter box and of the hoses. - Clean the outer air filter element 2 with compressed air from the inside to the outside. Maximum pressure = 43 psi (3 bar). Minimum distance = 1.25 in (30 mm). - Check the condition of the outer air filter element. - Clean the seal of the outer air filter element with a clean and slightly damp cloth. - Lubricate the seal of the outer air filter element with silicone lubricant (Manitou part number ). - Put the outer air filter element 2 back in place. Note: do not press the center of the outer air filter element. - Put the air filter box cover back in place, the vacuum diaphragm 4 pointing downwards. - Close the chassis right cover panel GREASE Steering pivots NOTICE GREASE THE STEERING PIVOTS MORE OFTEN WHEN THE MACHINE IS OPERATING IN A DUSTY ENVIRONMENT. - Remove the two grease fittings caps 1, left and right side. - Pump grease into the two steering pivots grease fittings, left and right side, refer to "LUBRICANTS, COOLANT AND FUEL". - Put the two grease fittings caps 1 back in place

96 EVERY 250 OPERATING HOURS OR EVERY 6 MONTHS CHECK Tightening torque of the wheel motors bolts CAUTION FAILURE TO OBSERVE THIS INSTRUCTION CAN CAUSE DAMAGES TO THE WHEEL MOTORS AND CAN CAUSE BOLTS FAILURE. - Remove one wheel, refer to "OCCASIONAL MAINTENANCE". - Check the tightening torque of the bolts 1: 81.9 ft-lbs ±8.2 ft-lbs (111 Nm ±11 Nm). - Put the wheel back in place, refer to "OCCASIONAL MAINTENANCE". - Repeat steps to check the tightening torque of all the wheel motors bolts. 1 CHECK Wheel nuts tightening torque CAUTION FAILURE TO OBSERVE THIS INSTRUCTION CAN CAUSE DAMAGES TO THE WHEEL STUDS AND CAN DEFORM THE WHEELS. CHECK - Check the wheels nuts tightening torque: Front and rear wheels = 184 ft-lbs ±18 ft-lbs (250 Nm ±25 Nm). Brakes BRAKING DISTANCE ON A LEVEL SURFACE - Start the engine. Set the machine in transport position. Set the turntable and the platform in neutral position. Fully lower the jib boom. - Select a level surface. - Put an additional mass in the platform equal to: 550 lbs (250 kg) minus the operator's mass. - Select the HARE speed (high speed). - Drive the machine forward until the maximum speed is reached. - Release the foot switch to brake the machine: The braking distance should be: 4 ft 7 in ±1.5 in (1400 mm ±40 mm). - Raise the jib boom for 2 seconds and extend the telescope boom for 2 seconds. - Drive the machine forward until the maximum speed is reached: The driving speed should be "Work position" speed. - Release the foot switch to brake the machine: The braking distance should be: 6.25 in ±1.5 in (160 mm ±40 mm). - Fully retract the telescope boom and fully lower the jib boom. BRAKING ON A SLOPE Note: the engine is running. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is fully lowered. An additional mass is in the platform. - Select the RAMP speed (slow speed with full power). - Raise the jib boom to the horizontal. - Select a 25% (14 ) slope. - Slowly drive the machine forward on the slope, facing it, platform downhill. - Release the foot switch to brake the machine on the slope: The machine should stay in place on the slope for a minimum of 1 minute. - Drive the machine out of the slope. - Fully lower the jib boom. - Stop the engine. Power down the machine. - Remove the additional mass from the platform. 3-16

97 CHECK Adjustment of the telescope boom CAUTION FAILURE TO OBSERVE THIS INSTRUCTION CAN CAUSE DAMAGES TO THE TELESCOPE BOOM. - Locate the four nuts 1 under the primary boom end. - Check the tightening torque of the four nuts 1: 51 ft-lbs ±5.1 ft-lbs (69 Nm ±6.9 Nm). - Check the plays between the round skids and the telescope boom: Play A (top skid 2) = 0.04 in (1 mm). Play B (side skids 3) = 0.02 in (0.5 mm). - Adjust the plays if needed, refer to the repair manual of the machine. 1 A B 2 3 CHECK Turntable motor oil level - Open the turntable left cover panel. - Remove the breather/filling plug 1. - The level is correct when the oil reaches the top of the filler hole. - If the level is not correct: Add oil by using a syringe until the correct level is reached, refer to "LUBRICANTS, COOLANT AND FUEL". Put the breather/filling plug 1 back in place. - If the level is correct: Put the breather/filling plug 1 back in place. 1 CHECK Manual rescue pump Note: the turntable left cover panel is open. - Test the rescue functions with the manual pump, refer to "2- INSTRUCTIONS: RESCUE FUNCTIONS". - Close the turntable left cover panel. CHECK Boom limit switches - Start the engine. Set the machine in transport position. Set the turntable and the platform in neutral position. Fully lower the jib boom. - Refer to "TEST THE PLATFORM CONTROLS AND THE ALARMS: WORK POSITION SPEED" in "2- INSTRUCTIONS: INSPECTIONS". CHECK Overload alarm Note: the engine is running. The machine is in transport position. The turntable and the platform are in neutral position. The jib boom is fully lowered. - Refer to "TEST THE GROUND CONTROLS AND THE ALARMS: OVERLOAD ALARM" in "2- INSTRUCTIONS: INSPECTIONS". - Stop the engine. Power down the machine. 3-17

98 CHECK/ADJUST Fan/alternator belt NOTICE IF ANY DOUBTS EIST ABOUT THE CONDITION OF THE FAN/ALTERNATOR BELT, REFER TO "REPLACE: FAN/ ALTERNATOR BELT". - Remove the chassis rear cover panel. - Open the chassis right cover panel. - Check the condition of the fan/alternator belt 1. Make sure it has no cracks. - Check the fan/alternator belt tension between the crankcase pulley and the alternator pulley: Apply a pressure with the thumb = 22 lbf (98 N). The play A must be between 0.27 in (7 mm) and 0.35 in (9 mm) to be correct. - Adust if needed: Loosen the screws 2. Adjust the fan/alternator belt tension by pivoting the alternator. Tighten the screws 2. Check again the fan/alternator belt tension. - Close the chassis right cover panel. - Put the chassis rear cover panel back in place. 1 A 2 2 CHECK/CLEAN Fuel filter element DANGER DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE WHEN CLEANING THE FUEL FILTER. ON NOTICE NEVER OPERATE THE MACHINE WITHOUT THE FUEL FILTER ELEMENT OR IF IT IS DAMAGED. IF ANY DOUBTS EIST ABOUT THE CONDITION OF THE FUEL FILTER ELEMENT, REFER TO "REPLACE: FUEL FILTER ELEMENT". - Remove the chassis left cover panel. - Clean the outside of the fuel filter assembly and its bracket with a clean cloth. - Turn the fuel filter valve 1 to the OFF position. - Unscrew the retaining ring 2. - Remove the housing 3 and clean the inside by using a brush soaked with clean diesel fuel, refer to "LUBRICANTS, COOLANT AND FUEL". - Remove the fuel filter element 4 and rinse it in clean diesel fuel. - Check the condition of the fuel filter element. - Check the condition of the fuel hoses. - Put the fuel filter element 4, the housing 3 and the retaining ring 2 back in place. - Bleed the fuel system, refer to "OCCASIONAL MAINTENANCE". 1 ON 4 OFF OFF

99 GREASE Pins, hubs and cylinder bushings - Remove the grease fittings caps. - Pump grease into each grease fitting, refer to "LUBRICANTS, COOLANT AND FUEL". - Put the grease fittings caps back in place. LEGEND PIN HUB CYLINDER BUSHING x2 x2 x2 x2 x2 3-19

100 GREASE Turntable ring gear - Open the turntable left cover panel. - Remove the two grease fittings caps 1, left and right side. - Pump grease into the two grease fittings of the turntable ring gear, left and right side, refer to "LUBRICANTS, COOLANT AND FUEL". - Put the two grease fittings caps 1 back in place. - Lubricate the turntable ring gear teeth 2 and the turntable motor gear teeth 3, refer to "LUBRICANTS, COOLANT AND FUEL". - Close the turntable left cover panel

101 3-21

102 EVERY 500 OPERATING HOURS OR EVERY YEAR CHECK Tightening torque of the turntable ring gear bolts CAUTION FAILURE TO OBSERVE THIS INSTRUCTION CAN CAUSE DAMAGES TO THE RING GEAR AND CAN CAUSE BOLTS FAILURE. - Open the turntable right cover panel. - Open the turntable left cover panel. - Check the tightening torque of the bolts 1: 89 ft-lbs ±8.9 ft-lbs (120 Nm ±12 Nm). - Locate the hole A on the right side and the hole B on the left side. - Start the engine. Rotate the turntable to align the holes A and B with the bolts 2. - Check the tightening torque of the bolts 2: 89 ft-lbs ±8.9 ft-lbs (120 Nm ±12 Nm). - Rotate the turntable to align the holes A and B with two other bolts 2. - Repeat steps until the tightening torques of all the bolts are checked. - Set the turntable in neutral position. - Stop the engine. Power down the machine. - Close the turntable right cover panel. 1 A 1 B 2 CHECK Tightening torque of the turntable motor bolts CAUTION FAILURE TO OBSERVE THIS INSTRUCTION CAN CAUSE DAMAGES TO THE TURNTABLE MOTOR AND CAN CAUSE BOLTS FAILURE. Note: the turntable left cover panel is open. - Check the tightening torque of the bolts 1: 59 ft-lbs ±5.9 ft-lbs (80 Nm ±8 Nm). 1 CHECK WARNING ALWAYS USE A PIECE OF PAPER OR A CARD-BOARD WHEN CHECKING HYDRAULIC LEAKS. REPLACE ANY DAMAGED HYDRAULIC HOSE Hydraulic hoses Note: the turntable left cover panel is open. - Open the chassis right cover panel. - Check the condition of the hydraulic hoses and check for hydraulic leaks. - Close the turntable left cover panel.

103 REPLACE Engine oil REPLACE Engine oil filter Note:the chassis right cover panel is open. DRAIN THE ENGINE OIL - Start the engine. Leave it running for 5 minutes and stop it. - Stop the engine. Power down the machine. - Remove the chassis left cover panel. - Remove the chassis rear cover panel. - Remove the chassis cover panel 1. - Locate the drain plug 3 under the chassis and put a drain pan underneath. - Remove the oil filler cap 2 and the drain plug 3. - Wait for the engine casing to be completely drained. REPLACE THE ENGINE OIL FILTER - Put a drain pan underneath the engine oil filter 4. - Replace the engine oil filter 4, refer to "FILTER ELEMENTS AND BELTS": Remove the used engine oil filter. Lubricate the seal of the new engine oil filter with clean engine oil, refer to "LUBRICANTS, COOLANT AND FUEL". Screw the new engine oil filter by hands and tighten it three-quarter turn by using an oil filter socket tool. FILL THE ENGINE - Put the drain plug 3 back in place. - Fill the engine with new engine oil, refer to "LUBRICANTS, COOLANT AND FUEL". - Wait 5 minutes for the oil to drain back into the engine casing. - Put the oil filler cap 2 back in place. - Check the engine oil level, refer to "ROUTINE MAINTENANCE". - Start the engine. Leave it running for 5 minutes. Check for oil leaks. - Stop the engine. Power down the machine. - Wait 5 minutes for the oil to drain back into the engine casing. - Check again the engine oil level. - Put the chassis cover panel 1 back in place. - Put the chassis rear cover panel back in place - Put the chassis left cover panel back in place. - Close the chassis right cover panel REPLACE Fuel prefilter DANGER DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE WHEN REPLACING THE FUEL PREFILTER. - Open the turntable right cover panel. - Replace the fuel prefilter 1, refer to "FILTER ELEMENTS AND BELTS": Remove the used fuel prefilter. Check the condition of the fuel hoses. Put the new fuel prefilter in place. Make sure that the clips are securely in place. Note: observe the correct orientation of the prefilter. - Bleed the fuel system, refer to "OCCASIONAL MAINTENANCE". - Close the turntable right cover panel

104 REPLACE Fuel filter element DANGER DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE WHEN REPLACING THE FUEL FILTER. ON NOTICE NEVER OPERATE THE MACHINE WITHOUT THE FUEL FILTER ELEMENT OR IF IT IS DAMAGED. - Remove the chassis left cover panel. - Clean the outside of the fuel filter assembly and its bracket with a clean cloth. - Check the condition of the fuel hoses. - Turn the fuel filter valve 1 to the OFF position. - Replace the fuel filter element 4, refer to "FILTER ELEMENTS AND BELTS": Unscrew the retaining ring 2. Remove the housing 3 and clean the inside by using a brush soaked with clean diesel fuel, refer to "LUBRICANTS, COOLANT AND FUEL". Remove the used fuel filter element 4. Put the new fuel filter element back in place. Put the housing 3 and the retaining ring 2 back in place. - Bleed the fuel system, refer to "OCCASIONAL MAINTENANCE". 1 ON 4 OFF OFF 3 2 REPLACE Outer air filter element NOTICE REPLACE THE OUTER AIR FILTER ELEMENT EVERY 250 OPERATING HOURS WHEN THE MACHINE IS OPERATING IN A DUSTY ENVIRONMENT. NEVER OPERATE THE MACHINE WITHOUT THE OUTER AIR FILTER ELEMENT OR IF IT IS DAMAGED. NEVER OPERATE THE MACHINE WITHOUT THE INNER AIR FILTER ELEMENT OR IF IT IS DAMAGED. IF ANY DOUBTS EIST ABOUT THE CONDITION OF THE INNER AIR FILTER ELEMENT, REFER TO "REPLACE: INNER AIR FILTER ELEMENT". - Open the chassis right cover panel. - Clean the outside of the air filter box 1 with a clean and slightly damp cloth. - Remove the air filter box cover. - Remove the used outer air filter element 2 with care to avoid dust spread. - Check the condition of the the inner air filter element 3 without removing it. - Clean the inside of the air filter box and of the cover with a clean and slightly damp cloth. - Check the condition of the air filter box and of the hoses. - Replace the outer air filter element 2, refer to "FILTER ELEMENTS AND BELTS": Clean the seal of the new outer air filter element with a clean and slightly damp cloth. Lubricate the seal of the new outer air filter element with silicone lubricant (Manitou part number ). Put the new outer air filter element back in place. Note: do not press the center of the outer air filter element. - Put the air filter box cover back in place, the vacuum diaphragm 4 pointing downwards

105 REPLACE Fan/alternator belt Note: the chassis right cover panel is open. - Remove the chassis rear cover panel. - Replace the fan/alternator belt 1, refer to "FILTER ELEMENTS AND BELTS": Loosen the screws 2. Remove the used fan/alternator belt by pivoting the alternator. Put the new fan/alternator belt in place. Adjust the fan/alternator belt tension by pivoting the alternator. Tighten the screws 2. - Check the fan/alternator belt tension between the crankcase pulley and the alternator pulley: Apply a pressure with the thumb = 22 lbf (98 N). The play A must be between 0.27 in (7 mm) and 0.35 in (9 mm) to be correct. - Adust if needed: Loosen the screws 2. Adjust the fan/alternator belt tension by pivoting the alternator. Tighten the screws 2. Check again the fan/alternator belt tension. - Put the chassis rear cover panel back in place. - Close the chassis right cover panel. 1 A 2 2 REPLACE Turntable motor oil - Open the turntable left cover panel. - Remove the breather/filling plug 1. - Put a drain pan underneath the drain plug 2. - Remove the drain plug 2. - Wait for the motor casing to be completely drained. - Put the drain plug 2 back in place - Fill with new oil by using a syringe, refer to "LUBRICANTS, COOLANT AND FUEL". The level is correct when the oil reaches the top of the filler hole. - Put the breather/filling plug 1 back in place. - Start the engine. Rotate the turntable to the left and to the right a small angle several times. Check for oil leaks. - Set the turntable in neutral position. - Stop the engine. Power down the machine

106 REPLACE Pressure hydraulic filter element Note: the turntable left cover panel is open. - Clean the outside of the pressure filter assembly 1 and its bracket with a clean cloth. - Put a drain pan underneath the pressure filter assembly 1. - Replace the pressure hydraulic filter element 2, refer to "FILTER ELEMENTS AND BELTS": Unscrew the pressure filter housing. Remove the old pressure hydraulic filter element. Put the new pressure hydraulic filter element back in place. Put the filter pressure housing back in place. - Start the engine. Raise and lower the jib boom several times. Check for oil leaks. - Fully lower the jib boom - Stop the engine. Power down the machine. - Close the turntable left cover panel. 1 2 REPLACE Hydrostatic filter element - Remove the chassis left cover panel. - Remove the chassis cover panel 1. - Clean the outside of the hydrostatic filter assembly 2 with a clean cloth. - Put a drain pan underneath the hydrostatic filter assembly 2. - Replace the hydrostatic hydraulic filter element 3, refer to "FILTER ELEMENTS AND BELTS": Unscrew the hydrostatic filter housing. Remove the old hydrostatic filter element. Put the new hydrostatic filter element back in place. Replace the o-ring 4 provided with the hydrostatic filter element 3. Put the hydrostatic filter housing back in place. - Start the engine. Drive forward and reverse several times. Check for oil leaks. - Stop the engine. Power down the machine. - Put the chassis cover panel 1 back in place. - Put the chassis left cover panel back in place

107 3-27

108 EVERY 1000 OPERATING HOURS OR EVERY 2 YEARS CHECK/CLEAN Fuel tank DANGER DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE WHEN CHECKING/CLEANING THE FUEL TANK. - Open the turntable right cover panel. - Remove the fuel tank cap 1. - Locate the drain plug 2 and put a drain pan underneath. - Remove the drain plug 2. - Wait for the fuel tank to be completely drained. - Rinse the fuel tank with 2.6 US gal (10 L) of clean diesel fuel, refer to "LUBRICANTS, COOLANT AND FUEL". - Put the drain plug 2 back in place when the fuel tank is completely drained. - Fill completely the fuel tank with clean diesel fuel, refer to "LUBRICANTS, COOLANT AND FUEL". - Put the fuel tank cap 1 back in place. - Start the engine. Leave it running for 5 minutes. Check for fuel leaks. - Stop the engine. Power down the machine. - Close the turntable right cover panel. 1 2 REPLACE Inner air filter element NOTICE NEVER OPERATE THE MACHINE WITHOUT THE OUTER AIR FILTER ELEMENT OR IF IT IS DAMAGED. NEVER OPERATE THE MACHINE WITHOUT THE INNER AIR FILTER ELEMENT OR IF IT IS DAMAGED. Note: refer to instructions described in "REPLACE OUTER AIR FILTER ELEMENT" except: - Replace the inner air filter element 3, refer to "FILTER ELEMENTS AND BELTS": Remove the used inner air filter element 3. Clean the seal of the new inner air filter element with a clean and slightly damp cloth. Lubricate the seal of the new inner air filter element with silicone lubricant (Manitou part number ). Put the new inner air filter element back in place. Note: do not press the center of the inner air filter element

109 REPLACE CLEAN Hydraulic oil Filling filter and suction strainers NOTICE THERE MAY BE A LEVEL DIFFERENCE FROM 3/8 IN TO 3/4 IN (10 TO 20 MM) BETWEEN A HOT AND A COLD OIL. IT IS RECOMMENDED TO CHECK AGAIN THE LEVEL WHEN THE HYDRAULIC OIL IS HOT. CLEAN THE OIL CAN BEFORE ADDING OIL IN THE HYDRAULIC TANK. USE A CLEAN FUNNEL TO ADD OIL IN THE HYDRAULIC TANK. DRAIN THE HYDRAULIC OIL - Start the engine. Rotate the turntable 90 to the left or to the right. - Stop the engine. Power down the machine. - Remove the front chassis cover panel. - Remove the hydraulic oil tank cap 1. - Locate the drain plug 4 under the machine chassis and put a drain pan underneath. - Remove the drain plug 4. - Wait for the hydraulic tank to be completely drained. CLEAN THE FILLING FILTER AND THE SUCTION STRAINERS - Remove the filling filter 5. - Clean the filling filter 5 with compressed air from the outside to the inside. Maximum pressure = 43 psi (3 bar). Minimum distance = 1.25 in (30 mm). - Check the condition of the filling filter. Replace it if needed, refer to "FILTER ELEMENTS AND BELTS". - Put the filling filter 5 back in place. - Remove the chassis cover panel 3. - Locate the hoses 6/7 and put a drain pan underneath. - Remove the hoses 6/7 and the suction strainers 8/9. - Clean the suction strainers 8/9 with compressed air from the inside to the outside. Maximum pressure = 43 psi (3 bar). Minimum distance = 1.25 in (30 mm). - Check the condition of the suction strainers. Replace them if needed, refer to "FILTER ELEMENTS AND BELTS". - Put the suction strainers 8/9 and the hoses 6/7 back in place. - Put the chassis cover panel 3 back in place. FILL THE HYDRAULIC TANK - Put the drain plug 4 back in place. - Fill the hydraulic tank with new hydraulic oil, refer to "LUBRICANTS, COOLANT AND FUEL". The level is correct when the hydraulic oil reaches the red point of the sight gauge 2. - Put the hydraulic oil tank cap 1 back in place. - Start the engine. Operate functions for 10 minutes. Check for oil leaks. - Stop the engine. Power down the machine. - Check again the hydraulic oil level, add hydraulic oil if needed. - Put the front chassis cover panel back in place. - Start the engine. Set the machine in transport position. Set the turntable and the platform in neutral position. Fully lower the jib boom. - Stop the engine. Power down the machine

110 CHECK Engine silent blocks * CHECK Engine speed * CHECK Valve clearances * CHECK Pressure of hydrostatic transmission system * CHECK Flow regulation of hydrostatic transmission * CHECK Speed of hydraulic movements * CHECK Condition of cylinders * CHECK Condition of the electrical wiring * * Consult your dealer. 3-30

111 3-31

112 EVERY 2000 OPERATING HOURS OR EVERY 4 YEARS REPLACE Coolant CAUTION IF THE ENGINE HAS BEEN RUNNING SINCE A SHORT TIME, WAIT FOR IT TO COOL DOWN. DO NOT REMOVE THE RADIATOR CAP UNTIL THE ENGINE HAS COOLED DOWN. NOTICE IT IS RECOMMENDED TO REPLACE THE COOLANT BEFORE WINTER. DRAIN THE COOLANT - Remove the chassis rear cover panel. - Open the chassis right cover panel. - Remove the chassis cover panel 1. - Remove the radiator cap 2. - Locate the drain plug 3 under the chassis and put a drain pan underneath. - Remove the drain plug 3. - Locate the drain valve 4 and put a drain pan underneath. - Open the drain valve 4. - Wait for the coolant circuit to be completely drained. FILL THE COOLANT CIRCUIT - Close the drain valve 4. - Put the drain plug 3 back in place. - Fill the coolant circuit with new coolant, refer to "LUBRICANTS, COOLANT AND FUEL". The level is correct when the coolant reaches the top of the filler hole. - Put the radiator cap 2 back in place. - Start the engine. Leave it running for 5 minutes. Check for coolant leaks. - Stop the engine. Power down the machine. - Wait for the engine to cool down. - Remove the radiator cap 2 - Check again the coolant level, add coolant if needed. - Put the radiator cap 2 back in place. - Put the chassis cover panel 1 back in place. - Close the chassis right cover panel. - Put the chassis rear cover panel back in place

113 CHECK Fuel injectors * CHECK Engine and oil radiators * CHECK Water pump and thermostat * CHECK Alternator and starter * CHECK Turbocharger * CHECK Injection pump * CHECK Pressure of hydraulic systems * CHECK Flow regulation of hydraulic systems * CLEAN Hydraulic oil tank * * Consult your dealer. 3-33

114 OCCASIONAL MAINTENANCE REPLACE Wheels DANGER REFER TO "2- INSTRUCTIONS: CHARACTERISTICS" OR TO THE APPLICABLE DECALS TO HAVE INFORMATION ABOUT THE TOTAL MASS OF THE MACHINE AND THE WHEEL LOAD. WHEN LIFTING THE MACHINE BY MEANS OF A HYDRAULIC JACK OR A MECHANICAL JACK: - ALWAYS USE AN APPROPRIATE JACK TO LIFT THE MACHINE. - IT IS RECOMMENDED TO SET THE TURNTABLE COUNTERWEIGHT ON OPPOSITE SIDE OF THE LIFTING. - MAKE SURE THAT THE TWO WHEELS ON OPPOSITE SIDE OF THE LIFTING ARE CHOCKED. - POSITION THE JACK CLOSE TO THE WHEEL TO BE REMOVED. - ALWAYS USE APPROPRIATE JACK STANDS TO SECURE THE LIFTED MACHINE. WHEN LIFTING THE MACHINE BY MEANS OF A HOIST: - REFER TO "2- INSTRUCTIONS: LIFTING INSTRUCTIONS". - ALWAYS USE APPROPRIATE JACK STANDS TO SECURE THE LIFTED MACHINE. WARNING THE MASS OF ONE WHEEL = 212 LBS (96 KG). - Lift the machine. - Remove the wheel nuts and the wheel. - Put the new wheel back in place. - Put the wheel nuts back in place and tighten them by hands. - Lower the machine to the ground. - Tighten the wheel nuts, refer to "CHECK: WHEEL NUTS TIGHTENING TORQUE". 3-34

115 BLEED DANGER DO NOT ALLOW FLAMES OR SPARKS AND DO NOT SMOKE WHEN BLEEDING THE FUEL SYSTEM. NOTICE MAKE SURE THERE IS ENOUGH FUEL IN THE TANK BEFORE BLEEDING THE FUEL SYSTEM. ALWAYS BLEED THE FUEL SYSTEM WHEN: - THE FUEL TANK HAS BEEN DRAINED. - A FUEL SYSTEM COMPONENT HAS BEEN REPLACED. - A FUEL EHAUSTION HAS BEEN NOTICED. Fuel system IF THE ENGINE IS RUNNING ROUGHLY OR IF IT STOPS WHEN THE FUEL SYSTEM HAS BEEN BLED, CHECK THE CONDITION OF THE COMPLETE FUEL SYSTEM. BLEED THE FUEL FILTER - Remove the chassis left cover panel. - Turn the fuel filter valve 1 to the ON position. - Loosen the bleed plug 2. - Operate the manual pump 3 until the fuel flows from the bleed plug 2. - Continue to pump and tighten the bleed plug 2. BLEED THE INJECTION PUMP - Loosen the bleed plug 4. - Operate the manual pump 3 until the fuel flows from the bleed plug 4. - Continue to pump and tighten the bleed plug 4. - Start the engine. Leave it running for 5 minutes. Check for fuel leaks. - Stop the engine. Power down the machine. - Put the chassis left cover panel back in place. 4 ON 2 1 ON ON OFF