Page 1 1650RT | 1650RT (EU) 1650RT X-Series 1950RT | 1950RT (EU) 1950RT X-Series Compact Track Loader Operator’s Manual 50950615EN-US Rev. A 07/24 Original Instructions (Supersedes 50950266)
Page 2 WARNING This product can expose you to lead which is known to the State of California to cause cancer and birth defects or other reproductive harm. For more information go to www.P65Warnings.ca.gov WARNING Breathing diesel engine exhaust exposes you to chemicals known to the state of California to cause cancer and birth defects or other reproductive harm.
Page 3 All other costs, including diagnostic costs, transport, towing, customs and taxes, are excluded. For the application of the warranty, MANITOU Group reserves the right to base its decision on the results of additional analyses, such as extractions of data (including data from MANITOU Group Services or Equipment)s, serial number records, oil, ﬂuid or fuel analyses, etc.
Page 4 The extended warranty granted on a "commercial" basis by MANITOU Group is not an acknowledgement of liability. MANITOU Group shall not be held liable for any direct or indirect damage resulting from the performance of its obligations under this warranty - including the consequences of immobilization of the Equipment during the warranty period - such as machine rental, ﬁnancial losses, production losses, operating loss,...
Page 5: Table Of Contents
1650RT and 1950RT Track Loader Operator’s Manual TABLE OF CONTENTS Introduction ........1 Safety .
Page 6 1. Manufacturer: Manitou Equipment America, LLC 2. Address: One Gehl Way West Bend, WI 53095 U.S.A 3. Technical Construction File Location: Manitou Interface and Logistics Europe 4. Authorized Representative: Manitou Interface and Logistics Europe 5. Address: Rue DesAndains 2 Perwez, 1360...
Page 7: Introduction
CHAPTER 1 INTRODUCTION Safety Symbol and Signal Words Manitou Group, in cooperation with the Society of Automotive Engineers, has adopted this: Safety Alert Symbol This symbol identifies potential safety hazards, which, if not properly avoided, could result in injury. When you see this symbol in this manual...
Page 8 Follow the instructions in the Operator’s Manual Safety, Operation and Maintenance chapters, concerning accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Manitou Group is not liable for injury or damage resulting from the failure to follow these regulations.
Page 9: Machine Orientation
Machine Orientation “Right” and “left”, as described in this manual, are determined from a position sitting in the operator’s seat and facing forward. 1. Attachment Bracket 7. Lift Arm Support Device 13. Fuel Cap Cover 14. Seat Plate (according to ISO 2.
Page 10: Proper Machine Use
Proper Machine Use Improper use of the machine can result in property WARNING damage, injury or death. The machine is designed only for moving earth, coarse gravel or ballast and rubble. Use with approved attachments is also allowed – See “Fields of Application” on page 6. Use in any other way is considered as contrary to the intended use.
Page 11: Model And Serial Numbers
Model and Serial Numbers Machine Model Number ____________________________________ Machine Serial Number ____________________________________ Engine Model Number ____________________________________ Engine Serial Number ____________________________________ Drive Motor Model Number ____________________________________ Drive Motor Serial Number ____________________________________ Hydraulic Pump Model Number ____________________________________ Hydraulic Pump Serial Number ____________________________________ 50950615EN-US/A0724...
Page 12: Fields Of Application
See the following “Fields of Application” table for information about approved attachments and their uses. Contact your dealer before using attachments or equipment not approved by Manitou Group. Use of non- approved attachments or unauthorized modifications is prohibited.
Page 13: Vibration Information
Vibration Information Compact construction equipment is generally used in harsh environments. This type of usage can expose an operator to uncomfortable levels of vibration. It is useful to understand exposure to vibration levels when operating compact equipment and what can be done to reduce vibration exposure.
Page 14: Fire Extinguisher Location
Important: Inspect the fire extinguisher at Location regular intervals as recommended by the fire extinguisher equipment manufacturer. Manufacturer Information Products described in this manual are manufactured by Manitou Group. Note: Not all models and options described in this manual are available in all areas. 50950615EN-US/A0724...
Page 15: Indicator And Operation Symbols
Indicator and Operation Symbols Safety Hazard Parking Brake High-Speed Float Hydraglide™ Pre-Heat Intake Hydraulic Oil Hydraulic Oil Elevated EGT Fasten Seat Belt Charging Fault Restriction Filter Warning Temp Warning Temp DPF Regen DPF Regen Regen Oil Pressure DPF Regen Engine Oil Accept Inhibited Maintenance...
Page 16 High-Flow Aftertreatment Reverse Error 50950615EN-US/A0724...
Page 17: Legal Disclaimer
Manitou Group. In the event that Manitou Group authorizes a Manitou Group machine user to access all or part of this database, Manitou Group, as producer of this database, cedes to the user only a right to personal, non-exclusive, non transferable use of the database, and only by access to an information technology platform hosted by a server owned or controlled by Manitou Group.
Page 18 The latest updated version in force and binding of this document is the version avail- able on demand. Only the electronic version is maintained. Contact MANITOU EQUIPMENT AMERICA, LLC Head Office: One Gehl Way, West Bend, Wisconsin USA 53090 Tel.: +1 262 334 9461 www.manitou-group.com...
Page 19: Safety
Manitou Group always takes operator’s safety into consideration during the design process. Guards and shields are provided, which protect the operator and bystanders from moving parts and other hazards.
Page 20: Mandatory Safety Shutdown Procedure
Different applications may require optional safety equipment, such as a back-up alarm, mirror, strobe light or an impact-resistant front door. Be sure you know the job site hazards and equip the machine as needed. Remember that some risks to your health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries.
Page 21 • The machine is designed and intended for use only with Manitou attachments or Man- itou-approved attachments. To avoid possible personal injury, equipment damage and/ or performance problems, use only approved attachments that are within the operating capacity of the machine. Contact your dealer or Manitou Group for information about attachment approval and compatibility with specific machine models.
Page 22: Additional Safety Equipment
• Machine stability is affected by: • The load being carried. • Height of the load. • Machine speed. • Abrupt control movements. • Driving and/or parked over uneven terrain. DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE MACHINE TO TIP, WHICH COULD THROW THE OPERATOR OUT OF THE SEAT OR MACHINE, AND COULD RESULT IN DEATH OR SERIOUS INJURY.
Page 23 • Operator visibility is limited in certain areas; ROPS/FOPS posts, attachments, the lift arm, items in the cab, etc., can obstruct the operator's view and could mask hazards or people in the area around the machine. It is very important the operator is aware of these masked visibility areas before operating the machine, especially on busy worksites.
Page 24 • Do not drive into materials at high speeds to avoid being thrown forward and injured. • Do not use the machine to lift or transport people. Never carry riders. Do not allow others to ride on the machine or attachments. •...
Page 25: Applications With Load-Handling Devices
• Never allow anyone under a raised lift arm. Lowering the lift arm or a falling load can result in death or serious personal injury. • Slow down the work cycle and use slower travel speeds in congested or populated areas.
Page 26: Parking The Machine
Parking the Machine • Never leave the operator's seat without lowering the lift arm/attachment flat on the ground or engaging the lift arm support device(s), and then stopping the engine and removing the ignition key. • When shutting the machine down for the day, plan ahead so the machine will be on a firm, level surface away from traffic and away from high walls, cliff edges and any area of potential water accumulation or runoff.
Page 27 Maintenance • Only trained and authorized personnel, with a full awareness of safe procedures, should be allowed to operate or perform maintenance or service on the machine. • Use warning tag/control lockout procedures during service. Alert others that service or maintenance is in progress by tagging the operator’s controls —...
Page 28 Unauthorized modifications to the machine can cause injury or death. Never make unauthorized modifications to any part of the machine. Any modification made with- out authorization from Manitou Group could create a safety hazard, for which the machine owner would be responsible.
Page 29: Battery Hazards
• Keep fuel and other fluid reservoir caps tight. Do not start the engine until caps have been secured. Battery Hazards • Sparks and open flames can set off explosive battery gas from incidental contact or static discharge. Turn off the engine and all switches when working on batteries. Keep battery terminals tight.
Page 30: Crystalline Silica Exposure
• Static electricity can produce dangerous sparks at the fuel-filling nozzle. Do not wear polyester, or polyester-blend clothing while fueling. Before fueling, touch the metal surface of the machine away from the fuel fill to dissipate any built-up static electric- ity.
Page 31: Loading And Transporting The Machine
• Lift the machine only with the standard bucket installed, with the bucket empty and in the transport position. • Persons must stay clear of, and out from under, the machine when it is lifted. • Fasten the rigging equipment so the machine is level when it is lifted. •...
Page 32 ANSI-Style Safety and Information Decals RIGHT LEFT FRONT OPERATOR’S POSITION Figure 2 – ANSI-Style Safety and Information Decal Locations 50950615EN-US/A0724...
Page 33 Note: Refer to Figure 2 on page 26 for decal locations. Located on the front panel below the door, behind the attachment hitch. DANGER: AVOID INJURY OR DEATH DANGER • Keep out from under work tool, unless lift AVOID INJURY OR DEATH Keep out from under work tool, unless lift arm is supported.
Page 34 Note: Refer to Figure 2 on page 26 for decal locations. WARNING Located on the side of the ROPS/FOPS. WARNING: Crush Hazard • Be sure lock mechanism is securely engaged before working under ROPS/ FOPS. Read instructions for use in Operator’s Manual. USE PROPER HYDRAULIC FLUID ONLY! Located near the hydraulic fluid reservoir filler neck.
Page 35 Note: Refer to Figure 2 on page 26 for decal locations. Located inside the engine compartment. WARNING: HOT SURFACE WARNING • Do not touch hot engine or hydraulic system parts. Located on the right door pillar, facing the operator. WARNING AVOID INJURY OR DEATH WARNING: AVOID INJURY OR DEATH Always follow "Mandatory...
Page 36 Note: Refer to Figure 2 on page 26 for decal locations. Located on the bottom of the ROPS/FOPS operator enclo- sure. WARNING: Crush Hazard • Be sure lock mechanism is securely engaged before working under ROPS/FOPS. • Read instructions for use in Operator’s Manual. Located behind the operator’s seat above rear window WARNING: AVOID INJURY OR DEATH...
Page 37 Note: Refer to Figure 2 on page 26 for decal locations. Located on attachment bracket (power hitch only) 50354137 Located on attachment bracket (manual hitch only) DANGER Hose removal or coponent failure can cause lift arm to drop. Always use lift arm support device when leaving lift arm raised for service. 137637 Located on the left lift arm near the lift arm support.
Page 38 ISO-Style (Used Internationally) Safety and Information Decals RIGHT LEFT FRONT OPERATOR’S POSITION Figure 3 – ISO-Style (Used Internationally) Safety and Information Decal Locations 50950615EN-US/A0724...
Page 39 Note: Refer to Figure 2 on page 26 for decal locations. Located on the front panel below the door, behind the attachment hitch. DANGER: AVOID INJURY OR DEATH A) Keep out from under work tool, unless lift arm is supported. B) No riders! Never use work tool as work platform.
Page 40 Note: Refer to Figure 2 on page 26 for decal locations. Located on the side of the ROPS/FOPS. WARNING: Crush Hazard • Be sure lock mechanism is securely engaged before working under ROPS/ FOPS. Read instructions for use in Operator’s Manual. USE PROPER HYDRAULIC FLUID ONLY! Located near the hydraulic fluid reservoir filler neck.
Page 41 Note: Refer to Figure 2 on page 26 for decal locations. Located on the right door pillar, facing the operator. DANGER: AVOID INJURY OR DEATH A) Crush hazard: Keep out from under lift arm unless lift arm is supported. B) Crush hazard: Hose removal or component failure can cause lift arm to drop.
Page 42 Note: Refer to Figure 2 on page 26 for decal locations. Located on the bottom of the ROPS/FOPS operator enclo- sure. WARNING: Crush Hazard • Be sure lock mechanism is securely engaged before working under ROPS/FOPS. • Read instructions for use in Operator’s Manual. Located behind the operator’s seat above rear window WARNING: AVOID INJURY OR DEATH...
Page 43 Note: Refer to Figure 2 on page 26 for decal locations. Located on the front of the lift arm cross- member. WARNING: AVOID INJURY OR DEATH • Before operating with attachment, check engagement of loader attachment bracket locking pin to the attachment. Located on attachment bracket (power hitch only) 50354137 Located on attachment bracket (manual hitch only)
Page 44: Product And Component Plate Locations
Product and Component Plate Locations Product and Component Plates 1. Operator protective system plate: with, e.g., model, certification and operator protective system serial number. 2. Seat plate according to ISO 7096 3. Product plate: with Product Identification Number and, e.g., model/type designation. 4.
Page 45: Safety Equipment
Know how to stop the machine before starting it. The machine is designed and intended to be used only with Manitou Group-approved attachments or accessories. Manitou Group cannot be responsible for operator safety if the machine is used with unapproved attachments. Guards and Shields Guards and shields are provided on the machine, wherever possible without effecting machine operation, to protect against potential hazards.
Page 46: Seat Suspension
Seat suspension Seat suspension can be adjusted as necessary to compensate for the drivers weight and preferred seat suspension stiffness. Mechanical suspension: While sitting in the operator’s seat, rotate knob (Z, Figure 5) as necessary to adjust seat suspension so weight indicator (X) is set to the approximate weight of the operator.
Page 47: Upper Torso Restraint (Option)
Upper Torso Restraint (Option) Always wear the upper-torso restraint (J, Figure 6) WARNING when operating in high speed. The seat belt should always be fastened during operation. Important: Inspect the seat belt(s) for damage before use, and replace if damaged. Keep seat belt(s) clean.
Page 48: Safety Interlock System (Hydraloc™)
Safety Interlock System (Hydraloc™) NEVER attempt to bypass or defeat the safety WARNING interlock system. Serious personal injury or death could result. The Hydraloc™ safety interlock system provides for operator safety. The interlock system: • Prevents the engine from starting unless the operator is sitting in the operator’s seat with the restraint bar lowered.
Page 49: Parking Brake
Parking Brake The machine is equipped with a spring- applied, hydraulically-released parking brake. The parking brake is automatically applied when the restraint bar is lifted, the operator’s seat is not occupied, or the engine is shut off. The brake can also be applied manually by pressing button (K, Figure 9) on the control keypad on the right door pillar.
Page 50: Engage Lift Arm Support
Lift Arm Support The lift arm support prevents the raised lift arm from lowering unexpectedly. The lift arm support must be applied whenever the lift arm is left in the raised position. A falling lift arm could result in severe injury or WARNING death.
Page 51: Disengage Lift Arm Support
7. Use the lift control to raise the lift arm until lift arm support (T, Figure 12) drops over the end of the lift cylinder and around the cylinder rod. 8. Slowly lower the lift arm until the free end of the support device contacts the top end of the lift cylinder (U).
Page 52: Battery Disconnect Switch
To prevent damage to the lift cylinder, do not lower CAUTION lift arm until the lift arm support is secured in the storage position. Battery Disconnect Switch The battery disconnect switch is located in the engine compartment. Turning the switch to the OFF position disconnects the battery from the electrical system.
Page 53: Indicators And Controls
Know how to stop the machine before starting it. The machine is designed and intended to be used only with Manitou-approved attachments or accessories. Manitou cannot be responsible for operator safety if the machine is used with unapproved attachments.
Page 54: Control Keypad
Control Keypad Control Keypad Indicators Note: Control panel indicators are illuminated only when the indicator lamps are activated. Figure 16 – Control Keypad Indicators Table 2: Control Keypad Indicators Indicator Description Details High-Speed Travel Range Indicates high-speed travel range is activated. Indicator Lift Arm Float Indicator Indicates lift arm float is activated.
Page 55 Table 2: Control Keypad Indicators Indicator Description Details Indicates engine air filter requires service. See “Engine Engine Air Filter Restriction Air Cleaner” on page 143. During normal operation this Indicator indicator should be OFF. Indicates hydraulic oil filter requires service. Hydraulic Oil Filter Warning See“Changing Hydraulic Oil Filter”...
Page 56: Control Keypad Buttons
Control Keypad Buttons Figure 17 – Control Keypad Buttons Table 3: Control Panel Buttons Button Description Function Parking Brake Engages / disengages parking brake. Activates optional beacon, position, and/or work lights. Beacon / Position / Work Lights See “Beacon/Position/Work Lights” on page 74. Cancels self-leveling function.
Page 57: Accessory Keypad Indicators/Buttons
Accessory Keypad Indicators/Buttons Heat Indicator: is lit when cab heat is activated Figure 18 – Accessory Keypad Indicators/Buttons Table 4: Accessory Keypad Buttons Button Description Function Turns cab heat/cool on/off. Low, medium and high HVAC Button settings are available. See “HVAC (Option)” on page 74.
Page 58: Optional Lights/Lockout Keypad Indicators/Buttons
Optional Lights/Lockout Keypad Indicators/Buttons Figure 19 – Road Lights Keypad Indicators/Buttons Table 5: Optional Road Lights Keypad Buttons Button Description Function Operates optional road lights, and works with main control keypad to control the beacon and position lights. If all lights are off, one press activates the beacon and all position lights;...
Page 59: Information Center Electronic Display
Information Center Electronic Display The information center electronic display is located on the right door pillar. It provides the following functionality: • Displays operational status such as engine fuel tank level, engine RPM, coolant tem- perature, service hours and system voltage. •...
Page 60: Information Center Electronic Display Symbols
O. Regen/Return Button – Used for different functions depending upon screen and context: • Switches to the Regen display mode if the R. Regen Inhibit Button – Press for 5 seconds to symbol is displayed on the screen. Also initiates inhibit DPF reset regeneration.
Page 61 Table 6: Symbols Descriptions Symbol Description Symbol Description Diesel Particulate Filter (DPF) regeneration inhibit. See “Diesel Particulate Filter (DPF) Regeneration Procedures” on Percentage of engine power based page 118. on load. Note: Strike-through line through the symbol is displayed in red when DPF regeneration is inhibited.
Page 62: Information Center Electronic Display Screens
Information Center Electronic Display Screens Note: Values may not display for all parameters, depending upon installed options and equipment. Table 7: Status, Maintenance and Error Code Screens Display Mode Description Status Screens Dual Gauge Display A. Fuel level. B. Engine coolant temperature. C.
Page 63 Table 7: Status, Maintenance and Error Code Screens Display Mode Description Single Gauge Display Displays single real time operating parameters. Switch between parameters using the navigation button (M, Figure 20). Used for various functions, depending upon screen and context. 1234.5 n/min Regeneration Screens These screens are associated with Diesel Particulate...
Page 64 Table 7: Status, Maintenance and Error Code Screens Display Mode Description UNITS Units Screen Press the top/bottom of navigation rocker button (M, Figure 20) to switch between SAE or metric units for values displayed in screens. LANGUAGE Language Screen ENGLISH The press the top/bottom of navigation rocker button (M, Figure 20) to switch between English or Spanish language for values displayed in screens.
Page 65: Ignition Keyswitch
Table 7: Status, Maintenance and Error Code Screens Display Mode Description DIAGNOSTICS INPUTS Input Status Alternator Float KP Ingnition Run Displays input information from electronic control Hydro Glide KP Ignition Start High Gear modules, showing real-time machine component/ KP Seat Switch Aux Detent control state.
Page 66: Throttle Controls
Throttle Controls On machines equipped with throttle knob (Q, Figure 22), engine speed is controlled with throttle knob and optional foot throttle (P, Figure 23), if installed. Throttle knob (Q) is the primary throttle control. The throttle is set with the knob to the desired idle/run position.
Page 67: Travel Drive, Lift And Tilt Controls
Travel Drive, Lift and Tilt Controls The machine is equipped with one of three control systems: • T-Bar Controls: see “T-Bar Controls” on page 61. • Joystick Controls: see “Joystick Controls” on page 64. • Hand and Foot Controls: see “Hand and Foot Controls” on page 67. T-Bar Controls On T-bar-equipped machines, the left T-bar controls the travel drive, and the right T-bar controls the attachment lift and tilt.
Page 68 On machines equipped with T-bar controls, the left T-bar controls the drive, and the right T-bar controls the lift/tilt. Drive Control (Left T-Bar) Forward, reverse, travel speed and turning maneuvers are controlled using the left T- bar (Figure 25): A. To go forward, push the left T-bar forward.
Page 69 Lift/Tilt Control (Right T-Bar) Lift arm raise and lower, and attachment tilt are controlled using the right T-bar (Figure 26): A. To lower the lift arm, push the right T-bar straight forward. B. To raise the lift arm, pull the right T-bar straight rearward.
Page 70: Joystick Controls
Joystick Controls On joystick-equipped machines, the left joystick controls the travel drive, and the right joystick controls the attachment lift and tilt. Left Joystick Right Joystick Figure 27 – Joystick Hand Controls Table 9: Joystick Controls Ref. Control Description Controls drive forward, reverse, turn, and speed. See Left Joystick “Drive Control (Left Joystick)”...
Page 71 Drive Control (Left Joystick) Forward, reverse, travel speed and turning maneuvers are controlled using the left joystick (Figure 28): A. To go forward, push the left joystick forward. B. To go in reverse, pull the left joystick rearward. C. To turn right, push the left joystick to the right.
Page 72 E. To lower the lift arm while tilting the attachment forward and down, move the right joystick forward and to the right. F. To lower the lift arm while tilting the attachment up and back, move the right joystick forward and to the left. G.
Page 73: Left Hand Control
Hand and Foot Controls On hand and foot controlled-equipped machines, the hand controls are used to control the travel drive, and the foot controls are used to control the attachment lift and tilt. Left Hand Control Right Hand Control Foot Controls Figure 30 –...
Page 74 Table 10: Hand and Foot Controls Ref. Control Description Auxiliary Hydraulics Rocker Controls auxiliary hydraulics flow direction and amount. Switch See “Auxiliary Hydraulic System” on page 80. Works with Auxiliary Hydraulics Rocker Switch to latch/ Auxiliary Hydraulics Continuous unlatch auxiliary hydraulics continuous flow. See “Auxiliary Flow Latch Trigger Hydraulic System”...
Page 75 Moving the hand controls farther from neutral increases the speed steadily to the maximum travel speed. Tractive effort decreases as wheel speed increases. For maximum tractive effort, move the hand controls only slightly away from the neutral positions. The engine will stall if the hand controls are moved too far forward when loading the bucket. Lift/Tilt Control (Foot Controls) Lift arm raise and lower, and attachment tilt are controlled using the foot controls...
Page 76 Press button (C, Figure 33) to switch between Left T-Bar high and low two-speed drive ranges. When the high-speed two-speed drive range is activated, the high-speed indicator ( ) on the control pad is lit. Left Joystick Left Hand Control Figure 33 –...
Page 77: Lift Arm Float
Lift Arm Float Make sure the attachment is lowered to the ground WARNING before activating the lift arm float. Activating float with the lift arm raised will cause the lift arm and attachment to fall to the ground, which can cause severe injury or death. The float mode WARNING Right T-Bar...
Page 78 2. To place the lift arm in the detent (“float”) position, use your toes to push the left pedal all the way down (A) into the detent. This position allows the lowered lift arm to “float” while traveling over changing ground conditions. To remove lift arm from the detent (“float”) position, use your heel to push the left pedal down (B) out of the detent position.
Page 79: Hydraglide™ Ride Control System (Option)
Hydraglide™ Ride Control System (Option) When Hydraglide™ ride control is activated, the lift WARNING arm may drop slightly without a load, or several inches with a heavy load. Do not use Hydraglide™ when using pallet forks. WARNING Hydraglide™ cushions lift arm loads during Right T-Bar transport.
Page 80: Beacon/Position/Work Lights
Beacon/Position/Work Lights The optional beacon, the rear red position lights. and the front and rear work lights are all operated using button (Z). Note: The rear work lights and red position lights are located at the top of the rear door. The front work lights are located at the top front corners of the ROPS/FOPS.
Page 81: Dome Light
Windshield Wiper/Washer Machines may be equipped with a wiper and washer on the rear window, machines equipped with a cab door are equipped with an additional wiper and washer on the front windshield. A. Windshield Wiper: Controls the front windshield wiper on machines equipped with a cab door.
Page 82: Accessory Plug
When the ignition is on, the light is activated by rotating it to either side (T, Figure 39); the light is deactivated by rotating it to the center. If the light is centered, the light will activate when the ignition is turned off. Note: The light will deactivate after approximately 10 seconds, if the ignition is turned on, or if the light is rotated by pressing on either side (T, Figure 39) of the light.
Page 83: Attachment Mounting
Attachment Mounting The machine is equipped with either the standard manual All-Tach® hitch or optional Power-A-Tach® system hitch for mounting a bucket or other attachments. All-Tach® Hitch A manual latch lever (E, Figure 42) engages the latch pins, which lock the attachment onto the hitch.
Page 84: Power-A-Tach® System
Power-A-Tach® System Buttons (G and H, Figure 44) on the control keypad are used to operate the Power-A- ® Tach System hitch. Refer to “Connecting Attachments” on page 98 for more information. Note: The Power-A-Tach® system hitch will not operate if the parking brake is engaged and/or the operator restraint bar is in the raised position.
Page 85: Activating The Warming Circuit
Activating The Warming Circuit ® Press the Power-A-Tach System lock (extend) button on the control keypad once to activate the warming circuit and to extend the locking pins. The warming circuit icon on the Information Center Electronic Display becomes illuminated at this time. Pressing the lock (extend) button a second time suspends the warming circuit.
Page 86: Auxiliary Hydraulic System
Auxiliary Hydraulic System Auxiliary hydraulics are used with attachments requiring hydraulic power. Always be sure the auxiliary hydraulic control is in WARNING neutral before starting the engine or disconnecting the auxiliary hydraulic couplers. Auxiliary Hydraulic Couplers Auxiliary hydraulic couplers (Figure 47) are located on top of the lift arm on the left side.
Page 87: Auxiliary Hydraulics Control
Auxiliary Hydraulics Control Rocker switch (F, Figure 48) controls the Right T-Bar direction and amount of auxiliary hydraulics flow. Auxiliary hydraulics control is proportional: the farther switch (F) is moved from center, the higher the flow through the auxiliary circuit. Flow direction is reversed when rocker switch (F) is moved in the opposite direction.
Page 88 High-Flow Auxiliary Hydraulic Control (Option) In addition to a standard-flow auxiliary hydraulic system, loaders may be equipped with a reversible high-flow auxiliary hydraulic system. The couplers are located on top or inside of the right lift arm. The high-flow auxiliary hydraulic system is used for operating certain hydraulic attachments (e.g., cold planer, snowblower) that require higher flows.
Page 89: Before Starting The Engine
CHAPTER 5 OPERATION Before Starting the Engine Before starting the engine and operating the WARNING machine: • Review and comply with all safety recommendations in the Safety chapter of this manual. • Know how to stop the machine before starting it. •...
Page 90: Checks During Operation
Table 12: Pre-Start Checks Check Refer To: Overall machine condition (including attachments) for bends, cracks, broken, loose or missing parts, etc. Engine cover securely closed and latched? Rags, tools, debris and other loose objects removed? (check especially after maintenance) Approved warning triangle, hazard warning light and first aid kit in the machine? Perform safety interlock system test See “Safety Interlock System Test”...
Page 91: Cab Entry And Exit
Cab Entry and Exit Use only WARNING steps (A, Figure 50) and handles (B) on the machine when entering/exiting. Keep the steps and the handles clean to ensure a secure hold at all times. Never use the controls as hand holds. Remove dirt (oil, grease, earth, snow and ice) from handles (B), steps (A) and your shoes before entering the cab.
Page 92 Operate the door latch inside the cab using lever (D, Figure 52) located along the interior door frame. Figure 52 – Cab Interior Door Han- Important: If the door is removed for any reason, make sure to re-connect the door electrical connection (E, Figure 53) when the door is replaced.
Page 93: Starting The Engine
Starting the Engine Be familiar with the “Mandatory Safety Shutdown WARNING Procedure” on page 14 before starting the machine. Always perform this procedure before exiting the machine. Note: The machine cannot be push- or tow-started. Attempting to push/tow start the machine may damage the drive systems of both the machine and the push/tow vehicle.
Page 94: Cold Starting
Important: The recommended limit of continuous starter engagement is 15 seconds, and the starter must never be energized for more than 30 seconds. If the starter is energized for 20-30 seconds, the ignition should be turned off for one minute or longer. To protect the starter (DPF Models), the E-ECU system turns off the starter circuit if it is energized for 30 seconds or longer.
Page 95: After Starting
After Starting 1. Check that the charge ( ) and oil pressure ( ) indicators go out after the engine starts. Important: If the charge ( ) and/or the engine oil pressure ( ) indicators do not go out when the engine is running, shut down the engine immediately and correct the problem.
Page 96: Run-In Period
Warm Up Do not operate the machine until the hydraulic WARNING system reaches operating temperature. When cold, hydraulic response is slow and can be unpredictable, presenting an unsafe condition. Damage to the machine can also result. 1. After starting, allow the engine to run at low idle with no load for a minimum of 5 minutes without operating the drive, lift, tilt or auxiliary functions.
Page 97: Jump-Starting
Parking the Machine Park the machine away from traffic on firm, level ground. If this is not possible, park the machine across the incline and block the tracks to prevent movement. After performing the “Mandatory Safety Shutdown Procedure” on page 14, perform the following: •...
Page 98 Important: The booster battery must have a voltage of 12-volts. 1. Turn the ignition keyswitches of both machines to the OFF position. Be sure the controls in both machines are in the neutral position and the machines are NOT touching each other. If the machine with the booster battery has a drive transmission, place the transmission into neutral and apply the parking brake.
Page 99: Travel Drive Operation
Do not connect the other end of the negative WARNING jumper cable clamp to the negative terminal (-) on the discharged battery. Gas emerging from the battery may ignite if sparks are formed. 7. Start the machine with the discharged battery. See “Starting the Engine” on page 87. If the engine does not start immediately, stop cranking after 10 seconds and repeat starting procedure after approximately 30 seconds.
Page 100: Transport On Public Roads
Driving on an Incline When traveling on an incline, travel with the heavy end pointing uphill. Driving over Rough Terrain When traveling over rough terrain, activate the Hydraglide™ ride control system and drive slowly with the bucket lowered in the transport position (“Attachment Transport Position”...
Page 101 If possible, avoid traveling in areas with loose rocks that could get stuck in the tracks, or between the tracks and the track wheels. Avoid using the machine in salt water areas. Salt can corrode the metal cores in the tracks. Clean any fuel, oil, salt, fertilizer or chemical solvents that might get on the tracks.
Page 102 Constant operation on slopes, side hills, crowns and depressions accelerates guide lug, idler, roller and sprocket wear. Avoid cutting across slopes. Instead, drive up or down them. It is best to climb straight up or down, and then turn when the machine is in a more level location.
Page 103 Sprocket wear (B) normally occurs along the sides and crests of the sprocket teeth (C). Use the sprocket tooth wear gauge (A - Manitou part # 50309811), included with the machine, to determine exact sprocket tooth wear: Figure 59 –...
Page 104: Lift Arm Operation
Lift Arm Operation Refer to lift and tilt control information starting on page 61. Do not lift loads exceeding rated operating WARNING capacity. See “Payloads/Capacities” on page 190. The float mode can be used where the engine has WARNING stopped, is unable to be started, and lowering the lift arm is necessary to allow the operator to exit the machine.
Page 105: Hydraglide™ Ride Control System
Float allows the lowered lift arm to follow the ground contour while traveling over changing ground conditions. It is useful when grading surfaces while driving the machine in reverse. Note: Lift arm float is not effective if the lift arm is lowered against the chassis frame. See “Lift Arm Float”...
Page 106: Changing Attachments
Changing Attachments To prevent unexpected release of the attachment WARNING from the hitch, make sure the attachment is fully locked onto the hitch before using the attachment. On manual All-Tach® hitches, rotate the latch levers fully. On Power-A-Tach® hitches, verify that the pin flags are all the way to the outside of the hitch.
Page 107 6. Place the attachment lock into the locked Manual Attachment Hitch In position (Figure 62): Locked Condition All-Tach® system manual hitch: Per- • form the “Mandatory Safety Shutdown Procedure” on page 14 and move hitch lock lever all the way to the left (G). •...
Page 108: Disconnecting Attachments
Disconnecting Attachments Position the attachment so that after WARNING disconnecting, the attachment will stand safely and not tip over. Serious injury can occur if an attachment tips over onto a person. 1. Empty the attachment and drive to an open, level area to disconnect the attachment. 2.
Page 109: Connecting Auxiliary Hydraulic Couplings
Connecting Auxiliary Hydraulic Couplings Important: Connect hydraulically-powered attachment hoses to the auxiliary circuits after the attachment is secured to the hitch. Disconnect hydraulically-powered attachment hoses from the auxiliary circuits before removing the attachment from the hitch. 1. Empty the attachment and lower it to the ground. 2.
Page 110: Disconnecting Auxiliary Hydraulic Couplings
Disconnecting Auxiliary Hydraulic Couplings 1. Empty the attachment and lower it to the ground. 2. Shut off the engine, but do not turn off the ignition. Move the auxiliary hydraulics control rocker switch (F, Figure 67) on the right T-bar, joystick or hand control back and forth to relieve pressure in the auxiliary hydraulics circuit.
Page 111 Self-Leveling (Option) Self-leveling automatically keeps the tilt angle Self-Leveling of the attachment constant, relative to the Operates When Lift ground plane, when the lift arm is raised (A, Arm is Raised Figure 68). This feature is especially useful when using pallet forks. Important: Self-leveling operates only when the lift arm is raised: when the lift arm is lowered (B), self-leveling is not activated.
Page 112: Self-Leveling Cancel
Self-Leveling Cancel The self-leveling cancel option allows deactivation of the self-leveling feature when equipped with this option. To deactivate self-leveling, press the self-level cancel button (E, Figure 69) on the control pad. To restore self-leveling, press button (E) again. Note: If equipped with this option, self- leveling is activated by default.
Page 113: Digging With A Bucket
Always carry the loaded bucket with the lift arm in the transport position. See “Attachment Transport Position” on page 98. For additional stability when operating on inclines, always travel with the heavier end of the machine toward the top of the incline. Make sure you have a good view of the material you are digging, and of the area you will be working in.
Page 114: Loading A Bucket
Loading a Bucket 1. (Figure 71) Lower the bucket to the ground. 2. Tilt the bucket slightly forward so the bucket cutting edge is pointing slightly down into the ground. 3. Drive forward until the bucket is filled with material. Adjust the bucket tilt as needed to remove an even layer of ground and to reduce...
Page 115: Loading Trucks (Or Hoppers)
Never push the “float” button with the bucket or WARNING attachment raised, because this will cause the lift arm to fall to the ground, which can cause severe injury or death. Loading Trucks (or Hoppers) Important: When the self- leveling feature is on, the tilt angle of the attachment is kept constant, relative to the ground plane, when the lift arm is...
Page 116: Backfilling Holes And Embankments
Backfilling Holes and Embankments Do not drive too close to an excavation or ditch. Be WARNING sure the surrounding ground has adequate strength to support the weight of the machine and the load. 1. (Figure 74) Lower the bucket a few inches from the ground.
Page 117: Grading Without Float
Grading Grading Without Float 1. (Figure 75) Raise the bucket slightly and tilt it forward. 2. Release material from the bucket while traveling forward. 3. Tilt the bucket forward and adjust the lift arm height until the cutting edge is slightly above the ground.
Page 118: Grading Using Float
Grading Using Float Make sure the bucket is lowered to the ground WARNING before activating the lift arm float. Activating float with an attachment raised will cause it to fall to the ground, which can cause severe injury or death. Do not drive the machine forward with the lift arm float activated.
Page 119: Using Pallet Forks
Using Pallet Forks Safety Instructions When Working with Pallet Forks Read the “Safety” section in this manual, starting WARNING on page 13, before working with pallet forks. Pay special attention to the “During Operation” information, starting on page 16. Follow all instructions in the Operator's Manual provided with the pallet forks.
Page 120 DO NOT push, pull or shove the fork arms, or move them in at a slanting angle; the resulting lateral forces can damage the fork arms. DO NOT pull loads off the fork arms, or allow loads to fall onto the forks arms.
Page 121: Transporting Loads Using Pallet Forks
Transporting Loads Using Pallet Forks Important: When the self-leveling feature is on, the tilt angle of the attachment is kept constant, relative to the ground plane, when the lift arm is raised. When the lift arm is lowered however, self-leveling is not activated. Refer to “Self-Leveling (Option)” on page 105 for more information about the self-leveling feature.
Page 122 15. Raise the pallet forks slightly above where the load will be placed. 16. Tilt the pallet forks as needed to level the fork arms. 17. Carefully drive slowly forward until the load is positioned precisely above where the load will be placed. Use care when aligning the load with a stack. 18.
Page 123: Loading And Transporting The Machine On A Transport Vehicle
Loading and Transporting the Machine on a Transport Vehicle Park the transport vehicle on a level surface. Be WARNING sure the vehicle and its ramps have the weight and size capacity to support the machine. Make sure the driver of the transport vehicle knows the overall height, width and weight of the vehicle, including the loaded machine, before starting transport.
Page 124 4. Slowly and carefully drive in reverse up the ramp onto the transport vehicle. Important: Do not adjust travel direction while traveling on the ramps. Instead, drive down off of the ramps, and re-align the machine with the ramps. 5. Position the machine at the lowest possible position on the transport platform, with the center of gravity of the load over centerline of the transport vehicle.
Page 125: Lifting The Machine Using A Crane Or Hoist
Lifting the Machine Using a Crane or Hoist Note: Single-point and four-point lift kits are available for lifting the machine. Contact you dealer for more information. Contact your dealer for available lift kits for the WARNING machine. Do not lift the machine without an approved lift kit installed.
Page 126 Diesel Particulate Filter (DPF) Regeneration Procedures The Diesel Particulate Filter (DPF) treats exhaust emissions in compliance with Tier 4 emission standards. The DPF filter relies on high exhaust temperatures. Periodic DPF maintenance (regeneration) is required, dependent upon machine operation load / temperature.
Page 127: Reset Regeneration
Reset Regeneration Important: Reset regeneration can be prevented from occurring. See “Reset Regeneration Inhibit” on page 121. Reset regeneration occurs automatically (unless inhibited) approximately every 100 hours of operation. Note: Reset regeneration effectiveness is improved if the machine is operated at mid- to high-throttle settings while regeneration is in progress.
Page 128: Stationary Regeneration
Stationary Regeneration Stationary regeneration may be periodically required to reduce DPF soot build-up. The frequency of stationary regeneration is dependent upon machine operation and engine load. The machine cannot be used during stationary n/min regeneration and cannot be moved without interrupting the stationary regeneration process.
Page 129: Forcing Stationary Regeneration
3. When all three checkmarks (A, B & C) are displayed on the Stationary Regeneration screen, press and hold the button (Z) until the Stationary Regeneration In-Progress screen displays (Figure 82) 22 % Note: Stationary regeneration can be interrupted at any time by releasing the parking brake, advancing the throttle, or stopping the engine.
Page 130: Dpf Maintenance
DPF Maintenance DPF soot filter replacement is required when the DPF (Diesel Particulate Filter) Service Screen (Figure 84) displays. Note: Contact your dealer when the DPF Service screen displays. Figure 84 – Stationary Regenera- tion In-Progress Screen Camera Observation System A camera observation system is optionally available on all models.
Page 131 the accessory power connections in the chassis harness are located in this region. Ver- ify that these connections are intact. • Remove the right A-pillar cover within the ROPS/FOPS and locate the fuse holder in the camera system power harness located therein. Verify that the two Amp fuse within is intact and fully inserted into the fuse holder terminals.
Page 132: Back-Up Alarm
Back-Up Alarm A back-up alarm system is optionally available which serves to warn people working in the area around the machine of the machine’s rearward movement. The back-up alarm is installed within the engine compartment on the inside surface of the rear door. The alarm emits a tone whenever the machine begins to move in the rearward direction.
Page 133: Maintenance
CHAPTER 6 MAINTENANCE Read and understand the “Safety” Chapter in this WARNING manual, starting on page 15, before servicing the machine. Follow all applicable warnings and instructions. Check for correct function after performing maintenance. Failure to follow instructions can result in injury or death. BEFORE performing any maintenance, perform the “Mandatory Safety Shutdown Procedure”...
Page 134 NEVER weld on the machine without consulting WARNING the manufacturer. Special metals may be used, which require special welding techniques or parts may be designed so that they should not be welded. NEVER cut or weld on fuel lines or tanks.
Page 135: Maintenance Schedules
Maintenance Schedules Table 14: Inspection, Checks and Cleaning Maximum Interval Service Procedure 10 Hours 500 Hours 250 Hours (or Daily) (or Annually) Remove foreign material (page 135). Check engine air cleaner restriction indicator (page 145). Check for loose or missing parts; repair/replace if necessary.
Page 136 Table 15: Leakage Check Maximum Interval Service Procedure 10 Hours 500 Hours 250 Hours (or Daily) (or Annually) Check engine for oil/coolant leaks. Check cooling system for leaks. Check hydraulic system for leaks. Table 16: Lubrication and Filter Changes Maximum Interval 250 Hours Service Procedure 10 Hours...
Page 137: Maintenance Log
Table 17: Functional Check Maximum Interval Service Procedure 10 Hours 500 Hours 250 Hours (or Daily) (or Annually) Check control switches/buttons, indicators and audible warning devices. Check lighting systems. Maintenance Log Log maintenance when it is performed in the following table. Table 18: Maintenance Log Date Hours...
Page 138 Table 18: Maintenance Log Date Hours Maintenance Procedure 50950615EN-US/A0724...
Page 139 Table 18: Maintenance Log Date Hours Maintenance Procedure 50950615EN-US/A0724...
Page 140: General Lubrication
General Lubrication Important: Use of lubricants not corresponding to manufacturer recommendations may invalidate warranty claims. Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain. See “Fluid Capacities/Lubricants”...
Page 141: Removing Foreign Material
Removing Foreign Material Remove dirt and other foreign matter from the following areas daily before operating the machine: • Around the lift cylinders. • At the front of the machine. • On the attachment hitch, especially around the tilt cylinder. •...
Page 142: Lowering The Rops/Fops
3. Tilt the ROPS/FOPS up and back, moving the control handles out of the way. Tilt the ROPS/FOPS back slowly, until locking mechanism (B, Figure 86) locks the ROPS/FOPS in the raised position. Note: A gas-charged spring helps balance the ROPS/FOPS as it tilts. A self-actuating lock mechanism engages to lock the ROPS/FOPS in the tilted position.
Page 143: Lifting The Machine
Lifting the Machine Use the following procedure to raise the machine off the ground for service: Do not rely on a jack or hoist to hold the machine WARNING in the lifted position without additional blocking and supports. Serious personal injury could result from improperly lifting or blocking the machine.
Page 144: Engine Maintenance
Engine Maintenance Engine Access 1. Lift the engine cover and pull the rear door latch (Z, Figure 88) up. 2. Carefully swing open the rear door. Note: Rear door prop (Y) near the top hinge pin of the door is used to secure the door open.
Page 145: Engine Mounting Hardware Inspection
Engine Mounting Hardware Inspection Perform the Mandatory Safety Shutdown WARNING Procedure. Allow hot engine and hydraulic system components to cool before servicing. All bolts that secure the engine mounting brackets to the engine and the chassis should be checked and re-tightened as necessary. Checking Engine Oil Level Check the engine oil level daily before starting the machine, or after every 10 hours of use.
Page 146 3. Wait until the engine has cooled, but is not completely cold. Note: Oil drains faster and more completely when warm. 4. Position a waste oil collection container under the engine oil drain plug to catch draining oil. 5. Engine oil drain plug (A, Figure 91) is located inside the left rear wheel well, on the outside of the chassis behind the left rear wheel.
Page 147: Fuel System Maintenance
11. Start the engine and let it run for several minutes at low idle. Watch for leaks at the oil filter and drain plug. Stop the engine and wait for it to cool. 12. Check the oil level. Add oil if necessary until the oil level is at the “Full” mark (H, Figure 90) on the dipstick.
Page 148: Water Separator Maintenance
Ultra-Low Sulfur Diesel (ULSD) poses a greater static ignition hazard than earlier diesel formulations. Avoid death or serious injury from fire or explosion; consult with your fuel or fuel system supplier to ensure the entire fuel delivery system is in compliance with fueling standards for proper grounding and bonding practices.
Page 149: Changing Water Separator Filter
3. Inspect the water separator (Figure 94) for the presence of water: • If the indicator ring (M) is at the bot- tom of the cup, no action is required. • If the indicator ring (M) is floating off the bottom of the cup, water is present and needs to be drained.
Page 150: Changing Fuel Filter
7. Prime the fuel system by turning the ignition key to the ON position without starting the engine for 30 seconds. Repeat this step 3 times to ensure the fuel system is completely primed. Do not use the starter motor to crank the engine to CAUTION prime the fuel system.
Page 151: Engine Air Cleaner
Do not use the starter motor to crank the engine to CAUTION prime the fuel system. Damage to the engine starter motor, coils, pinion/ring gear could result. 8. Start the engine and check for leaks. Engine Air Cleaner Important: Failure to follow proper air filter servicing instructions could result in catastrophic engine damage.
Page 152: Dpf Service
8. Check the inside of the housing for damage. 9. If applicable, install a new inner filter element (H). Make sure the sealing surfaces are clean and the new element is properly seated. 10. Install a new outer filter element (G). Make sure the sealing surfaces are clean and the new element is properly seated.
Page 153: Cooling System
Cooling System Important: Check the cooling system every day to prevent overheating, loss of performance or engine damage. Checking Coolant Level 1. Park the machine on a level surface. 2. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 3. Wait until the engine has cooled. Do not remove radiator cap when the coolant is WARNING hot.
Page 154: Draining/Flushing Cooling System
Draining/Flushing Cooling System 1. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 2. Wait until the engine has cooled. Do not remove WARNING radiator cap when the coolant is hot. Serious burns could result. 3. Slowly loosen radiator cap (P, Figure 101) and allow pressure to escape.
Page 155: Checking Hydraulic Oil Level
Checking Hydraulic Oil Level Check the hydraulic oil level daily before starting the machine, or after every ten hours of use. 1. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 2. Wait until the engine has cooled. 3. Open the engine compartment according to “Engine Access”...
Page 156: Changing Hydraulic Oil Filter
Changing Hydraulic Oil Filter 1. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 2. Wait until the engine has cooled. 3. Open the engine compartment according to “Engine Access” on page 138. 4. Place oil pan under the machine to catch the oil.
Page 157: Changing Hydraulic Oil
Changing Hydraulic Oil The hydraulic oil must be replaced if it becomes contaminated, after major repairs, and after 1000 hours or one year of use. 1. Perform the “Mandatory Safety Shutdown Procedure” on page 14. 2. Wait until the engine has cooled. 3.
Page 158: Hydraulic Hose Maintenance
Hydraulic Hose Maintenance Hydraulic hoses and connections must be WARNING inspected by a trained technician before the first use of the machine, and at least annually thereafter, for leaks and/or damage. Leakages and damaged pressure hose/lines must be immediately repaired or replaced by an authorized service center. Never use your hands to check for suspected hydraulic leaks.
Page 159: Travel Motor Maintenance
Travel Motor Maintenance Travel Motor Front Case Oil Replace the travel motor front case oil every 2000 hours/annually or if it becomes contaminated after major repairs. 1. Park the machine with one of the travel motor gearbox drain/fill hole plugs (S, Fig. 108) at the bottom.
Page 160: Track Replacement
• Avoid using the machine on the seashore. Sea salt can corrode the metal cores inside the tracks. • Immediately wipe any spilled fuel, oil, salt or chemical solvents off of the tracks, as these substances can corrode the coupling in the metal cores in the tracks, causing cor- rosion and peeling.
Page 161 Use solid support blocking. Never rely on jacks or WARNING other inadequate supports when maintenance work is being done. Never work under any equipment supported only by jacks. 5. Use a pry bar to pry/guide the old track at off the front idler wheel. 6.
Page 162: Seat And Restraint Bar Switches
Seat and Restraint Bar Switches Electrical switches in the seat and restraint bar must be closed (operator sitting in the seat and restraint bar lowered) and the auxiliary hydraulics must be in neutral to complete the circuit and start the engine. Bucket Cutting Edge The bucket cutting edge should be replaced when it is worn to within 25 mm (1 in.) of the bucket body.
Page 163: Fuses, Relays And Diodes
Fuses, Relays and Diodes Important: Blown fuses indicate electrical system malfunctions. Determine what caused the fuse to blow and repair the problem before replacing the fuse. The fuse, relay and diode boxes are located in the engine compartment, just behind the cab, on the right side of the machine.
Page 164 Table 20: Fuse Locations (Figure 112) Rated Rated Fuse Circuit Fuse Circuit Current (A)) Current (A) Control Keypad Windshield wiper, Door Electronic Control Unit Cab blower fan (ECU) Note: if required Dome light, Radio Horn, Alarm Exhaust Gas Recirculation Operator’s seat switch/ (EGR) optional air suspension Electronic display LCD...
Page 165 Battery Before servicing the battery or electrical system, WARNING be sure the battery disconnect switch (if equipped) is in the OFF position. If not equipped with a disconnect switch, disconnect the ground (-) terminal from battery. The battery is a 12-volt, wet-cell battery. To access the battery, remove front floor panel. The battery top must be kept clean.
Page 166: Windshield Washer Reservoir
Windshield Washer Reservoir The windshield washer reservoir (E, Figure 114) is located inside the engine compartment. Check the windshield washer reservoir level daily before starting the machine and fill if necessary. Important: Fill the windshield washer fluid reservoir with clean tap water or windshield washer fluid only.
Page 167: After Storage
After Storage 1. Replace and re-connect the battery. 2. If the machine is so equipped, turn the battery disconnect switch to the on position. See “Battery Disconnect Switch” on page 76. 3. Perform all steps for returning the engine to service according to long-term engine storage section in the engine operation manual.
Page 168: Final Shutdown / Decommissioning
Final Shutdown / Decommissioning Important: Dispose of all materials properly. Used oils/fluids are environmental contaminants and may only be disposed of at approved collection facilities. Never drain any oils/fluids onto the ground, dispose of in municipal waste collection containers, or in metropolitan sewer systems or landfills.
Page 169: Machine Disposal
Machine Disposal Make sure all materials are disposed of in an ecologically sound manner. Recycle the machine in accordance with the current state of the art at the time of recycling. Observe all accident prevention regulations. Dispose of all parts at the at the recycling sites specific to the material of the part. Take care to separate different materials for recycling.
Page 170 NOTES 50950615EN-US/A0724...
Page 171: Troubleshooting
CHAPTER 7 TROUBLESHOOTING Engine Troubleshooting Table 23: Engine Troubleshooting Problem Possible Cause Corrective Action Check circuit and replace fuse. See “Fuses, Blown fuse. Relays and Diodes” on page 155. Charge or replace battery—see “Jump- Dead battery. starting” on page 92. Battery disconnect switch in Place battery disconnect switch into closed open position or...
Page 172 Table 23: Engine Troubleshooting Problem Possible Cause Corrective Action Check battery and charge/replace as Engine cranking speed too necessary—tighten battery terminals. slow. In cold temperatures, pre-warm the engine. Fuel tank empty. Fill tank and vent fuel system if necessary. Fuel filter plugged or restricted. Change fuel filter. Fuel paraffin separation in Use winter grade diesel fuel.
Page 173 Table 23: Engine Troubleshooting Problem Possible Cause Corrective Action Black smoke indicates poor and incomplete diesel fuel combustion, which could be caused • Incorrect timing. • Dirty or worn injectors. • Incorrect valve clearance. • Incorrect air/fuel ratio. Black smoke •...
Page 174: Indicator Lamp Troubleshooting
Indicator Lamp Troubleshooting Table 24: Indicator Lamp Troubleshooting Indicator Icon Indicator Activated Possible Cause Corrective Action Stop engine immediately; Engine oil pressure too check oil level and top off low. oil if necessary; check oil pump. Engine oil pressure Top off oil. See “Fluid Capacities/Lubricants”...
Page 175: Seal And Hose Troubleshooting
Table 24: Indicator Lamp Troubleshooting Indicator Icon Indicator Activated Possible Cause Corrective Action Adjust V-belt tension. Alternator not charging Battery voltage properly. Repair/replace alternator. Replace air filter(s). See Air filter dirty/restricted. “Changing Air Filter Elements” on page 143. Engine air filter restriction Blockage in air filter Remove blockage.
Page 176 Table 26: Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Low hydraulic fluid level. Top off hydraulic fluid. Replace existing oil with proper viscosity oil. Hydraulic oil viscosity too See “Fluid Capacities/Lubricants” on page 187. heavy. Allow longer warm-up. Engine to pump coupling or hydraulic pump damaged.
Page 177 Table 26: Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Oil leaking past tilt cylinder seals (internal or external). Oil leaking past lift spool in Contact dealer. Attachment tilts control valve. down with tilt control Self-leveling valve malfunction. in neutral Leaking hydraulic hoses, tubes or fittings between control valve Repair as required.
Page 178 Table 26: Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Restraint bar raised. Lower restraint bar. Check electrical connections. Restraint bar switch malfunctioning. Contact dealer. Check electrical connections. Solenoid malfunctioning. Contact dealer. Auxiliary hydraulics Spool in control valve not do not function actuated or leaking.
Page 179: Hydrostatic Drive System Troubleshooting
Hydrostatic Drive System Troubleshooting Table 27: Hydrostatic Drive System Troubleshooting Problem Possible Cause Corrective Action Parking brake is applied. Release parking brake. Top off hydraulic oil. See “Checking Hydraulic Low hydraulic oil level. Oil Level” on page 147. See “Fluid Capacities/ Lubricants”...
Page 180 Table 27: Hydrostatic Drive System Troubleshooting Problem Possible Cause Corrective Action Top off hydraulic oil. See “Checking Hydraulic Low hydraulic oil level. Oil Level” on page 147. See “Fluid Capacities/ Lubricants” on page 187 for proper oil grade. Low hydrostatic system charge pressure.
Page 181: Electrical Troubleshooting
Electrical Troubleshooting Table 28: Electrical Troubleshooting Problem Possible Cause Corrective Action Turn battery disconnect switch to the ON Battery disconnect switch is in position. See “Battery Disconnect Switch” on OFF position. page 76. Battery terminals or cables Clean battery terminals and cables and loose or corroded.
Page 182 Table 28: Electrical Troubleshooting Problem Possible Cause Corrective Action Temperature sender Replace temperature sender. malfunction. Loose wiring/terminal Check wiring connections. connections. Coolant temperature gauge inoperative Check circuit and replace fuse. See “Fuses, Blown fuse. Relays and Diodes” on page 155. Coolant temperature gage Replace gauge.
Page 183: Error Codes
Error Codes The tables in this section describe error codes which may be reported on the information center electronic display screen. More than one error can be reported at one time and may be display on more than one screen. See page 58. Engine Diagnostic Trouble Codes (DTC) Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item...
Page 184 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Intake Air Temperature Intake air temperature sensor fault (high P040D Sensor voltage) Intake Air Temperature Intake air temperature sensor fault (low P040C Sensor voltage) P2230 Barometric Pressure Sensor Intermittent fault Atmospheric Pressure Atmospheric pressure sensor fault (high P2229...
Page 185 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Fuel temperature sensor temperature P0168 Fuel Temperature Sensor abnormally high Fuel temperature sensor fault (high P0183 Fuel Temperature Sensor voltage) Fuel temperature sensor fault (low P0182 Fuel Temperature Sensor voltage) P0219 Overspeed...
Page 186 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Injector 1 (Cylinder Number P1262 Injector 1 short circuit Injector 4 (Cylinder Number P1268 Injector 4 short-circuit Injector 1 (Cylinder Number Injector 1 open circuit (inherent location P0203 of the Injector) Injector 4 (Cylinder Number...
Page 187 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State P0634 ECU Internal Temperature Too high ECU Internal Temperature P1664 Intermittent fault Sensor 1136 ECU Internal Temperature P0669 Shorted to high source Sensor ECU Internal Temperature P0668 Shorted to low source Sensor 1202...
Page 188 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State VB power short-circuit of throttle valve P1661 Intake Throttle Drive Circuit drive H bridge output 2 2951 GND short-circuit of throttle valve drive H P1662 Intake Throttle Drive Circuit bridge output 2 DPF Inlet Temperature DPF inlet temperature sensor...
Page 189 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Engine Fuel Rack Actuator P1224 Intermittent fault Relay Engine Fuel Rack Actuator P1223 Circuit fault B Relay 522241 Engine Fuel Rack Actuator P1222 Circuit fault A Relay P1221 Reserved P1244...
Page 190 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State High-pressure pump drive circuit (drive P062A SCV (MPROP) current [high level]) 522572 High-pressure pump drive circuit (pump P1645 SCV (MPROP) overload error) 522573 P2463 Over-accumulation (method C) 522574 P1463 Over-accumulation (method P)
Page 191 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State Y_EC (CAN message) reception time U1293 CAN 2 out error 522600 P1637 ECU Internal Malfunction SW reset (recovery) execution 3 Y_RSS (CAN message) reception time U1294 CAN 2 out error 522601 WDA/ABE shut off due to dropped...
Page 192 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State 522751 P1443 Exhaust Throttle CAN fault P1633 ECU Internal Malfunction Actuator drive circuit 2 GND short-circuit P1607 ECU Internal Malfunction WDA/ABE communication error 522994 P1615 ECU Internal Malfunction CY320 SPI communication error P1616 ECU Internal Malfunction...
Page 193 Table 29: Yanmar Engine Diagnostic Trouble Codes (DTC) Error Item P-Code Part State PLV (Common Rail Rail pressure fault (the actual rail 523489 P1668 Pressure Limit Value); Rail pressure is too high during PRV limp Pressure Sensor mode) Rail Pressure Control/ Rail pressure fault (injector B/F temp 543491 P1669...
Page 194 NOTES 50950615EN-US/A0724...
Page 195: Specifications
CHAPTER 8 SPECIFICATIONS Fluid Capacities/Lubricants Table 30: Fluid Capacities/Lubricants Component/ Type 1650RT / 1950RT Application Refer to the Engine Operator’s Manual for specific engine oil recommendations. Service Classification: API-CK-4 preferred, API-CJ-4 SM acceptable. Conventional oils - select the oil viscosity based on the 9.5 L (10 qts.) ambient temperature where the engine is being operated.
Page 196 Table 30: Fluid Capacities/Lubricants Component/ Type 1650RT / 1950RT Application DPF Models: ULSD ultra-low sulfur only, below 15 PPM. ASTM D975 with biodiesel content limited to 5% of DIN EN14214 type (no additives allowed!) Non-DPF Models: 1650RT: 62.5 L (16.5 gal) Diesel Fuel Tank 1950RT: 58.6 L (15.5 gal.) ASTM D975-94 (no additives allowed!)
Page 197 Weights Table 31: Weights 1650RT Narrow 1650RT Wide Undercarriage Undercarriage 1950RT 66” Bucket 70” Bucket (1676.4 mm Bucket) (1778 mm Bucket) Operating Weight (without 3638 kg 3693 kg (8020 lbs.) (8143 lbs.) counterweight) Operating Weight (with 3744 kg 3800 kg 3697 kg (8255 lbs.) (8378 lbs.)
Page 198 Table 33: Track Drive 1650RT / 1950RT Gradeability 30° Brakes Mechanical / hydraulic; spring applied / hydraulically released 4344.5 kg Tractive effort (9578 lbs.) Track Type / Track Rollers / Roller Type Rubber / 3 / Steel 1650RT: 320 mm x 86 mm (12.6 in. x 3.4 in.) x 49 Pitches Track Dimensions (Standard) 1950RT: 320 mm x 86 mm (12.6 in.
Page 199 Table 35: Pallet Forks 1650RT / 1950RT 508 mm (20 in.) Load Center per EN 474-3 SAE Rated Operating Capacity @ 35% 544 kg (1199 lbs.) SAE Rated Operating Capacity @ 50% 777 kg (1712 lbs.) SAE Rated Operating Capacity @ 35% 582 kg (1284 lbs.) (with counterweight) SAE Rated Operating Capacity @ 50%...
Page 200 Engine Table 36: Engine 1650RT / 1950RT Yanmar 4TNV98C-NMS2V/ST5 (DPF Models) Engine Make/Model 4TNV98-ZNMS3R (Non-DPF Models) Displacement 3.3 L (202.5 in Bore and Stroke 98 × 110 mm Gross Power (DPF Models) 51.6 kW (69.3 HP) @ 2800 rpm Gross Power (Non-DPF Models) 52 kW (69.9 HP) @ 2800 rpm Net Power 51 kW (68.4 HP) @ 2800 rpm...
Page 201: Coolant Compound Mixtures
Coolant Compound Mixtures Table 37: Coolant Compound Mixtures Outside Temperature Water Anti-corrosion agent Antifreeze Up to °F (°C) % by volume in³/gal (cm³/L) % by Volume % by Volume 39 (4) – 14 (-10) -4 (-20) 2.6 (10) -13 (-25) -22 (-30) -44 (-42) Hydraulics...
Page 202: Travel Speeds
Travel Speeds Table 39: Travel Speeds 1650RT / 1950RT 0 - 10.5 km/h Low Speed Range (6.5 mph) 0 - 16.1 km/h High Speed Range (10 mph) Electrical System Table 40: Electrical System 1650RT / 1950RT Glow Plug (Engine Pre-heat) Auto with glow lamp Electrical System Voltage 12.6 V...
Page 203: Vibration Levels
Vibration Levels Table 42: Whole-Body and Hand-Arm Vibration Levels Whole Body Vibration Values Seat Option Vibration m/s Uncertainty m/s Standard Non-Suspension 1.28 Mechanical Suspension 1.10 Air Ride Suspension 0.99 Hand-Arm Vibration Values Control Option Vibration m/s Uncertainty m/s Hand/Foot 2.20 1.10 T-Bar 2.80...
Page 204 Dimensions [ X] [ Z] [ Y] [ F] [ D] [ C] [ A] [ B] [ E] [ L] [ G] [ J ] [ K] [ M] [ O] [ Q] [ N] [ R] [ S] [ U] [ P] [ I ]...
Page 205 Table 43: Dimensions 1650RT 1950RT Overall Width (w/o Bucket) - Narrow Tracks 1753 mm (69.0 in.) 1753 mm (69.0 in.) Overall Width (w/o Bucket) - Wide Tracks 1829 mm (72.0 in.) 1829 mm (72.0 in.) Bucket Width 1778 mm (70.0 in.) 1778 mm (70 in.) Clearance Radius –...
Page 206 Table 45: Optional Features Self-Leveling Lift Action with cancel button Engine Block Heater 3-inch Wide Seat Belt (Where Required by State Law) Four- and Single-Point Lift System Kits Sliding Side Windows Lift Kit - Single Point Lift System Rear-View Mirror Hydraglide™...
Page 207: Common Materials And Densities
Common Materials and Densities Table 46: Common Materials and Densities Density Material lbs./ft. kg/m Ashes 35-50 560-800 Brick-common 1792 Cement 1760 Charcoal Clay, wet-dry 80-100 1280-1600 Coal 3 53-6 848-1008 Concrete 1840 Cinders Coal-anthracite 1504 Coke Earth-dry loam 70-90 1121-1442 Earth-wet loam 80-100 1281-1602...
Page 208 Direct and/or Indirect Visibility Tested in accordance with ISO 5006: 2017. The machine has been subjected to a static visibility assessment with the lift structure in a carry position or 200 mm (7-78 in.) above the ground. The test simulates operator visibility from the operator’s position: •...
Page 209: Index
A0724INDEX Checking Hydraulic Oil Level . . . 149 Cleaning Radiator Fins ..147 Accessory Keypad Indicators/Buttons ... 51 Cold-Starting ....88 Accessory Plug .
Page 210 Engine..... 194 Indicators and Controls ..47 Engine Access ....138 Information Center Electronic Display .
Page 211 Service and Registration..4 Signal Words ....1 Operation....83 Sound Levels .
Page 212 Warm Up....90 Water Separator Maintenance . . 142 Weights ....191 Windshield Washer Reservoir .
Page 213: Torque Specifications
Torque Specifications Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise. UNIFIED GRADE 2 GRADE 5 GRADE 8 NATIONAL LUBED LUBED LUBED THREAD 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24...

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Manitou mustang 1650RT X Series Operator's Manual

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