Manitou MLT 634 service schedule

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Never work under a raised boom or attachment unless it is held up with a proper safety prop. The hydraulics alone are not safe to work under.
3. Wipe each grease nipple clean before greasing.
4. Grease the boom pivots and cylinder pins, then the wheel reducer pivots and axle oscillation points, until fresh grease shows.
5. Look at the boom pads for wear while you are there and get them checked if they are worn.

Tools: Grease gun, Rags

1. Stop the engine and take the key out.
2. Open the filter cover, take out the filter and clean the housing.
3. Fit the new filter the right way round and close the cover.

Tools: Screwdriver, Vacuum cleaner

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Let hot oil cool until it is warm, not scalding. Wear gloves and wash used oil off your skin promptly.
3. Open the engine cover, put the tray under the sump and take out the drain plug. Let it drain fully.
4. Clean round the filter head, unscrew the old filter and check its seal came off with it.
5. Oil the seal of the new filter and screw it on by hand. Do not over-tighten.
6. Refit the drain plug and fill with fresh oil through the filler to the top mark on the dipstick.
7. Run the engine for a minute, check for leaks, stop it, wait a few minutes and recheck the level.

Tools: Drain tray (15 L), Filter wrench, Socket for sump plug, Funnel, Gloves, Rags

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Do not smoke or work near a flame.
3. Clean the outside of both filters so no dirt gets in.
4. Drain the pre-filter bowl into a container, then change both elements, fitting new seals.
5. Bleed the fuel system as the handbook shows (G1 fuel system bleed) before starting.
6. Start the engine and check for leaks.

Tools: Filter wrench, Container for fuel, Rags, Gloves

1. Stop the engine and take the key out. Never run the engine with the filter out.
2. Open the filter housing and take out the main cartridge gently so dust does not fall in.
3. Wipe the housing and seal face with a clean damp cloth. Leave the safety cartridge in place.
4. Check the new cartridge is not damaged, push it in by its edges, not the middle, and close the housing.

Tools: Torch, Damp lint-free cloth

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Let hot oil cool until it is warm, not scalding. Wear gloves and wash used oil off your skin promptly.
3. Clean round the filter, unscrew it and catch the oil.
4. Oil the seal of the new filter and fit it by hand.
5. Run the engine, then check the gearbox level as the handbook shows and top up.

Tools: Filter wrench, Drain tray, Rags

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. With the engine off and the key at the on position (or as your handbook says), work the boom and attachment controls a few times to let out trapped hydraulic pressure. Oil at system pressure can pierce skin.
3. Clean round the filter housing on the tank before you open it.
4. Take out the old cartridge and fit the new one with a new seal.
5. Start the engine, check for leaks, then lower and retract the boom and check the tank level.

Tools: Spanners, Drain tray, Lint-free rags, Gloves

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Do it with the oil still warm.
3. Take out the drain plugs, the level plug and the filler plug so the axle empties fully.
4. Refit the drain plugs (34 to 49 N·m).
5. Fill through the filler port until oil is level with the edge of the level hole. Refit the level and filler plugs (34 to 49 N·m).
6. Do the same on the rear axle and check for leaks.

Tools: Drain tray, Spanners, Oil pump or squeeze bottle

1. Stop the engine and take the key out.
2. Take out the main cartridge, then ease out the safety cartridge without spilling dust into the intake.
3. Clean the seal face with a damp lint-free cloth.
4. Fit the new safety cartridge, pushing on its edges, then the main cartridge, and close the housing.

Tools: Torch, Damp lint-free cloth

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Let hot oil cool until it is warm, not scalding. Wear gloves and wash used oil off your skin promptly.
3. Drain the gearbox while the oil is warm, into a clean tray.
4. Take out and clean the sump strainer, and refit it with a new seal.
5. Fit a new gearbox filter.
6. Refit the plug and fill with fresh oil. Run the engine and check the level as the handbook shows.

Tools: Drain tray (25 L), Spanners and sockets, Filter wrench, Funnel, Gloves

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Do it with the oil still warm.
3. Put a tray under the drain plug, take out the plug, the dipstick and the filler cap so it drains fully.
4. Refit the drain plug (20 to 29 N·m).
5. Fill through the filler port until the level is between MIN and MAX on the dipstick, refit the cap and check for leaks.

Tools: Drain tray, Spanners, Funnel

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. With the engine off and the key at the on position (or as your handbook says), work the boom and attachment controls a few times to let out trapped hydraulic pressure. Oil at system pressure can pierce skin.
3. Never work under a raised boom or attachment unless it is held up with a proper safety prop. The hydraulics alone are not safe to work under.
4. Clean round the drain plugs and the suction cover on the tank before opening anything.
5. Drain the tank into a large container, with the filler cap off so it empties properly.
6. Take off the suction cover, clean the strainer with compressed air, check it and refit it. Tighten the cover to 81 N·m with its seal in place.
7. Change the return filter and the control head filter.
8. Refit the drain plugs (29 to 39 N·m) and fill with clean oil through a clean funnel until it reaches the red dot on the dipstick.
9. Fit a new filler cap and check for leaks.
10. Manitou says the dealer should run a hydraulic clean-up cycle after each oil change, so the return filter catches the dirt.

Tools: Container for at least 140 L, Spanners and torque wrench, Compressed air, Clean funnel, Gloves

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Chock the wheels. Do it with the oil still warm.
3. Move the machine so the hub plug is at the bottom (drain position), take it out and let it drain.
4. Move the machine so the plug hole is level (fill position) and fill until oil is flush with the edge of the hole.
5. Refit the plug (34 to 49 N·m). Repeat on all four hubs.

Tools: Drain tray, Spanners, Squeeze bottle

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Do not smoke or work near a flame.
3. Check the tank and fuel lines for leaks. Never weld or repair the tank yourself.
4. Drain the tank with the filler cap off, then rinse it with about 10 litres of clean diesel through the filler.
5. Refit the drain plug (29 to 39 N·m), refill with clean diesel and bleed the fuel system if needed.

Tools: Fuel-safe container, Spanners, Rags

1. Park on firm level ground. Lower the boom fully and retract it, put the attachment flat on the ground, put the parking brake on, stop the engine and take the key out.
2. Wait until the engine is cold. Never open a hot radiator.
3. Open the engine cover and lift the battery cover.
4. Drain the bottom radiator hose and the engine block drain plug into a tray, with the radiator cap off.
5. Check the hoses and clips and change any that are soft or cracked. Rinse with clean water.
6. Refit the hose and plug (40 N·m) and fill slowly to the middle of the gauge.
7. Run the engine at idle for a few minutes, check for leaks and top up.

Tools: Drain tray (25 L), Spanners, Funnel