ELECTRICITY

- ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL COMPONENTS LOCATION
- ELECTRICAL CONTROL AND ADJUSTEMENT
- ELECTRICAL COMPONENTS REFIT

80

- ELECTRICAL SPECIFIC TOOLING

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

pages
ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A
INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B

80

TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C

(30/01/2012)

80-01-M209EN

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

80

80-01-M209EN

(30/01/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

A1

ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW

pages

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3

80

80

(14/11/2012)

80-01-M209EN

A2

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

OPERATION
Telescope retraction control: VRP installed as part of the distributor raising/lowering system. Flow
limiting nozzle fitted to pressure distributor inlet descent control.
Boom extension control: SPU computer (signal is monitored).
Accessory line +/- cut-off: SPU calculator (signal is controlled).
Tilt +/- cut-off: VCI (Tilt cut-off valve) fitted externally.
Dangerous movements cut-out: Activated by VRP/SPU or VCI at 105% gauge signal, and if gauge signal
exceeds 120%, additional VS cut-out. (Percentages can change, depending on telescopic boom angle).
Control and change of rotational direction of the FAN DRIVE fan: SPU computer (the signal is checked).
Operation is identical to the MLT T = 2 cut-out thresholds, depending on strain gauge signal.

80

80

80-01-M209EN

(14/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

A3

SYSTEM OVERVIEW
Seat sensor

FNR
Thumbwheels
Parachute
switch

FAN DRIVE
Tin
sensor

130%

Gauge signal

-120%

-100%

VCI
Jib
Angle

Cut-off
redundancy

VRP

80

80

VS
SX14S
ADM2
Strain gauge
LLMI Module

MR2-PLD
Transmission

Can-Bus

Hydraulic operation

Stability monitoring

(14/11/2012)

Operator presence
80-01-M209EN

A4

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

80

80

80-01-M209EN

(14/11/2012)

ELECTRICAL CHARACTERISTICS
ANDSPECIFICATIONS

B1

INPUTS/OUTPUTS
pages

HYDRAULIC ECU INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3

ECU RC2-2/20 REXROTH (WITH CAN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
CASAPPA (CED100X) ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
SPU INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4
SPU 25-15 (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
ADM INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6
ADM 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6
PLD INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B8

80

PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8

(13/11/2012)

80-01-M209EN

ELECTRICAL CHARACTERISTICS
ANDSPECIFICATIONS

80

B2

80-01-M209EN

(13/11/2012)

ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS

B3

HYDRAULIC ECU INPUTS/OUTPUTS

ECU RC2-2/20 Rexroth (WITH CAN)
Key:
RC2-2

ECU: Electronic Control Unit

NC: Not Cabled

41

27 28
X109

Designation 18

52

14

ECU TYPE

CONNECTOR

PIN N

WIRE

Function on carriage

Power supply

X109

01

Red

Proportional outlet and all or nothing power supplies

GND

X109

02

Black

Ground RC2-2/20

X109

24

Black

CAN ground and RX/TX RS232

X109

27

Red

Proportional outlet and all or nothing power supplies

X109

28

Black

Ground RC2-2/20

X109

31

Brown

Control pump proportional output

X109

32

Black

Ground RC2-2/20

X109

39

Blue

CAN L

X109

40

Brown

CAN H

X109

41

Red

RC2-2/21 microcontroller power supply

X109

42

Red

RC2-2/21 microcontroller power supply

X109

50

Orange

RxD RS 232

X109

51

Grey/Purple

TxD RS 232

X109

52

Purple

Comments

CAN drain cable

Reserved for REXROTH software flashing

80

CASAPPA (CED100X) ECU

CASAPPA

X109/A

X109/A

X109/B

X109/B

Designation 18

ECU TYPE

CONNECTOR

PIN N

WIRE

Battery V

VBB

X109/A

01

Red/Black

CAN-Low

CAN-L

X109/A

06

Brown

CAN-L J1939

CAN-High

CAN-H

X109/A

07

Brown

CAN-H J1939

Black

CASAPPA ECU ground

Power Gnd + CAN Gnd

Function on carriage
CASAPPA ECU power supply

GND

X109/A

12

PWM output -

PWM -

X109/B

09

PWM -

PWM output +

PWM +

X109/B

11

PWM Control pump

(13/11/2012)

Comments

80-01-M209EN

B4

ELECTRICAL CHARACTERISTICS
ANDSPECIFICATIONS

SPU INPUTS/OUTPUTS
SPU 25-15 (LSU)
Key:
SPU

SPU: Signal Processing Unit

NC: Not Cabled

X57
X56

X56

X57

SPU 25-15 LSU

Designation 18

CONNECTOR

PIN N

WIRE

Function on carriage

12VB

X56

01

Red

12V + POST CONTACT (APC)

PWM 8 OUTPUT

HSD-08

X56

02

Red

+ DIRECTION SELECTOR ATTACHMENT

LOW SIDE 2 OUTPUT

LSD-02

X56

03

Red

BOOM HEAD ELECTROVALVE GROUND

LOW SIDE 2 OUTPUT

LSD-02

X56

04

LOW SIDE 1 OUTPUT

LSD-01

X56

05

Green

SAFETY ELECTROVALVE (VS) GROUND

LOW SIDE 1 OUTPUT

LSD-01

X56

06

Green

PROPORTIONAL ELECTROVALVE GROUND (Lowering)

12 V BATTERY POWER SUPPLY

12VP

X56

07

Yellow

12V BATTERY MICROSWITCH POWER SUPPLY

ANALOGUE INLET 2

UN-09

X56

08

Orange/Blue

LOGIC INPUT 19

FQ-04

X56

09

LOGIC INPUT 13

FQ-02

X56

10

LOGIC INPUT 04

UN-06

X56

11

LOGIC INPUT 14

UN-03

X56

12

Red

WUI

X56

13

Orange/Yellow

HSD-07

X56

14

Orange

12 V T APC POWER SUPPLY

ECU WAKE-UP INFO

PWM 7 OUTPUT

White/Green

SENSOR 2 BOOM ANGLE ANALOGUE SIGNAL INPUT

EASY CONNECT SYSTEM

Light blue/White 12V INPUT CUT-OFF (OVERRIDE)

X56

15

LOGIC INPUT 12

FQ-01

X56

16

Brown/Yellow

LOGIC INPUT 01

UN-05

X56

17

White/Blue
Yellow

SWITCH HELD AT 60 MAX

ROLLER 1 IS OUTSIDE OF THE NEUTRAL ZONE
THIS SUPPLY CAN BE CUT-OFF BY THE EMERGENCY STOP

DIRECTION 2 PROPORTIONAL ATTACHMENT CONTROL

TRANSMISSION CUT-OFF INPUT (ON ACCELERATOR)
TRANSMISSION CUT-OFF INPUT (ON GEAR LEVER)
HYDRAULIC MOVEMENT NEUTRALISATION GROUND INPUT

Brown/Green for MLT 845-120 H

Yellow/Red for MLT 845-120

12V SEAT INPUT SENSOR NO.

DRIVER PRESENCE

ROLLER 1 JSM ANALOGUE INPUT

FROM 0,5V TO 4,5V TELESCOPIC BOOM

X56

18

X56

19

GROUND

GROUND

X56

20

Black

ECU GROUND

STABILISED 200mA 10V REF OUTPUT

SENSOR

X56

21

Grey

ATTACHMENT CONTROL SELECTOR CONTROL / STRAIN GAUGE +12Vdc

LOGIC INPUT 03

UN-08

X56

22

Red/Green

LOGIC INPUT

UN-07

X56

23

Red

LOGIC INPUT 17

UN-04

X56

24

Yellow

ANALOGUE INLET 01

UN-01

X56

25

GROUND

X56

26

80-01-M209EN

GROUND INFO

ECU WAKE-UP INFO +12V apc

UN-02

GROUND

I FROM 0,5V TO 4,5V

12 V INPUT DIRECTION INFO ROLLER 1 JSM

U 5V INPUT

STABILISED 5V REF. OUTPUT

+ APC

NOT USED

FQ-03

ANALOGUE INLET 03

Comments

NOT USED

Brown/Green
Yellow/Red

LOGIC INPUT 10

80

ECU TYPE

NOT USED

FORCED OPERATION CONTROL

HAND BRAKE INFO
FAN SIGNAL INVERSION

Light blue/Yellow SENSOR 1 BOOM ANGLE ANALOGUE SIGNAL INPUT

Black

4 POSITIONS : 25% - 50% - 75% - 100%

FROM 0,5V TO 4,5V

ECU GROUND

(13/11/2012)

ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS

B5

SPU 25-15 LSU

ECU TYPE

CONNECTOR

PIN N

WIRE

Function on carriage

CAN HIGH

CAN H

X57

01

Brown

CAN H

CAN LOW

CAN L

X57

02

Blue

CAN L

SPU POWER SUPPLY + APC

12VD

X57

03

Red

ECU POWER SUPPLY + 12VD

Unpowered if emergency stop in operation

Unpowered if emergency stop in operation

12VD

X57

04

Red

ECU POWER SUPPLY + 12VD

PWM-06 OUTPUT

HSD-06

X57

05

Pink

DIRECTION ELECTROVALVE POWER SUPPLY + TELESCOPE

PWM-04 OUTPUT

HSD-04

X57

06

Purple

LOWERING PROPORTIONAL ELECTROVALVE POWER SUPPLY

PWM-01 OUTPUT

HSD-01

X57

07

Yellow

SAFETY ELECTROVALVE (VS) POWER SUPPLY

12V POWER SUPPLY

12VC

X57

08

Red

POWER SUPPLY + APC ECU + 12VC

12V POWER SUPPLY

12VC

X57

09

Red

POWER SUPPLY + APC ECU + 12VC

12V POWER SUPPLY + APC

CAN 2 HI

X57

10

NOT USED

CAN 1 120

X57

11

NOT USED

LOGIC INPUT 16

UN-19

X57

12

Red

ANALOGUE INLET 5

UN-17

X57

13

Orange/Green

LOGIC INPUT 9

UN-15

X57

14

Light blue/Black

LOGIC INPUT 5

UN-12

X57

15

Pink

ANALOGUE INLET 4

UN-10

X57

16

Purple

ROLLER 2 JSM ANALOGUE INPUT (Attachment)

PWM 2 OUTPUT

HSD-02

X57

17

Brown

TRANSMISSION CUT-OFF OUTPUT

CAN 2 60

X57

18

LOGIC INPUT 11

UN-20

X57

19

Green/Yellow

LOGIC INPUT 18

UN-18

X57

20

White

LOGIC INPUT 07

UN-16

X57

21

LOGIC INPUT 08

UN-14

X57

22

Pink

LOGIC INPUT 06

UN-13

X57

23

Orange

12V INPUT RETRACTED BOOM SENSOR

LOGIC INPUT 15

UN-11

X57

24

Orange

ROLLER 2 (Attachment) 12V SWITCH DIRECTION

PWM 9 OUTPUT

HSD-09

X57

25

White

LIN INTERFACE

LIN

X57

26

NOT USED

CAN 2 120

CAN 2 120

X57

27

NOT USED

CAN 1 MASSE

CAN GROUND

X57

28

Black

CAN 1 SHIELDING GROUND

PWM 5 OUTPUT

HSD-05

X57

29

Brown

TELESCOPE PROPORTIONAL ELECTROVALVE CONTROL OUTPUT

PWM 3 OUTPUT

HSD-03

X57

30

White

FAN INVERSION INPUT

GROUND A

X57

31

Green

ANALOGUE SENSOR GROUND

PWM 11 OUTPUT

HSD-11

X57

32

Pink/Grey

VCI (TILTING CUT-OFF CYLINDER) ELECTROVALVE

PWM 10 OUTPUT

HSD-10

X57

33

Yellow/Black

FORCED OPERATION INDICATOR LAMP OUTPUT

GROUND

X57

34

Black

CAN 2 HIGH
RESISTANCE 120

CAN 2 LOW

ANALOGUE SENSOR GROUND

ECU GROUND

(13/11/2012)

Comments

12V INPUT CONTACT BP1 EV TDF

FLOW SELECTOR ANALOGUE INPUT FORCED OPERATION ATTACHMENT
REVERSE GEAR INPUT INFO
12V INPUT BOOM RETRACTED SENSOR NO

NOT USED
ATTACHMENT 1 & 2 LOCKING CONTROL INPUT
PROPORTIONAL ELECTROVALVE FAN
NOT USED
FORWARD GEAR INFO INPUT

Roller 2 neutral zone output

FAN CONTROL INPUT

80

Designation 18

ECU GROUND

80-01-M209EN

B6

ELECTRICAL CHARACTERISTICS
ANDSPECIFICATIONS

ADM INPUTS/OUTPUTS
ADM 2
Key:
SPU: Signal Processing Unit
NC: Not Cabled

ADM2

ADM2-12

ADM2-15

ADM2-21

ADM2-21
ADM2-12
ADM2-15

ADM 2
Designation 18

ECU TYPE

80

P DOWN LOGIC INPUT

CONNECTOR

PIN N

WIRE

Function on carriage
STARTER SWITCH

Comments
+ APC

ADM2-12

01

Green

ADM2-12

02

Brown/Blue

ANALOGUE OUTPUT

ADM2-12

03

Blue/Pink

ANALOGUE OUTPUT

ADM2-12

04

Pink

LOW SIDE OUTPUT

ADM2-12

05

NOT USED

LOW SIDE OUTPUT

ADM2-12

06

NOT USED

P UP LOGIC INPUT

ADM2-12

07

NOT USED

P UP LOGIC INPUT

ADM2-12

08

NOT USED

P UP LOGIC INPUT

ADM2-12

09

NOT USED

P DOWN LOGIC INPUT

ADM2-12

10

P DOWN LOGIC INPUT

ADM2-12

11

NOT USED

SWITCH HELD AT 60 MAX

NOT USED

ON WALVOIL DISTRIBUTOR

NEUTRAL TRANSMISSION INPUT

THIS SUPPLY CAN BE CUT-OFF BY THE EMERGENCY STOP

Yellow/Red

DIAGNOSTICS
ENGINE OIL PRESSURE INDICATOR OUTPUT
OIL TEMPERATURE INDICATOR OUTPUT

PREHEATING OPTION INPUT

P DOWN LOGIC INPUT

ADM2-12

12

P UP LOGIC INPUT

ADM2-15

01

P UP LOGIC INPUT

ADM2-15

02

NOT USED

P UP LOGIC INPUT

ADM2-15

03

NOT USED

SUPPLY

ADM2-15

04

HIGH SIDE OUTPUT

ADM2-15

05

HIGH SIDE OUTPUT

ADM2-15

06

NOT USED

Pink/Black

NOT USED
Light blue

ACCELERATOR POTENTIOMETER POWER SUPPLY

P UP LOGIC INPUT

ADM2-15

07

NOT USED

ANALOGUE INLET

ADM2-15

08

NOT USED

LOW SIDE OUTPUT

ADM2-15

09

HIGH SIDE OUTPUT

ADM2-15

10

LOW SIDE OUTPUT

CONFIG 4 LS

ADM2-15

11

LOW SIDE OUTPUT

CONFIG 1 LS

ADM2-15

12

80-01-M209EN

I FROM 0,5V TO 4,5V

Blue/Black

FROM 0,5V TO 4,5V TELESCOPIC BOOM

PREHEATING OPTION RELAY

NOT USED

Pink/Green

MAX OIL TEMPERATURE OUTLET

NOT USED

ON WALVOIL DISTRIBUTOR

LOW SPEED CAN (HIGH)

CAN H

ADM2-15

13

Yellow

CAN GND

ADM2-15

14

Brown/Red

GROUND CAN

CAN L

ADM2-15

15

Light blue

LOW SPEED CAN (LOW)

(13/11/2012)

ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS

B7

ADM 2
Designation 18

ECU TYPE

CONNECTOR

PIN N

WIRE

Function on carriage

SUPPLY

ADM2-21

01

Red/Yellow

P DOWN LOGIC INPUT

ADM2-21

02

Brown

+12V INPUT

SUPPLY

ADM2-21

03

Black

GROUND

LOW SIDE OUTPUT

ADM2-21

04

LOW SIDE OUTPUT

ADM2-21

05

Red/Yellow

RED ENGINE STOP INDICATOR OUTPUT

LOW SIDE OUTPUT

ADM2-21

06

Blue/Yellow

YELLOW CHECK MACHINE INDICATOR OUTPUT

LOW SIDE OUTPUT

ADM2-21

07

Green/Grey

STARTER INDICATOR OUTPUT

LOW SIDE OUTPUT

ADM2-21

08

NOT USED

SUPPLY

ADM2-21

09

NOT USED

P DOWN LOGIC INPUT

ADM2-21

10

NOT USED

P DOWN ANALOGUE INPUT

ADM2-21

11

NOT USED

+12V BATTERY POWER SUPPLY

NOT USED

P DOWN LOGIC INPUT

ANA PISTE 1

ADM2-21

12

Light blue/Green

INPUT 2 ACCELERATOR POTENTIOMETER

P DOWN LOGIC INPUT

ANA PISTE 2

ADM2-21

13

Light blue/Yellow

INPUT 1 ACCELERATOR POTENTIOMETER

GND

ADM2-21

14

Light blue/Grey

ACCELERATOR POTENTIOMETER GROUND

P UP LOGIC INPUT

ADM2-21

15

NOT USED

P UP LOGIC INPUT

ADM2-21

16

PARKING BRAKE SWITCH INPUT

ADM2-21

17

NOT USED

ADM2-21

18

NOT USED

CAN H

ADM2-21

19

Yellow

CAN GND

ADM2-21

20

Brown/Red

CAN H GROUND

CAN L

ADM2-21

21

Light blue

CAN H LOW SPEED

CAN H HIGH SPEED

FROM 0,5V TO 4,5V

80

SUPPLY

Comments

(13/11/2012)

80-01-M209EN

B8

ELECTRICAL CHARACTERISTICS
ANDSPECIFICATIONS

PLD INPUTS/OUTPUTS
PLD
Key:
SPU: Signal Processing Unit
NC: Not Cabled

MR2
MR2-54
MR2

54

18

36

19

37

MR2-54

16

MR2

PLD
Designation 18

CONNECTOR

PIN N

WIRE

Function on carriage

START

OAB_S

MR2-54

00

OIL SEPARATOR

START

NW_B

MR2-54

01

CAMSHAFT SENSOR

START

KW_B

MR2-54

02

CRANKSHAFT ANGLE POSITION SENSOR

START

TMOT_B

MR2-54

03

COOLANT LIQUID TEMPERATURE SENSOR

START

TFUEL_B

MR2-54

04

FUEL TEMPERATURE SENSOR

START

POEL_M

MR2-54

05

FAN SPEED SENSOR

OUTPUT

POELAKT_P

MR2-54

06

OIL PRESSURE SENSOR

OUTPUT

P2_P

MR2-54

07

AIR SUPPLY PRESSURE SENSOR

START

NTL2_S

MR2-54

08

SPEED SENSOR

OUTPUT

MVB 2

MR2-54

09

INJECTOR VALVES 2

POELAKT_M

MR2-54

10

ACTIVE OIL PRESSURE SENSOR

OUTPUT

PV_M

MR2-54

11

PROPORTIONAL VALVE GROUND

OUTPUT

PVB_P

MR2-54

12

PROPORTIONAL VALVE

PDK_P

MR2-54

13

OPTIONAL FUEL PRESSURE

OUTPUT

P23_P

MR2-54

14

SLOPE SENSOR WHEN REMOVING REFUSE / FAN SPEED SENSOR

START

TOEL_P

MR2-54

15

OIL TEMPERATURE SENSOR

OUTPUT

MVB 1

MR2-54

16

INJECTOR VALVES 1

NLUE_S

MR2-54

17

SPEED SENSOR

OUTPUT

ANLA

MR2-54

18

STARTER

START

KW_A

MR2-54

19

CRANKSHAFT ANGLE POSITION SENSOR

START

NW_A

MR2-54

20

CAMSHAFT SENSOR

START

T2_B

MR2-54

21

TURBO AIR TEMPERATURE SENSOR

PDK_M

MR2-54

22

OPTIONAL FUEL PRESSURE

P2_M

MR2-54

23

AIR SUPPLY PRESSURE SENSOR

START

NTL_S

MR2-54

24

SPEED SENSOR

START

MSST_S

MR2-54

25

ENGINE START SWITCH

START

POEL_S

MR2-54

26

PASSIVE ENGINE OIL PRESSURE SENSOR

PV5

MR2-54

27

PROPORTIONAL VALVE 5

PDK_S

MR2-54

28

OPTIONAL FUEL PRESSURE

P2_S

MR2-54

29

PRESSURE INCREASE SENSOR

START

80

ECU TYPE

START

START

OUTPUT

START

80-01-M209EN

Comments

(13/11/2012)

ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS

B9

PLD
ECU TYPE

CONNECTOR

PIN N

WIRE

Function on carriage

OUTPUT

MSS_P

MR2-54

30

ENGINE GO: STOP SWITCH

START

P23_S

MR2-54

31

OPTIONAL SLOPE WHEN REMOVING REFUSE

START

POELAKT_S

MR2-54

32

ENGINE OIL PRESSURE SENSOR

START

HDEL_S

MR2-54

33

OIL LEVEL SENSOR

START

TMOT_A

MR2-54

34

COOLANT LIQUID TEMPERATURE SENSOR

START

MSSP_S

MR2-54

35

ENGINE STOP SIGNAL BUTTON

START

TFUEL_A

MR2-54

36

FUEL TEMPERATURE SENSOR

OUTPUT

MVH

MR2-54

37

INJECTION PUMP ELECTROVALVE (INJECTOR H)

OUTPUT

MVF

MR2-54

38

INJECTION PUMP ELECTROVALVE (INJECTOR F)

TOEL_A

MR2-54

39

OIL TEMPERATURE SENSOR

OUTPUT

PV6

MR2-54

40

PROPORTIONAL VALVE 6

OUTPUT

PV3

MR2-54

41

PROPORTIONAL VALVE 3

OUTPUT

PV6_P

MR2-54

42

PROPORTIONAL VALVE 6

OUTPUT

PV4

MR2-54

43

PROPORTIONAL VALVE 4

OUTPUT

MVD

MR2-54

44

INJECTION PUMP ELECTROVALVE (INJECTOR D)

OUTPUT

MVB

MR2-54

45

INJECTION PUMP ELECTROVALVE (INJECTOR B)

OUTPUT

MVG

MR2-54

46

INJECTION PUMP ELECTROVALVE (INJECTOR G)

OUTPUT

MVE

MR2-54

47

INJECTION PUMP ELECTROVALVE (INJECTOR E)

START

T2_A

MR2-54

48

CHARGE-AIR TEMPERATURE

START

HOEL_M

MR2-54

49

OIL LEVEL SENSOR

OUTPUT

PV2

MR2-54

50

PROPORTIONAL VALVE 1

OUTPUT

PV1

MR2-54

51

PROPORTIONAL VALVE 2

PV2_P

MR2-54

52

PROPORTIONAL VALVE 1

OUTPUT

MVC

MR2-54

53

INJECTION PUMP ELECTROVALVE (INJECTOR C)

OUTPUT

MVA

MR2-54

54

INJECTION PUMP ELECTROVALVE (INJECTOR A)

INPUT / OUTPUT

CAN H

MR2

01

Yellow

CAN H INTERFACE

INPUT / OUTPUT

CAN L

MR2

02

Light blue

CAN L INTERFACE

GROUND

HF-GND

MR2

03

Brown/Red

GROUND CAN

GROUND

HF-GND

MR2

04

Brown/Grey

GROUND CAN

12V POWER SUPPLY

KL30

MR2

05

Blue

BATTERY POWER SUPPLY (+12V)

12V POWER SUPPLY

KL30

MR2

06

Blue

BATTERY POWER SUPPLY (+12V)

NOT USED

NOT USED

(OT_TRIGGER)

MR2

07

KL50

MR2

08

Green

KEY START

GROUND

KL31

MR2

09

Black

BATTERIE GROUND (-)

OUTPUT

PVB_P

MR2

10

GROUND

KL31

MR2

11

Black

OUTPUT

ANLA

MR2

12

Orange

INPUT / OUTPUT

KDIAG

MR2

13

Grey/Blue

OUTPUT

PV3

MR2

14

START

KL15

MR2

15

OUTPUT

PV4

MR2

16

START

(13/11/2012)

Comments

80

Designation 18

NOT USED
BATTERIE GROUND (-)
STARTER
STEERING DIAGNOSTICS
NOT USED
Brown

+ 12V INPUT
NOT USED

80-01-M209EN

ELECTRICAL CHARACTERISTICS
ANDSPECIFICATIONS

80

B10

80-01-M209EN

(13/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C1

TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS

Dsignation

Pages

KEY

KEY OPERATED STARTER SWITCH

C2

S4

BRAKE FLUID LEVEL CONTACT

C3

S5

AIR FILTER SWITCH

C3

S12

TRANSMISSION OIL THERMOSWITCH

C4

S16+S37

STOP PRESSURE SWITCH

C4

S17

RANSMISSION OIL THERMOSWITCH (NO H)

C5

S52

EMERGENCY STOP

C5

Y1+Y4

REVERSE+SLOW SPEED ELECTROVALVE (H)

C6

Y10

HIGH SPEED ELECTROVALVE (H)

C6

Y6+Y7+Y8+Y9

PROPORTIONAL SOLENOID VALVE BOOM/ACCESSORY

C7

Y14

HYD CUT-OFF VALVE/VS

C7

Y15

PROPORTIONAL SOLENOID VALVE, BOOM DESCENT VRP

C8

Y16

VCI TILT CUT-OFF

C8

Y18

SOLENOID VALVE

C9

Y30

PEC (PRESSURE ELECTRONIC CONTROL) ON CASAPPA PUMP

C10

XTP

ACCELERATOR POTENTIOMETER

C11

X01

DECLUTCH PUSH BUTTON (No H)

C11

X14

HORN

C12

X15+X21

WHEEL ALIGNMENT SENSOR

C12

X36

JSM JOYSTICK

C13

INDICATOR LIGHT PANEL

C14

X68

FUEL LEVEL AND HOUR METER

C14

X77

FRONT WINDSCREEN WIPER MOTOR

C15

X89

WATER TEMPERATURE INDICATOR

C15

X99

STRAIN GAUGE

C16

X100

BOOM ANGLE ANGULAR SENSOR

C16

X134

RETRACTED BOOM SWITCH

C17

X165

FUEL GAUGE

C17

X188

LIGHTING STALK SWITCH

C18

X503

TRANSMISSION OIL TEMPERATURE SENSOR (NO H)

C19

X504

HYDRAULIC OIL TEMPERATURE SENSOR

C19

B18

ENGINE COOLANT TEMPERATURE SENSOR

C20

B19

ENGINE AIR TEMPERATURE SENSOR

C21

(16/11/2012)

80

Rep.
lectriques

80-01-M209EN

C2

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

KEY KEY OPERATED STARTER SWITCH

X54

PIN

+ Battery

+ Battery

Not used

Preload shunt

+ Post contact (+APC)

+ Post contact (+APC)

Starter

Preheating Shunt

Preheating relay control

10

Not used

X55
6
7
8
9

Function

10

Corresponding connector

KEY
X54-X55

80

Diagram

PIN

Minimum

Typical

Maximum

Switchable current

8A

On line drop

300 mV

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

S4

C3

BRAKE FLUID LEVEL CONTACT

PIN

Function

Module A1 info
(dashboard)

Cab Front Ground

S4

Corresponding connector

Diagram
PIN
Supply current

Minimum

Typical

Maximum

4 mA

6 mA

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

AIR FILTER SWITCH

PIN

Function

Clogging info

Engine Ground

S5

Corresponding connector

Diagram

Manimux current
Voltage threshold
Inlet type

PIN

Minimum

Typical

Maximum

4 mA

6 mA

U < 2V = 0

U > 6,5V = 1

Umax = 16V

Type 1 negative logic inlet (ELN1)

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

80

S5

C4

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

S12 TRANSMISSION OIL THERMOSWITCH

PIN

Function

Signal info

Signal Ground

S12

Diagram
PIN

Minimum

Typical

Maximum

Courant

mA

ECU current

U< V=0

U> V=1

Umax = V

Inlet type
Note:
Only forward motion clutch info

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

S16+S37

STOP PRESSURE SWITCH

80

PIN

Function

12 V supply

Stop Light Control

S16

Diagram

PIN

Minimum

Typical

Maximum

Supply voltage

12 V

42 V

Consumption

3,5 A

Note:
- The Pressostat contact closes at a pressure of 3 0,4 bar in the braking circuit.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C5

S17 RANSMISSION OIL THERMOSWITCH (NO H)

PIN

Function

Signal info

Signal Ground

S17

Diagram
PIN
ECU current

Minimum

Typical

Maximum

mA

0 mA

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

S52 EMERGENCY STOP

1
2
4
3

Function

Power supply
MR2+ADM2

+ Post contact

Power supply SPU

+ Post contact

S52

80

PIN

Corresponding connector

Diagram

PIN
Supply voltage

Minimum

Typical

Maxi

12 V

Consumption

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

C6

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

Y1+Y4

REVERSE+SLOW SPEED ELECTROVALVE (H)

PIN

Function

Power supply

Ground

Corresponding connector

Y1
Diagram
PIN

Minimum

Typical

Supply voltage

Maximum

12 V

Consommation
Note:

X313 - Y1 : Reverse solenoid valve

X312 - Y4 : Slow speed solenoid valve

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Y10 HIGH SPEED ELECTROVALVE (H)

80

PIN

Function

Power supply

Ground

Corresponding connector

Y10
Diagram
PIN
Supply voltage

Minimum

Typical

Maximum

12 V

Consommation

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

Y6+Y7+Y8+Y9

C7

PROPORTIONAL SOLENOID VALVE BOOM/ACCESSORY

PIN

1
2

Function

Power supply

Ground

Y6

Corresponding connector

Diagram
PIN

Minimum

Typical

Max

Supply voltage

5,45 V

Coil resistance (at 20C)

4,2

Tolerance

10%

Consumption

0 to 1,5 A

1,5 A

Note: Solenoid valve control is by current variation. Voltage is indicative only.

X28 - Y8 : Telescope retraction proportional solenoid valve
X29 - Y9 : Telescope extension proportional solenoid valve
X34 - Y7 : Accessory proportional solenoid valve (S1)
X35 - Y6 : Accessory proportional solenoid valve (S2)

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________

Y14 HYD CUT-OFF VALVE/VS

1
2

Function

Power supply

Ground

80

PIN

Y14

Corresponding connector

Diagram
PIN
Supply voltage

Minimum

Typical

Maximum

12 V

14 V

Resistance (at 20C)

9,6

Tolerance

10%

Consumption

1,4 A

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

C8

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

Y15 PROPORTIONAL SOLENOID VALVE, BOOM DESCENT VRP

PIN

1
2

Function

Power supply

Ground

Y15

Corresponding connector

Diagram

PIN

Minimum

Typical

Supply voltage

12 V

Coil resistance (at 20C)

3,5

Tolerance

10%

Consumption

0 to 1,5 A

Maximum

1,5 A

Note:
Solenoid valve control is by current variation. Voltage is indicative only.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

Y16 VCI TILT CUT-OFF

PIN

80

1
2

Function

Power supply

Ground

Y16

Corresponding connector

Diagram

PIN

Minimum

Typical

Supply voltage

6V

Coil resistance (at 20C)

4,2

Tolerance

10%

Consumption

Maximum

1,5 A

Comments:
Solenoid valve control is by current variation. Voltage is indicative only.
When cut-out is in effect, the VCI is not powered.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C9

Y18 SOLENOID VALVE

PIN

Function

+ Post contact

Parking brake switch

Corresponding connector

Y18

Diagram
PIN
Supply voltage

Minimum

Typical

Maximum

12 V

Consumption
Resistance

1.2

Note:
- Measurements taken at 20C

Notes: ____________________________________________________________________________________

80

___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

C10

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

Y30 PEC (PRESSURE ELECTRONIC CONTROL) ON CASAPPA PUMP

PIN

Function

PWM-OUT+

PWM-OUT-

1
2

Y30
Corresponding connector

Diagram

Minimum

Typical

Voltage

12 V (10%)

Resistance

6,2 (7%)

Maximum

Courant

1,25 A

Power

15 W

Pressure (bar)

80

PIN

Current (A)

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C11

XTP ACCELERATOR POTENTIOMETER

PIN

3
6

1
4

Function

8V to 36V supply

0V Ground

Signal 22% - 71%

Signal 78% - 29%

8V to 36V supply

0V Ground

XTP

Corresponding connector
PIN

Comments:

XTP

Diagram
Minimum

Typical

Maximum

Power supply

8V

36 V

Weight

0V

Signal

20%

80%

Power supply

8V

36 V

Ground

0V

Signal

80%

20%

Electrical range:

S1:
S2:

8V to 36V
36V to 8V

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

X01 DECLUTCH PUSH BUTTON (No H)

1
2

Function

Declutch Info

M1 chassis ground

X01

Corresponding connector

Diagram

Manimux current
Voltage threshold
Inlet type

PIN

Minimum

Typical

Maximum

4 mA

6 mA

U < 2V = 0

U > 6,5V = 1

Umax = 16V

Type 1 negative logic inlet (ELN1)

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

80

PIN

C12

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

X14 HORN
PIN
1

Function
Horn power supply

X14

Corresponding connector

CHASSIS GND (M3)

Diagram

Minimum

Typical

Maximum

Supply voltage

PIN

9V

12 V

15 V

Resistance (10%)

2,17

Nominal frequency

500 20 Hz

Average current

6A

Note:
- Sound level 107 dB(A) / 13V.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

X15+X21

WHEEL ALIGNMENT SENSOR

PIN

80

3
2

Function

Signal

Power supply

Ground

X15

Corresponding connector

X15
Diagram
Minimum

Typical

Maximum

Supply voltage

PIN

12 V

Direct current

10 mA

Outlet logic
Type of outlet

Switch closed = wheels aligned

PNP at Vbat

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C13

X36 JSM JOYSTICK

PIN

1
2
3
4
5
6

12
11
10
9
8
7

Function

JSM Earth

Roller 1 direction A (+)

Roller 1 direction B (-)

Roller 2 direction A (+)

Roller 2 direction B (-)

Signal Roller 1

Signal Roller 2

12V JSM Power supply

Optional BP jib head

solenoid valve

10

N/A

11

Forward gear

12

Reverse gear

Corresponding connector

X36

X36

PIN
6-7

Minimum

Typical

Maximum

1V

6V

11 V

12 V

Outlet voltage
2-3-4-5
Supply voltage
Potentiometer current below 5V 10%
Note:
- Direction A B + -:

12 V
/

1 mA

2 mA

0 = roller neutral
12 V = direction validation

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012)

80-01-M209EN

80

Diagram

C14

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

INDICATOR LIGHT PANEL

Connecteurs

PIN

PIN

Function

Oil pressure indicator lamp

Coolant temperature lamp

Not used

Air filter clogging lamp

Oil filter clogging lamp

Battery load lamp

Parking Brake Lamp

+ Post contact

Indicator lamp

Ground

High beam lamp

+ Post contact
Braking oil level lamp

Ground

Minimum

Diagram

Typical

Voltage

Maximum

12 V

Consommation

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

X68 FUEL LEVEL AND HOUR METER

80

PIN

00

00

Function

+ Post contact

Fuel level sensor

Ground

Frequency input

Rear lighting

X68

X68

Diagram

PIN
Voltage

Minimum

Typical

Maximum

10V

12V

16V

Consommation

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C15

X77 FRONT WINDSCREEN WIPER MOTOR

PIN

Function

+ Post contact

Engine power supply

Control switch

Ground

X77

X77
Diagram

PIN

Minimum

Typical

Voltage

12 V

Consommation

3.5 A

Maximum

Note:
- 32 tr/min

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

X89 WATER TEMPERATURE INDICATOR

PIN

8
4
5
1

Function
+ After ignition on

Ground

Not used

Not used

Resistive signal

Rear lighting

Not used

Not used

X89

80

Diagram

Corresponding connector

PIN
Voltage
Consommation

Minimum
10 V

Typical

Maximum

12V

16 V

100 mA without rear lighting

150 mA with rear lighting

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

C16

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

X99 STRAIN GAUGE

PIN

4
5
1

3
2

Function

Shielding

Power supply

Ground

CAN_H

CAN_L

X99

Corresponding connector

X99
Diagram

PIN

Minimum

Typical

Maximum

9V

10 V

16 V

Supply voltage
Consumption

150 mA

Note:
- CAN integrated terminal resistance 120 .

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

X100 BOOM ANGLE ANGULAR SENSOR

80

PIN

6
5
4
3

Function

X100

Common Ground

Common 5 V power supply

Track 1 angle signal

Common Ground

Common 5 V power supply

Track 2 angle signal

X100

Corresponding connector
Diagram
PIN

Minimum

Typical

Maximum

Supply voltage

5V

Direct current

8 mA

Outlet voltage

0,5 V

2,5 V

4,5 V

Load resistance

20 000

Angular range

90

Comment: Plan for min/max angle calibration on each machine at 0 km.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C17

X134 RETRACTED BOOM SWITCH

PIN

1
2

Function

NO Switch

NF Switch

Chassis Ground

Chassis Ground

X134
NF

X134

NO

Corresponding connector

Diagram

PIN
Voltage

Minimum

Typical

Maximum

9V

V Bat

16 V

Consumption

6 mA

Note:
When the boom is retracted, the NO switch is closed and the NF switch is open.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

X165 FUEL GAUGE

Function

Fuel level info

80

PIN

Corresponding connector

X165
CHASSIS GND
Diagram

PIN

Minimum

Typical

Maximum

Supply voltage

12 V

Empty tank resistance

345

Full tank resistance

Inlet type

Analogue inlet

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

C18

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

X188 LIGHTING STALK SWITCH

PIN

4
7

Function

Headlight power supply

+ Battery

Position lights

Low beam

Main beam

Horn power supply

+ Post contact

Horn

Right indicator

Indicator power supply

+ Post contact

Left indicator

X188

X188

Diagram

Corresponding connector
PIN

Minimum

Voltage
Consommation

Typical

Maximum

12 V
5A

7A

Notes: ____________________________________________________________________________________

80

___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C19

X503 TRANSMISSION OIL TEMPERATURE SENSOR (NO H)

PIN

Function

Supply

Oil temperature info

X503

2
1

Diagram

PIN
Temperature range

Minimum

Typical

Maximum

- 20C

75C

+ 110C

Activation threshold

89C

Deactivation threshold

69,5C

Comments:
The thermo switch powers the switch when its trigger threshold is reached, in order to activate the fan at maximum speed. When the deactivation
threshold is reached the thermo switch ceases to power the switch.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

X504 HYDRAULIC OIL TEMPERATURE SENSOR

Function

Supply

Oil temperature info

2
1

X504

Diagram
PIN
Temperature range

Minimum

Typical

Maximum

- 20C

90C

+ 110C

Activation threshold

116,4C

Deactivation threshold

84,6C

Comments:
The thermo switch powers the switch when its trigger threshold is reached, in order to activate the fan at maximum speed. When the deactivation
threshold is reached the thermo switch ceases to power the switch.

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012)

80-01-M209EN

80

PIN

C20

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

B18 ENGINE COOLANT TEMPERATURE SENSOR

PIN

PIN

Function

Temperature info

Engine Ground

Minimum

Typical

Maximum

Supply voltage

24 V

Temperature range

0 C

120 C

Resistance at 70 C

Resistance at 73 C

Resistance at 75 C

Resistance at 80 C

Resistance at 85 C

Resistance at 90 C

Resistance at 95 C

Resistance at 100 C

Comments:
The sensors current is variable, whereas the voltage is constant. There is a law relating current and temperature. This law defines the curve A = f (T C).
The responsiveness and precision of the sensor (usually 3,5 C) have to be known.

80

Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________

80-01-M209EN

(16/11/2012)

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

C21

B19 ENGINE AIR TEMPERATURE SENSOR

PIN

PIN

Function

Temperature info

Engine Ground

Minimum

Typical

Maximum

Supply voltage

24 V

Temperature range

0 C

120 C

Resistance at 38 C

Resistance at 48 C

Resistance at 52 C

Resistance at 41 C
Resistance at 43 C

Comments:
The sensors current is variable, whereas the voltage is constant. There is a law relating current and temperature. This law defines the curve A = f (T C).
The responsiveness and precision of the sensor (usually 3,5 C) have to be known.

Notes: ____________________________________________________________________________________

80

___________________________________________________________________________________________
___________________________________________________________________________________________

(16/11/2012)

80-01-M209EN

ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS

80

C22

80-01-M209EN

(16/11/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

pages
CODES ON THE ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CABLE MARKING ON AN ELECTRICAL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
MLT 845-120 H SERIES 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A

80

MLT 845-120 SERIES 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

(08/10/2012)

80-02-M209EN

ELECTRICAL SCHEMATIC DIAGRAMS

CODES ON THE ELECTRICAL DIAGRAMS

1

10

10
15
MR2

MR2

ADM-12

14

15

16

17

18

19

16

ADM2

12

7
2

13

toward (TAB.01)
toward (TAB.01)
toward (TAB.01)

F44

12

10

17

9
8

11

toward (TAB.01)
toward (TAB.01)
toward (TAB.01)

ADM-15

13

toward (TAB.01)

17

14

1
E

ADM-21

11

KN
G

S5

12

11

5
X121

17

12

80

GND

BATTEY 30

4
M

CHASSIS GND

Example of marking on cables and components on an electrical diagram

Key:
1
2
3
4
5
6
7
8
9

Power supply
Electrical component
Electrical component designation
Electrical connector
Electrical connector designation
Splice
Computer connector
Computer
Computer designation

80-02-M209EN

10
11
12
13
14
15
16
17

Computer connector designation

Wire N designation
Electrical connector PIN N designation
Grounds
CAN
CAN Shielding
Marking grid
Refer to diagram XX: toward (TAB.XX)
(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

CONNECTORS

Harness connector:
X8-2

Connector

Pin N

ADM2 module connector:

ADM2/12-4

Connector

Pin N

MR2 module connector:

MR2-13

Pin N

SPU module connector:

SPU X56-13

Pin N

80

Connector

(08/10/2012)

80-02-M209EN

ELECTRICAL SCHEMATIC DIAGRAMS

CABLE MARKING ON AN ELECTRICAL WIRING HARNESS

The electrical wiring harnesses installed on the truck are composed of connectors.
There are numbers on the connectors so that they can be identified.

X64

X32

There are inscriptions on the diagrams so that the wires can be identified (u Item 11: CABLE MARKING
ON AN ELECTRICAL WIRING HARNESS).

N 1,5

80

Colour

Section in mm

Colour codes:
A
B
C
G
H
L
M
N
R
S
V
Z

Light blue
White
Orange
Yellow
Grey
Blue
Brown
Black
Red
Pink
Green
Purple

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A1

MLT 845-120 H SERIES 4-E3

pages

POSITION OF CONNECTORS ON DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7
1 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
2 TRANSMISSION AND SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
3 CAN BUS AND DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
4 LIGHTING/SIGNALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A16
5 HYDRAULIC MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A18

80

6 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A20

(08/10/2012)

80-02-M209EN

A2

ELECTRICAL SCHEMATIC DIAGRAMS

MLT 845-120 H Series 4-E3

POSITION OF CONNECTORS ON DIAGRAMS

Connectors

Diag. 1

Diag. 2

Diag. 3

ADM2-12
ADM2-15

ADM2-21

F40

F41

F42

F43

F44

F45

G1

KA

KN

M1

Diag. 5

P06

P09

P10

P13

P12A

P12B

RC

XTP

X5

X6

X7

X8

X02

X04

X05

X10

X11

X12

X13

X14

X15

X16

X17

X19

X20

X21

X22

X23
X24
X26
X26.

80-02-M209EN

X09

X15

Diag. 7

P01

80

Diag. 6

M3
MR2

Diag. 4

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A3

MLT 845-120 H Series 4-E3

Connectors

Diag. 1

Diag. 2

Diag. 3

Diag. 4

X28

Diag. 5

Diag. 6

X29

X30

X33

X34

X35

X36

X39

X41

X45

X46
X47

X48

X50

X51

X52

X54

X55

X56

X57

X58

X68

X70

X71

X72

X73

X74

X77

X79

X87

X92

X93

X97

X99

X100

X104

X105

X109

X112

X113
X115

X116

X117

X117/A

(08/10/2012)

80

X89

X114

Diag. 7

80-02-M209EN

A4

ELECTRICAL SCHEMATIC DIAGRAMS

MLT 845-120 H Series 4-E3

Connectors

Diag. 1

Diag. 2

Diag. 3

Diag. 4

X117/B
X118

X149

X150

X151

X154

X155

X165

X188

X205

X206

X208

X209

X215

X221

X223

X224

X224.

X225

X226

X227

X228

X229

X232

X238

80

X239

X240

X241

X242

X243

X245

X246

X247

X248

X249

X355A

X355B

X356A

X356B

X300

X301

X302

X303

X304

X305

X306

X307

80-02-M209EN

Diag. 7

X134

X193

Diag. 6

X119
X121

Diag. 5

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A5

MLT 845-120 H Series 4-E3

Connectors

Diag. 1

Diag. 2

Diag. 3

Diag. 4

X308

X309

X313

X314

X315

X316

X317

X318

X319

X320

X321

X322

X323

X325

X326

X327

X329

X330

X331

X332

X333

X334

X335

X501

X502

X503

X504

X505

X506

80

X338

(08/10/2012)

Diag. 7

X312

X328

Diag. 6

X310
X311

Diag. 5

80-02-M209EN

A6

ELECTRICAL SCHEMATIC DIAGRAMS

80

MLT 845-120 H Series 4-E3

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A7

MLT 845-120 H Series 4-E3

ELECTRICAL DIAGRAMS
1 START-UP
Electrical connectors
Harness type

Item

Name of
component

Engine

ADM2-12

ADM2

ADM2 MODULE (CAB)

Engine

ADM2-15

ADM2

ADM2 MODULE (CAB)

E32

Engine

ADM2-21

ADM2

ADM2 MODULE (CAB)

G32

Engine

F40

F40

FUSE KEY SWITCH

E13

Engine

F41

F41

FUSE KEY SWITCH

E12

Engine

F42

F42

DIAGNOSTIC PLUG MR2-PLD

E11

Engine

F43

F43

ADM2 MODULE (CAB)

E10

Engine

F44

F44

ADM2 MODULE (CAB)

E9

Engine

F45

F45

STARTER

E8

Engine

G1

G1

ALTERNATOR

A5

Position on
diagram
A32

Engine

KA

KA

MERCEDES STARTING RELAY

C7

Engine

KN

KN

NEUTRAL SAFETY RELAY

E39

Engine

MR2

MR2

MR2-PLD MODULE (ENGINE)

A26

Engine

M1

M1

STARTER

Engine

RC

Engine

XTP

Engine

X5

Engine

X6

X6A

Engine

X7

KC + FC1

Engine

X8

S5

XTP

C8

NOT USED

O38

ACCELERATOR POTENTIOMETER

M36

DIAGNOSTIC PLUG MR2-PLD

E26

DIESEL DECONGEALANT HEATING ELEMENT

E15

AIR HEATING (OPTION)

E18

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

G38
M38

Main/Engine

X15

ENGINE/MAIN INTERFACE

Main/Engine

X24

MAIN/ENGINE INTERFACE

O7

Main/Electric plate

X41

ELECTRIC PLATE

O28

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

M18

Main

X47

F25

ANTI-START FUSE

O26

Main

X54

KEY

KEY SWITCH

M8

Main

X55

KEY

KEY SWITCH

M8

Main

X56

SPU

SPU MODULE

O22

Main

X57

SPU

SPU MODULE

O22 - O34 - Q37

Main

X114

S52

EMERGENCY STOP

O19

Main

X118

DIGICODE CONNECTOR

Q32

Main/Engine

X121

MAIN/ENGINE INTERFACE

K37

Main

X193

OPTIONAL CONNECTOR

Q28

Main/Electric plate

X308

ELECTRIC PLATE

Main/Electric plate

X311

REVERSE GEAR SHUTTLE CONNECTOR

Main

X317

Electric plate

X318

Main

X328

Main

X332

Main

X333

Main

X334

Main

X501

Main/Fan

X502

Fan

X503

Fan

X504

Fan
Fan
(08/10/2012)

F30

Hydraulic code
equivalence

80

Designation

O25 - Q24 - O29

Q24

INDICATOR LAMP FAULT + SPU

O16

ELECTRIC PLATE GROUND CONNECTOR

O24

F36

SPU FUSE

O18

H16

INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP

O13

H10

AIR HEATING INDICATOR LAMP

O14

H15

ENGINE FAULT INDICATOR LAMP

O15

X501

FAN SWITCH

O36

MAIN/FAN INTERFACE

Q36

X503

FAN THERMOSTAT

Q36

X504

FAN THERMOSTAT

Q34

X505

X505

PROPORTIONAL ELECTROVALVE FAN

S38

X506

X506

FAN INVERSION ELECTROVALVE

S39
80-02-M209EN

A8

ELECTRICAL SCHEMATIC DIAGRAMS

MLT 845-120 H Series 4-E3

Electrical components
Item
ADM2

Designation

Position on diagram

ADM2 MODULE (CAB)

A34

B1

12V BATTERY

A15

B2

12V BATTERY (OPTION)

A16

EH

AIR HEATING

E20

G1

ALTERNATOR

A6

H10

AIR HEATING INDICATOR LAMP

Q14

H15

ENGINE FAULT INDICATOR LAMP

Q15

H16

INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP

Q13

KEY

KEY SWITCH

M8

M1

STARTER

A8

MR2

MR2-PLD MODULE (ENGINE)

A27

RC1

RESISTANCE CAN (120)

O39

S5

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

G36

S46

BATTERY CUT-OFF

A13
O19

S52

EMERGENCY STOP

X6A

DIESEL DECONGEALANT HEATING ELEMENT

E16

X501

FAN SWITCH

O36

X503

TEMPERATURE SENSOR (NOT USED)

Q36

X504

HYDRAULIC OIL TEMPERATURE SENSOR

Q34

X505

PROPORTIONAL ELECTROVALVE FAN

S38

X506

FAN INVERSION ELECTROVALVE

S40

XTP

ACCELERATOR POTENTIOMETER

K37

Hydraulic code
equivalence

80

Fuses and relays

Item

Current

Designation

Position on diagram

F4

15A

FAN + DIAGNOSTICS + DIESEL FUEL THINNING FILTER

O29

F14

15A

DIGICODE + SENSORS

O28

F21

15A

DIGICODE + ROOF LIGHT + WARNING

O27

F25

25A

ANTI-START

O26

F30

10A

FAULT INDICATOR LAMP + SPU

O16

F36

10A

SPU

O18

F40

70A

KEY SWITCH

E13

F41

70A

KEY SWITCH

E12

F42

7,5A

DIAGNOSTIC PLUG MR2-PLD

E11

F43

10A

ADM2 MODULE (CAB)

E10

F44

15A

ADM2 MODULE (CAB)

E9

F45

30A

STARTER

FC

225A

AIR HEATING (OPTION)

A20

FC1

7,5A

AIR HEATING - ADM2 INFORMATION (OPTION)

C19

FG

125A

E8

MASTER POWER SWITCH

C13

K4

ANTI-START RELAY

O25

KA

MERCEDES STARTING RELAY

C7

KC

AIR HEATING RELAY (OPTION)

C20

KN

NEUTRAL SAFETY RELAY

E39

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A9

DIAGRAM 1
1

10

11

12

13

14

G1

15

16

B1

M1

17

18

19

20

21

22

23

24

25

FC

B2

26

27

MR2

MR2

28

29

30

31

32

33

ADM-12

34

35

36

37

38

39

40

41

42

ADM2

S46

G1

KC

M1

FG

C
ADM-15

KA

FC1
ENGINE GND

EH
X5

CHASSIS GND

F45

F44

F43

F42

F41

X7

F40

ENGINE GND

KN
X6A

X6

ADM-21

S5

X121

XTP

KEY
X54-X55

X15

X45
RC

F25
F30
O

F21

F14

F4
RC1

F36

X501

S52

K4

STOP

H16

H10

H15

X193

X118

X504

X503

(08/10/2012)

X506

X24
CHASSIS GND

CHASSIS GND

GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

X505

80-02-M209EN

80

XTP

A10

ELECTRICAL SCHEMATIC DIAGRAMS

2 TRANSMISSION AND SENSORS

MLT 845-120 H Series 4-E3

80

Electrical connectors

80-02-M209EN

Harness type

Item

Name of
component

Engine

ADM2-12

ADM2

Engine

ADM2-15

ADM2

ADM2 MODULE (CAB)

K7

Main

X8

S5

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

O9

X02

SEAT SWITCH (NO)

O28

Designation
ADM2 MODULE (CAB)

Position on
diagram
K7

Main

X02

Main/Electric plate

X04

Main

X09

Y2

FORWARD GEAR ELECTROVALVE

Q33

Main

X10

Y3

REVERSE GEAR ELECTROVALVE

Q35

Main

X12

S37

HAND BRAKE PRESSURE SWITCH

Q17

Main

X15

X15.

FRONT WHEEL ALIGNMENT SENSOR

O4

Main

X20

X20

REVERSING SOUND ALARM (OPTION)

K39

Main

X21

X21

REAR WHEEL ALIGNMENT SENSOR

O3

Main

X22

S17

HYDRAULIC OIL FILTER

Q13

Main/Engine

X24

MAIN/ENGINE INTERFACE

K10

Main

X36

Main/Electric plate

X41

ELECTRIC PLATE

X36

JSM (JOYSTICK SWITCH AND MOVE)

ELECTRIC PLATE
ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

C6

G29
E23 - I8

Main/Electric plate

X45

Main

X46

K8

Main

X50

H11

FRONT WHEEL ALIGNMENT LIGHT

M5

Main

X51

H14

REAR WHEEL ALIGNMENT LIGHT

M3

Main

X52

X52

WHEEL ALIGNMENT SWITCH

Main

X56

SPU

SPU MODULE

I24 - M25

Main

X57

SPU

SPU MODULE

I24 - M25

Main

X68

X68

HOUR METRE / FUEL LEVEL

I21

Main

X71

X71

BRAKE PEDAL SWITCH

G31

Main

X72

S4

BRAKE LIQUID LEVEL CONTACT

O11

NEUTRAL SAFETY RELAY

A4
M38

Q6

Main

X89

COOLANT LIQUID TEMPERATURE INDICATOR

I17

Main

X118

DIGICODE CONNECTOR

G23

Main/Engine

X121

Main

X165

MAIN/ENGINE INTERFACE

K10

X165

FUEL LEVEL SENSOR

I21

X238

S48

BRAKE CIRCUIT PRESSURE SWITCH

Main

X300

K18

HAND BRAKE RELAY

Main

X301

K12

SNAIL SPEED

K29

Main

X302

K13

SLOW SPEED

M29

Main

X303

K14

REVERSE GEAR RELAY

I38

Main

X304

X304

SLOW SPEED SWITCH

Q29

Main

X305

X305

FAST / SLOW SPEED SWITCH

G34

Main

X306

H15.

SLOW SPEED

M3

H10.

FAST SPEED

M33

Main

X307

Main/Electric plate

X308

Main

X309

Main

X310

Main/Electric plate

X311

Main

X312

Main
Main

X309

Hydraulic code
equivalence

E4
Q19

ELECTRIC PLATE

G8

ACCELERATOR PEDAL SWITCH

G23

REVERSE GEAR INFORMATION

G37

REVERSE GEAR SHUTTLE CONNECTOR

G36

Y4.

SNAIL SPEED ELECTROVALVE

Q26

X313

Y1

REVERSE GEAR ELECTROVALVE

Q27

X314

Y10

FAST SPEED ELECTROVALVE

Q31

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A11

MLT 845-120 H Series 4-E3

Electrical connectors
Harness type

Item

Name of
component

Designation

Position on
diagram

Electric plate

X318

ELECTRIC PLATE GROUND CONNECTOR

Main/Electric plate

X319

BRAKE CIRCUIT CONNECTOR

Main

X320

OPTIONAL CONNECTOR

E7

Main

X321

NOT USED

I16

Main

X322

Main

X323

X323

Main

X325

Main

X326

Main

X327

Y18

X355A

Hydraulic code
equivalence

A37
I6

NEUTRAL SWITCH INFORMATION (OPTION)

G33

HAND BRAKE SWITCH

M19

D4 - D5

DIODE CONNECTOR

K37

D4 - D5

DIODE CONNECTOR

K37

HAND BRAKE ELECTROVALVE

Q23

PARKING BRAKE SWITCH/X41

M17
M17

X41/PARKING BRAKE SWITCH

PARKING BRAKE SWITCH/SPU

M16

X356B

SPU/PARKING BRAKE SWITCH

M16

80

X355B
X356A

(08/10/2012)

80-02-M209EN

A12

ELECTRICAL SCHEMATIC DIAGRAMS

MLT 845-120 H Series 4-E3

Electrical components

80

Item

Designation

Position on diagram

H10.

FAST SPEED

M34

H11

FRONT WHEEL ALIGNMENT LIGHT

M5

H14

REAR WHEEL ALIGNMENT LIGHT

M4

H15.

SLOW SPEED

M33

S4

BRAKE LIQUID LEVEL CONTACT

Q11

S5

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

Q9

S17

HYDRAULIC OIL FILTER

Q13

S37

HAND BRAKE PRESSURE SWITCH

Q17

S48

BRAKE CIRCUIT PRESSURE SWITCH

G3

D4

DIODE - SAFETY RELAY/REVERSE GEAR

K37

D5

DIODE - SAFETY RELAY/FORWARD GEAR

K36

X02

SEAT SWITCH (NO)

O28

X15.

FRONT WHEEL ALIGNMENT SENSOR

O5

X20

REVERSING SOUND ALARM (OPTION)

K38

X21

REAR WHEEL ALIGNMENT SENSOR

O4

X36

JSM (JOYSTICK SWITCH AND MOVE)

G25

X52

WHEEL ALIGNMENT SWITCH

Q6

X68

HOUR METRE / FUEL LEVEL

G18

X71

BRAKE PEDAL SWITCH

G31

X165

FUEL LEVEL SENSOR

I21

X304

SLOW SPEED SWITCH

Q29

X305

FAST / SLOW SPEED SWITCH

G34

X309

ACCELERATOR PEDAL SWITCH

G23

X323

HAND BRAKE SWITCH

M19

Y1

REVERSE GEAR ELECTROVALVE

K39

Y2

FORWARD GEAR ELECTROVALVE

Q34

Y3

REVERSE GEAR ELECTROVALVE

Q36

Y4.

SNAIL SPEED ELECTROVALVE

Q26

Y10

FAST SPEED ELECTROVALVE

Q32

Y18

HAND BRAKE ELECTROVALVE

Q23

Hydraulic code
equivalence

Fuses and relays

Item

Current

Designation

Position on diagram

F2

5A

ECU + WHEEL ALIGNMENT + DIAGNOSTICS

C8

F11

10A

SUSPENSION ELECTROVALVE + BRAKE PRESSURE

C7

F12

7,5A

PARKING BRAKE

C8

F13

15A

FNR TRANSMISSION

C22

F15

5A

INSTRUMENTS + INDICATORS

C9

K0

NC TRANSMISSION CUT-OFF RELAY

C30

K1

RELAY (NOT USED)

C26

K2

FORWARD GEAR RELAY

C33

K3

REVERSE GEAR RELAY

C37

K5

TRANSMISSION PRESSURE RELAY

K8

NEUTRAL SAFETY RELAY

K12

SNAIL SPEED

K31

K13

SLOW SPEED

M31

K14

REVERSE GEAR RELAY

G40

K18

HAND BRAKE RELAY

Q21

K21

BRAKE CIRCUIT RELAY

80-02-M209EN

C6
M40

E7

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A13

DIAGRAM 2
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

A
X45

F13
C

K5

F11

F2

F12 F15

K1

K0

K2

K3

X41

K21

S48

X36

X118

X311

X71

X309

X68

X309
CHASSIS GND

X305

X36
X308

K14

X89
X68
X303

X165

X41

X326

X121

D5

K12

Y1

D4

K
X301

X20

K13

H15

H10
K8

H14

X302

H11

X323
X46

X02

X21

X21

X15

K18

X15
S5
X52

S4

S17
S37

X304
X300

Y18

Y4

Y10

Y2

Y3

(08/10/2012)

S
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

CHASSIS GND

80-02-M209EN

80

X24

A14

ELECTRICAL SCHEMATIC DIAGRAMS

3 CAN BUS AND DIAGNOSTICS

MLT 845-120 H Series 4-E3

Electrical connectors

Electrical components

Harness type

Item

Name of
component

Engine

ADM2-12

ADM2

ADM2 MODULE (CAB)

Q5

RC1

RESITANCE CAN (120)

M39

Engine

ADM2-21

ADM2

ADM2 MODULE (CAB)

M38

A12

LONGITUDINAL SECURITY MODULE

A29

Engine

MR2

MR2

MR2-PLD MODULE (ENGINE)

S5

X99

STRAIN GAUGE

C24

Engine

RC

RC1

RESITANCE CAN (120)

M37

RC2-2

MODULE RC2-2

K4

Main/Engine

X15

ENGINE/MAIN INTERFACE

K33

Main/Electric plate

X41

ELECTRIC PLATE

C11

Designation

Position on
diagram

Hydraulic code
equivalence

Item

Designation

Position on diagram

Hydraulic code
equivalence

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A5

Main

X48

F31

REXROTH ECU RC2-2

I9

Main

X56

SPU

SPU MODULE

M20

Main

X57

SPU

SPU MODULE

M20

F2

5A

ECU + WHEEL ALIGNMENT + DIAGNOSTICS

A8

Main

X58

A12

LONGITUDINAL SECURITY MODULE

E30

F14

15A

DIGICODE + SENSORS

A10

Fuses and relays

Item

Current

Designation

Position on diagram

Main

X99

X99

STRAIN GAUGE

C25

F31

5A

REXROTH ECU RC2-2

I9

Main

X109

RC2-2

MODULE RC2-2

K6

F34

5A

DIAGNOSTICS

I10

Main

X115

OBD CONNECTOR DIAGNOSTICS

C18

F35

5A

DIAGNOSTICS

C4

Main/Electric plate

X308

ELECTRIC PLATE

C8

Main

X315

F34

FUSE DIAGNOSTICS

I10

Main

X316

F35

FUSE DIAGNOSTICS

C4

Main/Engine

X335

MAIN/ENGINE INTERFACE

K33

CAN Network

80

PAD

LLMI

SPU
VCI

CAN A
CAN B

ECU RC2-2/20

80-02-M209EN

ECM ADM2

ECM MR2

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A15

DIAGRAM 3
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

A12

X45

26

F2

F14

X99
X115

X308
X41
X99

F35
X58

F31

F34

K
X109

RC

RC1

(08/10/2012)

S
CHASSIS GND
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

80-02-M209EN

80

RC2-2

A16

ELECTRICAL SCHEMATIC DIAGRAMS

4 LIGHTING/SIGNALING
MLT 845-120 H Series 4-E3

Electrical connectors
Item

Main

M3

X14

HORN GROUND

G40

V5

DIODE POSITION LIGHT / WORKING LIGHTS

G31

Cab

P09

P09

ROOF WINDSCREEN WIPER MOTOR

Q8

V6

DIODE

E34
Q40

Harness type

80

Electrical components

Name of
component

Position on
diagram

Designation

Hydraulic code
equivalence

Item

Designation

Position on diagram

Cab

P10

P10

REAR WINDSCREEN WIPER MOTOR

Q10

X13

FRONT RIGHT HEADLIGHT

Cab

P12A

P12A

HEATING

O16

X14

HORN

G40

Cab

P12B

P12B

HEATING

O17

X16

REAR RIGHT HEADLIGHT

Q33

Main/Electric plate

X04

E7

X17

REAR RIGHT HEADLIGHT

Q28

Main

X13

X13

FRONT RIGHT HEADLIGHT

Q40

X18

REAR LICENSE PLATE LIGHT

O33

Main

X14

X14

HORN

G40

X20

REVERSING SOUND ALARM (OPTION)

O29

Main

X16

X16

REAR RIGHT HEADLIGHT

Q33

X30

HEATING FAN SWITCH

I24

Main

X17

X17

REAR RIGHT HEADLIGHT

Q27

X74

FRONT LEFT HEADLIGHT

Q35

Main

X19

REAR TRAILER CONNECTOR (OPTION)

K29

X77

FRONT WINDSCREEN WIPER MOTOR

Q20

Main

X20

REVERSING SOUND ALARM (OPTION)

O29

X79

FRONT WINDSCREEN WIPER SWITCH

M24

MAIN/CAB INTERFACE

M9

X149

REAR AND ROOF WINDSCREEN WIPER SWITCH

K24

HEATING FAN SWITCH

I24

X150

REVOLVING LIGHT SWITCH

G4

ELECTRIC PLATE

X20

Main/Cab

X26

Main

X30

Main/Electric plate

X39

ELECTRIC PLATE

G33

X151

FRONT AND REAR WORKING LIGHT SWITCH

K4

Main/Electric plate

X41

ELECTRIC PLATE

E40

X152

WORKING LIGHT SWITCH ON BOOM (OPTION)

E24

Main/Electric plate

X45

Main

X70

Main
Main

X30

Hydraulic code
equivalence

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A4

X187

WARNING SWITCH

E31

M3

WINDSCREEN WASHER PUMP

Q23

X188

LIGHT COMMUTATOR SWITCH

A34

X73

S16

BRAKE CIRCUIT PRESSURE SWITCH

O26

X210

LEFT SIDE WORKING LIGHT

C23

X74

X74

FRONT LEFT HEADLIGHT

Q35

X211

RIGHT SIDE WORKING LIGHT

C21

Main

X77

X77

FRONT WINDSCREEN WIPER MOTOR

Q20

Main

X79

X79

FRONT WINDSCREEN WIPER SWITCH

M24

Main

X149

X149

REAR AND ROOF WINDSCREEN WIPER SWITCH

K24

Main

X150

X150

REVOLVING LIGHT SWITCH

G4

Main

X151

X151

FRONT AND REAR WORKING LIGHT SWITCH

K4

Item

Main

X154

V5

DIODE POSITION LIGHT / WORKING LIGHTS

G30

F3

10A

HORN + STOP LIGHT

C19

X155

V5

DIODE POSITION LIGHT / WORKING LIGHTS

G32

F5

7,5A

LEFT INDICATOR LIGHTS

E37

Electric plate

X188

X188

LIGHT COMMUTATOR SWITCH

C36

F6

7,5A

RIGHT SIDELIGHT

E34

Main/Electric plate

X308

ELECTRIC PLATE

E18

F7

7,5A

LEFT SIDELIGHT

E33

Main

X329

WORKING LIGHTS FUSE

C4

F8

7,5A

ROTATING LIGHT

C9

Main

X330

WORKING LIGHT ON BOOM (OPTION)

E4

F9

15A

REAR WORKING LIGHTS

C9

F10

15A

FRONT WORKING LIGHTS

C10

F16

10A

WARNING INDICATOR LIGHTS

C17

F17

10A

FRONT WINDSCREEN WIPER

C18

F18

15A

MAIN BEAM HEADLIGHTS

E36

F19

7,5A

RIGHT INDICATOR LIGHTS

E37

F20

15A

DIPPED BEAM HEADLIGHTS

E35

F21

15A

DIGICODE + ROOF LIGHT + WARNING

C7

F22

25A

LIGHT COMMUTATOR SWITCH

C7

F23

15A

REAR WINDSCREEN WIPER + ROOF WINDSCREEN WIPER

C11

F24

15A

HEATING + AIR CONDITIONING

C12

F33

15A

WORKING LIGHTS

C4

F33

Fuses and relays

Electrical components
Item

Designation

Position on diagram

K6

FLASHING/WARNING UNIT

C31

M3

WINDSCREEN WASHER PUMP

Q24

P06

ROTATING LIGHT

O7

P07

FRONT LEFT WORKING LIGHTS

Q15

P08

REAR LEFT WORKING LIGHTS

Q16

P09

ROOF WINDSCREEN WIPER MOTOR

Q8

P10

REAR WINDSCREEN WIPER MOTOR

Q10

P12A

HEATING

O16

P12B

HEATING

O17

P14

REAR RIGHT WORKING LIGHTS

Q19

P15

FRONT RIGHT WORKING LIGHTS

Q18

P16

CEILING LIGHT

Q13

S16

BRAKE CIRCUIT PRESSURE SWITCH

O27

80-02-M209EN

Hydraulic code
equivalence

Current

Designation

Position on diagram

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A17

DIAGRAM 4
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

X188
X45

X211
F21 F22

F8

F9

F10

F23

F24

F16

F17

X210

F3

K6

C
X188

F33
V6

X04
X308

X152

X187

F7

F6

F20

F18

F19

F5
X14

V5

X39

G
CHASSIS GND (M3)

X150
X30

X151
X19

X149

M
X26

X79
X20

S16

X20

P12A

X18

P12B

X74

P09

X77

P10

P07

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

P09

(08/10/2012)

P10

CABIN CHASSIS GND

P16

P15
P08

M3

X17

X13

X16

X74
P14

X77

X17

X13

X16

CHASSIS GND

S
GND

P06

80-02-M209EN

80

A18

ELECTRICAL SCHEMATIC DIAGRAMS

5 HYDRAULIC MOVEMENT
MLT 845-120 H Series 4-E3

Electrical connectors
Name of
component

Designation

Electrical components
Position on
diagram

Hydraulic code
equivalence

Harness type

Item

Main/Electric plate

X04

S29

COMPENSATION PRESSURE SWITCH

Distributor

X23

Y14

HYDRAULIC CUT-OFF ELECTROVALVE/VS

Q17

S30

COMPENSATION PRESSURE SWITCH

M7

Distributor

X28

Y8

TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE

Q27

X33

MOVEMENT NEUTRALISATION SWITCH

C22

ELECTRIC PLATE

E7

Item

Designation

Position on diagram
I7

Distributor

X29

Y9

TELESCOPE EXTENSION PROPORTIONAL ELECTROVALVE

Q30

X100

BOOM ANGLE SENSOR

G19

Main

X33

X33

MOVEMENT NEUTRALISATION SWITCH

C22

X117

ATTACHMENT LOCKING SWITCH

C26

Distributor

X34

Y7

PROPORTIONAL ELECTROVALVE ATTACHMENT (S1)

Q23

X119

OVERRIDE SWITCH

C17

Distributor

X35

Y6

PROPORTIONAL ELECTROVALVE ATTACHMENT (S2)

Q25

X134

RETRACTED BOOM SENSOR

K19

Main/Electric plate

X41

ELECTRIC PLATE

C12

Y4

COMPENSATION ELECTROVALVE (BASE)

Q8

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A5

Y5

COMPENSATION ELECTROVALVE (HEAD)

Q6

Main

X56

SPU

SPU MODULE

A38

Y6

PROPORTIONAL ELECTROVALVE ATTACHMENT (S2)

Q26

Main

X57

SPU

SPU MODULE

E38

Y7

PROPORTIONAL ELECTROVALVE ATTACHMENT (S1)

Q23

Main/Distributor

X87

MAIN/DISTRIBUTOR INTERFACE

K31

Y8

TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE

Q28

Distributor

X92

Y15

BOOM LOWERING PROPORTIONAL ELECTROVALVE

Q20

Y9

TELESCOPE EXTENSION PROPORTIONAL ELECTROVALVE

Q30

Distributor

X93

Y16

TILTING CUT-OFF ELECTROVALVE/VCI

Q14

Y14

HYDRAULIC CUT-OFF ELECTROVALVE/VS

Q17

Main

X100

X100

BOOM ANGLE SENSOR

G17

Y15

BOOM LOWERING PROPORTIONAL ELECTROVALVE

Q20

Main

X104

Y30

LSU PUMP ELECTROVALVE

Q38

Y16

TILTING CUT-OFF ELECTROVALVE/VCI

Q15

Distributor

X105

DISTRIBUTOR HARNESS GROUND

S30

Y30

LSU PUMP ELECTROVALVE

Q38

Main

X117

X117

ATTACHMENT LOCKING SWITCH

C26

SPU

SPU MODULE

A40

Main

X119

X119

OVERRIDE SWITCH

C17
K17

Main

X134

X134

RETRACTED BOOM SENSOR

X240

S29

COMPENSATION PRESSURE SWITCH

I7

X241

S30

COMPENSATION PRESSURE SWITCH

M7

X242

Y4

COMPENSATION ELECTROVALVE (BASE)

O7

Item

X243

Y5

COMPENSATION ELECTROVALVE (HEAD)

O5

F11

10A

SUSPENSION ELECTROVALVE + BRAKE PRESSURE

C7

OPTIONAL CONNECTOR

G7

F14

15A

DIGICODE + SENSORS

A12

X320
X117/A

X117

ATTACHMENT LOCKING SWITCH

C29

X117/B

X117

ATTACHMENT LOCKING SWITCH

E29

Fuses and relays

Current

Designation

Position on diagram

80

Main

Hydraulic code
equivalence

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A19

DIAGRAM 5
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

X45

38

39

1
2
3

toward (TAB.06)

42

41

SPU

X56
toward (TAB.01)

40

+12V (APC)
ATTACHEMENT (S1)
BOOM HEAD VALVE GND

4
5

F14

6
7

toward (TAB.03)

F11

SAFETY VALVE GROUD

BOOM LOWERING VALVE GROUD
MICRO RELAIS SUPLY
ANALOG SENSOR ANGLE 2

9
10

toward (TAB.06)

11

12

toward (TAB.02)
toward (TAB.01)

13
14

X41

X119

X33

15

toward (TAB.02)

X117

16
17

toward (TAB.02)
toward (TAB.02)

X04

18

EASY CONNECT SYSTEM

MOVENTS FORCING

ROLLER 1
IN TIMER ECU +12V APC
ATTACHEMENT (S2)
TRANSMISION CUT
HYDRAULIC MOVENTS INHIBITION
SEAT MICROSWITCH (NO)
JSM ROLLER 1

19
20

toward (TAB.01&03)
toward (TAB.03)
toward (TAB.06)
toward (TAB.02)
toward (TAB.01)

21
22
23

GROUD
+12Vdc
OIL FLOW CONTINUOUS
PARKING BRAKE INFO

24
25
26

toward (TAB.01&03)

ANALOG SENSOR ANGLE 1

GROUD

X57
toward (TAB.03)
toward (TAB.03)
toward (TAB.01)
toward (TAB.01)

1
2
3
4
5
6

X100

X100

toward (TAB.01)
toward (TAB.01)

8
9

CAN H
CAN L
SPU +APC
SPU +APC
EV. SENS+ TELECOPE
BOOM LOWERING PROP. VALVE
SAFETY VALVE

+12V APC
+12V APC

10
11

toward (TAB.02)
toward (TAB.06)
toward (TAB.02)

12
13
14
15

toward (TAB.02)
toward (TAB.02)

16
17

BP1 ev TDF
ANALOG INPUT OIL FLOW CONTINUOUS
GEAR INFO
ANALOG SENSOR (N.O.) BOOM RETRACTION
JSM ROLLER 2
TRANSMISSION CUT

18
19

S29

toward (TAB.01)

20

ATTACHM. LOCK

FAN PROP. VALVE

21

toward (TAB.02)

22
23

toward (TAB.02)
toward (TAB.01)

X134

24
25

GEAR INFO
ANALOG SENSOR (N.F.) BOOM RETRACTION
ROLLER 2
FAN PROP. VALVE

26

X87

27

toward (TAB.03)

28
29

toward (TAB.01)

30
31

32

toward (TAB.06)
toward (TAB.01&03)

33
34

CAN GND
TELECOPIC BOOM PROP. OUT
FAN INVERSION
ANALOG SENSORS GND

VCI VALVE
OIL FLOW CONTINUOUS SIGN. LAMP
GROUD

S30
M

Y5

Y4
Y16

Y14

Y15

Y7

Y6

Y8

Y9

(08/10/2012)

HYDRAULIC
DISTRIBUTOR GND (X105)

CHASSIS GND

S
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

Y30

80-02-M209EN

80

X134

A20

ELECTRICAL SCHEMATIC DIAGRAMS

6 OPTIONS
MLT 845-120 H Series 4-E3

Electrical connectors
Harness type

Item

Name of
component

P01
P06

B1

Cab

P12A

P12A

Cab

P12B

P12B

P13

B2,

Main/Electric plate

Main/Cab

X04

Designation

Electrical components
Position on
diagram

Hydraulic code
equivalence

Item

Designation

Position on diagram

LOUDSPEAKER HARNESS ON CAR RADIO

E15

B1,

LEFT LOUDSPEAKER

G15

B2,

RIGHT LOUDSPEAKER

G17

HEATING

Q23

G1

ALTERNATOR

Q14

HEATING

Q25

M11

AIR CONDITIONING PUMP

Q26

RIGHT LOUDSPEAKER

G17

M12

PNEUMATIC SEAT COMPRESSOR

ELECTRIC PLATE

LEFT LOUDSPEAKER

G15

I8

E23 - C25

P11

AIR CONDITIONING THERMOSTAT

Q21

I3

P12A

HEATING

Q23

X05

K23

BOOM HEAD ELECTROVALVE RELAY

X11

M12

PNEUMATIC SEAT COMPRESSOR

G8

P12B

HEATING

Q25

MAIN/CAB INTERFACE

O20

S28

PRESSURE SWITCH

G32

X26
X26

M11

AIR-CONDITIONING COMPRESSOR

Q27

S29,

PRESSURE SWITCH

I32

Main

X30

X30

HEATING FAN SWITCH

I24

S31

PRESSURE SWITCH

E32

Main/Electric plate

X41

ELECTRIC PLATE

E12

S44

BOOM PRESSURE SWITCH

E35

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A4

S47

OIL THERMOSTAT

Q11

Main

X56

SPU

SPU MODULE

E6 - K15

S51

TELESCOPE HEAD ELECTROVALVE REEL

Main

X57

SPU

SPU MODULE

I11 - I15 - M15

V1

DIODE

K4
M38

Main

X97

K23

BOOM HEAD ELECTROVALVE RELAY

G5

X30

HEATING FAN SWITCH

I26

Main

X112

X112

PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP

K14

X112

PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP

K16

Main

X113

X113

CONTINUE FLOW POTENTIOMETER

I14

X113

CONTINUE FLOW POTENTIOMETER

I15

Main

X116

X116

EASY CONNECT SYSTEM (ECS) (NF)

O9

X116

EASY CONNECT SYSTEM (ECS) (NF)

Q8

AIR CONDITIONING MODULE

M29

X157

OIL FAN

Q17
Q28

X205

80

X206

Hydraulic code
equivalence

AIR CONDITIONING MODULE

O27

X208

AIR-CONDITIONING FAN

X208

X208

AIR-CONDITIONING FAN

O28

X209

AIR-CONDITIONING FAN

Q30

X209

X209

AIR-CONDITIONING FAN

O29

X221

BOOM SUSPENSION TIME DELAY RELAY

M40

X215

K22

OIL FAN RELAY

Q15

X222

TELESCOPE SUSPENSION SWITCH

C31

X221

X221

BOOM SUSPENSION TIME DELAY RELAY

M39

X224

AIR CONDITIONING PUMP PRESSURE SWITCH

M25

X223

Y20

LEFT 2 BOOM SUSPENSION ELECTROVALVE

O34

X248

ANGULAR SWITCH

C33

X224

Y22

RIGHT 2 BOOM SUSPENSION ELECTROVALVE

O32

Y13

BOOM HEAD ELECTROVALVE

M4

X224

X224

AIR CONDITIONING PUMP PRESSURE SWITCH

M24

Y19

LEFT LIFTING ELECTROVALVE S1

Q38

X225

S28

PRESSURE SWITCH

G31

Y20

LEFT LIFTING ELECTROVALVE S2

Q34

X226

S29

COMPENSATION PRESSURE SWITCH

I31

Y21

RIGHT LIFTING ELECTROVALVE S1

Q36

X227

K19

BOOM SUSPENSION CUT-OFF RELAY

K38

Y22

RIGHT LIFTING ELECTROVALVE S1

Q33

X228

K20

BOOM SUSPENSION RELAY

G38

X229

V1

DIODE

M38

X232

V2

DIODE

G34

X239

S47

OIL THERMOSTAT

O12

X245

Y19

LEFT 1 BOOM SUSPENSION ELECTROVALVE

O38

F1

10A

PNEUMATIC SEAT

C9

X246

Y21

RIGHT 1 BOOM SUSPENSION ELECTROVALVE

O36

F11

10A

SUSPENSION ELECTROVALVE + BRAKE PRESSURE

C25

X247

S31

PRESSURE SWITCH

E31

F14

10A

DIGICODE + SENSORS

C12

X248

X248

ANGULAR SWITCH

C33

F24

15A

HEATING + AIR CONDITIONING

C23

X249

S44

BOOM PRESSURE SWITCH

E34

F27

10A

BOOM HEAD ELECTROVALVE

E9

F45,

30A

THERMAL FUSE

O16
M28

Fuses and relays

Item

Current

Designation

Position on diagram

E4

Main/Electric plate

X308

ELECTRIC PLATE

Electric plate

X318

ELECTRIC PLATE GROUND CONNECTOR

G18

F46

THERMAL FUSE

Main

X320

OPTIONAL CONNECTOR

E25

K19

BOOM SUSPENSION CUT-OFF RELAY

K39

Main/Electric plate

X331

SEAT COMPRESSOR CONNECTOR

G9

K20

BOOM SUSPENSION RELAY

G39

Main

X338

HEAD TELESCOPE ELECTROVALVE FUSE

E5

K22

OIL FAN RELAY

Q17

K23

BOOM HEAD ELECTROVALVE RELAY

80-02-M209EN

F27

I5

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

A21

DIAGRAM 6
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

42

41

A
X45

X222

F11

X248

X248
F1

F14

F24

X04

F27
E

X308

S31

X41
P01

P01

P06

P13

S44

X97

K20

S28

X11

B1

B2

K23
M12
I

X113

S51

S29

X113

X30
K19

X112

X112
K

Y13

V1

X224

X205
X221
CONDITIONING
MODULE

F45
X206

X116

K22

S47

P11
X208
P12A

X209

Y22

Y20

Y21

Y19

P12B
M11

G1

(08/10/2012)

X157

CABIN CHASSIS GND

Q
CABIN CHASSIS GND

ENGINE GND

S
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

CHASSIS GND

80-02-M209EN

80

F46

ELECTRICAL SCHEMATIC DIAGRAMS

80

A22

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B1

MLT 845-120 SERIES 5-E3

pages

POSITION OF CONNECTORS ON DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2

ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B7
1 START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
2 TRANSMISSION AND SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10
3 CAN BUS AND DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
4 LIGHTING/SIGNALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14
5 HYDRAULIC MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B16

80

6 OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B18

(08/10/2012)

80-02-M209EN

B2

ELECTRICAL SCHEMATIC DIAGRAMS

MLT 845-120 Series 5-E3

POSITION OF CONNECTORS ON DIAGRAMS

Connectors

Diag. 1

Diag. 2

Diag. 3

ADM2-12

ADM2-15

ADM2-21

F40

F41

F42

F43

F44

F45

G1

KA

KN

M1

Diag. 5

P01

P06

P09

P10

P12A

P12B

P13

80

Diag. 6

M3
MR2

Diag. 4

RC

XTP

X5

X6

X7

X8

X01

X02

X04

X05

X08

X09

X10

X11

X12

X13

X14

X15
X15

X16

X17

X19

X20

X21

X23
X24
X26
X26

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B3

MLT 845-120 Series 5-E3

Connectors

Diag. 1

Diag. 2

Diag. 3

Diag. 4

X28

Diag. 5

Diag. 6

X29

X30

X33

X34

X35

X36

X39

X41

X45

X46
X47

X48

X50

X51

X52

X54

X55

X56

X57

X58

X61

X68

X70

X71

X72

X73

X74

X77

X79

X87

X92

X93

X97

X98

X99

X100

X104

X104/A

X105

X109

X109/A

X109/B

X112

X113
X114
X115

X116
X117/A

(08/10/2012)

80

X89

80-02-M209EN

B4

ELECTRICAL SCHEMATIC DIAGRAMS

MLT 845-120 Series 5-E3

Connectors

Diag. 1

Diag. 2

Diag. 3

X118

X118.S

Diag. 4

X117/B

X118S

X119

X134

X149

X150

X151

X154

X155

X165

X188

80

X193

Diag. 6

X118P

X121

Diag. 5

X205

X206

X208

X209

X215

X221

X223

X224

X224

X225

X226

X227

X228

X229

X232

X238

X239

X240

X241

X242

X243

X245

X246

X247

X248

X249

X300
X308

X310
X311

X315

X316

X317

X318

X319

X320

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B5

MLT 845-120 Series 5-E3

Connectors

Diag. 1

Diag. 2

X322

X323

X325

X326

X327
X328

Diag. 3

Diag. 4

Diag. 5

Diag. 6

X329

X330

X331

X332

X333

X334

X335

X335P

X335S

X336

X337

X338

X355A

X355B

X356A

X356B

X502

X503

X504

X505

X506

80

X501

(08/10/2012)

80-02-M209EN

B6

ELECTRICAL SCHEMATIC DIAGRAMS

80

MLT 845-120 Series 5-E3

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B7

MLT 845-120 Series 5-E3

ELECTRICAL DIAGRAMS
1 START-UP
Electrical connectors
Harness type

Item

Name of
component

Engine

ADM2-12

ADM2

ADM2 MODULE (CAB)

Engine

ADM2-15

ADM2

ADM2 MODULE (CAB)

E32

Engine

ADM2-21

ADM2

ADM2 MODULE (CAB)

G32

Engine

F40

F40

FUSE KEY SWITCH

E13

Engine

F41

F41

FUSE KEY SWITCH

E12

Engine

F42

F42

DIAGNOSTIC PLUG MR2-PLD

E11

Engine

F43

F43

ADM2 MODULE (CAB)

E10

Engine

F44

F44

ADM2 MODULE (CAB)

E9

Engine

F45

F45

STARTER

E8

Engine

G1

G1

ALTERNATOR

A5

Engine

KA

KA

MERCEDES STARTING RELAY

C7

Position on
diagram
A32

Engine

KN

KN

NEUTRAL SAFETY RELAY

E39

Engine

MR2

MR2

MR2-PLD MODULE (ENGINE)

A26

Engine

M1

M1

STARTER

Engine

RC

Engine

XTP

Engine

X5

Engine

X6

X6A

Engine

X7

KC + FC1
S5

XTP

C8

NOT USED

O38

ACCELERATOR POTENTIOMETER

M36

DIAGNOSTIC PLUG MR2-PLD

E26

DIESEL DECONGEALANT HEATING ELEMENT

E15

AIR HEATING (OPTION)

E18

Engine

X8

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

G38

Engine/Casappa

X15

ENGINE/CASAPPA INTERFACE

M38

Main/Engine

X24

MAIN/ENGINE INTERFACE

O7

Main/Electric plate

X41

ELECTRIC PLATE

O28

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

K18

Main

X47

F25

ANTI-START FUSE

O25

Main

X54

KEY

KEY SWITCH

M8

Main

X55

KEY

KEY SWITCH

M8

Main

X56

SPU

SPU MODULE

O21

Main

X57

SPU

SPU MODULE

O21 - O37

Main

X114

S52

EMERGENCY STOP

O19

Main

X118

DIGICODE CONNECTOR

O30

Main

X118.S

DIGICODE CONNECTOR

Q32

Main/Engine

X121

MAIN/ENGINE INTERFACE

K37

Main

X193

OPTIONAL CONNECTOR

Main/Electric plate

X308

ELECTRIC PLATE

Main/Electric plate

X311

Main

X317

Electric plate

X318

Main

X328

Main

X332

Main

X333

Main
Main
Main/ Fan

X502

Fan

X503

X503

Fan

X504

Fan
Fan
(08/10/2012)

Q27
O25 - O28

REVERSE GEAR SHUTTLE CONNECTOR

Q23

INDICATOR LAMP FAULT + SPU

O16

ELECTRIC PLATE GROUND CONNECTOR

O23

F36

SPU FUSE

O18

H16

INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP

O13

H10

AIR HEATING INDICATOR LAMP

O14

X334

H15

ENGINE FAULT INDICATOR LAMP

O15

X501

X501

FAN SWITCH

O36

MAIN/FAN INTERFACE

Q36

FAN THERMOSTAT

Q36

X504

FAN THERMOSTAT

Q34

X505

X505

PROPORTIONAL ELECTROVALVE FAN

S38

X506

X506

FAN REVERSAL ELECTROVALVE (OPTION)

S39

F30

Hydraulic
equivalence code

80

Designation

80-02-M209EN

B8

ELECTRICAL SCHEMATIC DIAGRAMS

MLT 845-120 Series 5-E3

Electrical components
Item
ADM2

Designation

Position on diagram

ADM2 MODULE (CAB)

A34

B1

12V BATTERY

A15

B2

12V BATTERY (OPTION)

A16

EH

AIR HEATING (OPTION)

E20

G1

ALTERNATOR

A6

H10

AIR HEATING INDICATOR LAMP

Q14

H15

ENGINE FAULT INDICATOR LAMP

Q15

H16

INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP

Q13

KEY

KEY SWITCH

M8

M1

STARTER

A8

MR2

MR2-PLD MODULE (ENGINE)

A27

S5

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

G36

S46

BATTERY CUT-OFF

A13

S52

EMERGENCY STOP

O18

XTP

ACCELERATOR POTENTIOMETER

K37

X6A

DIESEL DECONGEALANT HEATING ELEMENT

E16

X501

FAN SWITCH

O36

X503

TRANSMISSION OIL TEMPERATURE SENSOR

Q35

X504

HYDRAULIC OIL TEMPERATURE SENSOR

Q34

X505

PROPORTIONAL ELECTROVALVE FAN

S38

X506

FAN REVERSAL ELECTROVALVE (OPTION)

S40

Hydraulic code
equivalence

80

Fuses and relays

Item

Current

F4

15A

FAN + DIAGNOSTICS + DIESEL FUEL THINNING FILTER

O28

F14

15A

DIGICODE + SENSORS

O27

F21

15A

DIGICODE + ROOF LIGHT + WARNING

O26

F25

25A

ANTI-START

O25

F30

10A

FAULT INDICATOR LAMP + SPU

O16

F36

10A

SPU

O18

F40

70A

KEY SWITCH

E13

F41

70A

KEY SWITCH

E12

F42

7,5A

DIAGNOSTIC PLUG MR2-PLD

E11

F43

10A

ADM2 MODULE (CAB)

E10

F44

15A

ADM2 MODULE (CAB)

E9

F45

30A

STARTER

FC

225A

AIR HEATING (OPTION)

FC1

7,5A

AIR HEATING - ADM2 INFORMATION (OPTION)

C19

FG

125A

MASTER POWER SWITCH

C13

K4

ANTI-START RELAY

O24

KA

MERCEDES STARTING RELAY

C7

KC

AIR HEATING RELAY (OPTION)

C20

KN

NEUTRAL SAFETY RELAY

E39

80-02-M209EN

Designation

Position on diagram

E8
A20

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B9

DIAGRAM 1
1

10

11

12

13

14

G1

15

16

B1

M1

17

18

19

20

21

22

23

24

25

FC

B2

26

27

MR2

MR2

28

29

30

31

32

33

ADM-12

34

35

36

37

38

39

40

41

42

ADM2

S46

G1

KC

M1

FG

C
ADM-15

KA

FC1
ENGINE GND

EH
X5

CHASSIS GND

F45

F44

F43

F42

F41

X7

F40

ENGINE GND

KN
X6A

X6

ADM-21

S5

X121

XTP

KEY
X54-X55

X15

X45

F25
F30
O

F36

RC

F21

F14

F4
X501

S52

K4

STOP

H16

H10

H15

X193

X118

X118.S

X504

X503

(08/10/2012)

X506

X24
CHASSIS GND

CHASSIS GND

GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

X505

80-02-M209EN

80

XTP

B10

ELECTRICAL SCHEMATIC DIAGRAMS

2 TRANSMISSION AND SENSORS

MLT 845-120 Series 5-E3

80

Electrical connectors

Electrical components

Harness type

Item

Name of
component

Engine

ADM2-12

ADM2

ADM2 MODULE (CAB)

K7

H11

Engine

ADM2-15

ADM2

ADM2 MODULE (CAB)

K7

H14

REAR WHEEL ALIGNMENT LIGHT

M3

Main

X8

S5

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

O9

S4

BRAKE LIQUID LEVEL CONTACT

O11

Main

X01

X01

GEAR LEVER

M34

S5

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

O9

Main

X02

X02

SEAT SWITCH (NO)

O28

S12

TRANSMISSION OIL PRESSURE SWITCH

O12

Main/Electric plate

X04

C6

S17

TRANSMISSION OIL TEMPERATURE SENSOR

Q14

Main

X08

S17

TRANSMISSION OIL THERMOSWITCH

O13

S37

HAND BRAKE PRESSURE SWITCH

Q17

Main

X09

Y2

FORWARD GEAR ELECTROVALVE

Q33

S48

BRAKE CIRCUIT PRESSURE SWITCH

G3

Main

X10

Y3

REVERSE GEAR ELECTROVALVE

Q35

D4

DIODE - SAFETY RELAY/REVERSE GEAR

K37

Main

X12

S37

HAND BRAKE PRESSURE SWITCH

Q17

D5

DIODE - SAFETY RELAY/FORWARD GEAR

K36

Main

X15

X15.

FRONT WHEEL ALIGNMENT SENSOR

O4

X01

GEAR LEVER

M34

X21

Designation

ELECTRIC PLATE

Main

X21

Main/Engine

X24

Main

X36

Main/Electric plate

X41

Main/Electric plate

X45

Main

X46

K8

Main

X50

Main

X36

Position on
diagram

Hydraulic code
equivalence

Item

Designation

Position on diagram

FRONT WHEEL ALIGNMENT LIGHT

M5

REAR WHEEL ALIGNMENT SENSOR

O3

X02

SEAT SWITCH (NO)

O28

MAIN/ENGINE INTERFACE

K10

X15.

FRONT WHEEL ALIGNMENT SENSOR

O5

JSM (JOYSTICK SWITCH AND MOVE)

G29

X21

REAR WHEEL ALIGNMENT SENSOR

O4

E23 - I9

X36

JSM (JOYSTICK SWITCH AND MOVE)

G29

ELECTRIC PLATE
ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

Hydraulic code
equivalence

A4

X52

WHEEL ALIGNMENT SWITCH

NEUTRAL SAFETY RELAY

M38

X61

TRANSMISSION CUT-OFF SWITCH

M31

H11

FRONT WHEEL ALIGNMENT LIGHT

M5

X68

HOUR METRE / FUEL LEVEL

G21

X51

H14

REAR WHEEL ALIGNMENT LIGHT

M3

X71

BRAKE PEDAL SWITCH

K29

Main

X52

X52

WHEEL ALIGNMENT SWITCH

Q6

X165

FUEL LEVEL SENSOR

I21

Main

X56

SPU

SPU MODULE

I24 - M26

X323

HAND BRAKE SWITCH

M19

Main

X57

SPU

SPU MODULE

I24 - M26

Y2

FORWARD GEAR ELECTROVALVE

Q33

Main

X61

X61

TRANSMISSION CUT-OFF SWITCH

M31

Y3

REVERSE GEAR ELECTROVALVE

Q35

Main

X68

X68

HOUR METRE / FUEL LEVEL

I21

Y18

HAND BRAKE ELECTROVALVE

Q23

Main

X71

X71

BRAKE PEDAL SWITCH

K29

Main

X72

S48

BRAKE LIQUID LEVEL CONTACT

O11

Main

X89

Main

X98

Main

Q6

COOLANT LIQUID TEMPERATURE INDICATOR

I18

TRANSMISSION OIL PRESSURE SWITCH

O12

X118

DIGICODE CONNECTOR

G23

Main/Engine

X121

MAIN/ENGINE INTERFACE

K10

F2

5A

ECU + WHEEL ALIGNMENT + DIAGNOSTICS

Main

X165

X165

FUEL LEVEL SENSOR

I21

F11

10A

SUSPENSION ELECTROVALVE + BRAKE PRESSURE

C7

X238

S48

BRAKE CIRCUIT PRESSURE SWITCH

E4

F12

7,5A

PARKING BRAKE

C8

Main

X300

K18

HAND BRAKE RELAY

Q19

F13

15A

FNR TRANSMISSION

C22

Main/Electric plate

X308

ELECTRIC PLATE

G8

F15

5A

INSTRUMENTS + INDICATORS

C9

X310

NOT USED

G37

K0

NC TRANSMISSION CUT-OFF RELAY

C30

Main/Electric plate

X311

REVERSE GEAR SHUTTLE CONNECTOR

G36

K1

RELAY (NOT USED)

C26

Electric plate

X318

ELECTRIC PLATE GROUND CONNECTOR

A37

K2

FORWARD GEAR RELAY

C33

Main/Electric plate

X319

BRAKE CIRCUIT CONNECTOR

I6

K3

REVERSE GEAR RELAY

C37

Main

X320

OPTIONAL CONNECTOR

E7

K5

TRANSMISSION PRESSURE RELAY

C21

X322

NOT USED

G37

K8

NEUTRAL SAFETY RELAY

M40
O21

S12

Fuses and relays

Item

Current

Designation

Main

X323

X323

HAND BRAKE SWITCH

M19

K18

HAND BRAKE RELAY

Main

X325

D4 - D5

DIODE CONNECTOR

K37

K21

BRAKE CIRCUIT RELAY

Main

X326

D4 - D5

DIODE CONNECTOR

K37

Main

X327

Y18

HAND BRAKE ELECTROVALVE

Q23

Main

X118.S

DIGICODE CONNECTOR

G23

X355A

PARKING BRAKE CONNECTOR SWITCH/X41

M17

80-02-M209EN

X355B

CONNECTOR X41/PARKING BRAKE SWITCH

M17

X356A

CONNECTOR PARKING BRAKE SWITCH/SPU

M16

X356B

SPU CONNECTOR/PARKING BRAKE SWITCH

M16

Position on diagram
C8

E7

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B11

DIAGRAM 2
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

A
X45

F11

F2

K5

F12 F15

F13

K1

K0

K2

K3

X41

K21

X36

S48

X311

X68

X308

X36

CHASSIS GND

X89
X68

X165
X41
X121
X326

D5

X71

D4

X01

K8
H14

H11

X323
X46

X02

X21

X21

X15

S12
K18

X15
S5
X52

S4
S17

S37

X300

Y18

Y2

Y3

(08/10/2012)

S
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

CHASSIS GND

80-02-M209EN

80

X61

X24

B12

ELECTRICAL SCHEMATIC DIAGRAMS

3 CAN BUS AND DIAGNOSTICS

MLT 845-120 Series 5-E3

Electrical connectors

Electrical components

Harness type

Item

Name of
component

Engine

ADM2-12

ADM2

ADM2 MODULE (CAB)

O5

A12

LONGITUDINAL SECURITY MODULE

A25

Engine

ADM2-21

ADM2

ADM2 MODULE (CAB)

I39

X99

STRAIN GAUGE

A22

Engine

MR2

MR2

MR2-PLD MODULE (ENGINE)

O5

Designation

Position on
diagram

Hydraulic code
equivalence

Item

Engine

RC

NOT USED

I39

Engine/Casappa

X15

ENGINE/CASAPPA INTERFACE

I35

Main/Engine

X24

MAIN/ENGINE INTERFACE

O9

Main/Electric plate

X41

ELECTRIC PLATE

C11

Item

Designation

Hydraulic code
equivalence

Position on diagram

Fuses and relays

Current

Designation

Position on diagram

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A5

F2

5A

ECU + WHEEL ALIGNMENT + DIAGNOSTICS

A8

Main

X48

F31

REXROTH ECU FUSE

G9

F14

15A

DIGICODE + SENSORS

A11

Main

X56

SPU

SPU MODULE

K19

F31

5A

REXROTH ECU

G9

Main

X57

SPU

SPU MODULE

K19

F34

5A

DIAGNOSTICS + CASAPPA

G10

Main

X58

A12

LONGITUDINAL SECURITY MODULE

E27

F35

5A

DIAGNOSTICS

C4

Main

X99

X99

STRAIN GAUGE

C23

Main

X104

OPTION

M6

Main

X109

Casappa A

X109/A

CASAPPA

OPTION

Casappa B

X109/B

CASAPPA

Main

X115

I5

CASAPPA ELECTRONICS CONTROL UNIT

O27

CASAPPA ELECTRONICS CONTROL UNIT

M27

OBD CONNECTOR DIAGNOSTICS

C18

Main

X118

DIGICODE CONNECTOR

M28

Main/Casappa A

X118P

DIGICODE INTERFACE

M28

Main/Casappa A

X118S

DIGICODE INTERFACE

M30

Main/Engine

X121

MAIN/ENGINE INTERFACE

Q30

Main/Electric plate

X308

ELECTRIC PLATE

C8

Main

X315

F34

DIAGNOSTICS FUSE + CASAPPA

G10

F35

FUSE DIAGNOSTICS

C4

MAIN/CASAPPA INTERFACE

I32

Main

X316

Main/Casappa A

X335

Main/Casappa A

X335P

MAIN/CASAPPA CONNECTOR

I35

Engine/Casappa A

X335S

ENGINE CONNECTOR/CASAPPA

I32

CAN Network

PAD

LLMI

80

SPU
VCI

CAN A
CAN B

ECU PP LSU

80-02-M209EN

ECM ADM2

ECM MR2

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B13

DIAGRAM 3
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

A12

X45

25

F2

F14

X99
X115

X308

F35

X41
X99
X58

F31

F34
X335 X335S

X109

X335P X15

M
X109/A

X109/B

(08/10/2012)

S
CHASSIS GND
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

80-02-M209EN

80

RC

B14

ELECTRICAL SCHEMATIC DIAGRAMS

4 LIGHTING/SIGNALING
MLT 845-120 Series 5-E3

Electrical connectors
Item

Main

M3

X14

HORN GROUND

G40

P16

CEILING LIGHT

Q13

Cab

P09

P09

ROOF WINDSCREEN WIPER MOTOR

Q8

S16

BRAKE CIRCUIT PRESSURE SWITCH

O27
G31

Harness type

Position on
diagram

Designation

Hydraulic code
equivalence

Item

Designation

Position on diagram

Hydraulic code
equivalence

Cab

P10

P10

REAR WINDSCREEN WIPER MOTOR

Q10

V5

DIODE

Cab

P12A

P12A

HEATING

O16

V6

DIODE

E34

Cab

P12B

P12B

HEATING

O17

V7

DIODE

M29

Main/Electric plate

X04

E7

X13

FRONT RIGHT HEADLIGHT

Q40

Main

X13

X13

FRONT RIGHT HEADLIGHT

Q40

X14

HORN

G40

Main

X14

X14

HORN

G40

X16

REAR RIGHT HEADLIGHT

Q33

Main

X16

X16

REAR RIGHT HEADLIGHT

Q33

X17

REAR RIGHT HEADLIGHT

Q28

Main

X17

X17

REAR RIGHT HEADLIGHT

Q28

X18

REAR LICENSE PLATE LIGHT

O33

Main

X19

REAR TRAILER CONNECTOR

K29

X20

REVERSING SOUND ALARM (OPTION)

O30

Main

X20

REVERSING SOUND ALARM (OPTION)

O30

X30

HEATING FAN SWITCH

I24

Main/Cab

X26

MAIN/CAB INTERFACE

M9

X74

FRONT LEFT HEADLIGHT

Q35

Main

X30

HEATING FAN SWITCH

I24

X77

FRONT WINDSCREEN WIPER MOTOR

Q20

Main/Electric plate

X39

ELECTRIC PLATE

G33

X79

FRONT WINDSCREEN WIPER SWITCH

M24

Main/Electric plate

X41

ELECTRIC PLATE

E40 - K31

X149

REAR AND ROOF WINDSCREEN WIPER SWITCH

K24

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A4

X150

REVOLVING LIGHT SWITCH

G4

Main

X70

M3

WINDSCREEN WASHER PUMP

Q23

X151

FRONT AND REAR WORKING LIGHT SWITCH

K4

Main

X73

S16

BRAKE CIRCUIT PRESSURE SWITCH

O26

X152

TELESCOPE WORKING LIGHT SWITCH (OPTION)

E24

Main

X74

X74

FRONT LEFT HEADLIGHT

Q35

X187

WARNING SWITCH

E30

Main

X77

X77

FRONT WINDSCREEN WIPER MOTOR

Q20

X188

LIGHT COMMUTATOR SWITCH

C36

Main

X79

X79

FRONT WINDSCREEN WIPER SWITCH

M24

X210

LEFT SIDE WORKING LIGHT

C23

Main

X149

X149

REAR AND ROOF WINDSCREEN WIPER SWITCH

K24

X211

RIGHT SIDE WORKING LIGHT

C21

Main

X150

X150

REVOLVING LIGHT SWITCH

G4

Main

X151

X151

Main

X154

V5

DIODE

G30

X155

V5

DIODE

G32

X188

X188

LIGHT COMMUTATOR SWITCH

C36

Item

ELECTRIC PLATE

E18

F3

10A

HORN + STOP LIGHT

C19

F33

WORKING LIGHTS FUSE

C4

F5

7,5A

LEFT INDICATOR LIGHTS

E38

WORKING LIGHT ON BOOM (OPTION)

E4

F6

7,5A

RIGHT SIDELIGHT

E34

Cab

80

Electrical components

Name of
component

ELECTRIC PLATE

X20
X30

FRONT AND REAR WORKING LIGHT SWITCH

K4
Fuses and relays
Current

Designation

Position on diagram

Main/Electric plate

X308

Main

X329

Main

X330

Main

X336

V7

DIODE

M30

F7

7,5A

LEFT SIDELIGHT

E33

Main

X337

V7

DIODE

M28

F8

7,5A

ROTATING LIGHT

C9

Electrical components
Item

Designation

Position on diagram

K6

FLASHING/WARNING UNIT

C31

M3

WINDSCREEN WASHER PUMP

Q24

P06

ROTATING LIGHT

O7

P07

FRONT LEFT WORKING LIGHTS

Q15

P08

REAR LEFT WORKING LIGHTS

Q16

P09

ROOF WINDSCREEN WIPER MOTOR

Q8

P10

REAR WINDSCREEN WIPER MOTOR

Q10

P12A

HEATING

O16

P12B

HEATING

O17

P14

REAR RIGHT WORKING LIGHTS

Q19

P15

FRONT RIGHT WORKING LIGHTS

Q17

80-02-M209EN

Hydraulic code
equivalence

F9

15A

REAR WORKING LIGHTS

C10

F10

15A

FRONT WORKING LIGHTS

C10

F16

10A

WARNING INDICATOR LIGHTS

C17

F17

10A

FRONT WINDSCREEN WIPER

C18

F18

15A

MAIN BEAM HEADLIGHTS

E36

F19

7,5A

RIGHT INDICATOR LIGHTS

E37

F20

15A

DIPPED BEAM HEADLIGHTS

E35

F21

15A

DIGICODE + ROOF LIGHT + WARNING

C7

F22

25A

LIGHT COMMUTATOR SWITCH

C8

F23

15A

REAR WINDSCREEN WIPER + ROOF WINDSCREEN WIPER

C11

F24

15A

HEATING + AIR CONDITIONING

C12

F33

15A

WORKING LIGHTS

C4

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B15

DIAGRAM 4
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

X188
X45

X211
F21 F22

F8

F9

F10

F23

F24

F16

F17

X210

F3

K6

C
X188

F33
V6

X04
X308

X152

X187

F7

F6

F20

F18

F19

F5
X14

V5

X39

G
CHASSIS GND (M3)

X150
X30

X151
X19

X149

V7

X26

X79
X20

S16

X20

P12A

X18

P12B

X74

P09

X77

P10

P07

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

P09

(08/10/2012)

P10

CABIN CHASSIS GND

P16

P15
P08

M3

X17

X13

X16

X74
P14

X77

X17

X13

X16

CHASSIS GND

S
GND

P06

80-02-M209EN

80

B16

ELECTRICAL SCHEMATIC DIAGRAMS

5 HYDRAULIC MOVEMENT
MLT 845-120 Series 5-E3

Electrical connectors
Name of
component

Designation

Electrical components
Position on
diagram

Hydraulic code
equivalence

Harness type

Item

Main/Electric plate

X04

E7

SPU

SPU MODULE

Distributor

X23

Y14

HYDRAULIC CUT-OFF ELECTROVALVE/VS

Q17

S29

COMPENSATION PRESSURE SWITCH

I7

Distributor

X28

Y8

TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE

Q28

S30

COMPENSATION PRESSURE SWITCH

M7

ELECTRIC PLATE

Item

Designation

Position on diagram
A40

Distributor

X29

Y9

TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE

Q30

X33

MOVEMENT NEUTRALISATION SWITCH

C22

Main

X33

X33

MOVEMENT NEUTRALISATION SWITCH

C22

X100

BOOM ANGLE SENSOR

G17

Distributor

X34

Y7

PROPORTIONAL ELECTROVALVE ATTACHMENT (S1)

Q23

X117

ATTACHMENT LOCKING SWITCH

C26

Distributor

X35

Y6

PROPORTIONAL ELECTROVALVE ATTACHMENT (S2)

Q26

X119

OVERRIDE SWITCH

C17

Main/Electric plate

X41

ELECTRIC PLATE

C12

X134

RETRACTED BOOM SENSOR

K17

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A5

Y4

COMPENSATION ELECTROVALVE (BASE)

Q8

Main

X56

SPU

SPU MODULE

A38

Y5

COMPENSATION ELECTROVALVE (HEAD)

Q6

Main

X57

SPU

SPU MODULE

E38

Y6

PROPORTIONAL ELECTROVALVE ATTACHMENT (S2)

Q26

Main/Distributor

X87

MAIN/DISTRIBUTOR INTERFACE

K31

Y7

PROPORTIONAL ELECTROVALVE ATTACHMENT (S1)

Q23

Distributor

X92

Y15

BOOM LOWERING PROPORTIONAL ELECTROVALVE

Q20

Y8

TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE

Q28

Distributor

X93

Y16

TILTING CUT-OFF ELECTROVALVE/VCI

Q15

Y9

TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE

Q30

Main

X100

X100

BOOM ANGLE SENSOR

G17

Y14

HYDRAULIC CUT-OFF ELECTROVALVE/VS

Q17

Distributor

X105

DISTRIBUTOR HARNESS GROUND

S30

Y15

BOOM LOWERING PROPORTIONAL ELECTROVALVE

Q20

Main

X119

X119

OVERRIDE SWITCH

C17

Y16

TILTING CUT-OFF ELECTROVALVE/VCI

Q15

Main

X134

X134

RETRACTED BOOM SENSOR

K17

Y30

LSU PUMP ELECTROVALVE

Q37

X240

S29

COMPENSATION PRESSURE SWITCH

I7

X241

S30

COMPENSATION PRESSURE SWITCH

M7

X242

Y4

COMPENSATION ELECTROVALVE (BASE)

O7

X243

Y5

COMPENSATION ELECTROVALVE (HEAD)

O5

OPTIONAL CONNECTOR

G7

Item

Main

X320

Casappa B

X104/A

Y30

Casappa B

X109/B

CASAPPA

Main

X117/A

Main

X117/B

Hydraulic code
equivalence

Fuses and relays

Current

Designation

Position on diagram

Q37

F11

10A

SUSPENSION ELECTROVALVE + BRAKE PRESSURE

C7

O38

F14

15A

DIGICODE + SENSORS

A12

X117

ATTACHMENT LOCKING SWITCH

C29

X117

ATTACHMENT LOCKING SWITCH

E29

80

LSU PUMP ELECTROVALVE

CASAPPA ELECTRONICS CONTROL UNIT

80-02-M209EN

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B17

DIAGRAM 5
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

X45

38

39

1
2
3

toward (TAB.06)

42

41

SPU

X56
toward (TAB.01)

40

+12V (APC)
ATTACHEMENT (S1)
BOOM HEAD VALVE GND

4
5

F14

6
7

toward (TAB.03)

F11

SAFETY VALVE GROUD

BOOM LOWERING VALVE GROUD
MICRO RELAIS SUPLY
ANALOG SENSOR ANGLE 2

9
10

toward (TAB.06)

11

12

toward (TAB.02)
toward (TAB.01)

13
14

X41

X119

X33

15

toward (TAB.02)

X117

16
17

toward (TAB.02)
toward (TAB.02)

X04

18

EASY CONNECT SYSTEM

MOVENTS FORCING

ROLLER 1
IN TIMER ECU +12V APC
ATTACHEMENT (S2)
TRANSMISION CUT
HYDRAULIC MOVENTS INHIBITION
SEAT MICROSWITCH (NO)
JSM ROLLER 1

19
20

toward (TAB.01&03)
toward (TAB.03)
toward (TAB.06)
toward (TAB.02)
toward (TAB.01)

21
22
23

GROUD
+12Vdc
OIL FLOW CONTINUOUS
PARKING BRAKE INFO

24
25
26

toward (TAB.01&03)

ANALOG SENSOR ANGLE 1

GROUD

X57
toward (TAB.03)
toward (TAB.03)
toward (TAB.01)
toward (TAB.01)

1
2
3
4
5
6

X100

X100

toward (TAB.01)
toward (TAB.01)

8
9

CAN H
CAN L
SPU +APC
SPU +APC
EV. SENS+ TELECOPE
BOOM LOWERING PROP. VALVE
SAFETY VALVE

+12V APC
+12V APC

10
11

toward (TAB.02)
toward (TAB.06)
toward (TAB.02)

12
13
14
15

toward (TAB.02)
toward (TAB.02)

16
17

BP1 ev TDF
ANALOG INPUT OIL FLOW CONTINUOUS
GEAR INFO
ANALOG SENSOR (N.O.) BOOM RETRACTION
JSM ROLLER 2
TRANSMISSION CUT

18
19

S29

toward (TAB.01)

20

ATTACHM. LOCK

FAN PROP. VALVE

21

toward (TAB.02)

22
23

toward (TAB.02)
toward (TAB.01)

X134

24
25

GEAR INFO
ANALOG SENSOR (N.F.) BOOM RETRACTION
ROLLER 2
FAN PROP. VALVE

26

X87

27

toward (TAB.03)

28
29

toward (TAB.01)

30
31

32

toward (TAB.06)
toward (TAB.01&03)

33
34

CAN GND
TELECOPIC BOOM PROP. OUT
FAN INVERSION
ANALOG SENSORS GND

VCI VALVE
OIL FLOW CONTINUOUS SIGN. LAMP
GROUD

S30
M

Y5

Y4
Y16

Y14

Y15

Y7

Y6

Y8

Y9
Q

(08/10/2012)

HYDRAULIC
DISTRIBUTOR GND (X105)

CHASSIS GND

S
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

Y30

80-02-M209EN

80

X134

B18

ELECTRICAL SCHEMATIC DIAGRAMS

6 OPTIONS
MLT 845-120 Series 5-E3

Electrical connectors
Harness type

Item

Name of
component

P01

Main/Electric plate

Main

Designation

Electrical components
Position on
diagram

Hydraulic code
equivalence

Item

Designation

Position on diagram

LOUDSPEAKER HARNESS ON CAR RADIO

E15

B1

LEFT LOUDSPEAKER

P06

B1

LEFT LOUDSPEAKER

G15

B2

RIGHT LOUDSPEAKER

G17

P13

B2

RIGHT LOUDSPEAKER

G17

G1

ALTERNATOR

Q14

P12A

P12A

HEATING

Q23

M11

AIR CONDITIONING PUMP

Q26

P12B

P12B

HEATING

Q25

M12

PNEUMATIC SEAT COMPRESSOR

X04

ELECTRIC PLATE

G15

I8

E23 - C25

P11

AIR CONDITIONING THERMOSTAT

Q21

I3

P12A

HEATING

Q23

X05

K23

BOOM HEAD ELECTROVALVE RELAY

X11

M12

PNEUMATIC SEAT COMPRESSOR

G8

P12B

HEATING

Q25

ELECTRICAL CAB CONNECTOR

O20

S28

PRESSURE SWITCH

G32

X26
X26

M11

AIR CONDITIONING PUMP

Q27

S29

PRESSURE SWITCH

I32

Main

X30

X30

HEATING FAN SWITCH

I24

S31

PRESSURE SWITCH

E32

Main/Electric plate

X41

ELECTRIC PLATE

E12

S44

BOOM PRESSURE SWITCH

E35

Main/Electric plate

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

A4

S47

OIL THERMOSTAT

Q11

Main

X56

SPU

SPU MODULE

E6 - K15

S51

TELESCOPE HEAD ELECTROVALVE REEL

Main

X57

SPU

SPU MODULE

I11 - I15 - M15

V1

DIODE

K4
M38

Main

X97

K23

BOOM HEAD ELECTROVALVE RELAY

G5

X30

HEATING FAN SWITCH

I26

Main

X112

X112

PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP

K14

X112

PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP

K16

Main

X113

X113

CONTINUE FLOW POTENTIOMETER

I14

X113

CONTINUE FLOW POTENTIOMETER

I15

Main

X116

X116

EASY CONNECT SYSTEM (ECS) (NF)

O9

X116

EASY CONNECT SYSTEM (ECS) (NF)

Q8

AIR CONDITIONING MODULE

M29

X157

OIL FAN

Q17
Q28

X205

80

X206

Hydraulic code
equivalence

AIR CONDITIONING MODULE

O27

X208

AIR-CONDITIONING FAN

X208

X208

AIR-CONDITIONING FAN

O28

X209

AIR-CONDITIONING FAN

Q30

X209

X209

AIR-CONDITIONING FAN

O29

X221

BOOM SUSPENSION TIME DELAY RELAY

M40

X215

K22

OIL FAN RELAY

Q15

X222

TELESCOPE SUSPENSION SWITCH

C31

X221

X221

BOOM SUSPENSION TIME DELAY RELAY

M39

X224

AIR CONDITIONING PUMP PRESSURE SWITCH

M25

X223

Y20

LEFT 2 BOOM SUSPENSION ELECTROVALVE

O34

X248

ANGULAR SWITCH

C33

X224

X224

AIR CONDITIONING PUMP PRESSURE SWITCH

M24

Y13

BOOM HEAD ELECTROVALVE

M4

X224

Y22

RIGHT 2 BOOM SUSPENSION ELECTROVALVE

O32

Y19

LEFT 1 BOOM SUSPENSION ELECTROVALVE

Q38

X225

S28

PRESSURE SWITCH

G31

Y20

LEFT 2 BOOM SUSPENSION ELECTROVALVE

Q34

X226

S29

COMPENSATION PRESSURE SWITCH

I31

Y21

RIGHT 1 BOOM SUSPENSION ELECTROVALVE

Q36

X227

K19

BOOM SUSPENSION CUT-OFF RELAY

K38

Y22

RIGHT 2 BOOM SUSPENSION ELECTROVALVE

Q33

X228

K20

BOOM SUSPENSION RELAY

G38

X229

V1

DIODE

M38

X232

V2

DIODE

G34

X239

S47

OIL THERMOSTAT

O12

X245

Y19

LEFT 1 BOOM SUSPENSION ELECTROVALVE

O38

F1

10A

PNEUMATIC SEAT

C9

X246

Y21

RIGHT 1 BOOM SUSPENSION ELECTROVALVE

O36

F11

10A

SUSPENSION ELECTROVALVE + BRAKE PRESSURE

C25

X247

S31

PRESSURE SWITCH

E31

F14

10A

DIGICODE + SENSORS

C12

X248

X248

ANGULAR SWITCH

C33

F24

15A

HEATING + AIR CONDITIONING

C23

X249

S44

BOOM PRESSURE SWITCH

E34

F27

10A

BOOM HEAD ELECTROVALVE

E4

E9

K19

BOOM SUSPENSION CUT-OFF RELAY

K38

Fuses and relays

Item

Current

Designation

Position on diagram

Main/Electric plate

X308

ELECTRIC PLATE

Electric plate

X318

ELECTRIC PLATE GROUND CONNECTOR

G18

K20

BOOM SUSPENSION RELAY

G38

Main

X320

OPTIONAL CONNECTOR

E25

K22

OIL FAN RELAY

Q17

SEAT COMPRESSOR CONNECTOR

G9

K23

HEAD TELESCOPE ELECTROVALVE FUSE

E5

F45

Main/Electric plate

X331

Main

X338

F27

F46

80-02-M209EN

BOOM HEAD ELECTROVALVE RELAY

30A

I5

THERMAL FUSE

O16

THERMAL FUSE

M28

(08/10/2012)

ELECTRICAL SCHEMATIC DIAGRAMS

B19

DIAGRAM 6
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

42

41

A
X45

X222

F11

X248

X248
F1

F14

F24

X04

F27
E

X308

S31

X41
P01

P01

P06

P13

S44

X97

K20

S28

X11

B1

B2

K23
M12
I

X113

S51

S29

X113

X30
K19

X112

X112
K

Y13

V1

X224

X205
X221
CONDITIONING
MODULE

F45
X206

X116

K22

S47

P11
X208
P12A

X209

Y22

Y20

Y21

Y19

P12B
M11

G1

(08/10/2012)

X157

CABIN CHASSIS GND

Q
CABIN CHASSIS GND

ENGINE GND

S
GND

ING KEY 15

ING KEY 15

ING KEY 30

BATTEY 30

CHASSIS GND

80-02-M209EN

80

F46

ELECTRICAL SCHEMATIC DIAGRAMS

80

B20

80-02-M209EN

(08/10/2012)

ELECTRICAL COMPONENTS LOCATION

pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ELECTRIC FUSE PLATE AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
CAB HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
ENGINE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

80

CONTROL VALVE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(15/11/2012)

80-03-M209EN

ELECTRICAL COMPONENTS LOCATION

KEY
CONNECTORS
Position on harness diagram

80

Item

DESIGNATION

Harness Electric
assembly plate

(A)

DASHBOARD INDICATOR LAMPS

E36

(B)

DASHBOARD INDICATOR LAMPS

E37

Q14

(C)

WARNING SWITCH

E37

Q11

(D)

CAR RADIO

E40

S12

(E)

ADAPTATION TUV

E38

S7

(F)

REAR ELECTRIC SOCKET

Cab Main Engine Distributor

Comments

Q14

I5

ADM2-12

ADM2 MODULE (CAB)

G36

S33

ADM2-15

ADM2 MODULE (CAB)

G25

Q33

ADM2-21

ADM2 MODULE (CAB)

G27

M33

F40

FUSE KEY SWITCH

A35

A36

F41

FUSE KEY SWITCH

A35

C36

F42

DIAGNOSTIC PLUG MR2-PLD

A38

I34

F43

ADM2 MODULE (CAB)

A38

I34

F44

ADM2 MODULE (CAB)

A37

I34

F45

STARTER

A37

I34

G1

ALTERNATOR

Q17

E5

KA

MERCEDES STARTING RELAY

A36

G36

KN

NEUTRAL SAFETY RELAY

A36

E36

M1

STARTER

O17

E9

MR2

MR2-PLD MODULE (ENGINE)

Q21

O12E

RC

NOT USED

A35

P01

LOUDSPEAKER HARNESS ON CAR RADIO

E39

A2

P02

CAB/MAIN INTERFACE

K27

E2

P05

LEFT LOUDSPEAKER

G16

A12

P06

ROTATING LIGHT

G15

I12

P07

FRONT LEFT WORKING LIGHT

G27

A15

P08

REAR LEFT WORKING LIGHT

G16

I15

P09

ROOF WINDSCREEN WIPER MOTOR

G21

K7

P10

REAR WINDSCREEN WIPER MOTOR

I14

S7

P11

AIR CONDITIONING THERMOSTAT

K19

S15

P12

HEATING

K18

K18

P13

RIGHT LOUDSPEAKER

K16

K12

P14

REAR RIGHT WORKING LIGHT

K7

S12

P15

FRONT RIGHT WORKING LIGHT

I24

K16

P16

CEILING LIGHT

I19

S16

XTP

ACCELERATOR POTENTIOMETER

M25

E28

X5

DIAGNOSTIC PLUG MR2-PLD

A35

O28

X6

DIESEL DECONGEALANT HEATING ELEMENT

M25

Q14

X7

AIR HEATING (OPTION)

O17

G5

X8

ENGINE AIR FILTER CLOGGING PRESSURE SWITCH

O17

E11

X01

GEAR LEVER

K26

I31

X02

SEAT SWITCH (NO)

G17

I15

X04

ELECTRIC PLATE

A39

X08

TRANSMISSION OIL THERMOSWITCH

K24

A24

X09

FORWARD GEAR ELECTROVALVE

K23

A22

X10

REVERSE GEAR ELECTROVALVE

M23

A21

X12

HAND BRAKE PRESSURE SWITCH

M32

E34

X13

FRONT RIGHT HEADLIGHT

Q30

A35

X14

HORN

M32

E18

80-03-M209EN

Fan

O24

I11

(Not H)

S17
(Not H)

(15/11/2012)

ELECTRICAL COMPONENTS LOCATION

Position on harness diagram

Item

DESIGNATION

Harness Electric
assembly plate

Cab Main Engine Distributor

X15

FRONT WHEEL ALIGNMENT SENSOR

M32

X15

ENGINE/MAIN INTERFACE

M25

X16

REAR RIGHT HEADLIGHT

Q5

X17

REAR RIGHT HEADLIGHT

G5

C15

X19

REAR TRAILER CONNECTOR (OPTION)

I26

Q37

X20

REVERSING SOUND ALARM (OPTION)

K2

C17

X21

REAR WHEEL ALIGNMENT SENSOR

K10

C19

X22

HYDRAULIC OIL FILTER

I24

A40

X23

HYDRAULIC CUT-OFF ELECTROVALVE/VS

K23

X24

MAIN/ENGINE INTERFACE

M25

A29

X26

MAIN/CAB INTERFACE

I27

I18

X28

TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE

K23

I6

X29

TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE

K23

I8

X30

HEATING FAN SWITCH

E37

K10

X33

MOVEMENT NEUTRALISATION SWITCH

E40

I2

X34

PROPORTIONAL ELECTROVALVE ATTACHMENT (S1)

K22

K12

X35

PROPORTIONAL ELECTROVALVE ATTACHMENT (S2)

K22

M15

X36

JSM (JOYSTICK SWITCH AND MOVE)

I21

X39

ELECTRIC PLATE

A38

I8

K38

X41

ELECTRIC PLATE

A39

G15

S26

X45

ELECTRIC PLATE POWER SUPPLY (KEY SWITCH)

C41

Q13

I36

X46

NEUTRAL SAFETY RELAY

C41

S31

X47

ANTI-START FUSE

A36

I33

X48

ECU FUSE

I17

C3

X50

FRONT WHEEL ALIGNMENT LIGHT

E33

S12

X51

REAR WHEEL ALIGNMENT LIGHT

E33

S11

X52

WHEEL ALIGNMENT SWITCH

E33

S10

X54

KEY SWITCH

E38

S8

X55

KEY SWITCH

E38

S9

X56

SPU MODULE

I15

E7

X57

SPU MODULE

I15

E8

X58

LONGITUDINAL SECURITY MODULE

E41

S16

X61

TRANSMISSION CUT-OFF SWITCH

E39

K2

X68

HOUR METRE / FUEL LEVEL

C38

O41

X70

WINDSCREEN WASHER PUMP

I25

A39

X71

BRAKE PEDAL SWITCH

G25

S19

X72

BRAKE LIQUID LEVEL CONTACT

G25

S22

X73

BRAKE CIRCUIT PRESSURE SWITCH

G25

S21

X74

FRONT LEFT HEADLIGHT

G30

A34

X77

FRONT WINDSCREEN-WIPER MOTOR

I28

S7

X79

FRONT WINDSCREEN WIPER SWITCH

E38

K10

X87

MAIN/DISTRIBUTOR INTERFACE

K24

S24

X89

COOLANT LIQUID TEMPERATURE INDICATOR

C34

I25

X92

BOOM LOWERING PROPORTIONAL ELECTROVALVE

K21

K10

X93

TILTING CUT-OFF ELECTROVALVE/VCI

K23

E5

X97

HEAD TELESCOPE ELECTROVALVE RELAY (OPTION)

I25

K20

X98

TRANSMISSION OIL PRESSURE SWITCH

K22

A23

(15/11/2012)

Fan

Comments

E35
E24
C13

(H)
M14
E20

80

I20

(Not H)

G15

(Not H)
80-03-M209EN

ELECTRICAL COMPONENTS LOCATION

Position on harness diagram

Item

Harness Electric
assembly plate

Fan

Comments

STRAIN GAUGE

X100

BOOM ANGLE SENSOR

M2

C11

X104

LSU ELECTROVALVE PUMP (OPTION)

K18

G15

LSU PUMP ELECTROVALVE

K18

MODULE RC2-2

K15

G4

(H)

NOT USED (OPTION)

K15

G4

(Not H)

X109/A

CASAPPA ELECTRONICS CONTROL UNIT

K15

(Not H)

X109/B

CASAPPA ELECTRONICS CONTROL UNIT

K15

(Not H)

X112

PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP

E32

X113

CONTINUE FLOW POTENTIOMETER

E32

I27

X114

EMERGENCY STOP

G38

K40

X115

OBD CONNECTOR DIAGNOSTICS

I15

G22

X116

EASY CONNECT SYSTEM (ECS) (NF)

I32

E31

X117

ATTACHMENT LOCKING SWITCH (OPTION)

E38

M2

X118

DIGICODE CONNECTOR

I25

I22

X119

OVERRIDE SWITCH

E40

M2

X121

MAIN/ENGINE INTERFACE

K17

A3

X134

RETRACTED BOOM SENSOR

M3

C10

X149

REAR AND ROOF WINDSCREEN WIPER SWITCH

E39

M10

X150

REVOLVING LIGHT SWITCH

E39

M10

X151

FRONT AND REAR WORKING LIGHT SWITCH

C39

I9

X154

DIODE POSITION LIGHT / WORKING LIGHTS

I27

I17

X165

FUEL LEVEL SENSOR

K23

C37

X188

LIGHT COMMUTATOR SWITCH

E36

X193

OPTIONAL CONNECTOR

I27

I16

X300

HAND BRAKE RELAY

C41

S30

X301

SNAIL SPEED

A40

I28

(H)

X302

SLOW SPEED

A40

I29

(H)

X303

REVERSE GEAR RELAY

A40

I30

(H)

X304

SLOW SPEED SWITCH

E33

Q14

(H)

X305

FAST / SLOW SPEED SWITCH

E32

Q14

(H)

X306

SLOW SPEED

E32

Q14

(H)

X307

FAST SPEED

E32

S14

(H)

X308

ELECTRIC PLATE

A37

X309

ACCELERATOR PEDAL SWITCH

C39

S29

(H)

X310

REVERSE GEAR INFORMATION

A41

I30

(H)

X311

REVERSE GEAR SHUTTLE CONNECTOR

A35

X312

SNAIL SPEED ELECTROVALVE

M22

C26

(H)

X313

REVERSE GEAR ELECTROVALVE

M22

C26

(H)

X314

FAST SPEED ELECTROVALVE

M22

C26

(H)

X315

FUSE DIAGNOSTICS

I17

C3

X316

FUSE DIAGNOSTICS

I17

C3

X317

INDICATOR LAMP FAULT + SPU

I17

X318

ELECTRIC PLATE GROUND CONNECTOR

C41

Q13

I37

X319

BRAKE CIRCUIT CONNECTOR

A38

G6

Q39

X320

CONNECTOR (OPTION)

A39

S17

X321

NOT USED (OPTION)

C39

S27

(H)

X322

NEUTRAL SWITCH INFORMATION (OPTION)

C39

S28

(H)

X323

HAND BRAKE SWITCH

E39

K2

X324

NOT USED (OPTION)

C39

I9

X109

80-03-M209EN

O9

Cab Main Engine Distributor

X99

X104/A

80

DESIGNATION

E4

(Not H)

I26

K33

S10

I4

Q8

Q40

I21

A7

(15/11/2012)

ELECTRICAL COMPONENTS LOCATION

Position on harness diagram

Position on harness diagram

Item

DESIGNATION

Harness Electric
assembly plate

Cab Main Engine Distributor

Fan

Comments

Item

Current

DESIGNATION

F4

15A

FAN + DIAGNOSTICS + DIESEL FUEL THINNING FILTER

A6

Harness Electric
Cab Main Engine Distributor
assembly plate

X325

DIODE CONNECTOR

C42

S33

X326

DIODE CONNECTOR

C42

S33

X327

HAND BRAKE ELECTROVALVE

M32

E32

F5

7,5A

LEFT INDICATOR LIGHTS

A7

X328

SPU FUSE

I17

A8

F6

7,5A

RIGHT SIDELIGHT

A8

I34

F7

7,5A

LEFT SIDELIGHT

A9

I38

F8

7,5A

ROTATING LIGHT

A10

Q38

F9

15A

REAR WORKING LIGHTS

A10

15A

FRONT WORKING LIGHTS

A11

X329

WORKING LIGHTS FUSE

A36

X330

WORKING LIGHT ON BOOM (OPTION)

C41

X331

SEAT COMPRESSOR CONNECTOR

A37

G3

X332

INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP

C35

I14

F10

X333

AIR HEATING INDICATOR LAMP

E35

I13

F11

10A

SUSPENSION ELECTROVALVE + BRAKE PRESSURE

A12

7,5A

PARKING BRAKE

A13

X334

ENGINE FAULT INDICATOR LAMP

C35

I12

F12

X335

MAIN/ENGINE INTERFACE

M26

A28

F13

15A

FNR TRANSMISSION

A13

Q36

(Not H)

F14

15A

DIGICODE + SENSORS

A14

(Not H)

F15

5A

INTRUMENTS + INDICATORS

C4

X336

DIODE CONNECTOR

K26

X337

DIODE CONNECTOR

K26

Q35

X338

HEAD TELESCOPE ELECTROVALVE FUSE

A36

I35

F16

10A

WARNING INDICATOR LIGHTS

C5

K9

F17

10A

FRONT WINDSCREEN WIPER

C6

X501

FAN SWITCH (OPTION)

E36

X502

MAIN/FAN HARNESS INTERFACE

M21

I15

F18

15A

MAIN BEAM HEADLIGHTS

C7

7,5A

RIGHT INDICATOR LIGHTS

C8

Fan

Comments

X503

TRANSMISSION OIL TEMPERATURE SENSOR

Q23

G8

F19

X504

FAN THERMOSTAT

S23

M8

F20

15A

DIPPED BEAM HEADLIGHTS

C9

F21

15A

DIGICODE + ROOF LIGHT + WARNING

C10

X505

PROPORTIONAL ELECTROVALVE FAN

O26

K8

F22

25A

LIGHT COMMUTATOR SWITCH

C10

X506

FAN REVERSAL ELECTROVALVE (OPTION)

Q25

I8

F23

15A

REAR WINDSCREEN WIPER + ROOF WINDSCREEN WIPER

C11

F24

15A

HEATING + AIR CONDITIONING

C12

F25

25A

ANTI-START

I33

On X47

F27

10A

BOOM HEAD ELECTROVALVE

I36

On X338

F30

10A

FAULT INDICATOR LAMP + SPU

I32

On X317

F31

5A

REXROTH ECU

C1

On X48

F33

15A

WORKING LIGHTS

I35

On X329

F34

5A

DIAGNOSTICS

C1

On X315

GROUNDS
Position on harness diagram

FG

DESIGNATION

Harness Electric
assembly plate

ENGINE HARNESS GROUND

Cab

Main

O22

Engine Distributor

Fan

Comments

E14

F35

5A

DIAGNOSTICS

C1

On X316

E17

F36

10A

SPU

I34

On X328

70A

KEY SWITCH

A35

A36

GND

ENGINE HARNESS GROUND

O22

M1

FRONT LEFT CAB GROUND

G28

I11

F40

M2

FRONT RIGHT CAB GROUND

K28

I11

F41

70A

KEY SWITCH

A35

C36

E29

F42

7,5A

DIAGNOSTIC PLUG MR2-PLD

A38

I34

A3

F43

10A

ADM2 MODULE (CAB)

A38

I34

Q25

F44

15A

ADM2 MODULE (CAB)

A37

I34

F45

30A

STARTER

A37

I34
G38

M3
M4
M5

CHASSIS/HORN GROUND

M31

REAR CAB GROUND

I15

DISTRIBUTOR SUPPORT BRACKET GROUND

K24

P03

CAB GROUND

K28

X105

DISTRIBUTOR SUPPORT BRACKET GROUND

K24

G2
C12

FUSES AND RELAYS

Position on harness diagram
Item

Current

DESIGNATION

Harness Electric
Cab Main Engine Distributor
assembly plate

Comments

MERCEDES STARTING RELAY

A36

NEUTRAL SAFETY RELAY

A36

K0

NC TRANSMISSION CUT-OFF RELAY

E16

K1

n/a

C16

K2

FORWARD GEAR RELAY

C13

K3

REVERSE GEAR RELAY

E13

K4

ANTI-START RELAY

K5

TRANSMISSION PRESSURE RELAY

K6

FLASHING UNIT

E9

K7

BUZZER

E7

K8

NEUTRAL SAFETY RELAY

E36

E4
C16

S31

On X46

K12

SNAIL SPEED

I28

(H)
On X301

A4

K13

SLOW SPEED

I29

(H)
On X302

A5

K14

REVERSE GEAR RELAY

I30

(H)
On X303

K18

HAND BRAKE RELAY

S30

On X300

F1

10A

PNEUMATIC SEAT

A3

F2

5A

ECU + WHEEL ALIGNMENT + DIAGNOSTICS

F3

10A

HORN + STOP LIGHT

(15/11/2012)

Fan

KA
KN

80

Item

80-03-M209EN

ELECTRICAL COMPONENTS LOCATION

HARNESS ASSEMBLY

2D LOCATION
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

37

38

39

40

41

42

Electric fuse plate and relay view

Key:

RC

F40

KN

F44

F42

X5

F41

KA

F45

F43

Main harness

X320

Electric plate fuse and relay

X329

Cab harness

X47

X308

X39

X331

X319

X303

X04

X310

X302

X338
X41

X301

X311

Engine harness

X321

X300

X326

X322

X46

X325

X309

Control valve harness

X330

Fan harness

X334

X324

X332

Additional harnesses

X89

Connection between harnesses

X112

X113

X333

(A)

X150

(E)

X188

X318

X151

X68

(B)

X119
X58

X50

Connector MLT 845-120 H Series 4-E3

X305

X304

X307

Connector MLT 845-120 Series 4-E3

X30

X51
X52

X45

X501

X306

X117
(C)

X79
X54

X61

X149
X323

P01

X33

(D)

X55
P07

P08

M1
ADM2-15 ADM2-12 ADM2-21

X114
X74

P06

Dashboard view

P06

X72

X02

X73

X17

P09
X71

P09

X17
(F)

X317

M4

X22

X328

X77

X70

P16

X154

X56

X316

X118

X57

X315

X97

X115

X48

X193

P15
X36
X165

X109
P11

P13
X121
X20

M5
X92

X109/A
P14

X109/B

X34

X28

X93

X105

X35

X29

X23

X87

X19

X26

X336

P02

X116
M2

X337
P03
X01

P12

X104
X104/A

80

X21

X98

X09

X314

X10

X08

X15

X313

X335

X15

X312

M3

X335
X24

M
X134

X502

X14
X327
X12

XTP

X15

X100
X6
FG
GND
X99

M1

X7
X505
MR2
X506

X16

X8

X13

X503
G1
X504

Forward gear
80-03-M209EN

(15/11/2012)

ELECTRICAL COMPONENTS LOCATION

ELECTRIC FUSE PLATE AND RELAYS

1

F1 F2 F3

F4

F5

F3

10

F7

F8

11

12

F9 F10 F11

13

14

15

16

17

18

19

F12 F13 F14

K5
F15

F16 F17

F18

F19

F20

F21 F22 F23 F24

K4

K6

K7

K2

K1

K3

K0

X41
G

X331

X319

X308

X39

X04

K2

K4

K7

F1
5

F1

K6

F1

F1

F2

F1

F2

F1
9

F3

F2

F4

K3

F2

F5

F2

F2

F6

F2

F7

K0

F8

80

F9

K1

F1
1

F1

F1

K5

F1
4

X45
X311
D

X318

X188
X188
S

(15/11/2012)

80-03-M209EN

ELECTRICAL COMPONENTS LOCATION

CAB HARNESS
1

10

11

12

13

14

15

16

17

18

19

P07
A

P05

P01
P01

P02

P03
P06

P08

P09

P15

P12

80

P13

Key:
S

P11
P14
P10

P16

Splice
80-03-M209EN

(15/11/2012)

ELECTRICAL COMPONENTS LOCATION

MAIN HARNESS
1

F30

F36

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

X335
X10

X121

X317

X09

36

37

38

39

40

41

42

X13

X74

X24

(Non H)(Non H)
X98 X08

35

X70

X328

(H)
X22

M4
X16

X134

X17

X20

(H)
X314

X21

X100

F31

X48

F34

X315

(H)
X313

X316

(H)
X312

F35

X165

X99
E

X14
X56

X116

M3

X327

X12

X15

X57

(H)

X324

M2

X334 X333 X332

X02

X193

X154

K12

X26

X36

X311
X89

X118

X151

X33

X112

X113

K13

F25

F33

F27

X47

X329

X338

F14

(H)
(H)
(H) (H)
(Non H)
X301 X302 X303 X310 X01

X45

X318

X330

X501

X323

X30

X119

X79

X39

X114 X97

X149

X117
M

X150

X304 (H)
Q

X305 (H)
X308

X306 (H)
X87

X307 (H)

Key:
S

(H) : MLT 845-120 H Srie 4-E3

X77

X54

X55

X52

X51 X50

X58

X04 X320

X71 X71
(Non H) (H)

X73

M5

X321 X322
(H) X309
(H)
(H)

X72

X300

X46

K18

K8

X326

X325

X337 X336
(Non H) (Non H)

X68

X331 X319

00

00

X19

X41

(Non H) : MLT 845-120 Srie 5-E3

(15/11/2012)

80-03-M209EN

80

X61
(Non H)
K

M1

X104

X502

X115

X109

10

ELECTRICAL COMPONENTS LOCATION

ENGINE HARNESS
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

36

F40

F41

37

38

39

40

41

42

G1
E

KN
M1

X8

GND

FG

X24

X15

XTP
KA

X7

F45
F44
I

F43
F42

80

X121

ADM2-21
MR2
RC

X5

ADM2-15
Q

X6
ADM2-12
S

80-03-M209EN

(15/11/2012)

ELECTRICAL COMPONENTS LOCATION

11

CONTROL VALVE HARNESS

1

10

11

12

13

14

15

16

17

18

19

X105

EV

X93

X87
G

X28
I

X29

X92
K

X34
EV

80

X23
M
ACCESS. SENS +

X35

STOP

EV / VS

O
ACCESS. SENS -

(15/11/2012)

80-03-M209EN

12

ELECTRICAL COMPONENTS LOCATION

10

11

12

13

14

15

16

17

18

19

(Non H)
E

X503
(H)
G

X506
I

X502

X505

80

X504

Key:
(H) : MLT 845-120 H Srie 4-E3
S

(Non H) : MLT 845-120 Srie 5-E3

80-03-M209EN

(15/11/2012)

ELECTRICAL CONTROL AND ADJUSTMENT

pages
LONGITUDINAL STABILITY INDICATOR (LLMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE . . . . . . . . 3
CALIBRATION OF THE STRAIN GAUGE AND THE ANGLE SENSOR
(DEALER PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
RECALIBRATION OF STRAIN GAUGE (OWNER PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . 6
GENERIC REGULATION LAW EN15000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

80

LED ILLUMINATION AS A FUNCTION OF THE CHANGING GAUGE SIGNAL. . . . . . . . . 8

(26/09/2012)

80-04-M209EN

ELECTRICAL CONTROL AND ADJUSTMENT

LONGITUDINAL STABILITY INDICATOR (LLMI)

ERROR CODES
The error codes are indicated by LEDs A3 to A7 on the warning device and
longitudinal stability limiter.

A7
A6
A5
A4
A3

ERROR CODES
A7

A6

LEDS
A5 A4

DESCRIPTIONS

A3

Regulating fault (fault detected during the test).

Lowering regulating valve fault.
Safety valve cut-off fault (fault detected during the test).
Safety valve fault.
Gauge calibration fault (fault detected during the test).

Resetting the longitudinal stability limiter and warning device may resolve the problem.
(o : 3 - MAINTENANCE: G - OCCASIONAL MAINTENANCE)
Angle calibration fault (fault detected during the test).
Inclination cut-off valve fault.
Strain gauge fault.
Jib angle sensor fault.
Telescope or attachment control fault.

80

Telescope retracted senor fault.

Computer earth output fault.
Aggravating hydraulic movement cut-off disable fault.
Fan drive valve fault.
Stability indicator fault.
Electronic handling controller fault.
Hydraulic control lever control setting fault.
Transmission cut-off output fault.
Electronic handling controller supply fault.
Telescope retracted sensor fault (fault detected during the test).
Tilt cut-off valve fault (according to model)
Boom head solenoid valve fault. (OPTION)
Button fault, accessory hydraulic easy attachment (OPTION)
Electrovalve attachment hydraulic control and electrical jib provision fault button. (OPTION)
Forced operation indicator fault (OPTION)
Electric handling controller 10 V output fault.
Forced operation button fault (OPTION)
80-04-M209EN

(26/09/2012)

ELECTRICAL CONTROL AND ADJUSTMENT

TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE

These tests are essential for checking the correct operation and adjustment of the different components of the device.
Place the lift truck on fl at, level ground with the wheels straight.

Use the test button

only when instructed, following the guidance for a short press (less than 1 second)
or a long press (5 seconds).
In case of doubt during the test procedure, a clean exit can be made by a short press on the BUCKET MODE
or SUSPENDED LOAD buttons

Long press on the test button

- An audible beep.
- First green LED flashing.
- Test button lit.

STAGE 2

- Place the lift truck without any

attachment, with the jib fully
retracted and raised.
- On stabilizers if fitted.

- First green LED continuously lit.

- Second green LED flashing.
- Test button lit.

-- Lower the jib with the engine

running at full revs and the
hydraulic control at the maximum
setting. Lowering slows until
movement is cut-off.

STAGE 3

2
1

- The first and second green LEDS

continuously lit.
- The third green LED flashing.
- Test button lit.

- Lower the jib until the movement is

cut-off.
- Try in the following order a reverse
tilt, a forward tilt (dumping) and a
telescope extension. None of these 3
movements should be possible.

- The fault indicator

- Press the button

STAGE 4

- The fault warning light remains

permanently on until the error is
repaired.

TEST NOT OK
- Two audible beeps and lighting of
the fault warning light
- Exit test mode.
- Go to stage 4.

Short
press
the test
button.

TEST OK
- One audible beep and progresses to
stage 2.

TEST OK
- One audible beep and progresses to
stage 3.
TEST NOT OK
- Two audible beeps and lighting of
the fault warning light
- Exit test mode.
- Go to stage 4.

Short
press
the test
button.

TEST OK
- Conformity of aggravating
movement cut-off.
- Exit test mode. All the LEDs will light
for 2 seconds and an audible beep
will be sounded.
TEST NOT OK
- Fault warning light comes on
- Exit test mode.
- Go to stage 4.

and a beep indicate a fault.

briefly to view the error code.

- If there are several error codes, press the button

briefly several times to loop through
the error codes.
NOTE: A defective fuse can generate several error codes. If this is the case, check the fuses (see: 2 DESCRIPTION: 11 - FUSES AND RELAYS IN THE CAB)
Should there be the error code shown
A7
opposite, adjusting the longitudinal
stability limiter and warning device
A6
may solve the problem (see: 3 A4
MAINTENANCE: G - OCCASIONAL
MAINTENANCE).
A3
- Consult your dealer, specifying the error codes(s).
NOTE: For the stage 3 test, specify the non-conforming aggravating hydraulic movements, if
necessary.

(26/09/2012)

80-04-M209EN

80

STAGE 1

Short
press
the test
button.

ELECTRICAL CONTROL AND ADJUSTMENT

CALIBRATION OF THE STRAIN GAUGE AND THE ANGLE SENSOR (DEALER

PROCEDURE)
Stability limit
light

Overload
indicator

Error light

BUCKET mode
switch
SUSPENDED
LOAD mode
indicator

Test button

Machine position: flat ground, wheels pointing forward, parking brake on, safe area.
RECORDING MINIMUM ANGLE:
- Press the PARACHUTE switch (activated for the next 10 seconds).
STAGE - Before the end of the 10 seconds press at the same time the SUSPENDED LOAD and TEST buttons.
1

- Completely retract and lower the boom.

- Press the TEST button (short press) to record stage 1.

RECORDING THE MAXIMUM ANGLE + MAXIMUM GAUGE STRAIN:

STAGE
- Completely raise and retract the boom, without accessories. (If applicable use the ground stabilizers)
2

80

- Press the TEST button (short press) to record stage 2.

MEASURING THE TIME OF DESCENT FROM MAXIMUM TO MINIMUM ANGLE:

STAGE
- Lower the boom to its stop with the engine running at maximum revolutions (boom retracted).
3
- Press the TEST button (short press) to record stage 3.

STAGE
4

- Ensure that the boom is below 4 (boom retracted).

- Press the TEST button (short press) to record stage 4.

80-04-M209EN

(26/09/2012)

ELECTRICAL CONTROL AND ADJUSTMENT

RECORDING MINIMUM GAUGE STRAIN:

- Activate the PARACHUTE switch to enable hydraulic movements.

STAGE
5

The boom must be below 4.

- Extend the boom until the rear wheels leave the ground.
Wait several seconds for the machine to stabilize.
- Press the TEST button (short press) to record stage 5.

After this calibration, check that movement cut-offs work correctly.

80

(26/09/2012)

80-04-M209EN

ELECTRICAL CONTROL AND ADJUSTMENT

RECALIBRATION OF STRAIN GAUGE (OWNER PROCEDURE)

According to the use the telehandler is put to, the strain gauge may require to be periodically reset.
This operation can be carried out by the operator. The procedure is described below. Only the gauge is calibrated.
Main conditions:
Have a load at equal to at least half the machines maximum capacity.
The rear axle temperature must be below 50C. If this temperature is exceeded the operator must not carry out the procedure.
The procedure must be carried out on flat ground with all wheels facing the front.

Simultaneously press and hold down

STAGE 1
START

the BUCKET MODE

- Without attachments.
- Jib fully retracted and raised.
- On stabilizers if fitted.

STAGE 2

- An audible beep.
- First green LED flashing.
- Flashing test button.

and TEST

. buttons

- Two audible beeps will be sounded and all the LEDs will flash twice to confirm the start of the procedure.

- Without attachments.
- Stabilizers raised, if fitted.
- Carriage tilted fully backward.
- Jib fully retracted and in the down position a few centimeters off the ground.

/
- With the fork carrier or the bucket and a load (keep jib retracted to allow all other
hydraulic movements).
- Jib fully retracted and in the down position a few centimeters off the ground.

80

STAGE 3

- First green led continuously

lit.
- Second green led flashing.
- Flashing test button.

STAGE 4
FINISH

/
Keep the load as close to the ground as possible throughout this operation.

- Hold down the disable the

aggravating hydraulic movement cut-off
button (indicator lamp lit), and extend the jib until the rear wheels are off the
ground.
NOTE: This stage consists of unloading the rear axle. It can be done using a jack
but without bearing on the rear axle..

Short press
the test
button.

Short press
the test
button.

- Two audible
beeps will
be sounded
and all the
LEDs will
flash twice to
confirm the
end of the
procedure.

/
- After completing the resetting procedure, the telehandler is in an overloaded condition. Retract the
boom to restore the situation.
- All LEDs lit.
- A continuous audible beep

When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see: TESTING THE LONGITUDINAL
STABILITY LIMITER AND WARNING DEVICE (LLMC).

80-04-M209EN

(26/09/2012)

ELECTRICAL CONTROL AND ADJUSTMENT

GENERIC REGULATION LAW EN15000

Governing start

Cut-off

Vs cut-off zone

115%

Cut-off zone
95%

Regulation zone
Gauge (%)

75%

55%

Nominal zone
35%

15%

-10%

-5% 0

10

20

30

40

50

60

70

80

Angle ()

With a 20 boom angle, the regulation of dangerous movements will begin when the strain gauge shows
95% (blue line). The end of regulation for the first cut-out is reached with a gauge signal of 110% (red
line). If necessary, the VS safety valve will cut-out at a gauge signal of 120% (white line).
There are, therefore, two possible cut-outs on these machines.

Example for all other machines:

With a boom angle of 20, the regulation of dangerous movements will begin with a 90% strain gauge
signal (blue line). The end of this regulation and the VS safety valve cut-out will take effect with a 110%
gauge signal (red line).
These machines have just one cut-out.
Machine stability loss starts at a gauge signal of 130%.
The above values are indicative only. Each machine has its own, different rules.

(26/09/2012)

80-04-M209EN

80

Example for MLT LSU:

ELECTRICAL CONTROL AND ADJUSTMENT

LED ILLUMINATION AS A FUNCTION OF THE CHANGING GAUGE SIGNAL

OPERATION OF THE LLMI (LONGITUDINAL STABILITY INDICATOR)

L8
L7
L6
L5
L4
L3
L2
L1

LLMI Mode 1 algorithm

LEDs (L1 to L8)

Conditions if gauge is increasing

Conditions gauge is falling

None

None

L1+L2

Gauge >= 52%

Gauge >= 50%

L1+L2+L3

Gauge >= 60%

Gauge >= 58%

L1+L2+L3+L4

Gauge >= 68%

Gauge >= 66%

L1+L2+L3+L4+L5

Gauge >= 76%

Gauge >= 74%

L1+L2+L3+L4+L5+L6

Gauge >= 84%

Gauge >= 82%

L1+L2+L3+L4+L5+L6+L7

Gauge >= 92%

Gauge >= 90%

L1+L2+L3+L4+L5+L6+L7+L8

Gauge >= 100%

Gauge >= 98%

80

L1 (always lit)

80-04-M209EN

(26/09/2012)

ELECTRICAL COMPONENTS REFIT

pages
STRAIN GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CHARACTERISTICS OF THE AXLE SURFACE IN CONTACT WITH
THE STRAIN GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARACTERISTICS OF PRODUCTS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CHARACTERISTICS OF THE ATTACHMENT SCREWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

80

PRECAUTIONS FOR ASSEMBLY AND TIGHTENING TORQUE. . . . . . . . . . . . . . . . . . . . . . . 4

(11/10/2012)

80-07-M209EN

ELECTRICAL COMPONENTS REFIT

STRAIN GAUGE
LOCATION

80

Key :
A - Strain Gauge

PREPARATION AND SAFETY INSTRUCTIONS

The wheels should be aligned and the rear axle should be free of any strains (tipped truck).
The contact surface should be perfectly clean.
Do not apply Loctite to the screws.
Replace the gauge if it is faulty.
Gauge and axle stored at the same temperature.
Wear a mask and gloves when applying the glue.

80-07-M209EN

(11/10/2012)

ELECTRICAL COMPONENTS REFIT

CHARACTERISTICS OF THE AXLE SURFACE IN CONTACT WITH THE STRAIN GAUGE

The area in contact with the strain gauge (Item 1) has a

protective painted coating. Scrape this surface with a filling
knife in order to remove the paint film to the best extent
possible. To remove and remaining traces of adhesive use
the Soft Surface Cleaner Degreaser (aerosol).

Abrade the area to be stuck to provide a key for the glue

(Item 2).

80

CHARACTERISTICS OF PRODUCTS USED

ACROBOND PU 284/30 (two-part polyurethane structural glue): Part No 273504.
Handling time before start of polymerization and hardening phase is 30 minutes approx.

If the product stays inside the mixer for more than 30 min., change the mixer.

(11/10/2012)

80-07-M209EN

ELECTRICAL COMPONENTS REFIT

CHARACTERISTICS OF THE ATTACHMENT SCREWS
The bolts used are delivered with the strain gauge.
Bolt H, M10x30 pitch 1.5 Class 10.9.

PRECAUTIONS FOR ASSEMBLY AND TIGHTENING TORQUE

1

The two components (strain gauge and axle) must be

kept at the same temperature for at least 4 hours before
commencing assembly.
The strain gauge should be assembled with a completely
unloaded axle.
To ensure this:
1 - Lift the rear axle from the floor using a hydraulic jack
(Item 1) (Part No Manitou 505507).
2 - Make the machine safe by placing 2 stands (Item 2)
(Part No Manitou 554772) on each side of the chassis.
3 - Remove the jack to completely unload the rear axle.

80

80-07-M209EN

(11/10/2012)

ELECTRICAL COMPONENTS REFIT

1st stage :
Using a gun, apply the two-part mixture to the axle by
placing 4 balls of glue as shown opposite (Item 1).

Wear a mask and gloves when applying this product.

2nd stage :
Insert two M10x30 bolts into the strain gauge, then place
the assembly on the axle.
Take care to keep the central part of the gauge free of glue.

Zone with no
trace of glue

3rd tape :

(11/10/2012)

80

The 2 M10 bolts should tightened progressively and in the following way:
Torque bolt No. 1 to 34 N.m
Torque bolt No. 2 to 34 N.m
Torque bolt No. 1 to nominal torque 67 N.m 5%
Torque bolt No. 2 to nominal torque 67 N.m 5%

80-07-M209EN

ELECTRICAL COMPONENTS REFIT

4rd stage :

Then fit the plastic housing (Item 1) and secure it with

two pan-head screws M4x10.

Do not use any grease on the M10x30 bolt heads

as grease is incompatible with the glue.

80

80-07-M209EN

(11/10/2012)

ELECTRICAL TROUBLESHOOTING

pages
DESCRIPTION ENGINE FAULTS CODES (MR2-PLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
FAULT PRIORITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
FAULT PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FAULT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FAULTS CODES - ENGINE (MR2-PLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FAULTS CODES - TRUCK (SPU 25-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

80

FAULTS CODES - LONGITUDINAL STABILITY INDICATOR (LLMI) . . . . . . . . . . . . . . . . . . . . .26

(06/12/2012)

80-08-M209EN

ELECTRICAL TROUBLESHOOTING

DESCRIPTION ENGINE FAULTS CODES (MR2-PLD)

The fault codes can be read off with a diagnosis unit (e.g. minidiag2).
The display differentiates between current and non-current faults.
Current fault codes cannot be cleared.
The fault codes listed apply to the MR2-PLD.
The fault codes stored in the control unit describe the priority (valence = w), path (pp) and type (aa)
of the fault which has developed.
Example of a fault code: 10605
1
06
05

=
=
=

fault priority (w)

fault path (pp)
fault type (aa)

FAULT PRIORITY
In the 5-digit fault code, the first digit (0,1 or 2) indicates the fault priority. Proceed as follows, depending
on the fault priority:

Fault priority 0
If necessary, these faults can be rectified during the next maintenance service.

80

Fault priority 1
The fault must be rectified as soon as possible.
It can be expected that the running characteristics of the engine will be affected.
The driving and the braking characteristics of the vehicle may have changed if driving mode is active. If
working speed governor mode is active, the operating characteristics of the equipment may have changed.

Fault priority 2
The fault must be rectified immediately.
The running characteristics of the engine will be affected (emergency running programme).
The driving and braking characteristics of the vehicle will have changed if driving mode is active. If working
speed governor mode is active, the operating characteristics of the equipment will have changed.
Have priority 2 malfunctions rectified immediately in a Daimler Chrysler Service Station
or specialist workshop.

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

FAULT PATH
PLD MERCEDES (MR2)
Fault N

Fault

Repair instructions

00

Not assigned

01

CAN interface

02

not assigned

03

crankshaft sensor

04

camshaft sensor

05

engine

06

not assigned

07

carburation system / lambda control

air monitoring, gas monitoring CNG

08

knock sensor

CNG ecu

09

lambda sensor (LSU)

CNG ecu

10

engine-oil temperature sensor

11

fuel temperature sensor

12

charge-air temperature sensor

13

ambient pressure sensor

14

charge-air pressure sensor

15

coolant temperature sensor

16

engine-oil pressure sensor

17

fuel pressure sensor

fuel monitoring (also in the case of CNG)

18

booster path / boost pressure control

air routing, Wastegate, VTG etc.

19

fuel circulation

fuel pump, fuel filter etc.

20

engine-oil circulation

oil pump etc.

21

coolant circulation

water pump etc.

22

terminal 15 detection (ignition)

23

terminal 30 detection (supply)

24

scavenging gradient sensor (P2S-P3)

25

engine-oil level sensor

26

speed sensor booster 1

boost pressure control

27

speed sensor booster 2

boost pressure control

30
31-39

CNG ecu: gas temperature

not assigned

80

28-29

only if no clear assignment is possible

fuel pressure sensor**

not assigned

40

control unit internal fault

41

not assigned

CAUTION: measure: exchange control unit!

in-gas valves cylinder 1-6

electric circuit, CNG- ECU

48

control MV bank 1

electric circuit

49

control MV bank 2

electric circuit

50

control MV cylinder 1

electric circuit

51

control MV cylinder 2

electric circuit

52

control MV cylinder 3

electric circuit

53

control MV cylinder 4

electric circuit

54

control MV cylinder 5

electric circuit

55

control MV cylinder 6

electric circuit

56

control MV cylinder 7

electric circuit

57

control MV cylinder 8

electric circuit

ignition output stage cylinder 1-6

electric circuit, CNG- ECU

42-47

58-63
64

heater flange**

65

oil separator

66-68

not assigned

(06/12/2012)

80-08-M209EN

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Fault

Repair instructions

69

gas shut-off valve

electric circuit, CNG- ECU

70

proportional valve 1

electric circuit

71

proportional valve 2

electric circuit

72

proportional valve 3

73

proportional valve 4

electric circuit

74

proportional valve 5

electric circuit

75

ECU voltage supply

terminal 30 / battery

76

proportional valve 6

electric circuit

77

proportional valve bank 1

electric circuit

78

proportional valve bank 2

electric circuit

79

not assigned

80

starter/starter control

81

throttle valve angle sensor B

electric circuit, CNG- ECU

82

throttle valve angle sensor A

electric circuit, CNG- ECU

83

throttle valve-motor

electric circuit, CNG- ECU

84

Lambda sensor (heater circuit)

electric circuit, CNG- ECU

85-89

not assigned
Cylinder 1

mechanical/hydraulic fault, e.g. LRR, EZA

91

Cylinder 2

mechanical/hydraulic fault, e.g. LRR, EZA

92

Cylinder 3

mechanical/hydraulic fault, e.g. LRR, EZA

93

Cylinder 4

mechanical/hydraulic fault, e.g. LRR, EZA

94

Cylinder 5

mechanical/hydraulic fault, e.g. LRR, EZA

95

Cylinder 6

mechanical/hydraulic fault, e.g. LRR, EZA

96

Cylinder 7

mechanical/hydraulic fault, e.g. LRR, EZA

97

Cylinder 8

mechanical/hydraulic fault, e.g. LRR, EZA

98

not assigned

99

immobilizer

80

90

**diagnosis version 6 and newer

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

FAULT TYPE
PLD MERCEDES (MR2)
Fault

Repair instructions

00

communication line 1 defective

communication interface (e.g. CAN)

01

communication line 2 defective

communication interface (e.g. CAN)

02

data not plausible

communication interface (e.g. CAN)

03

not assigned

04

no communication

communication interface (e.g. CAN)

05

shortened to battery voltage (+lead)

plus-lead shorted to battery voltage (e.g.

terminal 30)

06

ground short (-lead)

minus-lead shorted to ground

07

shortened to battery voltage (-lead)

minus-lead shorted to battery voltage (e.g.

terminal 30)

08

ground short (+lead)

plus-lead shorted to ground

09

open circuit fault

general open circuit

10

signal level too low

crankshaft/camshaft

11

signal assignment not plausible

crankshaft/camshaft

12

signal timeout

generally speed sensor

13

signal polarity wrong

crankshaft/camshaft

14

not assigned

15

measuring range exceeded

16

remains under measuring range

analogue sensor - voltage signal

17

measuring value not plausible

analogue sensor

18

booster path defective

19

signal inconsistent

20

pressure too high

21

pressure too low

22

temperature too high

23

temperature too low

24

auxiliary controller /
microcontroller 2 defective

25

fluid level too high

26

fluid level too low

27

control disturbed

injector valves

28

injector valve-solenoid valve shorted

injector valves

29

fill level to high**

30

engine speed too high

31

engine speed too low

32

not assigned

33

starter relay hangs

starter

34

Highside transistor high-resistance

internal fault, PV-bank 1

35

Highside transistor high-resistance

internal fault, PV-bank 2

36

Highside transistor high-resistance

internal fault, PV5

37

cylinder number not plausible

internal fault

38

starter driver high-resistance

internal fault

39

starter driver low-resistance

internal fault

40

level-detection starter defective

internal fault, starter

41

transistor defective

internal fault, proportional valves

42

nominal range exceeded

e.g. battery voltage

43

remains under nominal range

e.g. battery voltage

(06/12/2012)

analogue sensor - voltage signal

internal fault

80

Fault N

80-08-M209EN

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Repair instructions

44

limit value achieved

engine-smoothness control

45

limit value achieved

individual cylinder adaptation

46

EZA- Timeou

individual cylinder adaptation

47

fuel map (characteristic data map)

defective

internal fault

48

cylinder number <> engine type not

plausible

internal fault

49

calibration fault

50

hardware detection wrong

internal fault

51

EEPROM- read error 1

internal fault

52

EEPROM- read error 2

internal fault

53

EEPROM- read error 3

internal fault

54

CAN data area defective

internal fault

55

AD converter monitoring

internal fault

56

run off control defective

internal fault**

57

power supply defective

internal fault (so far only at CNG)**

58

fuel map data set manipulated

internal fault**

59

not assigned

60

key number limited to 8

WSP (immobilizer)

61

counter overflow

WSP (immobilizer)

62

not assigned

63

no signal from redundant source

e.g. WSP : TPC via CAN TPC (TransPonder

Code)

64

no signal from signal source

e.g. WSP : TPC via terminal 50

65

valid but incorrect signal code

e.g. WSP: key wrong

66-72

80

Fault

not assigned

73

limit value achieved

loader ganging governor

74

set value deviation too high

integrator monitoring (e.g. booster)

75

system deviation too high

monitoring system deviation (e.g. booster)

76

limit value not achieved

e.g. boost pressure in booster trailing-throttle

77

control current not within tolerance

e.g. CNG, throttle valve setting-forces too high

78

general actuator fault

e.g. CNG, mechanical throttle valve failure

79

not assigned

80

knocking combustion

CNG: problem gas quality

81

combustion with misfiring

CNG

82-85
86
81-99

not assigned
starter does not engage

starter

not assigned

**diagnosis version 6 and newer

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

FAULTS CODES - ENGINE (MR2-PLD)

MR2

PLD MERCEDES (MR2)

Fault

Repair instructions

oil temperature sensor

measuring range exceeded

- check oil temperature sensor B11, replace if necessary.

nominal value: 2.4 kOhm (corresponds to 21 C)
- check wire N3/39 - B11/1 for open circuit fault and if
shortened to battery
voltage, repair if necessary.
- check wire N3/15 - B11/2 for open circuit fault, repair if
necessary.
- if fault code is still present: replace and program ECU
engine control
(e.g. MR-PLD).
- perform functional check

oil temperature sensor

remains under measuring
range

-check oil temperature sensor B11 and replace if necessary.

nominal value: 2.4 kOhm (corresponds to 21 C)
- check wire N3/39 - B11/1 for ground short, repair if
necessary.
- if fault code still present: replace and program ECU engine
control
(e.g. MR-PLD).
- perform functional check

ambient pressure sensor

measuring range exceeded

- if fault codes 11415 or 11416 are present, remove them

first
- fault code 01315 remains present: read out actual values
014 and 015 and
compare with each other.
- actual value inside tolerance band (+/- 10%) while engine
stops: replace and
program ECU engine control (e.g. MR-PLD).

0 13 16

ambient pressure sensor

remains under measuring
range

- if fault codes 11415 or 11416 are present, remove them

first
- fault code 01316 remains present: read out actual values
014 and 015 and
compare with each other.
- actual value inside tolerance band (+/- 10%) while engine
stops: replace and
program ECU engine control (e.g. MR-PLD).

0 18 22

booster path:
temperature to high

boost air temperature to high

0 18 74

booster path (control) set

value deviation too high

0 20 20

engine oil circulation

pressure too low

0 20 26

engine oil circulation

fluid level too high / too low

0 21 22

coolant circulation
temperature too high

0 10 15

0 10 16

0 13 15

(06/12/2012)

80-08-M209EN

80

Fault N

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

0 25 09

0 25 15

0 25 16

0 25 17

0 40 37

0 40 38

0 40 40

Repair instructions

oil level sensor

open circuit fault

- check oil level sensor B14, replace if necessary.

- check wire N3/33 - B14/1 for open circuit fault, repair or
replace if necessary.
- check wire N3/49 - B14/2 for open circuit fault, repair or
replace if necessary
- perform functional check

oil level sensor

measuring range exceeded

- check oil level, correct if necessary.

- check wire N3/33 - B14/1 if shortened to battery voltage,
repair of replace if
necessary.
- check oil level sensor B14 resistance, replace if necessary
- nominal value: 20-25 Ohm
- perform functional check.

oil level sensor

remains under measuring
range

- check oil level, correct if necessary.

- check wire N3/33 - B14/1 for ground short, repair or
replace if necessary.
- check oil level sensor B14 resistance, replace if necessary.
nominal value: 20-25 Ohm
- perform functional check.

oil level sensor

measured value not plausible

- check oil level during engine standstill, correct if

necessary.
- check calibration of oil pan type, correct if necessary.
- calibration of oil level sensor, correct if necessary.
- check cable, plug, plug connections and electrical
components for damage,
correct connection, loose contact and corrosion, repair if
necessary.
- check oil level sensor B14 resistance, replace if necessary.
nominal resistance: 22 Ohm when oil pan filled.
- perform functional check.

internal fault:
auxiliary controller defective

- check all affected connectors, plug connections and

electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit
- perform functional check.

internal fault:
cylinder number implausible

- check all affected connectors, plug connections and

electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit.
- perform functional check.

internal fault:
high resistance starter driver
(redundant-/auxiliary path)

- if fault code 07543 is present, remove this fault code first.

- check all affected connectors, plug connections and
electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit.
- perform functional check.

internal fault:
level detection starter defective

- check all affected connectors, plug connections and

electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit.
- perform functional check.

80

0 40 24

Fault

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Fault

Repair instructions

internal fault:
cylinder number implausible

- check all affected connectors, plug connections and

electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit.
- perform functional check.

internal fault:
incorrect hardware detection

- check all affected connectors, plug connections and

electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit.
- perform functional check.

0 40 51

internal fault:
EEPROM: Checksum failure
1 (memory fault)

- check all affected connectors, plug connections and

electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit.
- perform functional check.

0 40 56

internal fault:
backup control defective

0 65 06

oil separator:
short circuit to ground
diagnostic line

0 65 64

oil separator:
oil separator defective

0 75 42

battery voltage:
nominal range exceeded

possible sources of fault:

- generator or governor defective.

battery voltage:
remains below nominal range

possible sources of fault:

- battery discharged or defective.
- generator or governor defective.
- fuse F30 at the basic module is defective.
- wires of voltage supply are defective.

0 40 47

0 40 48

0 40 50

0 75 43

(06/12/2012)

80

internal fault:
characteristic data map defective

- check all affected connectors, plug connections and

electrical components for
damage, loose contact, corrosion etc. and repair if
necessary.
- if fault code is still present, renew and program control
unit.
- perform functional check.

80-08-M209EN

10

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Fault

Repair instructions

engine-smoothness control:
LRR-limitation cylinder 1

important note:
- upon removing mechanical or electrical faults at the
injector valves, the enginesmoothness
control has to be set to zero.
- the engine smoothness control can be set to zero in the
menu controls at the
menu level check of the engine-smoothness control.
note:
- injection quantity adjustment for the engine-smoothness
control for cylinder 1
not within the authorized tolerance ( 6 %).
- check engine-smoothness control via the select menu
controls.
- perform compression check via the select menu
controls.
- check tightening torque of the pressure-pipe tube at the
injection nozzle. Check
pressure-pipe tube for cracks.
- exchange the injector valve of the affected cylinder with
the injector valve of a
cylinder which is not affected.
- exchange injection nozzle of the affected cylinder with an
injection nozzle of a
cylinder which is not affected.

0 90 45

individual cylinder
adaption:
EZA-limitation cylinder 1

important note:
- upon removing mechanical or electrical faults at the
injector valves, the engine
smoothness control has to be set to zero
- the engine smoothness control can be set to zero in the
menu controls at the
menu level check of the engine-smoothness control.
- perform compression check via the select menu
controls.
- compression of the affected cylinder < 75 % of the
nominal value? Remove
mechanical faults (valves, piston ring etc.).
- compression is OK: exchange the injector valve of the
affected cylinder with the
injector valve of a cylinder which is not affected. Have the
engine run. Perform
individual cylinder adaptation.
- the other cylinder is now affected by the deviation:
replace the exchanged
injector valve.
- deviation does not change due to the exchange of the
injector valves: check
injection nozzle of the affected cylinder and replace if
necessary. Check high
pressure side tube to injector valve for leakage. Eliminate
leakage problem of
the affected cylinder.

0 91 44

engine-smoothness control:
LRR-limitation cylinder 2

refer to fault code of example 09044...

0 91 45

individual cylinder
adaptation:
EZA-limitation cylinder 2

refer to example of fault code 09045...

0 92 44

engine-smoothness control:
LRR-limitation cylinder 3

refer to fault code of example 09044...

0 92 45

individual cylinder
adaptation:
EZA-limitation cylinder 3

refer to example of fault code 09045...

80

0 90 44

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

11

PLD MERCEDES (MR2)

Fault

Repair instructions

0 93 44

engine-smoothness control:
LRR-limitation cylinder 4

refer to fault code of example 09044...

0 93 45

individual cylinder adaption:

EZA-limitation cylinder 4

refer to example of fault code 09045...

0 94 44

engine-smoothness control:
LRR-limitation cylinder 5

refer to fault code of example 09044...

0 94 45

individual cylinder
adaptation:
EZA-limitation cylinder 5

refer to example of fault code 09045...

0 95 44

engine-smoothness control:
LRR-limitation cylinder 6

refer to fault code of example 09044...

0 95 45

individual cylinder adaption:

EZA-limitation cylinder 6

refer to example of fault code 09045...

0 96 44

engine-smoothness control:
LRR-limitation cylinder 7

refer to fault code of example 09044...

0 96 45

individual cylinder
adaptation:
EZA-limitation cylinder 7

refer to example of fault code 09045...

0 97 44

engine-smoothness control:
LRR-limitation cylinder 8

refer to fault code of example 09044...

0 97 45

individual cylinder
adaptation:
EZA-limitation cylinder 8

refer to example of fault code 09045...

0 98 46

individual cylinder adaption:

timeout

CAN connection:
CAN-High defective

- check wire A6 X1 16/1 - A3 X4 18/1 for open circuit fault,

repair or replace if
necessary.
- switch on ignition
- delete fault memory in ECU engine control (e.g. MR-PLD)
- delete fault memory in SG FRE
- perform functional check

1 01 01

CAN connection:
CAN-Low defective

- check wire A6 X1 16/2 - A3 X4 18/1 for open circuit fault,

repair of replace if
necessary
- switch on ignition
- delete fault memory in ECU engine control (e.g. MR-PLD)
- delete fault memory in SG FRE
- perform functional check

1 01 02

CAN connection:
CAN data not plausible

- work off actual faults of SG FRE apart from CAN data bus
fault codes 10201,
00202 and 10203.
- perform functional check

1 01 04

CAN connection:
no connection to CAN

- check CAN connection to SG FRE

- check cables, connectors, plug connectors and electrical
components for
damage, correct connection, loose contact and corrosion,
repair if necessary.
- remove engine CAN bus fault in the SG FRE
- perform functional check
- communication with the ECU engine control (e.g. MRPLD) restored: check
calibration of ECU engine control (e.g. MR-PLD) for one wire
capability.

1 01 49

CAN connection:
parameter fault CAN

- check parameters 10 and 13 and correct if necessary.

- perform functional check

1 01 00

(06/12/2012)

80-08-M209EN

80

Fault N

12

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Repair instructions

1 03 08

crankshaft position sensor:

crankshaft sensor ground
short

- check wire N3/2 - N3/19 and position sensor for ground

short, replace if
necessary
- nominal value 1.2 kOhm

1 03 09

crankshaft position sensor:

crankshaft sensor open circuit
fault

- check wire N3/2 - N3/19 and position sensor for open

circuit fault, replace if
necessary
- nominal value 1.2 kOhm

crankshaft position sensor:

crankshaft level too low

- pull out position sensor while engine is stopped and

perform visual check.
- remove metal pieces/shavings if necessary.
- replace position sensor in the case of mechanical damage
(clear stress marks)
- replace clamping sleeve of the position sensor if
necessary.
- press-in speed (position) sensor during engine standstill
until mechanical limit
stop.
- perform functional check

crankshaft position sensor:

crankshaft/camshaft signal
assignment not plausible

- pull out position sensor during engine standstill and

perform visual check.
- replace position sensor in the case of mechanical damage
(clear stress marks).
- check crankshaft- and camshaft position sensor for tight
fitting, replace
clamping sleeve if necessary.
- press in both speed (position) sensor during engine
standstill until mechanical
limit stop.
- check wires at plug connection N3 for damage, correct
connection and
corrosion, repair if necessary.
- check crankshaft- and camshaft position sensor at plug N3
for interchanging.

1 03 12

crankshaft position sensor:

crankshaft timeout - no
crankshaft signal

- press in speed (position) sensor during engine standstill

until mechanical limit
stop.
- fault code 10309 actual: work off this fault code.
- fault code 10312 actual: check crankshaft position sensor,
replace if necessary.
- nominal value 1.2 kOhm

1 03 13

crankshaft position sensor:

crankshaft sensor wrong
polarity

- connect the position sensor correctly with the pin N3 of

the control unit MR
- perform functional check

1 04 08

camshaft position sensor:

camshaft sensor ground short

- check wire N3/1 - N3/20 and position sensor for ground

short, replace if
necessary.
- nominal value: 1.2 kOhm

1 04 09

camshaft position sensor:

camshaft sensor open circuit
fault

- check wire N3/1 - N3/20 for open circuit, replace if

necessary
- nominal value: 1.2 kOhm

1 03 10

1 03 11

80

Fault

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

13

PLD MERCEDES (MR2)

Fault

Repair instructions

1 04 12

camshaft position sensor:

camshaft time-out (no camshaft
signal)

- if fault codes 10408 and 10409 are current, remove them

first
- pull out position sensor B16 during engine standstill and
perform visual check
- remove metal pieces/shavings if necessary.
- replace position sensor in the case of mechanical damage
(clear stress marks).
- press in speed (position) sensor during engine standstill
until mechanical limit
stop.
- perform functional check.

1 04 13

camshaft position sensor:

camshaft sensor wrong
polarity

- position sensor B16 correctly with pin N3 of the ECU

engine control
(e.g. MR-PLD)
- perform functional check

1 05 30

engine:
engine speed too high

- inform about authorized engine speed

- delete fault memory

1 11 15

fuel temperature sensor

measuring range exceeded

- check wire B10, repair or replace if necessary.

- nominal value: 2.4 kOhm (corresponds to 21C)
- check wire N3/36 - B10/1 if shortened to battery voltage
and if open circuit
fault, repair if necessary.
- check wire N3/4 - B10/2 for open circuit fault, repair if
necessary.
- perform functional check

1 11 16

fuel temperature sensor

remains under measuring
range

- check sensor B10, repair or replace if necessary.

- nominal value: 2.4 kOhm (corresponds to 21C)
- check wire N3/36 - B10/1 for short circuit to ground, repair
if necessary.
- perform functional check

1 12 15

boost temperature sensor

measuring range exceeded

- check temperature sensor B9, replace if necessary.

- nominal value: 2.4 kOhm (corresponds to 21C)
- check wire N4/48 - B9/1 if connected to battery voltage
and if open circuit fault,
repair if necessary.
- check wire N3/21 - B9/2 for open circuit fault, repair if
necessary.
- perform functional check.

1 12 16

boost temperature sensor

remains under measuring
range

- check temperature sensor B9, replace if necessary.

- nominal value: 2.4 kOhm (corresponds to 21C)
- check wire N3/48 - B9/1 for short circuit to ground, repair
if necessary.
- perform functional check.

boost pressure sensor

measuring range exceeded

- check boost pressure, replace if necessary.

- check wire N3/29 - B13/2 for open circuit fault and if
shorted to battery voltage,
repair if necessary.
- check wire N3/23 - B13/1 for open circuit fault, repair if
necessary.
- perform functional check.

boost pressure sensor

remains under measuring
range

- unplug the connector from combination sensor. fault

codes 01215 and 11415
actual: replace combination sensor.
- check wire N3/7 - B13/3 for short circuit to ground, repair
if necessary.
- check wire N3/29 - B13/2 for short circuit to ground, repair
if necessary.
- perform functional check.

1 14 15

1 14 16

(06/12/2012)

80-08-M209EN

80

Fault N

14

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Repair instructions

boost pressure sensor

measured value not plausible

- check wire N3/7 - B13/3 for open circuit fault, repair if

necessary.
- check boost pressure sensor, replace if necessary.
- perform functional check.
- if fault code 01315 or 01316 also actual: replace and
calibrate ECU engine
control (e.g. MR-PLD).

1 15 15

coolant temperature sensor

measuring range exceeded

- check sensor B65, repair or replace if necessary.

- nominal value: 2.4 kOhm (corresponds to 21C)
- check wire N3/34 - B65/1 for open circuit fault or if
shortened to battery
voltage, repair if necessary.
- check wire N3/3 - B65/2 for open circuit fault, repair or
replace if necessary.
- perform functional check

1 15 16

coolant temperature sensor

remains under measuring
range

- check sensor B65, repair or replace if necessary.

- nominal value: 2.4 kOhm (corresponds to 21C)
- check wire N3/34 - B65/1 for open circuit fault, repair or
replace if necessary.
- perform functional check.

1 16 15

oil pressure sensor

measuring range exceeded

- check oil pressure sensor, replace if necessary.

- check wire N3/26 - B12/K1 for open circuit fault or if
shortened to battery
voltage, repair if necessary.
- check wire N3/5 - B12/K2 for open circuit fault, repair if
necessary.
- perform functional check.

1 16 16

oil pressure sensor

remains under measuring
range

- check oil pressure sensor, replace if necessary.

- check wire N3/26 - B12/K1 for short circuit to ground,
repair if necessary.
-.perform functional check.

1 16 17

oil pressure sensor

signal not plausible

- check oil level, correct if necessary.

- check wire N3 55/6 - B110/3 for open circuit fault, repair or
replace if
necessary.
- check oil pressure sensor, replace if necessary.
- perform functional check.

1 17 15

combination input
(FPS, P-DK):
measuring range exceeded

1 17 16

combination input
(FPS, P-DK):
remains under measuring
range

1 17 17

combination input
(FPS, P-DK):
signal not plausible

1 14 17

80

Fault

booster path:
booster path defective

- check tubes and connections between turbocharger,

boost air cooler and the
boost air tubes for leakage.
- check boost air cooler.
- perform functional check.

1 18 20

booster path:
boost pressure too high

- if fault codes 11415 or11417 are also present, process

them first.
- boost pressure system (boost air tubes, boost air cooler)
visual check..
- perform functional check.

1 18 73

max. output of booster speed

balancing governor

1 18 18

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

15

PLD MERCEDES (MR2)

Fault N

Fault

1 18 74

booster path / boost pressure

control:
set value deviation too high
(with power reduction)

1 18 75

booster path / boost pressure

control:
boost pressure deviation too
high

1 18 76

booster path / boost pressure

control:
braking power too low

1 19 17

fuel circulation:
measured value not plausible

Repair instructions

1 23 19

terminal 50 detection:
inconsistency MR<->FR

- check wires and plug connectors between S1/2 and A3 X1

18/18 for open
circuit fault, repair if necessary.
- check wires and plug connectors between S1/2 and A6 X1
16/8 for open circuit
fault, repair if necessary.
- perform functional check.

1 24 15

scavenging gradient sensor

(P2S-P3):
measuring range exceeded

1 24 16

scavenging gradient sensor

(P2S-P3):
remains under measuring
range

1 26 12

no speed booster 1

1 27 12

no speed booster 2

1 40 34

internal fault:
HS-transistor PVB1
high-resistance

1 40 35

internal fault:
HS-transistor PVB2
high-resistance

1 40 36

internal fault:
HS-transistor PV5
high-resistance

1 40 38

internal fault:
starter driver high-resistance
(main path)

1 22 19

1 40 39

1 40 41

80

terminal 15 detection:
inconsistency MR<->FR

- check fuse F30, replace if necessary.

- check wires and plug connectors between S1/1 and A3 X2
18/3 or A6 X1 16/15
for open circuit fault, repair or replace if necessary.
- perform functional check.

internal fault:
starter driver low-resistance
(main path or auxiliary path)

- check all affected plugs, plug connectors and electrical

components for damage,
loose contact, corrosion etc. and repair if necessary.
- if fault code is still present, replace and program control
unit.
- perform functional check.

internal fault:
PV- Highside- transistor
defective

- check all affected plugs, plug connectors and electrical

components for damage,
loose contact, corrosion etc. and repair if necessary.
- if fault code is still present, replace and program control
unit.
- perform functional check.

(06/12/2012)

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ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Fault

Repair instructions

internal fault:
parametrization fault

- check all affected plugs, plug connectors and electrical

components for damage,
loose contact, corrosion etc. and repair if necessary.
- if fault code is still present, replace and program control
unit.
- perform functional check.

internal fault:
EEPROM: CKS- fault 2
(groups vehicle parameters)

- check all affected plugs, plug connectors and electrical

components for damage,
loose contact, corrosion etc. and repair if necessary.
- if fault code is still present, replace and program control
unit.
- perform functional check.

1 40 54

internal fault:
CAN-data area defective

- check all affected plugs, plug connectors and electrical

components for damage,
loose contact, corrosion etc. and repair if necessary.
- if fault code is still present, replace and program control
unit.
- perform functional check.

1 40 58

internal fault:
fuel map data set manipulated

An inadmissible change was recognized by the fuel map

data set (tuning), which
engine operated in the CAN backup mode (backup engine
speed).

contact recognition
injector-/solenoid valve:
no contact cylinder 1

important note:
- upon removing mechanical or electrical faults at the
injector valves, the enginesmoothness
control has to be set to zero.
- the engine-smoothness control can be set to zero in the
menu controls at the
menu level check of engine-smoothness control.
- if fault code 07543 actual, process this fault code first.
- if fuel filter installed: check fuel filter and clean or replace
it if necessary.
- bleed fuel line, after work at fuel system,.
- fault code 15026 remains actual: carry out subsequent
checks.
- corresponding fault code actual at another cylinder of the
same bank: check
electrical supply lines of the affected injector valve(s) for
short circuit, repair or
replace if necessary.
- corresponding fault code actual at another cylinder of the
same bank: exchange
injector valve of the affected cylinder with the injector
valve of a cylinder which
is not affected. Have the engine run.
- fault code moves on (with the injector valve) to the other
cylinder. Replace
exchanged injector valve.

1 40 49

1 40 52

80

1 50 26

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ELECTRICAL TROUBLESHOOTING

17

PLD MERCEDES (MR2)

Fault N

Fault

Repair instructions

control failure
injector-/solenoid valve:
control cylinder 1 disturbed

1 51 26

contact recognition
injector-/solenoid valve:
no contact cylinder 2

refer to example of fault code 15026...

1 51 27

control failure
injector-/solenoid valve:
control cylinder 2 disturbed

refer to example of fault code 15027...

1 52 26

contact recognition
injector-/solenoid valve:
no contact cylinder 3

refer to example of fault code 15026...

1 52 27

control failure
injector-/solenoid valve:
control cylinder 3 disturbed

refer to example of fault code 15027...

1 53 26

contact recognition
injector-/solenoid valve:
no contact cylinder 4

refer to example of fault code 15026...

1 53 27

control failure
injector-/solenoid valve:
control cylinder 4 disturbed

refer to example of fault code 15027...

1 54 26

contact recognition
injector-/solenoid valve:
no contact cylinder 5

refer to example of fault code 15026...

1 54 27

control failure
injector-/solenoid valve:
control cylinder 5 disturbed

refer to example of fault code 15027...

1 55 16

contact recognition
injector-/solenoid valve:
no contact cylinder 6

refer to example of fault code 15026...

1 55 27

control failure
injector-/solenoid valve:
control cylinder 6 disturbed

refer to example of fault code 15027...

1 56 26

contact recognition
injector-/solenoid valve:
no contact cylinder 7

refer to example of fault code 15026...

1 56 27

control failure
injector-/solenoid valve
control cylinder 7 disturbed

refer to example of fault code 15027...

(06/12/2012)

80

1 50 27

important note:
- upon removing mechanical or electrical faults at the
injector valves, the
engine-smoothness control has to be set to zero.
- the engine-smoothness control can be set to zero in the
menu controls at the
menu level check engine-smoothness control.
- if fault code 07543 actual, process this fault code first.
- check screw terminals at the affected injector valve for
tight fitting.
- check the supply line of the affected injector valve for
interruption.
- check connectors X1 and N3 of the ECU engine control
(e.g. MR-PLD) for
correct contacting.
- fault code 15027 remains present: exchange injector valve
of the affected
cylinder with the injector valve of a cylinder which is not
affected. Have the
engine run.
- fault code moves on (with the injector valve) to the other
cylinder. Replace
exchanged injector valve.

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ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Repair instructions

1 57 26

contact recognition
injector-/solenoid valve:
no contact cylinder 8

refer to example of fault code 15026...

1 57 27

control failure
injector-/solenoid valve:
control cylinder 8 disturbed

refer to example of fault code 15027...

heater flange: open circuit

fault
(heater flange defective)

Condition:
The heating flange becomes after Kl. 15 uniquely briefly
switched on. Here if no
break-down of the battery voltage is recognized, the
heating flange is classified as
defective. Error threshold and cyclic duration are deposited
in the data record.

1 70 06

proportional valve 1:
short circuit to ground (-lead)

note: ECU engine control (e.g. MR-PLD) wrong calibration.

- check parametrization.
- parameter 06 has to be set to NOT ACTIVE
- if not, then the data set of ECU engine control (e.g. MRPLD) is wrong
- replace and program ECU engine control (e.g. MR-PLD).
- perform functional check.

1 70 07

proportional valve 1:
shortened to battery voltage
(-lead)

1 64 09

proportional valve 1:
open circuit fault

note: ECU engine control (e.g. MR-PLD) wrong calibration.

- check parametrization.
- parameter 06 has to be set to NOT ACTIVE
- if not, then the data set of ECU engine control (e.g. MRPLD) is wrong
- replace and program ECU engine control (e.g. MR-PLD).
- perform functional check.

1 71 06

proportional valve 3:
short circuit to ground (-lead)

note: ECU engine control (e.g. MR-PLD) wrong calibration /

short circuit to
ground
- check calibration, correct if necessary. Parameter 008 has
to be set to NOT
ACTIVE.
- if the calibration is OK, check wire N3/41 - Y70/1 for short
circuit to ground,
repair or replace if necessary.
- if still no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD).
- perform functional check.

1 71 07

proportional valve 3:
shortened to battery voltage
(-lead)

1 70 09

80

Fault

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(06/12/2012)

ELECTRICAL TROUBLESHOOTING

19

PLD MERCEDES (MR2)

Fault

Repair instructions

1 71 09

proportional valve 3:
open circuit fault

note: ECU engine control (e.g. MR-PLD) wrong calibration/

open circuit fault
- check calibration, correct if necessary. Parameter 008 has
to be set to NOT
ACTIVE.
note:
- if a Linnig-fan is installed, the following calibration applies:
parameters 8 and 9 have to be set to ACTIVE.
parameter 14 has to be set to Type 0.
- fault code 17109 still actual: check wires N3/41 - Y70/1 and
N3/12 - Y70/2 for
open circuit fault, repair or replace if necessary.
- if no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD).
- perform functional check.

1 71 12

fan speed
no signal (timeout)

currently not fan speed detection installed.

- check calibration, correct if necessary. Parameter 14 has to
be set to Type 0.

1 72 06

proportional valve 4:
short circuit to ground (-lead)

note: ECU engine control (e.g. MR-PLD) wrong calibration /

short circuit to
ground
- check calibration, correct if necessary. Parameter 009 has
to be set to NOT
ACTIVE.
- if the calibration is OK, check wire N3/43 - Y70/3 for short
circuit to ground,
repair or replace if necessary.
- if still no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD).
- perform functional check.

1 72 07

proportional valve 4:
shortened to battery voltage
(-lead)

proportional valve 4:
open circuit fault

note: ECU engine control (e.g. MR-PLD) wrong calibration /

open circuit fault
- check calibration, correct if necessary. Parameter 009 has
to be set to NOT
ACTIVE.
note:
- if a Linnig-fan is installed, the following calibration applies:
a) parameters 8 and 9 have to be set to ACTIVE.
b) parameter 14 has to be set to Type 0.
- fault code17209 remains actual: check wires N3/43 - Y71/3
und N3/12 - Y71/4
for open circuit fault, repair or replace if necessary.
- if no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD)
- perform functional check.

1 73 06

proportional valve 2:
short circuit to ground (-lead)

note: ECU engine control (e.g. MR-PLD) wrong calibration

- check calibration, correct if necessary. Parameter 007 has
to be set to NOT
ACTIVE.
- if not, then the data set of the control unit MR is wrong.
- replace and program ECU engine control (e.g. MR-PLD).
- perform functional check.

1 73 07

proportional valve 2:
shortened to battery voltage
(-lead)

1 72 09

(06/12/2012)

80-08-M209EN

80

Fault N

20

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

80

Fault N

Fault

Repair instructions

1 73 09

proportional valve 2:
open circuit fault

1 74 05

proportional valve 5:
shortened to battery voltage
(+lead)

1 74 08

proportional valve 5:
short circuit to ground (+lead)

1 76 09

proportional valve 6:
open circuit fault

1 77 05

proportional valve bank 1:

shortened to battery voltage
(+lead)

1 77 08

proportional valve bank 1:

short circuit to ground (+lead)

1 78 05

proportional valve bank 2:

shortened to battery voltage
(+lead)

1 78 08

proportional valve bank 2:

short circuit to ground (+lead)

1 80 05

starter control :
starter relay external current
supply

- check wire N3/18 - terminal 50 input (terminal 86) of

starter relay if shortened
to battery voltage, repair or replace if necessary.
- check starter relay, replace if necessary.
- restore electrical connection(s)

1 80 08

starter control:
short circuit to ground

- check wire N3/18 - terminal 50 input (terminal 86) of the

starter relay for short
circuit to ground, repair or replace if necessary.
- check starter relay, replace if necessary.

1 80 09

starter control:
open circuit fault

- disconnect battery
- check wire N3/18 - terminal 50 input (terminal 86) of the
starter relay for open
circuit fault, repair or replace if necessary.
- check starter relay, replace if necessary.

1 80 33

starter control:
starter relay fixed in closed
position

- check starter relay, replace if necessary.

1 80 39

Starter output stage with low

impedance (main branch or
branch of emergency) or load
(relay) also to high resistance
and/or to high inductance.

Main branch:
During the controller initialization the two transistors of the
main branch are
alternating switched on briefly. The level at the starter
output changes thereby on
High, the main branch is classified as low impedance.
Backup branch:
If that changes for clamp 50 signal on High and follows
this level change a
change of the level at the starter output before the starter
output stage was
activated, the backup branch is classified as low
impedance.

1 80 86

starter control:
starter does not engage

- check starter electrically and mechanically

- perform functional check.

immobilizer:
key number limited to 8

- a maximum of eight key- transponder codes can be stored

in the ECU engine
control (e.g. MR-PLD).
- if this number of keys has already been lost, train the new
keys via the select
menu train transponder key. This requires a FDOCauthorization.

1 99 60

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

21

PLD MERCEDES (MR2)

1 99 61

1 99 62

1 99 63

1 99 64

Fault

Repair instructions

immobilizer:
counter overflow

note:
- ECU engine control (e.g. MR-PLD) is unserviceable,
because manipulations for
the decoding of the transponder codes (immobilizer) have
been made at the
vehicle.
- replace and program ECU engine control (e.g. MR-PLD)
- perform functional check.

immobilizer:
X5 has been with drawn

note:
- a ECU engine control (e.g. MR-PLD) for applications
without immobilizer has
been installed in a vehicle with immobilizer. The ECU
engine control
(e.g. MR-PLD) has activated the immobilizer, i.e. it became
unserviceable for
the prior application. The SG can only be used for an
operation with an
immobilizer.
- train transponder key via the select menu train
transponder key. This requires
FDOC-authorization.
- in the case of power shortage or excessive fuel
consumption a new ECU engine
control (e.g. MR-PLD) (adjusted to the respective engine)
has to be installed.

immobilizer:
no TPC via CAN

- fault code 19964 also actual: use spare transponder key in

order to start
- engine starts with spare key: try to train the defective
transponder key via the
select menu train transponder key.
if the trial fails, order and train a new transponder code
(FDOC authorization
required).
- engine does not start with spare key. Check voltage
supply and wiring of the
readout-electronics, repair if necessary. If no fault is
detected, replace readoutelectronics
of the immobilizer.
- fault code 19964 not actual: check calibration of the SG
FRE for immobilizer.
- in the SG FRE no parameters are set for the immobilizer:
calibrate the SG FRE
for immobilizer.
- SG FRE is calibrated for immobilizer: check fault memory
for actual fault code
12319.
- fault code 12319 actual: check wire of terminal 50
between driving switch and
SG FRE for open circuit fault, repair or replace if necessary.
- fault code 12319 not actual: work off stored CAN-bus
faults.

immobilizer:
no TPC via terminal 50

note.
- the readout-electronics read the transponder code and
sends it permanently to
the control units FRE and MR via the wire terminal 50.
- if fault code 19963 actual, process this fault code first.
- check wire of terminal 50 between driving switch and ECU
engine control
(e.g. MR-PLD) for open circuit fault, repair or replace if
necessary.

(06/12/2012)

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Fault N

22

ELECTRICAL TROUBLESHOOTING

PLD MERCEDES (MR2)

Fault N

Fault
internal fault
EEPROM: Checksum- fault 3
(block production or immobilizer)

2 48 05

control solenoid valve:

shortened to battery voltage
Highside
bank 1

2 46 06

control solenoid valve:

ground short Lowside bank 1

2 49 05

control solenoid valve:

shortened to battery voltage
Highside
bank 2

2 49 06

control solenoid valve:

ground short Lowside bank2

2 50 28

short circuit injector-/

solenoid valve cylinder 1

2 51 28

short circuit injector-/

solenoid valve cylinder 2

2 52 28

short circuit injector-/

solenoid valve cylinder 3

2 53 28

short circuit injector-/

solenoid valve cylinder 4

2 54 28

short circuit injector-/

solenoid valve cylinder 5

2 55 28

short circuit injector-/

solenoid valve cylinder 6

2 56 28

short circuit injector-/

solenoid valve cylinder 7

2 57 28

short circuit injector-/

solenoid valve cylinder 8

80

2 40 53

2 99 65

immobilizer
wrong key

80-08-M209EN

Repair instructions
- check all affected connectors, plug connections and
electric components for
damage, loose contact, corrosion etc., and repair if
necessary.
- if fault code still present, renew and calibrate control unit.
- perform functional check

important note:
- upon removing mechanical or electrical faults at the
injector valves, the enginesmoothness
control has to be set to zero.
- The engine smoothness control can be set to zero in the
menu controls in the
menu level check engine smoothness control.
- switch off ignition for at least 10s after each testing stage,
start engine and read
out actual fault.
- general visual check (damage, loose contact, corrosion
etc.), remove fault if
necessary.
- check electrical screw connections of the affected injector
valve for short
circuit.
- disconnect electrical screw connections of the affected
injector valve.
example for fault code 25028
- Fault code 25028 not actual: injector valve of the affected
cylinder
- fault code 25028 remains actual: check electrical supply
lines of the respective
injector valve(s) for short circuit, repair or replace if
necessary.
check electrical supply line of the affected injector valve if
shorted to battery
voltage and ground short, repair or replace if necessary.
- if fault code 25028 remains present: replace and program
ECU engine control
(e.g. MR-PLD)
- perform functional check
note:
-several attempts were made to start the vehicle with a
non-trained key.
- wait for the end of the timeout with the ignition switched
on, train transponder
key after that via the select menu train transponder key
(FDOC authorization
required).
- the duration of the timeout depends on the number of
the previous starting trials.

(06/12/2012)

23

80

ELECTRICAL TROUBLESHOOTING

(06/12/2012)

80-08-M209EN

24

ELECTRICAL TROUBLESHOOTING

FAULTS CODES - TRUCK (SPU 25-15)

SPU

SPU 25-15

80

Error code
(DTC)
Hexadecimal

Component

Description

010203

Sensor power supply outlet

Signal voltage very high: Short circuit at battery + terminal

010204

Sensor power supply outlet

Signal voltage very low: Short circuit at ground

010303

Continue flow button indicator light

Signal voltage very high: Short circuit at battery + terminal

010304

Continue flow button indicator light

Signal voltage very low: Short circuit at ground

010603

Boom head solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

010604

Boom head solenoid valve output

Signal voltage very low: Short circuit at ground

010605

Boom head solenoid valve output

Circuit impedance very high: Open circuit

010703

Body roll authorization output

Signal voltage very high: Short circuit at battery + terminal

010704

Body roll authorization output

Signal voltage very low: Short circuit at ground

010705

Body roll authorization output

Circuit impedance very high: Open circuit

011203

Lifting cut off solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

011204

Lifting cut off solenoid valve output

Signal voltage very low: Short circuit at ground

011205

Lifting cut off solenoid valve output

Circuit impedance very high: Open circuit

011303

Transmission authorization output

Signal voltage very high: Short circuit at battery + terminal

011304

Transmission authorization output

Signal voltage very low: Short circuit at ground

011305

Transmission authorization output

Circuit impedance very high: Open circuit

012103

Safety 2 solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

012104

Safety 2 solenoid valve output

Signal voltage very low: Short circuit at ground

012105

Safety 2 solenoid valve output

Circuit impedance very high: Open circuit

012303

Cut-off solenoid valve outputs

Signal voltage very high: Short circuit at battery + terminal

012304

Cut-off solenoid valve outputs

Signal voltage very low: Short circuit at ground

012305

Cut-off solenoid valve outputs

Circuit impedance very high: Open circuit

012503

Telescope extension solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

012504

Telescope extension solenoid valve output

Signal voltage very low: Short circuit at ground

012505

Telescope extension solenoid valve output

Circuit impedance very high: Open circuit

013103

Inclination neutralization solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

013104

Inclination neutralization solenoid valve output

Signal voltage very low: Short circuit at ground

013105

Inclination neutralization solenoid valve output

Circuit impedance very high: Open circuit

01330D

Strain gauge calibration error

Signal value outside calibration range: Calibration not

performed or incorrectly performed

013403

Safety solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

013404

Safety solenoid valve output

Signal voltage very low: Short circuit at ground

013405

Safety solenoid valve output

Circuit impedance very high: Open circuit

013507

Safety solenoid valve operational error

Defective actuator (mechanical problem)

80-08-M209EN

(06/12/2012)

ELECTRICAL TROUBLESHOOTING

25

SPU 25-15
Error code
(DTC)
Hexadecimal

Component

Description

Control solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

013604

Control solenoid valve output

Signal voltage very low: Short circuit at ground

013605

Control solenoid valve output

Circuit impedance very high: Open circuit

013707

Adjustment solenoid valve operational error

Defective actuator (mechanical problem)

014503

Telescope retracted solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

014504

Telescope retracted solenoid valve output

Signal voltage very low: Short circuit at ground

014505

Telescope retracted solenoid valve output

Circuit impedance very high: Open circuit

014603

Attachment line A control solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

014604

Attachment line A control solenoid valve output

Signal voltage very low: Short circuit at ground

014605

Attachment line A control solenoid valve output

Circuit impedance very high: Open circuit

014703

Attachment line B control solenoid valve output

Signal voltage very high: Short circuit at battery + terminal

014704

Attachment line B control solenoid valve output

Signal voltage very low: Short circuit at ground

014705

Attachment line B control solenoid valve output

Circuit impedance very high: Open circuit

014803

Ventilation rotation direction solenoid valve

output

Signal voltage very high: Short circuit at battery + terminal

014804

Ventilation rotation direction solenoid valve

output

Signal voltage very low: Short circuit at ground

014805

Ventilation rotation direction solenoid valve

output

Circuit impedance very high: Open circuit

014903

Fan speed control solenoid output

Signal voltage very high: Short circuit at battery + terminal

014904

Fan speed control solenoid output

Signal voltage very low: Short circuit at ground

014905

Fan speed control solenoid output

Circuit impedance very high: Open circuit

020102

Continue flow button

Signal value erratic

020402

Boom head solenoid valve activation button

Signal value erratic

020502

Accessory line decompression button

Signal value erratic

021007

Retracted telescope not detected

Defective actuator (mechanical problem)

021402

JSM FNR selector

Signal value erratic

021602

Longitudinal stability display

Signal value erratic

02160C

Longitudinal stability display

Defective sensor or actuator

021702

Aggravating movement contact1

Signal value erratic

022202

Override button

Signal value erratic

022402

Telescope retracted sensor

Signal value erratic

022602

Boom lift angle sensor

Signal value erratic

022609

Boom lift angle sensor

Information unavailable on CAN bus

022610

Boom lift angle sensor

Sensor signal value greater than normal value

022612

Boom lift angle sensor

Sensor signal value lower than normal value

022700

Strain gauges

Sensor signal value greater than normal value

022701

Strain gauges

Sensor signal value lower than normal value

022702

Strain gauges

Signal value erratic

80

013603

022709

Strain gauges

Information unavailable on CAN bus

02270A

Strain gauges

Signal value variation abnormal for correct operation

022713

Strain gauges

Signal value transmitted to CAN bus is invalid

02320D

Boom angle sensor calibration error

Signal value outside calibration range: Calibration not

performed or incorrectly performed

024102

Telescope roller sensor

Signal value erratic

024110

Telescope roller sensor

Sensor signal value greater than normal value

024113

Telescope roller sensor

Sensor signal value lower than normal value

(06/12/2012)

80-08-M209EN

26

ELECTRICAL TROUBLESHOOTING

SPU 25-15
Error code
(DTC)
Hexadecimal

Component

Description

024202

Attachment roller sensor

Signal value erratic

024210

Attachment roller sensor

Sensor signal value greater than normal value

024213

Attachment roller sensor

Sensor signal value lower than normal value

024302

Inclination movement spool contact

Signal value erratic

024402

Accessory movement spool contact

Signal value erratic

024A05

Air inlet temperature sensor

Circuit impedance very high: Open circuit

031101

ECU power supply voltage

Sensor signal value lower than normal value

041609

Longitudinal stability display

Information unavailable on CAN bus

044009

CAN bus error

Information unavailable on CAN bus

051500

ECU

Sensor signal value greater than normal value

05150C

ECU

Defective sensor or actuator

80

FAULTS CODES - LONGITUDINAL STABILITY INDICATOR (LLMI)

i Chapter 80 : ELECTRICAL CONTROL AND ADJUSTMENT

80-08-M209EN

(06/12/2012)

ELECTRICAL SPECIFIC TOOLING

pages
DIAGNOSTIC TOOLKIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RECEPTION STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WORKSHOP AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BREAKOUT BOX KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

80

SOLENOID ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

(26/09/2012)

80-09-M209EN

ELECTRICAL SPECIFIC TOOLING

80

DIAGNOSTIC TOOLKIT

80-09-M209EN

(26/09/2012)

ELECTRICAL SPECIFIC TOOLING

12

11

10

13

1
3

7
4

80

Diagnostic case ........................................................................................................ 746120

Consisting of:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
(26/09/2012)

1 Cigarette lighter connector supply cable ....................................................745240

1 Red battery clip cable .........................................................................................745241
1 Black battery clip cable ......................................................................................745242
1 Supply cable ...........................................................................................................745243
1 VCI portable cable ................................................................................................745244
1 Manitou OBD Diag. Cable..................................................................................745245
1 Manitou RC2 / RC4 Diag. Cable .......................................................................745246
1 CE standard section lead L: 3m .......................................................................745247
1 Diag Supply Unit 3G 60W ..................................................................................745251
1 Battery LI-ION 7,4V / 9,6AH ...............................................................................745367
1 PAD (PC + case assembly) .................................................................................745438
1 VCI (Vehicle Communication Interface / PAD)...........................................745439
Styli (batch of 3)........................................................................................................745368
80-09-M209EN

ELECTRICAL SPECIFIC TOOLING

RECEPTION STATION

Reception station (battery charging) .................................................................... 745236

80

WORKSHOP AREA

Workshop area (area + station) .............................................................................. 745235

80-09-M209EN

(26/09/2012)

ELECTRICAL SPECIFIC TOOLING

BREAKOUT BOX KIT

Breakout box (DT connectors)

Breakout box (DTM connectors)

Breakout box kit ...................................................................................................... 785503

Consisting of:
1 breakout box (DT connectors).........................................................................785504
1 breakout box (DTM connectors) .....................................................................785505

80

1.
2.

SOLENOID ADAPTER

Solenoid adapter ..................................................................................................... 662196

(26/09/2012)

80-09-M209EN

ELECTRICAL SPECIFIC TOOLING

DIAGNOSTIC TOOL MERCEDES

80

Minidiag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774616

80-09-M209EN

(26/09/2012)