MRT 1850,2150,2540 Euro 3 Repair Manual M146EN 04.2011

REPAIR MANUAL
MANUEL DE RÉPARATION
REPARATURANLEITUNG
MANUAL DE REPARACIÓN
MANUALE RIPARAZIONE
This document has been printed from my e doc
MANITOU BF
Head office: 430, Rue de l’Aubinière
44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
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droits réservés.
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or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization
that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil
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diritti sono riservati.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
Group 00 (General characteristics and safety) 1-1
ENGINE
Group 10 (Engine) 2-1
OPTIONS - ACCESSORIES
Group 110 (Options - Attachments) 3-1
TRANSMISSION
Groupe 20 (Transmission) 4-1
AXLE ASSEMBLY - AXLE

Group 30 (Axle) 5-1
BRAKE
Group 40 (Brake) 6-1
TELESCOPIC BOOM
Group 50 (Boom) 7-1
HYDRAULIC
Group 70 (hydraulic) 8-1
ELECTRICITY
Group 80 (Electricity) 9-1
FRAME - BODY
Group 90 (Frame - Body) 10-1
00
GENERAL
- GENERAL INSTRUCTIONS AND SAFETY

NOTICE
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
page
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POSITION FOR MAINTENANCE TASKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(14/04/2011) 00-M146EN
2
General instructions and safety notice
00
FOREWORD
This section contains general instructions and notes on safety for inspection and maintenance
tasks.
Other instructions and warnings are given in the relevant competence sections.
In order to reduce accident risks, ensure the following:

- Follow the instructions given in the operator and maintenance manual for the fork lift
truck.
A manual is supplied with each truck.
- Comply with the instructions given in the safety manual.
- Use suitable instruments for all operations.
- Use original Manitou spare parts.
Failure to comply with the above increases the risk of accidents that can cause serious injury
or even death.
If the operator follows the safety instructions and the truck is maintained correctly, factors such
as efficiency, reliability and profitability are guaranteed.
When you see the symbol:
It means: Danger! Warning! Danger for your health, the safety of third parties or the safety of
the fork lift truck itself.
The manufacturer cannot foresee all possible dangerous situations. Consequently, the safety
instructions given in the safety manual may not cover all possible dangerous situations.
During repair and maintenance work or when driving the truck, the operator must always foresee
any risk to his safety, that of others or to the equipment itself.
Manitou shall not be responsible for the use of any lifting equipment, instrument or method
of operation other than those specified.
00-M146EN (14/04/2011)
3
00
POSITION FOR MAINTENANCE TASKS
2 4
1 3
Before any repair work:
1 - Position the machine on a level surface and lock the wheels.

2 - Stop the engine and remove the key from the ignition switch.
3 - Allow the machine to cool down.
4 - Depressurize all the circuits concerned.
(14/04/2011) 00-M146EN
4
00
RULES FOR MAINTENANCE
Do not carry out any work on the machine without the correct
training and necessary knowledge.
Ensure that you have read all the labels on the machine and in
the instruction manual.
If work has to be done before the machine has had time to cool
down, there is a danger of burns in the event of contact with
hot liquids or parts.
Before carrying out any work on components with an electrical

1
supply, set the battery switch to OFF.
2
If the machine does not have a battery switch, disconnect the
battery terminals and then replace them later.
Before carrying out any welding work, disconnect the

computers.
ECU
A machine that is operating in a contaminated environment

(toxic or harmful to health) must be suitably equipped. The
carrying out of maintenance and repair work on such machines
is also subject to the local safety instructions.
00-M146EN (14/04/2011)
5
00
Do not walk on any part of the machine that was not designed
for this purpose.
Never wear clothing, jewellery or objects that may become

trapped while working and cause accidents
Always wear goggles, protective gloves and safety boots and

any other protection necessary for the work to be carried out.
If maintenance work is carried out near to a movable object,

ensure that it is firmly secured.
While replacing or draining oil or fuel, or other work with liquids,

solids or gases that are harmful to the environment, ensure that
all necessary precautions are taken to prevent environmental
contamination.
(14/04/2011) 00-M146EN
6
00
When lifting or propping up a component of the machine, ensure

that the tools used are at least suitable for the load of the
component to be lifted and that they comply with the national
requirements for lifting devices.
If a jack is used, ensure that it is used on a level, uniform

surface, that it is strong enough to support the load, that its
lifting range is sufficient and that it is correctly located and
positioned under the machine.
Ensure that there are no objects or instruments that could

cause accidents if left in the machine.
Do not check for any missing items by using your hands.
max.
min.
Do not adjust a component beyond the maximum range indicated
by the manufacturer.
MAX
MIN
00-M146EN (14/04/2011)
ENGINE
10
- ENGINE COMPONENTS REMOVAL
- ENGINE COMPONENTS REFIT
M
R
- CHARACTERISTICS AND SPECIFICATIONS 647370EN
- COMPONENTS CONTROLS (Motor OM 904 LA

AND ADJUSTMENT 120-150-175 cv EURO 3)
10
ENGINE COMPONENTS REMOVAL
page
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

ALTERNATOR BELT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
STARTER MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
ENGINE COOLING WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
TURBOCHARGER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
(27/04/2011) 10-06-M146EN
2
Engine components removal
10
PREPARATION AND SAFETY INSTRUCTIONS

Turn off the ignition switch and disconnect the negative battery terminal.
10-06-M146EN (27/04/2011)
3
10
ALTERNATOR BELT REMOVAL
1
Remove the protective housing (Item 1) by unscrewing the
2 screws (Item 2).
2
Connect an unlocking lever to the screw (Item 3), tilt the

belt tensioning roller upwards (Item 4) and remove the belt
(Item 5).
5
4
ALTERNATOR REMOVAL
1 2 After removing the belt as indicated above, the alternator

1
1
can be removed.
Unscrew the 6 screws (Item 1) and remove the lower casing
1 (Item 2).
1 1
(27/04/2011) 10-06-M146EN
4
Slacken the 2 nuts (Item 3) locking the 2 clamps (Item 4),

holding the air breather pipe (Item 5), thereby facilitating
4 access to the alternator mounting.
10
Unscrew the 4 screws (Item 6) locking the alternator

mounting (Item 7).
Unscrew the 2 screws (Item 8), slacken the screws (Item 9)

and turn the mounting of the air coupling (Item 10) upwards
9
to facilitate extracting the alternator.
8
8
10
Unscrew the 2 screws (Item 11).
11
10-06-M146EN (27/04/2011)
5
Disconnect the electric cables (Item 12 and 13) connected

to the alternator.
10
12
13
The alternator (Item 14) can now be removed.
14
(27/04/2011) 10-06-M146EN
6
10
STARTER MOTOR REMOVAL

1 2 (Item 2).
1
1
1
1 1
Disconnect the electric cables (Item 3 and 4) connected to

the starter motor.
3
Slacken the 2 nuts (Item 5) locking the 2 clamps (Item 6)

6
holding the air breather pipe (Item 7), thereby facilitating
access to the starter motor.
10-06-M146EN (27/04/2011)
7
Unscrew the screws and washers (Item 8 and 9) and remove

the slave relay (Item 10) from the starter motor (Item 11).
9 8
10
10
11
Unscrew the 3 screws (Item 12) and remove the starter

motor (Item 11) from the motor mounting plate.
12
11
Remove the starter motor (Item 11) by passing it through

the opening on the lower side of the motor mounting plate.
11
(27/04/2011) 10-06-M146EN
8
10
ENGINE COOLING WATER PUMP REMOVAL
Only work on the cooling system if the temperature

1 2
1 of the coolant is below 30°C.
1

1
1
(Item 2).
1
Remove the protective casing (Item 3) by unscrewing the

2 screws (Item 4).
3
Connect an unlocking lever to the screw (Item 5), turn the

tensioning roller (Item 6) upwards and remove the belt
(Item 7).
10-06-M146EN (27/04/2011)
9
Slacken the 2 clamps (Item 8) on the lower sleeve

(Item 9).
9
10
8
Obtain receptacles of adequate size for the quantity of liquid

to be collected and place them under the engine sump.
Disconnect lower coupling (Item 9) from the pump. Perform
this operation slowly to release the pressure in the system
and allow the liquid to drain from the cooling system,
emptying it completely.
Slacken the 2 clamps (Item 10) on the upper coupling

10 (Item 11) and remove it from the pump.
11
10
Unscrew the 4 screws (Item 12) and remove the pulley

(Item 13).
13
12
(27/04/2011) 10-06-M146EN
10
Unscrew the screws (Item 14) and remove the belt tensioner
(Item 15).
10
14
15
Unscrew the screws (Item 16 and 17) and remove the clamp
(Item 18).
16
17
18
16
Slacken the clamp (Item 19) and disconnect the drain tube
from the thermostatic valve (Item 20).
20
19
Disconnect the temperature sensor (Item 22) from the

thermostatic valve (Item 21).
21
22
10-06-M146EN (27/04/2011)
11
Unscrew the screws (Item 23 and 24) securing the

10
23
24
21
21
Unscrew the 7 screws (Item 25), remove the pump (Item 26)
and the thermostatic valve (Item 21).
26
25
25
25 25
25
25 25
(27/04/2011) 10-06-M146EN
12
10
TURBOCHARGER REMOVAL

1 2
1 (Item 2).
1
1
1 1
Unscrew the 2 nuts (Item 3) and remove the 2 clamps

4 (Item 4) holding the air breather pipe (Item 5).
Unscrew the screws (Item 6 and 7) and remove the clip

(Item 8).
6
7
10-06-M146EN (27/04/2011)
13
Slacken the clamp (Item 9) and remove the coupling

(Item 10).
Plug all the pipes to prevent foreign bodies from

10
10
entering the system.
9
Slacken the 2 clamps (Item 11) and remove the inlet coupling
on the (Item 12) air cooler.
12
11
11
Slacken the clamp (Item 13) and remove the inlet coupling
(Item 14) from the turbocharger (Item 15).
15
13
14
Unscrew the fixing (Item 16) and remove the oil outlet pipe
(Item 17) from the turbocharger.
17
16
(27/04/2011) 10-06-M146EN
14
Unscrew the fixing (Item 18) and remove the oil inlet pipe
(Item 19).
19
10
18
Unscrew the 4 screws (Item 20) and remove the protective

plate (Item 21) from the exhaust manifold.
21
20
Unscrew the screws (Item 22) holding the turbocharger.
22
Slacken the 2 clamps (Item 23) and remove the inlet coupling
(Item 24) from the engine.
23
23
24
10-06-M146EN (27/04/2011)
15
Unscrew the 8 screws (Item 25) and remove the exhaust

manifold (Item 26).
25
10
25
25
26
Unscrew the nuts (Item 27) and remove the turbocharger

15
(Item 15) from the exhaust manifold (Item 26).
27
27
26
27
26
27
15
(27/04/2011) 10-06-M146EN
16
10
10-06-M146EN (27/04/2011)
10
ENGINE COMPONENTS REFIT
page

TURBOCHARGER REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
ENGINE COOLING WATER PUMP REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
STARTER MOTOR REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
ALTERNATOR REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
ALTERNATOR BELT REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(27/04/2011) 10-07-M146EN
2
Engine components refit
10

Turn off the ignition switch and disconnect the negative battery terminal.
10-07-M146EN (27/04/2011)
3
10
TURBOCHARGER REFIT
Refit the turbocharger (Item 1) to the exhaust manifold

(Item 2) by screwing the nuts on again (Item 3); use a
3
2 tightening torque of 30 Nm.
3
3
3
Refit the exhaust manifold (Item 2) to the engine crankcase

by screwing in the 8 screws (Item 4); use a tightening torque
4 of 30 Nm.
(27/04/2011) 10-07-M146EN
4
Reconnect the inlet coupling (Item 5) to the engine and

tighten the 2 clamps (Item 6).
10
Screw on the turbocharger with the screws (Item 7).
Refit the protective plate (Item 8) to the exhaust manifold by

screwing in the 4 screws (Item 9).
8
Refit the inlet lubrication tube (Item 10) by screwing on the

coupling (Item 11).
10
11
10-07-M146EN (27/04/2011)
5
Refit the lubrication supply tube (Item 12) from the

turbocharger by screwing on the coupling (Item 13).
12
10
13
Refit the inlet coupling (Item 14) to the turbocharger (Item 1)

by tightening the clamps (Item 15).
1
15
14
Refit the inlet coupling (Item 16) to the air radiator by

tightening the 2 clamps (Item 17).
16
17
17
Refit the coupling (Item 18) by tightening the clamp

(Item 19).
18
19
(27/04/2011) 10-07-M146EN
6
Refit the bracket (Item 20) to the air unit by screwing in the
screws (Item 21 and 22).
21
22
10
20
21
Refit the air inlet pipe (Item 23) locking it with the 2 brackets
(Item 24) and screwing the nuts (Item 25) on again.
24
23
25
Refit the lower housing (Item 26) by screwing in the 6 screws

(Item 27).
27 26
27
27
27
27 27
10-07-M146EN (27/04/2011)
7
10
2
ENGINE COOLING WATER PUMP REFIT
Replace the seals with new ones and refit the pump (Item 1)
and thermostatic valve (Item 2) to the engine by screwing in
1
the 7 screws (Item 3), to which loctite threadlock is applied;
3
use a tightening torque of 25 Nm.
3
3
3
3
3 3
Relock the thermostatic valve (Item 2) by screwing in the

screws (Item 4 and 5), to which loctite threadlock is applied;
use a tightening torque of 25 Nm.
4
5
Reconnect the temperature sensor (Item 6) to the

(27/04/2011) 10-07-M146EN
8
Refit the exhaust pipe (Item 7) to the thermostatic valve by

tightening the clamps (Item 8).
10
7
8
Refit the bracket (Item 9) to the air unit by screwing in the

screws (Item 10 and 11).
10
11
10
Refit the pulley (Item 12) by screwing in the screws (Item 13)
to which loctite threadlock is applied.
12
13
Refit the belt tensioner (Item 14) by screwing in the screws

(Item 15), to which loctite threadlock is applied, using a
tightening torque of 50 Nm.
15
14
10-07-M146EN (27/04/2011)
9
Refit the belt (Item 16) on all the pulleys except the belt
tensioner roller.
Lift the belt tensioner roller (Item 14) with a lever, fit the
belt, then move the belt tensioner roller back.
10
Remove the unlocking lever and check that the belt is
correctly seated on the pulleys.
16
14
Fully tighten the screws (Item 13) using a tightening torque

of 25 Nm.
13
13
13 13
Refit the protective housing (Item 17) by screwing in the

2 screws (Item 18).
17
18
18

(Item 20).
20 19
20
20
20
20 20
(27/04/2011) 10-07-M146EN
10
Reconnect the upper coupling (Item 21) to the pump and

retighten the 2 clamps (Item 22).
22
10
21
22
Reconnect the lower coupling (Item 23) to the pump and

retighten the 2 clamps (Item 24).
23
24
24
Fill. the cooling system tank (Item 25) with the appropriate
fluid; the level of the fluid must be between the maximum
and minimum level lines (about 18 litres).
25
Remove the container from under the engine sump.
10-07-M146EN (27/04/2011)
11
10
STARTER MOTOR REFIT
4 3 Remove the remote switch (Item 2) from the new starter

motor (Item 1) by unscrewing the screws and washers
(Item 3 and 4).
2
Insert the starter motor (Item 1) through the opening on the

base of the engine crankcase.
1
Refit the starter motor (Item 1) to the engine crankcase by

screwing in the 3 screws (Item 5).
5
(27/04/2011) 10-07-M146EN
12
Refit the remote switch (Item 2) to the starter motor (Item 1)

by screwing in the screws and washers (Item 3 and 4).
4 3
10
Refit the air inlet pipe (Item 6), locking the 2 brackets
(Item 7) and screwing on the 2 nuts (Item 8) again.
7
Reconnect the electric cables (Item 9 and 10) to the starter

motor.
9
10

(Item 12).
12 11
12
12
12
12 12
10-07-M146EN (27/04/2011)
13
10
ALTERNATOR REFIT
Insert the new alternator (Item 1).
Reconnect the electric cables (Item 2 and 3) to the

alternator.
2
3
Attach the mounting (Item 4) to the engine by screwing in

the 4 screws (Item 5).
(27/04/2011) 10-07-M146EN
14
Screw in the 2 screws (Item 6) to secure the alternator.

10
Reposition the air coupling mounting (Item 7), screw in the

2 screws (Item 8) and tighten the (Item 9).
9
8
8
7
Refit the air inlet pipe (Item 10), locking the 2 brackets
(Item 11) by screwing the 2 nuts (Item 12) on again.
11
10
12

(Item 14).
14 13
14
14
14
14 14
10-07-M146EN (27/04/2011)
15
ALTERNATOR BELT REFIT
Refit the belt (Item 1) on all the pulleys except the belt
tensioning roller.
10
Lift the belt tensioner roller (Item 2) with a lever located on
the screw (Item 3), fit the belt, then move back the tensioner
1
roller.
2
Remove the unlocking lever and check that the belt is
correctly seated on the pulleys.
3
Refit the protective housing (Item 4) by screwing in the 2

screws (Item 5).
4
(27/04/2011) 10-07-M146EN
16
10
10-07-M146EN (27/04/2011)
OPTIONS - ATTACHMENTS
- OPTIONS - ATTACHMENTS SCHEMATIC

DIAGRAMS
- OPTIONS - ATTACHMENTS COMPONENTS

LOCATION
- OPTIONS - ATTACHMENTS CONTROL

AND ADJUSTMENT
- FITTING OPTIONS - ATTACHMENTS
- CHARACTERISTICS AND SPECIFICATIONS M 647391

R
(Radio control
- COMPONENTS CONTROLS
series C26-PRO)
AND ADJUSTMENT
110
OPTIONS - ATTACHMENTS SCHEMATIC
DIAGRAMS
page
ELECTRICAL PUSHBUTTON PANEL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– PUSHBUTTON PANEL DIAGRAM PART 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– PUSHBUTTON PANEL DIAGRAM PART 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
AIR CONDITIONING ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– FUSE AND RELAY BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– POSITION OF THE COMPONENTS ON THE DIAGRAMS . . . . . . . . . . . . . . . . . . . 7
ELECTRICAL DIAGRAMS BY FUNCTION:

– 1 - CABLED AIR CONDITIONING BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– 2 - CONDENSER ELECTRICAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– 3 - REAR CAB AIR CONDITIONING UNIT WIRING . . . . . . . . . . . . . . . . . . . . . . . 12
– 4 - AIR CONDITIONING WIRING IN CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
110
(23/01/2012) 110-02-M146EN
2 Options - attachments
schematic diagrams
ELECTRICAL PUSHBUTTON PANEL DIAGRAMS

PUSHBUTTON PANEL DIAGRAM PART 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
J3 MICRO DOOR
C sez. 1.5mm MICRO
+12V
sez. 1.5mm OVERLOADING
+12V-SEZ sez. 1mm
sez. 1mm
sez. 1mm
sez. 1mm
+12V
HEADER 6X2
J2
HEADER 24
E sez. 1.5mm
EV OSCILLATION RELEASE
BASKET PENDULUM 3D
EMERGENCY BUTTON
sez. 1mm STOP ENGINE
+12V
N.A. BUTTON
sez. 1mm START ENGINE +12V-SEZ
N.A. BUTTON
sez. 1mm KLAXON
+12V
I
sez. 0.33mm INPUT PENDULUM OR SAFETY SISTEM
sez. 1mm EV OSCILLATION BASKET PENDULUM 3D
sez. 0.33mm ERROR LIGHT

N.A. BUTTON
sez. 1mm EMERGENCY PUMP
+12V
sez. 1mm
K
J2-17
PE D2
D1 D3 D4
M +12V
sez. 1.5mm 1N4004 1N4004 1N4004 1N4004
D5
K5
LP1 LP2
1N4004 +12V-SEZ
D6
LS1
FBR51
BUZZER
O 1N4004
Q
110
110-02-M146EN (23/01/2012)
Options - attachments 3
schematic diagrams
PUSHBUTTON PANEL DIAGRAM PART 2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
+12V-SEZ +12V-SEZ
R1 R1
2K 2K
+12V-SEZ
C POT. Y POT. X
+12V-SEZ
JOYSTICK
UP DW SX DX
SELECTOR LEVER
3 POSITIONS
+12V
J2 R2 R2
HEADER 24 2K 2K
E
sez. 1.5mm
sez. 0.33mm LIFTING
sez. 0.33mm EXTENDING
sez. 0.33mm ROTATION
sez. 0.33mm TILTING
G
sez. 0.33mm OPTIONAL
+12V-SEZ +12V-SEZ
sez. 0.33mm MICROSWITCH JOYSTICK

5 POSITIONS ROTATING
sez. 0.33mm MOVEMENTS CONSENT

I
+12V-SEZ +12V-SEZ
SELECTOR
POSITION 3
POSITION 4
POSITION 1
POSITION 5
POSITION 2
ACTIVE 3D R4 R5
BASKET SIGNAL 100K 100K
sez. 1mm
+12V
K sez. 1mm LIFTING PEND 3D
sez. 1mm ROTATION PEN. 3D
sez. 1mm TILTING PEN. 3D
R5 R5
PE 100K 100K
sez. 1.5mm
M
+12V-SEZ +12V-SEZ
K1 K3
O
D7 D9
FBR51 FBR51
1N4004 1N4004
K2 K4
D8 D10
FBR51 FBR51
Q
1N4004 1N4004
110
(23/01/2012) 110-02-M146EN
schematic diagrams
AIR CONDITIONING ELECTRICAL DIAGRAMS

FUSE AND RELAY BOX
COMPONENTS
Ref Description Position on the diagram
E1 Relay K11
E2 Relay I11
E3 Relay I11
E4 Relay I11
E5 Relay G11
F1 Fuse 7,5A M9
F2 Fuse 7,5A M10
F3 Fuse 25A M10
F4 Fuse 25A M11
F5 Fuse 25A M11
F6 Fuse 25A M12
110
110-02-M146EN (23/01/2012)
schematic diagrams
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
E5
E4
I E3
E2
K E1
7.5
7.5
25
25
25
25
7.5
7.5
25
25
25
25
F1 F2 F3 F4 F5 F6
M
Q
110
(23/01/2012) 110-02-M146EN
schematic diagrams
110
110-02-M146EN (23/01/2012)
schematic diagrams
POSITION OF THE COMPONENTS ON THE DIAGRAMS

Component Diagram 1 Diagram 2 Diagram 3 Diagram 4
E1 √
E2 √
E3 √
E4 √
E5 √
F1 √
F2 √
F3 √
F4 √
F5 √
F6 √
I16a √
I123 √
MV1 √
MV2 √√
U7 √
U11 √
U14 √ √
U15 √ √
U16 √
U17 √
U18+ √
U18- √
U19 √ √
U28 √
U29 √
U33 √
U34 √
XA/C √
XC1 √
110
(23/01/2012) 110-02-M146EN
schematic diagrams
1 - CABLED AIR CONDITIONING BOX
COMPONENTS
E1 Relay I6
E2 Relay I10
E3 Relay I12
E4 Relay I15
E5 Relay I18
F1 Fuse 7,5A C3
F2 Fuse 7,5A C4
F3 Fuse 25A C5
F4 Fuse 25A C7
F5 Fuse 25A C8
F6 Fuse 25A C9
U19 Fuse box connector S6
110
110-02-M146EN (23/01/2012)
E
A
S
K
C
Q
O
G
M
1
V2.5
2
L
(23/01/2012)
K
J RN2.5
I C2.5
3
F1
H C RN
G V1.5
7.5A
F R1.5
4
E
R2.5 R1.5
F2 RV1.5
D
C R2.5 7.5A
B
5
A R4
VN F3
N
19 V2.5 A2.5
C
18 25A
85
86
U19
6
17
E1
16
15 RN F4
R2.5 A2.5
S2.5
14
7
S2.5 R2.5 25A
87 87a
30
13
12
11 F5
RN2.5 S2.5
8
10 N
25A
9
8 G
CB1.5
V
7
N
9
MB1.5 F6
6 C2.5 S2.5
85
86
5 M1.5 25A
RB1.5
E2
4
R1.5
10
3
2 V A2.5
A2.5 R4
87 87a
1
30
11
N
VN
85
86
12
E3
V1.5
13
RV1.5
87 87a
30
14
N
85
86
15
E4
CB1.5
MB1.5
87 87a
M1.5
30
16
N
schematic diagrams
17
Options - attachments
85
86
E5
18
CB1.5
RB1.5
87 87a
R1.5
30
19
110-02-M146EN
9
110
schematic diagrams
2 - CONDENSER ELECTRICAL WIRING
COMPONENTS
Item Description Position on the diagram
I16a Air conditioning pressure switch G7
MV1 Fan motor 1 G11
MV2 Fan motor 2 G15
XC1 Upper cab condenser O3
110
110-02-M146EN (23/01/2012)
schematic diagrams
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
E
1
2
G I16a MV1 G1.5
MV2
G1.5
N1.5
N1.5
V
L
V
4
L
3
XC1 2
N2.5
G2.5
1
Q
110
(23/01/2012) 110-02-M146EN
schematic diagrams
3 - REAR CAB AIR CONDITIONING UNIT WIRING
COMPONENTS
U14 System isolating connectors G18
U15 System isolating connectors M18
U16 Air conditioning compressor O5
U17 Alternator O10
U18+ Battery O6 / O7
U18- Battery O8
U19 Fuse box connector G2
XA/C Truck system connector for cab fans E9
110
110-02-M146EN (23/01/2012)
schematic diagrams
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
XA/C
1
4
3
2
V1.5
V1.5
S
VN
G
U19 U14
S
V2.5 1
L B
2
K V
RN2.5 3
J
I C2.5 4
N1.5
H 5
G V1.5 RN
6
I F R1.5 G
7
E CB1.5
8
D R2.5
MB1.5
R2.5 9
C M1.5
10
B RB1.5
A R4 11
VN R1.5
19 12
18
17
K 16
15 RN C2.5
A
14 RN2.5
B
13
N2.5
12 C
11
10 N
U15
9
8 G
7 CB1.5
M 6 MB1.5
5 M1.5
4 RB1.5
3 R1.5
2 V
1
R2.5
R2.5
R1.5
N1.5
N2.5
V1.5
R4
R6
R6
N6
N6
R6
R6
N6
N6
N
U16 U18+ U18- U17
Q
110
(23/01/2012) 110-02-M146EN
schematic diagrams
4 - AIR CONDITIONING WIRING IN CAB
COMPONENTS
I123 Instrument panel interface connector C7
U7 Front evaporator unit E15
U11 Provision for rear ventilation unit K17
U14 System isolating connectors O2
U15 System isolating connectors K2
U28 Air conditioning switch ON/OFF I6
U29 Ventilation speed switch G15
U33 Additional alternator load warning lights Q6
U34 Heating control connector Q8
110
110-02-M146EN (23/01/2012)
schematic diagrams
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
I123
4
C
RV
V
U7
GV 1 1
CB1.5 2 2
M1.5
E 3 3
V1.5
4 4
R1.5
A A
N1.5
B B
MB1.5
RB1.5
CB1.5
N1.5
N1.5
C2.5
U29
RV
1 7 2 8 10 4 8 3 7 10
1 0 2 1 0
I
U28 5 6 9 2 6 1 5 9
RN
V2.5
RV
V2.5
V2.5
V
U15
A
C2.5 U11
K
RN2.5 RN2.5
B 1 1
N2.5 N2.5 2 2
C
GV
3 3
S S
1 4 4
B
2
V
3
4
N1.5
5
M RN
6
G
7
CB1.5
8
MB1.5
9
M1.5
10
RB1.5
11
R1.5
12
O
U14
C+C
B+B
C
B
Q
2
1
2
1
U33 U34
110
(23/01/2012) 110-02-M146EN
schematic diagrams
110
110-02-M146EN (23/01/2012)
OPTIONS - ATTACHMENTS COMPONENTS
LOCATION
page
AIR CONDITIONING COMPONENTS LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
POSITION OF THE AIR CONDITIONING CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . 6

– DIAGRAM 1 CONDENSER WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– DIAGRAM 2 REAR CAB UNIT WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– DIAGRAM 3 CAB INTERNAL WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
110
(20/01/2012) 110-03-M146EN
components location
110
110-03-M146EN (20/01/2012)
3
Options - attachments components location
POSITION OF THE AIR CONDITIONING CONNECTORS
90°
Maximum
valve
90°
Hydraulic
pump
Condenser
kit
Compressor
Heater
Evaporator
Hydraulic
motor
Alternator
110
(20/01/2012) 110-03-M146EN
4
110
110-03-M146EN (20/01/2012)
components location
110
(20/01/2012) 110-03-M146EN
components location
Position on the diagrams

Ref Description Comments
Diagram 1 Diagram 2 Diagram 3
I16a Air conditioning pressure switch Q29
I123 Instrument panel interface connector I27
MV1 Fan motor 1 I29
MV2 Fan motor 2 M29
U7 Front evaporator unit E30
U11 Provision for rear ventilation unit E14
U14 System isolating connectors I35 C6
U15 System isolating connectors M35 I6
U16 Air conditioning compressor M19
U17 Alternator K26
U18+ Battery M17
U18- Battery M13/M14
U19 Fuse box connector M6
U28 Air conditioning switch ON/OFF I15/I16
U29 Ventilation speed switch I11
U33 Additional alternator load warning lights K23
U34 Heating control connector I19
XA/C Truck system connector for cab fans G25
XC1 Upper cab condenser K8
110
110-03-M146EN (20/01/2012)
7
DIAGRAM 1 CONDENSER WIRING
1 2 3 4 5 6 7 8 9 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 A
C C
E E
G G
MV1
I I
XC1
K K
MV2
M M
O O
I16a
Q Q
110
S S
(20/01/2012) 110-03-M146EN
8
DIAGRAM 2 REAR CAB UNIT WIRING
1 2 3 4 5 6 7 8 9 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 A
C C
E E
G XA/C G
U14
I I
K K
U17
U16
M U19 M
U18- U18+ U15
_ +
O O
12V
45Ah
360A
Q Q
110
S S
110-03-M146EN (20/01/2012)
9
DIAGRAM 3 CAB INTERNAL WIRING
1 2 3 4 5 6 7 8 9 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 A
C C
U14
U7
U11
E E
G G
U15
I I
I123
U29 U28 U34
U33
K K
M M
O O
Q Q
110
S S
(20/01/2012) 110-03-M146EN
10
110
110-03-M146EN (20/01/2012)
OPTIONS - ATTACHMENTS CONTROL
AND ADJUSTMENT
page
MRT 1850/2150/2540 EURO 3 POTENTIOMETERS ADJUSTMENT . . . . . . . . . . . . . . 2
110
(22/08/2011) 110-04-M146EN
2 Options - attachments control
and adjustment
MRT 1850/2150/2540 EURO 3 POTENTIOMETERS ADJUSTMENT
SPEED OF ROTATION
MAX MAX MAX MAX MAX MAX
RAMP RAMP LIFTING TRAVERSING

STOPPED STARTING
MAX MAX
Trolley 1850 2150 2540

Maximum height/time (meters/second) 17,7/46 20,4/53 24,6/63
Maximum radius/time (meters/revolution) 14,9/180 14,4/180 15/180
The position of the potentiometers is for information only.

Use the values in the table.
110
110-04-M146EN (22/08/2011)
FITTING THE COMPONENTS
OPTIONS - ATTACHMENTS
page
FITTING THE AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

– GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– FITTING THE AIR CONDITIONING MOTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– FITTING AIR CONDITIONING TO THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– FITTING THE AIR CONDITIONING HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . 10
– CONTROLS AND TESTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
110
(17/01/2012) 110-07-M146EN
2 Fitting the components
options - attachments
FITTING THE AIR CONDITIONING
90°
90°
GENERAL INFORMATION
To reach the various components, the order of removal must be observed.
Place the truck on a horizontal surface and extend the stabilisers to ensure the greatest stability
and safety.
110
Special instruments:
- Lifting crane (5000 kg. minimum).
110-07-M146EN (17/01/2012)
Fitting the components 3
FITTING THE AIR CONDITIONING MOTORS
6
Fit the battery mounting (Item 1) to its base with the screws
and washers (Item 2, 3 and 4).
Fit the rubber battery mounting (Item 5) and the battery
2
(Item 6) there.
3
4
1
5
Fit the edge cover (Item 7) and the battery rest (Item 8) on
the mounting (Item 1) locking it with the screw (Item 9),
washers (Item 10 and 11) and nut (Item 12).
6
9
7 10
8 11
12
14
15
16 Fit the bracket (Item 13) to the cab with the screws and
washers (Item 14, 15 and 16).
13
Fit the compressor/alternator mounting bracket

18 (Item 17) to the compressor (Item 18) with the screws and
washers (Item 19 and 20).
Fit the pin (Item 21) for the belt tensioning bracket, the nut
(Item 22) and screw (Item 23) to the bracket (Item 17).
Lock the pin (Item 21) with the nut and washer (Item 24
19
20
and 25).
23
110
25
22
24
21
17
(17/01/2012) 110-07-M146EN
Fit the compressor (Item 18) to the bracket (Item 13) with
the screws and washers (Item 19 and 20).
13
19 20
18
Fit the alternator (Item 26) to the bracket (Item 17) with the
13
screws and washers (Item 27 and 28).
Fit the belt tensioning bracket (Item 29) to the mounting
28 bracket (Item 17).
30
27
17
Fit the hydraulic motor (Item 30) to the bracket (Item 13).
29
26
Lock the belt tensioning bracket (Item 29) with the washer
(Item 32) and nut (Item 31), without fully tightening it.
32
Lock the alternator (Item 26) with the nut (Item 31).
31 31
26
18
Fit the pulley (Item 33) to the alternator (Item 26) and
34 the pulley (Item 34) with the spacer (Item 35) and screw
(Item 36) to the compressor (Item 18).
Fit the belt (Item 37) on the pulleys (Item 33 and 34) and on
36
35 the compressor pulley (Item 18).
110
37
33
110-07-M146EN (17/01/2012)
Tension the belt (Item 37) with the bracket (Item 17).
17
37
Fit the spring clips (Item 39) to the housing mounting bracket
(Item 38).
39
39
38
Fit the housing mounting bracket (Item 38) to the belt

tensioning bracket (Item 17) with the screw and washer
17 (Item 40 and 41).
40
41 38
43 Fit the housing (Item 42) with the screws (Item 43), washers
44 45
(Item 44) and nuts (Item 45).
42
110
(17/01/2012) 110-07-M146EN
Connect the hydraulic pipes (Item 46 and 47).
47
46
Connect the hydraulic pipes (Item 48, 49 and 50) to the

49
hydraulic motor.
48
50
Fit the pump suction hose (Item 52), to the motor, with the
seal (Item 51).
51
Screw in the screws and washers (Item 53 and 54).
52
54
53
Connect the cast iron pipe (Item 55) to the truck engine and
fit it above the nipple (Item 56) and the pipe.
55
56
110
110-07-M146EN (17/01/2012)
FITTING AIR CONDITIONING TO THE CAB
Fit the heater (Item 1) to the appropriate mounting

(Item 2).
2
Fit the three-way duct (Item 3) to the mounting (Item 2) with

the appropriate screws (Item 4).
6 Fit the air pipe (Item 5), to the heater (Item 1) and to the
three-way duct (Item 3), locking it with the clips (Item 6).
3
4
6
1
Fit the evaporator mounting (Item 7) to the truck cab with

the screws and washers (Item 8, 9 and 10).
9
10
8
11 Fit the edge cover (Item 11) to the mounting (Item 7).
Fit the evaporator (Item 12), to the mounting (Item 7),
with the screws and washers (Item 13 and 14) and nut
(Item 15).
110
12
7
15
13
14
(17/01/2012) 110-07-M146EN
Fit the air pipe (Item 16), to the evaporator (Item 12) and
17
the three-way duct (Item 3), locking it with clips (Item 17).
16
3 17 12
Fit the hydraulic pipe (Item 18) to the pump (Item 19).
19
18
Fit the left (Item 20) and right (Item 21) mounting to the
condenser kit (Item 22) screwing in the screws and washers
27 (Item 23 and 24).
26
25
Fit the kit (Item 22) above the cab, locking it with the screws
and washers (Item 25, 26 and 27).
24
23
20 21
22
Fit the lower protective grille (Item 28) with the screws and
washers (Item 29 and 30), fit the left (Item 31) and right
35
31 (Item 32) lamp covers with the screws and washers (Item 33
36
and 34).
37 29 30 33
38 34
Fit the upper bonnet (Item 35) with the screws and washers
(Item 36, 37 and 38).
32
110
28
110-07-M146EN (17/01/2012)
43 44
Fit the electric socket mounting (Item 39) on the truck with
the screw (Item 40), washer (Item 41) and nut (Item 42).
Fit the rotating lamp (Item 43) and emergency lamp
(Item 44) and connect the electric sockets (Item 45).
39
45 40
41
42
Connect the pipes (Item 46) to the condenser kit (Item 47)
and the condenser filter.
47
46
Connect the pipes (Item 48 and 49) to the evaporator.
49
48
Connect the pipes (Item 50 and 51) to the compressor

(Item 52).
52 50
110
51
(17/01/2012) 110-07-M146EN
Connect the electric cables (Item 53).

53
Fit the small duct (Item 54) to the mounting (Item 55) with
56 the screws and washers (Item 56 and 57).
55
57
54
FITTING THE AIR CONDITIONING HYDRAULIC

1
2 SYSTEM
3
Fit the washer (Item 2) and reducer (Item 3), to the exhaust
manifold (Item 1), above the tyre carrier connection
(Item 4) on which the tube will be mounted (Item 5); lock the
4 tube with the clamp (Item 6).
6
5
Fit the edge cover to the base (Item 7), to prevent wear on
8
the base.
Lock the tube to the engine with the clamp (Item 8) and
screw (Item 9).
9
7
110
110-07-M146EN (17/01/2012)
11 Mount the connectors (Item 11, 12, 13, 14 and 15) on the
12
exhaust valve (Item 10).
Lock the tube (Item 16) to the base with the clamp (Item 17),
10 screws and washers (Item 18 and 19).
13
14
18 19
15
17
16
24 26 23 Fit the exhaust valve (Item 10) to the mounting (Item 23),
25 locking it with the screws and washers (Item 20, 21 and
20 22).
10
21
22 Fit the mounting (Item 23) to the base with the screws and
washers (Item 24, 25 and 26).
Fit the connectors (Item 27) to the manifold (Item 28).
28
27
Fit the connectors (Item 29 and 30) to the hydraulic manifold

31 (Item 31).
29
110
30
(17/01/2012) 110-07-M146EN
CONTROLS AND TESTS
After fitting the kit, proceed as follows:
1. Charge the system compressor and fill with oil according to the following instructions:
The quantity of R134a gas necessary to charge the system is Kg. 0,800.
Simultaneously with charging, a quantity of 100 gr. of special oil for the SANDEN compressor fitted
must be added to the system.
Oil code: AT41234 to be requested from DELPHI product distribution and sales centres for.
2. Checking the pressure in the hydraulic system and checking the number of revolutions of the
compressor electropulley:
The pressure in the hydraulic system, at maximum engine revolutions, must be 200 bar (the
pressure is adjustable using the VLP valve by connecting a manometer to the pressure test socket
on the “T” coupling of the valve).
Check that, at minimum engine speed, the rotation of the compressor electropulley is between
900 ÷ 1000 r.p.m (check the number of revolutions with a revolution counter).
Optimum operation of the air conditioning is obtained with an electropulley speed of 3500 r.p.m
with the engine at maximum revolutions and with a hydraulic system pressure of 170 bar.
110
110-07-M146EN (17/01/2012)
TRANSMISSION
- TRANSMISSION CHARACTERISTICS
AND TECHNICAL SPECIFICATIONS
- TRANSMISSION SCHEMATIC DIAGRAMS
20
- TRANSMISSION COMPONENTS LOCATION
- TRANSMISSION CONTROL
AND ADJUSTMENT
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT
- TRANSMISSION SPECIFIC TOOLING

M
R
- COMPONENTS CONTROLS (Pump series A4VG)

AND ADJUSTMENT
M
R
647031EN
(Motor series A6VM)

M
R
647039EN
(Pump series H1 45/53)

M
R
647040EN
(Motor series 51/51-1)

M
R
647379
(Gear change Dana 357)

20
TRANSMISSION CHARACTERISTICS
AND SPECIFICATIONS
page
SAUER HYDROSTATIC TRANSMISSION
– BOOSTER PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– PUMP/ENGINE CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– PRESSURE LIMITING VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– FLUXING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– NFPE AUTOMOTIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SERIES H1 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– NFPE PROPORTIONAL ELECTRICAL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– PUMP REGULATOR VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– FILTER (TOTAL PRESSURE FILTRATION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SERIES 51 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– EXCHANGE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– CONNECTING THE HYDRAULIC CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
PLUS+1 TM MC024-021 AUTOMOTIVE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– AUTOMOTIVE CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– SELECTOR (FORWARD/NEUTRAL/REVERSE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– INCHING SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– MODE SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– MOTOR CONTROL CURVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– LIMITATION OF CARDAN SHAFT REVOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– CONNECTION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(11/01/2012) 20-01-M146EN
2 Transmission characteristics
and specifications
REXROTH HYDROSTATIC TRANSMISSION
– SPECIAL ADVANTAGES OF HYDROMATIK TRANSMISSIONS . . . . . . . . . . . . . . . . . . . 16

– MAIN CIRCUIT OF HYDROSTATIC TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . 17
20
– DESCRIPTION OF OPERATION OF THE HYDROMATIK TRANSMISSION . . . . . . . . . . . . . 18

– GENERAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– KINEMATIC CHAIN OF TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– HYDROSTATIC TRANSMISSION AND REAR AXLE LOCK . . . . . . . . . . . . . . . . . . 20
– HYDRAULIC TRANSMISSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
A4VG/71 DA/1D2 PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
– CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
– CROSS SECTION OF A4VG/DA PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
– OPERATION OF “DA” REGULATION CARTRIDGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
– CHARACTERISTICS OF DR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
– ROLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
– COMPOSITION OF THE DR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
– CROSS SECTIONAL VIEW OF THE DR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . 25
– DR VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
– INCHING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
A6VM / 107 DA / 1 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
– CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
– DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
20-01-M146EN (11/01/2012)
Transmission characteristics 3
and specifications
SAUER HYDROSTATIC TRANSMISSION

BOOSTER PUMP
Usually built into the body of the main pump, it prevents cavitation of the system by replacing fluid
lost by blow-by, also supplying the necessary pressure to the displacement variation system of the
main pump.
20
PUMP/ENGINE CONTROLS
These are the parts that control the displacement variation of both components.
PRESSURE LIMITING VALVES
These limit the maximum pressure in both branches of the transmission.
FLUXING VALVE
The purpose of using this valve is to optimise the working conditions, by eliminating contamination
from the closed circuit, aiding thermal stability and rapidly expelling the air present in the circuit.
(11/01/2012) 20-01-M146EN
and specifications
HYDRAULIC CIRCUIT
20
Heat Exchanger
Bypass Valve
Reservoir
Heat Exchanger
Electric
Displacement
Control
Bent Axis Variable

Charge Check/ Displacement Motor
Servo Cylinder Pressure Limiter High Pressure
Valve Relief Valve
Pump
Swashplate
Output
Shaft
Loop
Flushing
Charge Pressure Valve
Filter
Charge
Pump
Input Synchronizing
Shaft Shaft
Charge To Motor Swashplate

Pressure Motor
Variable Relief Charge Check/ Case
Displacement Valve High Pressure
Pump Pressure Limiter Valve Relief Valve
Working loop B Case Working loop A (low pressure) Servo

Suction
(high pressure) drain and charge pressure pressure
20-01-M146EN (11/01/2012)
and specifications
NFPE AUTOMOTIVE SYSTEM
20
(11/01/2012) 20-01-M146EN
and specifications
SERIES H1 PUMP
20
20-01-M146EN (11/01/2012)
and specifications
NFPE PROPORTIONAL ELECTRICAL CONTROL
NFPE Proportional Actuation
100 %
NFPE control
r
0 ba
20
bar
= 30
=0
Δp
Δp
Signal Current (mA(DC avg ))
Displacement
0 ba
bar
= 30
=0
Δp
Δp 100 %
NFPE / C1 and C2 Location
NFPE Schematic
M14
C2 C1
C1
C2
F00B F00A T P
(11/01/2012) 20-01-M146EN
and specifications
PUMP REGULATOR VALVES
078 Single Pump

20
Adjustment of
pressure cutoff
Electric
proportional
pressure
reducing valves
Charge Pressure Relief Valve
Load pressure
reducing valve
High Pressure Relief and Charge Check

Valve with Bypass Valve in Charging Mode
High Pressure Relief and Charge Check

Valve with Bypass Valve in Relief Mode
Maximum pressure
valve
20-01-M146EN (11/01/2012)
and specifications
FILTER (TOTAL PRESSURE FILTRATION)
Technical Data, Pressures
20
Maximum Charge Pressure 30 bar [435 psi]
Filter Bypass Sensor Δp 3.7 - 5.1 bar Connector
Switch Closure [54 - 74 psi] Deutsch DTM04-2P
Δp 5.6 ± 0.9 bar

Bypass Valve
[80 ± 13 psi]
M6
Before Filter (upstream)
0.5625-18UNF-2B
Technical Data, Electric [9/16 -18UNF-2B]
Max. Voltage 48 V
Max. Power 0.6 W
Resistor R1 510 Ω
Schematic
Resistor R2 160 Ω M6 1 2
Resistor Tolerance 1% R1
-20 °C ÷ +100 °C
R2
Temperature Range
[-4 °F ÷ +212 °C]
IP Rating (DIN 40 050) with
IP 69K
Mating Connector
Integral Filter Head with Filter Bypass Sensors

Filter
element
in out
Filter
bypass sensor
Bypass spool
(11/01/2012) 20-01-M146EN
and specifications
SERIES 51 MOTOR
20
20-01-M146EN (11/01/2012)
and specifications
HYDRAULIC CIRCUIT
20
EXCHANGE VALVE
(11/01/2012) 20-01-M146EN
and specifications
CONNECTING THE HYDRAULIC CONTROLS

20
20-01-M146EN (11/01/2012)
and specifications
PLUS+1 TM MC024-021 AUTOMOTIVE SYSTEM
The microprocessor manages both the pump and the engine by means of electrical pressure
reducers located on the controls.
AUTOMOTIVE CURVE
20
The two different curves were designed in agreement with the customer, taking into account the
torque characteristics of the diesel engine and the power necessary for the auxiliary services.
SELECTOR (FORWARD/NEUTRAL/REVERSE)
The direction of travel can be selected by using a three-way electrical selector

The deceleration and acceleration times are set according to the position of the selector.
INCHING SENSOR
The inch-brake pedal connected to the potentiometric sensor reduces the current to the proportional
valves of the pump, until it is fully zeroed, if necessary.
This function enables the operator to reduce the speed of the vehicle during particular movements
in which a high engine speed must be used and provides a way in which the services can operate
efficiently.
(11/01/2012) 20-01-M146EN
and specifications
MODE SWITCH
Two independent control curves (translation/working).
MOTOR CONTROL CURVE
The control curve of the motor reducer is generated by a calibration that is dependent on the
20
engine r.p.m.
LIMITATION OF CARDAN SHAFT REVOLUTIONS
To avoid overspeed of the cardan shaft, the function reduces the current to the control reducer
valves.
20-01-M146EN (11/01/2012)
and specifications
CONNECTION DIAGRAM
Deutsch connector, 12pin

C1
Power (-) 1 C1:

C 1: 01
Power (+) 2 C1:

C 1: 02
CAN+ 3 C1:
C1: 03
C1:
C 1: 04
CAN Bus
Terminals
Batt. (+)
Connections
CAN- 4
Terminals
Analog Input 2 5 Sensor (+) C1:
C1: 08
08
Rv Terminals necessary
20
Batt. (-)
C1:05
C1:05 Creeper drive
6
Digital Input 1
Digital Input 2 7
Terminals
C1:
C1: 09
Rv Options
Sensor (-)
+5VDC 8 C1:
C1: 06
C1:07
C1:07
Fwd
Rev
Hand Brake
Seat-Switch
used
Sensor Ground 9 C1: 08
Analog Input 1 10
C1: 09
FNR switch Options
Rv
C1:
C
C1:10
1: 08
PPU Input 1 11
C1:
C1: 10 Inch pedal
PPU Input 2 12 C1:
C1: 09
Rv
C1:
C1: 08
C1:
C 1: 11 PPU motor
C1:
C 1: 09
C1: 08
C1: 12 PPU engine
C1: 09 Requirement read
by the CAN Bus
Deutsch connector, 12pin
C2
Mode switch
C2:
C 2: 01
Digital Input 3 1
Digital Input 4 2 Creep drive switch
C2: 02
PWM Output 1 3
PWM Output 2 4 C2:
C 2: 03
Reverse Forward
C2:
C 2: 04
Digital Output 4 5 NFPE Valve
Digital Output 5 6
PWM Output 5 7 C2:
C2: 05 Retarder Signal Error signalling
Digital Output 1 8 C2:
C2: 06 Reverse
Digital Output 2 9 3 Buzzer
C2:
C2: 07
Digital Output 3 10
C2:
C2: 08 BPD PROP
Power (+) 11 3 Motor
displacement
Power (+) 12
C2:
C 2: 09
3
Brake light
C2:
C 2: 10
3
Parking Brake
C2:
C 2: 11+12 1
S1 2
F
+ Batt. -
12VDC
(11/01/2012) 20-01-M146EN
and specifications
REXROTH HYDROSTATIC TRANSMISSION

SPECIAL ADVANTAGES OF HYDROMATIK TRANSMISSIONS
Before making any adjustment to DA motors, it is essential to comply with the following operating
conditions:
– The adjustment, putting into operation or checking of the operating data of the A4VG71DA 1D2
20
primary part must be carried out before any recalibration of the A6VM107DA 1 secondar. part.
– The operating temperature must be about 50 - 60 °C (circuit temperature).
– Pressure splitting or cutting must be in operation. On vehicles not fitted with splitting, check that
the safety valves are not operating.
Never carry out adjustments or calibrations on a variable motor without a manometer.
All adjustments and calibrations must be made at maximum working pressure and maximum
engine revolutions (under load).
For all adjustments on a variable motor, adequate precautions must be taken to prevent unexpected
movement of the vehicle.
The best precaution is to raise the vehicle and lock the wheels with the brakes.
Apart from the classical characteristics of hydrostatic transmissions (freedom of installation of
the transmission, minimum bulk, instantaneous drive reversal, elimination of friction, dynamic
braking), HYDROMATIK transmissions have the following advantages:
1) A4VG71DA 1D2 pumps are the most powerful on the market.
2) The high rotation speed of A4VG71DA 1D2 pumps and A6VM107DA 1 motors.
3) Inclined body construction of A6VM107DA 1 engines; the pistons do not have guides,
which enables it to transmit 90% of the nominal torque when starting and a possible
wide variation in displacement.
4) Automatic, continuous variation of the transmission ratio, depending on the

requirement of the operator (accelerator pedal) or according to the load and best
use of the installed power.
5) Conventional control with an accelerator pedal, brake pedal and transmission cutoff
(inching).
6) DA regulation acts like a “limited load power adjustment”. The pump with DA regulation
is normally mounted on the engine and does not require power calibration, making
the corresponding adjustments easier. DA regulation enables maximum pressure
and displacement to be obtained, even before the maximum speed of the engine
(1600/2000 r.p.m.-1) so that the force of the engine at 75% of the movement speed
gives a low specific fuel consumption.
7) In the case of an application under load, the average speed of movement is high
and the traction force is maximum at a reasonable engine speed, the efficiency of
the engine (hourly cubic volume/hourly consumption) is very high.
8) The inching valve, fixed for the first part of the brake pedal stroke, reduces the
speed of movement of the vehicle, increasing the engine speed and, consequently,
20-01-M146EN (11/01/2012)
and specifications
Achievement of the maximum lifting speed is then possible at reduced speed, giving
improved working efficiency.
Thanks to the inching valve at the moment the driver brakes, initially there is
hydrostatic braking, then normal braking, therefore giving economy and long life of
the braking system.
9) Slight reduction in engine speed at full load.
20
10) No overloading of the engine.
11) On lowering the engine speed, the power of the engine is not converted into heat;
the HP limiters do not open thanks to the joint double system: return and DR valve.
12) Checking the displacement of the A6VM variable motor using the same control
pressure as the pump (still unique on the market).
13) Installing the DA regulated variable motor enables the displacement of the pump
to be adapted ideally to the thermal power (and not the apparent power of the
engine).
In this way, the constant flow of power of the pump is optimal and remains
satisfactory with the transfer of power to truck movement hydraulics.
14) HP blocking system on A6VM motors that enables them to note the direction of the
torque in relation to the direction of travel thereby avoiding harsh and unexpected
braking.
MAIN CIRCUIT OF HYDROSTATIC TRANSMISSIONS
1 2 4 3
6 6
5
1) PERKINS series 1104C.44T/

Adjustment and 1104C.44TA engine
reversal 2) A4VG71DA 1D2 series variable
displacement hydrostatic pump
3) A6VM107DA 1 series hydrostatic motor
with variable displacement
4) Booster gear pump
5) Maximum boost valve
6) High pressure valve
(11/01/2012) 20-01-M146EN
and specifications
DESCRIPTION OF OPERATION OF THE HYDROMATIK TRANSMISSION
GENERAL
The hydrostatic transmission optimises the torque available from the engine to the wheels,
according to the resistance encountered from the engine and the speed desired by the operator.
The transmission ratio varies continuously and automatically.
20
The system transmits the power because mineral oil is practically incompressible and can withstand
heavy loads.
The A4VG HYDROMATIK.. DA/A6VM..DA transmission consists of two separate parts.
1° An A4VG axial piston with swashplate type pump, flange-mounted to the engine and
driven directly from the flywheel by a flexible coupling.
2° An A6VM axial piston type hydraulic motor with inclined body, flange-mounted to a two-
speed gearbox located on a differential axle that transfers motion to the wheels.
The pump and hydraulic motor are connected together by flexible pipes as are the various
accessories necessary for operation: tank, filter, drainage return to the radiator, etc…
The pump absorbs the maximum power available from the engine and converts it into hydraulic
power (product of pressure and flow).
The hydraulic motor, which is the receiving component, absorbs all the hydraulic power.
Producing at the output shaft a torque and speed of rotation that is taken up by an axle and
distributed to the wheels.
The transmission ratio is varied by varying the displacement of the pump and the hydraulic
motor.
The drive pressure acts against the high pressure on the servo-positioner in a predetermined fixed
ratio (1/3).
The preponderance of one in relation to the other determines whether the motor does or does not
enter into regulation.
The minimum displacement of the motor is limited by a stop screw.
A regulation system controls the switching time of the motor.
20-01-M146EN (11/01/2012)
and specifications
KINEMATIC CHAIN OF TRANSMISSION
1 2 1
20
3
4
7
6 6
10
11
1) Brakes
2) Differential axle
3) 2-speed gearbox
4) Variable displacement motor
5) Oil radiator
6) High pressure flexible pipes
7) Tank
8) Filtration
9) Boost pump
10) Variable displacement pump
11) Engine
(11/01/2012) 20-01-M146EN
and specifications
HYDROSTATIC TRANSMISSION AND REAR AXLE LOCK

20
HYDRAULIC TRANSMISSION SYSTEM
M.C.
3 bar
T A
b a
R T1 T2 Ps Fa Fe MB
450bar B
M. 450bar 35bar 440bar
A
X1 X2 S
M.I.
P.I. G MA
X1 X2 B
RAD.
F.A.
R.
20-01-M146EN (11/01/2012)
and specifications
A4VG / 71 DA / 1D2 PUMP
CHARACTERISTICS
As in the A4V series, this pump is fitted with:

• tachymetric speed regulation,
20
• return regulation of the swashplate,
but also:
• DR regulation, known as flow “CANCELLATION VALVE” with pressure maintenance.
Starting from pulley block 71, a locking screw for the orientation bearings of the
swashplate is located on the fixing flange part of the pump. Not to be confused with a
pressure takeoff plug.
DR valve
Orifice, dia. 0.8 ÷ 1.2
HP valve
Inching valve
output
PS
“DA” regulation
cartridge
HP valve
Maximum boost valve
Mechanical zero
End of regulation screw
(11/01/2012) 20-01-M146EN
and specifications
CROSS SECTION OF A4VG / DA PUMP

20
20-01-M146EN (11/01/2012)
and specifications
OPERATION OF “DA” REGULATION CARTRIDGE
The drive pressure is taken through the boost system regulation cartridge slider of the boost
circuit. At maximum engine speed, the drive pressure is a few bar lower than the boost pressure.
At minimum speed (850 r.p.m.-1), the boost flow, which passes through the calibrated hole in the
regulation cartridge element, is not sufficient to create a loss of load that can move the slider
(Item 1) due to the force of the spring (Item 2). The drive pressure is therefore zero.
20
When the operator speeds up the engine to increase the boost flow (to about 1050 r.p.m.-1), the
boost flow increases; the loss of load in front of the calibrated hole becomes sufficient to move
the slider to the left, compressing the spring, thereby uncovering the drive hole.
When the drive pressure reaches about 6 ÷ 7 bar, the servo control cylinder begins to move, tilting
the swashplate of the variable flow pump.
The pump begins to deliver (start of regulation). The more the engine speed increases, the more the
boost flow and drive pressure increase, and giving greater drive from the pump, and consequently,
higher speed of the truck.
To stop, the operator stops accelerating, the boost flow falls, the loss of charge decreases and the
spring (Item 2) pushes back the slider (Item 1) stopping the boost flow towards the drive piping.
The residual drive pressure is released into the sump.
Variable flow pump
Servo control cylinder
Forward-reverse
electrovalve
Pressure limiter
2
1
Regulation cartridge
Accelerator
Calibration screw for start of regulation
(11/01/2012) 20-01-M146EN
and specifications
CHARACTERISTICS OF DR VALVE
ROLE
Cancelling the flow while maintaining the pressure. This corresponds to returning the pump
displacement to “0” before the calibration point of the HP valve is reached.
20
This valve prevents activation of the HP limiters when accelerating or decelerating (rapid increase
in pressure).
The maximum pressure is cut by the HP limiters that also protect the circuit against extremely
rapid fluctuations. The flow cancellation calibration while maintaining the pressure extends to all
working pressure surfaces. The corresponding calibration values must however be 20 to 30 bar
less than those of the HP limiters.
- Less noisy transmission.

- Wider range of calibration.
COMPOSITION OF THE DR VALVE
1) HP circuit flow selector.

2) A slider that connects the drive circuit to the tank to control the pump and maintain 400 bar
(start of regulation at 6 ÷ 7 bar, 20 bar up to regulation with max. flow).
The DR valve reduces the basic flow at max. torque.
OPERATION
The MA or MB HP passes through the HP circuit selector upwards or downwards and closing the
opposite low pressure orifice (in the direction HP from A to B, the HP passes through the centre of
the selector through a small passage).
In all cases, the HP presses against the pin, Item 4, which, at the same time raises the regulation
slider (Item 3) enabling the drive orifice to communicate with the exhaust, thereby reducing the
drive pressure.
This has the effect of reducing the displacement of the pump, so reducing the flow to maintain the
HP at 400 bar (reduction of flow for max. torque).
This drive action of the pump acts in the same direction as the return forces generated by the HP
and the locking of the distribution plate.
20-01-M146EN (11/01/2012)
and specifications
CROSS SECTIONAL VIEW OF THE DR VALVE
11 9
20
1
8
10 2
7 3
12
Vo
8
4
MB 5
MA 6
1) Restraining bush
2) Bronze slider
3) Slider for DR registration
4) Pin
5) HP selector
6) Seat
7) Spring
8) Spacer
9) Adjusting screw
10) Seal
11) Locknut
12) Drive
(11/01/2012) 20-01-M146EN
and specifications
DR VALVE
Adjusting screw
Drive pin
20
Hole for removal

Slider of blow-by
Spring
HP selector
DR regulation slider
Seat
If there is a large drop in engine speed, check that the drive pin has not “seized” in the
slider.
20-01-M146EN (11/01/2012)
and specifications
INCHING CIRCUIT
20
Inching
valve
(11/01/2012) 20-01-M146EN
and specifications
A6VM / 107 DA / 1 MOTOR

CHARACTERISTICS
Series 6 variable displacement motor- for open and closed circuits - conical axial piston type with
gas-tight piston rings and inclined axis. Displacement 28 to 200 - nominal pressure: 400 bar -
maximum pressure: 450 bar.
20
Suitable for fixed and mobile installations.

Its wide range of adjustment enables this motor to meet the requirements of high torque and
speed.
The displacement is variable in the ratio:
V g max / V g min = 4,85 continuous.
The output speed is proportional to the flow absorbed and inversely proportional to the displacement.
The output torque varies as a function of the pressure difference between the high and low pressure
outputs, or as a function of the displacement.
DETAILS:
- Wide range of regulation for hydrostatic transmissions.

- Various displacement adjustment devices.
- Reduced cost of the transmissions thanks to the deletion of change in speed or the use of low
displacement pumps.
- Small, strong taper roller bearings.
- High maximum power.
- Good starting characteristics.
20-01-M146EN (11/01/2012)
TRANSMISSION SCHEMATIC DIAGRAMS
20
page
SAUER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
REXROTH TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
(23/11/2011) 20-02-M146EN
A2
Transmission schematic diagrams
20
20-02-M146EN (23/11/2011)
A3
SAUER TRANSMISSION
page
FORWARD GEAR HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
REVERSE GEAR HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . A6
20
(23/11/2011) 20-02-M146EN
A4
20
20-02-M146EN (23/11/2011)
A5
DIAGRAM OF SAUER FORWARD GEAR HYDROSTATIC TRANSMISSION
Key:
High pressure
Low pressure
Control pressure
Drainage pressure
20
Load pressure
Inlet pressure
VSLR MC
EV(S28)
EV(S27)
Return to outlet
B A
1 2 PF § 70 See section “70 – hydraulics”
S.
T P CR Hydraulic manifold
EV(S21) Forward gear electrovalve
EV(S22) Reverse gear electrovalve
EV(S27) High speed electrovalve
EV(S28) Low speed electrovalve
EV(S40) Motor displacement reduction electrovalve
FDAR Rear disk brakes
CR FDAV Front disk brakes
FORWARD gear MC Brake pump
M.I. Variable displacement motor
PF Brake pedal
P.I. Hydrostatic pump
R. Oil tank
VCLR
RAD. Radiator
S. Oil tank
M14 M6 1 2
R1
VCLR Low speed command cylinder
VSLR Slow-fast selector valve
R2
C2 C1
EV EV
(S22) (S21) L2 M4 M3 N
M8 L1 L2 MA A
A
XB XA M1
FDAV F0OB F0OA 480bar
max.
FDAR
34bar disp.
450bar
350bar
480bar
M5
450bar
CW
EV
(S40) (M5) X3
M4 B
M7
FRONT B M2 REAR
P.I. S L3 L4 MB L1
M.I.
AXLE max 3 bar
AXLE
143,5 psi
RAD.
§ 70
R.
(23/11/2011) 20-02-M146EN
A6
DIAGRAM OF SAUER REVERSE GEAR HYDROSTATIC TRANSMISSION
Key:
High pressure
Low pressure
Control pressure
20
Drainage pressure
Load pressure
VSLR MC
EV(S28)
EV(S27)
Inlet pressure
B A
1 2 PF Return to outlet
S.
T P
§ 70 See section “70 – hydraulics”
CR Hydraulic manifold
EV(S40) Motor displacement reduction electrovalve
FDAV Front disk brakes
CR
MC Brake pump
REVERSE gear M.I. Variable displacement motor
PF Brake pedal
VCLR R. Oil tank
RAD. Radiator
S. Oil tank
M14 M6 1 2
R1
R2
C2 C1
EV EV
(S22) (S21) L2 M4 M3 N
M8 L1 L2 MA A
A XB XA M1
F0OB F0OA 480bar
max.
450bar 34bar disp.
FDAV FDAR
350bar
480bar
M5
CW 450bar
EV
(S40) (M5) X3
M4 B
M7
B M2
S
P.I. L3 L4 MB L1
M.I.
FRONT max 3 bar
REAR
143,5 psi
AXLE § 70
RAD. AXLE
R.
20-02-M146EN (23/11/2011)
B1
REXROTH TRANSMISSION
page
FORWARD GEAR HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
REVERSE GEAR HYDROSTATIC TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
20
(23/11/2011) 20-02-M146EN
B2
20
20-02-M146EN (23/11/2011)
B3
DIAGRAM OF REXROTH FORWARD GEAR HYDROSTATIC TRANSMISSION
Key:
High pressure
Low pressure
Control pressure
VSLR MC Drainage pressure
EV(S28)
EV(S27)
20
B A Load pressure
1 2 PF
S. Inlet pressure
T P
Return to outlet
CR
FORWARD gear FDAR Rear disk brakes
M. I.C. engine
MC Brake pump
PF Brake pedal
VCLR R. Oil tank
RAD. Radiator
3 bar S. Oil tank
EV EV VCLR Low speed command cylinder
(S22) (S21) T A
b a
R T1 T2 Ps Fa Fe MB
450bar B
M.
450bar 35bar 440bar
P.I. A
FDAV X1 X2 G S MA
M.I. FDAR
X1 X2 B
§ 70
FRONT REAR
AXLE RAD.
AXLE
R.
(23/11/2011) 20-02-M146EN
B4
DIAGRAM OF REXROTH REVERSE GEAR HYDROSTATIC TRANSMISSION
Key:
High pressure
Low pressure
Control pressure
VSLR MC Drainage pressure
20
EV(S28)
EV(S27)
B A Load pressure
1 2 PF
Inlet pressure
T P
S.
Return to outlet
REVERSE gear CR
M. I.C. engine
MC Brake pump
PF Brake pedal
R. Oil tank
VCLR RAD. Radiator
S. Oil tank
3 bar
EV EV
(S22) (S21) T A VSLR Slow-fast selector valve
b a
R T1 T2 Ps Fa Fe MB
450bar B
M.
450bar 35bar 440bar
P.I. A
FDAV M.I. FDAR
X1 X2 G S MA
X1 X2 B
§ 70
FRONT
AXLE
RAD.
R.
20-02-M146EN (23/11/2011)
TRANSMISSION COMPONENTS LOCATION
20
page
HYDROSTATIC TRANSMISSION CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

HYDROSTATIC TRANSMISSION COOLING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(14/12/2011) 20-03-M146EN
2
Transmission components location
20
20-03-M146EN (14/12/2011)
3
HYDROSTATIC TRANSMISSION CIRCUIT
Hydrostatic
pump
20
Hydrostatic
motor
Switch
Rear axle
Cardan
shaft
Working
pump
Front axle
(14/12/2011) 20-03-M146EN
4
HYDROSTATIC TRANSMISSION COOLING CIRCUIT
20
Air
radiator
Water
radiator
Oil
radiator
20-03-M146EN (14/12/2011)
20
TRANSMISSION CONTROL AND ADJUSTMENT
page
SAUER TRANSMISSION
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– PRESSURE TEST POINTS ON THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– PRESSURE TEST POINTS ON THE MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– PRESSURE TEST POINTS ON THE A4VG 71 PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– CONTROL PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– BOOST PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– CASING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– PRESSURE TEST POINTS ON A6VM 107 MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– HIGH PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– SWITCHING PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TRANSMISSION CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– POINTS ADJUSTMENT ON THE TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– A4VG PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– A6VM MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– TESTS BEFORE SETTING THE TRANSMISSION TO WORK OR AFTER A REPAIR . . . . . . . 11
– SETTING TO WORK: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– BOOST PRESSURE CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– ADJUSTING THE MECHANICAL “0” OF THE PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– CHECK THE ADJUSTMENT: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
(11/01/2012) 20-04-M146EN
2
Transmission control and adjustment
– START OF REGULATION CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . 14

20
– START OF REGULATION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– END OF REGULATION CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . 15
– TESTING:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– END OF REGULATION:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– HP LIMITERS CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– ADJUSTING THE HP LIMITERS: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– A6VM MOTOR ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
– A. MINIMUM DISPLACEMENT CONTROL (MAX. SPEED): . . . . . . . . . . . . . . . . . . 17
– B. START OF REGULATION CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
– C. MAX. DISPLACEMENT: (MAX TRACTION FORCE) . . . . . . . . . . . . . . . . . . . . . 17
– FAULT FINDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– PUMP / MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
20-04-M146EN (11/01/2012)
3
SAUER TRANSMISSION
PRESSURE TEST
PRESSURE TEST POINTS ON THE PUMP
Servo Gage Port “M4” Connector : Case Drain Port “L1”
Port ISO 11926-1 – 7/16 -20
20
Deutsch DT04-2P Port ISO 11926-1 – 7/8 -14
to be paint free
System Port “B”

Ø25.4 – 450 bar Connections
Split Flange Boss
per ISO 6162
M12 x 1.75
Pressure test
20 min. points
Full Thread Depth
Electrical
connections
Port Description
Port Description Sizes
A System Port “A” Ø 25.4
B System Port “B” Ø 25.4
Charge Filtration Port,
E / -14
7 8
from Filter
System Port “A” Case Drain Port “L4” F Charge Filtration Port, to Filter / -14
7 8
Ø25.4 – 450 bar Port ISO 11926-1 – 1 1/16 -12
Split Flange Boss Charge Inlet Port “S” L1 Case Drain Port / -14
7 8
per ISO 6162 Port ISO 11926-1 – 1 5/16 -12

M12 x 1.75
L2 Case Drain Port 1 1/16 -12
20 min. L3 Case Drain Port 7/8 -14
Full Thread Depth
System “A
““A”” Gage Port “MA” MA System “A” Gage Port 9/16 -18
Port ISO 11926-1 – 9/16-18
MB System “B” Gage Port 9/16 -18
Charge Gage Port,

M3 / -18
9 16
after Filtering
M4 Servo Gage Port / -20
7 16

7 16
M14 Case Gage Port 7/16 -20
S Charge Inlet Port 1 5/16 -12
(11/01/2012) 20-04-M146EN
4
System “B” Gage Port “MB”

Port ISO 11926-1 – 9/16-18
Connections
Pressure test
points
Electrical
connections
20
Charge Filtration Port “F”

Port ISO 11926-1 – 7/8 -14
to Filter
Charge Filtration Port “E”

Case Gage Port “M14” Port ISO 11926-1 – 7/8 -14
Port ISO 11926-1 – 7/16 -20 from Filter
Port Description
Connector : Servo Gage Port “M5” Port Description Sizes
Case Drain Port “L3”
Port ISO 11926-1 – 7/16 -20
Port ISO 11926-1 – 7/8 -14 Deutsch DT04-2P A System Port “A” Ø 25.4
to be paint free
E / -14
7 8
from Filter
F Charge Filtration Port, to Filter / -14
7 8
L1 Case Drain Port / -14

7 8

L3 Case Drain Port 7/8 -14
L4 Case Drain Port 1 /16 -12

1
MA System “A” Gage Port 9/16 -18
Charge Gage Port,

M3 / -18
9 16
after Filtering
7 16

7 16

Case Drain Port “L2” Charge Gage Port “M3”
Port ISO 11926-1 – 1 1/16 -12 Port ISO 11926-1 – 9/16 -18
aft
f er ﬁltering
after
20-04-M146EN (11/01/2012)
5
20
[4.85 ± 0.039]
123.3 ± 1.0
[7.33 ± 0.039]
[6.31 ± 0.039]
[8.21 ± 0.039]
186.3 ± 1.0
160.3 ± 1.0
208.7 ± 1.0
Connector :
Deutsch DTM04-2P
to be paint free
62.2 ± 1.0
[2.45 ± 0.039]
Charge Gage Port “M6” 32.8 ± 1.0
[1.50 ± 0.039] 276.4 ± 1.0
Port ISO 11926-1 – 9/16 -18 [10.88 ± 0.039]
before
befo
f re Filter 38.2 ± 1.0 285.0 ± 1.0
[1.50 ± 0.039] [11.22 ± 0.039]
77.75 ± 1.0
[3.06 ± 0.039]
Port Description
Connections Port Description Sizes
Pressure test A System Port “A” Ø 25.4
points
Electrical
connections E / -14
7 8
from Filter
F Charge Filtration Port, to Filter / -14
7 8
L1 Case Drain Port / -14

7 8

L3 Case Drain Port 7/8 -14

MA System “A” Gage Port 9/16 -18
Charge Gage Port,

M3 / -18
9 16
after Filtering
7 16

7 16
(11/01/2012) 20-04-M146EN
6
PRESSURE TEST POINTS ON THE MOTOR
Y 77.0
]
[3.03
77.0
X [3.03
]
222.0 Gage port M3

[8.75] Servo pressure min.. angle
20
Loop flushing 0.5625-18UNF-2B

shuttle valve [9/16-18UNF-2B]
Charge pressure
relief valve
69.05 Control start
[2.72] adjustment
M3
Case drai
drain
in L1
1
1.0625-12UN-2B
2UN
[1-1/16-12UN-2B]
2UN A
[7.30]
185.0
Y
[3.62]
92.0
M1
57.1 ]
[2.25
[1.91] Gage port M2

49.0
Gage port M5
5
System pressure B
Servo pressure supply
M5
19˚ 0.5625-18UNF-2B
6 0.5625-18UNF-2B Gage port M1
27.7 ] [9/16-18UNF-2B]
[ 9
1 .0 [9/16-18UNF-2B] System pressure A
0.5625-18UNF-2B
[3.48]
88.5
[4.50]
114.0
[4.06]
103.0
[9/16-18UNF-2B]
Alternate
e position
positio
o n
case drain L2
2 Control mounting
Min. angle stop
1.0625-12UN-2B
2UN Gage port M7 surface
adjustment
[1-1/16-12UN-2B]
12UN Control pressure U Split flange boss A+B
0.5625-18UNF-2B
107.05 DN 25 Typ
T II 40 MPa
MPa series
[9/16-18UNF-2B]
[4.21] per ISO 6162 [SAE 1.00]
305.0 4 Thread: 0.4375-14UNC-2B Connections
[12.00] [7/16-14UNC-2B] Pressure test
21 [0.83] min.
full thread depth points
Electrical
connections
Port Description
A Pressure port A
B Pressure port B
L1 Drainage port
L2 Drainage port
M1 Measuring point A
M2 Measuring point B
M3 Min. pressure cc
M4 Max. pressure cc
M5 Piston servo power supply
XA Reverse input A
XB Reverse input B
20-04-M146EN (11/01/2012)
7
Gage port M4
Y Servo pressure max.. angle
77.0 0.5625-18UNF-2B
]
[3.03 [9/16-18UNF-2B]
77.0
]
[3.03 W
M4
20
Supply pressure
W shuttle valve
0.5625-18UNF-2B Connections
[9/16-18UNF-2B] Pressure test
points
Electrical
connections
Gage port M2
System pressure B
0.5625-18UNF-2B Port Description
Gage port M1 [9/16-18UNF-2B]
System pressure A A Pressure port A
0.5625-18UNF-2B B Pressure port B
[9/16-18UNF-2B]
L1 Drainage port
L2 Drainage port
M1 Measuring point A
M2 Measuring point B
Control pressure port XA M3 Min. pressure cc
0.5625-18UNF-2B M4 Max. pressure cc
[9/16-18UNF-2B]
M5 Piston servo power supply
XA Reverse input A
[2.32]
59.0
XB Reverse input B
[2.76]
70
[4.33]
110.0
Electr. prop. pressure

reducing valve
Control pressure port XB

0.5625-18UNF-2B
[9/16-18UNF-2B]
(11/01/2012) 20-04-M146EN
8
PRESSURE TEST
PRESSURE TEST POINTS ON THE A4VG 71 PUMP
Casing pressure socket Control pressure socket
20
HP pressure takeoff
Boost pressure takeoff
It is necessary (to have basic manometers Item 549671 + Hydromatik Kit Item 209572 in the
carrying case)
20-09 Specific transmission tooling
CONTROL PRESSURE
•2 165711 couplings (Item 55) (M 14 x 150)

•2 58181 Manometer sockets (Item 49) (M 8 x 100)
•2 Manometers (0÷40 bar)
•2 Flexible test hoses 549887
HIGH PRESSURE
• 2 Manometer sockets 477484 (Item 51) (M 12 x 1,5)

• 2 Manometers (0÷600 bar)
• 2 Flexible test hoses 549887
BOOST PRESSURE
• 1 set of couplings + manometer socket 199175 (Item 53.1) (M 18 x 1,5)

• 1 Manometer (0÷40 bar)
CASING PRESSURE
• 1 Manometer socket 477484 (Item 51) (M 12 x 1,5)

• 1 Manometers (0÷10 bar)
20-04-M146EN (11/01/2012)
9
PRESSURE TEST POINTS ON A6VM 107 MOTOR
HP takeoff
20
Switching pressure
takeoff
NB: Il the actual installation of the motor differs from the diagram in that it is turned by 180°.
It is necessary (to have basic manometers Item 549671 + Hydromatik Kit Item 209572 in the
carrying case)
20-09 Specific transmission tooling
HIGH PRESSURE
• 1 Manometer socket 58189 (Item 52) (M 14 x 150)

SWITCHING PRESSURE
• 1 Manometer socket 477484 (Item 51) (M 12 x 150)

(11/01/2012) 20-04-M146EN
10
TRANSMISSION CONTROL AND ADJUSTMENT
POINTS ADJUSTMENT ON THE TRANSMISSION
A4VG PUMP
20
Checking the mechanical

DR valve “0” of the swashplate
HP valve
“DA” regulator valve
Adjusting the start of “DA” regulation
Boost valve
HP valve
Eccentric adjustment of the plate

up to regulation
A6VM MOTOR
Minimum displacement
adjusting screw (do not disturb)
Switching regulation
adjusting screw
20-04-M146EN (11/01/2012)
11
TESTS BEFORE SETTING THE TRANSMISSION TO WORK OR AFTER A REPAIR

• Check the oil level in the tank.
• Check that all the couplings of the flexible hoses are fully tightened.
• Check the electrical connections of the electrovalves.
• Ensure that the circuit is completely filled, and at the same time fill the oil filter before fitting.
• Check that the control tubes are correctly fitted:
20
– X1 pump with X2 motor,
– X2 pump with X1 motor.
• In all cases, the control is the opposite of the HP hoses. (Example: if the forward gear HP hose
is on the right of the motor, the forward control hose will be on the left and vice versa for reverse
gear).
• Connect the boost pressure - control - HP - casing manometers.
SETTING TO WORK:
• For safety reasons, support the vehicle on trestles.

• Turn the engine without starting it to purge the circuit completely. (Disconnect the wire from the
stop electrovalve on the injector pump).
• Ensure that the boost pressure rises to at least 15 bar when turning with the starter motor.
“It is essential not to start the transmission with insufficient boost pressure as this will wear
the transmission”.
• Reconnect the stop electrovalve to the injector pump.

• Start the engine for a few minutes at minimum speed, boost pressure 35 ÷ 40 bar.
Instability of the needle indicates inlet of air (emulsified oil in the tank and cavitation noise in
the transmission).
“Selector in neutral” in both HP circuit orifices. The pressure is equal to the boost pressure.
• Heat the oil in the circuit by gradually accelerating (keep the handbrake on to permit measurement
of the HP with blocked load).
• When the oil is at a temperature of 50°÷ 60° check the speed of the engine: minimum, maximum
and off load. (See technical specifications).
(11/01/2012) 20-04-M146EN
12
BOOST PRESSURE CONTROL AND ADJUSTMENT

20
The series A4VG 71 pump is fitted with an adjustable limiter.

To increase the boost pressure, screw in the screw.
At max engine speed, 40 bar.
The oil temperature must not exceed 40 °C.
The pump is already fitted with a pressure socket as in the diagram.
The vehicle must be fully braked.
Check that there is no blow-by in the inching valve.
“FE” boost pressure socket
20-04-M146EN (11/01/2012)
13
ADJUSTING THE MECHANICAL “0” OF THE PUMP
20
– Connect two small scale manometers (40 ÷ 100 bar) to the HP pressure sockets.
– Ensure that the hand brake is disengaged and that the vehicle is on trestles (wheels suspended
in the air).
– Engine at minimum speed.
– Gear selector in neutral.
– Slacken the locknut of the mechanical “0” adjusting screw (19 wrench). Turn the screw slowly
clockwise (no. 6 Allen key) until you have noted the lowest speed variation of the HP.
– Mark the direction of the key.
Turn anticlockwise to vary the HP in the other direction of travel.
Mark the direction of the key.
– After that, turn the adjusting screw until the key is half way between the two marks previously
made. Tighten the locknut.
CHECK THE ADJUSTMENT:
– Connect 2 600 bar manometers to the HP socket:
1) Check the start of regulation in forward and reverse gear with a revolution counter.
Accelerate the engine gently, with the selector in forward gear, until the wheels begin to move.
Note the engine speed.
Repeat the operation in reverse.
Check the two engine speeds which must be the same.
2) Checking the HP and corresponding control pressure, wheels locked, selector in forward gear,
gradually accelerate the engine to max. speed.
Note the forward gear and control HP and forward gear pressures.
Repeat for reverse gear; the values must be the same.
(11/01/2012) 20-04-M146EN
14
START OF REGULATION CONTROL AND ADJUSTMENT

20
“DA” regulator valve
Adjusting the start

of “DA” regulation
START OF REGULATION:
• Measure the minimum engine speed which must be ~ 850 r.p.m.-1.

Regulation must start at 1050 r.p.m-1. To adjust, turn the adjusting screw on the end of the
regulation start valve:
– Screw in to delay the start of advance.
– Unscrew to advance the start of advance.
• Changing the start of regulation of the delayed advance point displaces the range of adjustment
of the pump. The end of “400 bar adjustment for the engine speed in question” regulation must
be systematically checked”. (1600 ÷ 1800 r.p.m.-1).
• Checking the regulation is equivalent to checking the mechanical “0” - Para. 2.
20-04-M146EN (11/01/2012)
15
END OF REGULATION CONTROL AND ADJUSTMENT
20
End of regulation
TESTING:
– The vehicle must be on trestles, with the brakes on and inching (brake) in by pass.
– Selector in forward gear.
– With the motor at minimum, check the engine speed.
– Accelerate gradually and check the engine speed (1600 ÷ 1800 r.p.m.-1) when the forward gear
HP reaches 400 bar.
END OF REGULATION:
The end of regulation of the pump is adjusted by turning the eccentric screw that changes the
position of the plate (in the direction of rotation). This has the effect of increasing or decreasing
the return force of the tilting swashplate.
This adjustment is made on the test bench by the

manufacturer and must not be altered without prior
authorisation from head office.
The milled part of the eccentric must be oriented towards
the side of the boost pump.
The margin of adjustment is only 90 % to the right and
90 % to the left. Do not exceed this percentage (risk of
mechanical breakage due to interference between the plate
and the casing). As for adjusting the HP, this adjustment
must be made with the DR valve over calibrated.
(11/01/2012) 20-04-M146EN
16
HP LIMITERS CONTROL AND ADJUSTMENT
• Checking and adjusting the HP limiters is carried out with the vehicle on trestles (wheels
suspended in the air) and the brakes applied.
The inching valve must be bypassed eliminate discharging of the pump flow.
• Over calibrate the DR valve -Item 1- to check the actual calibration value of the HP limiters.
20
• Screw in the screw (Item 1) one turn.

• The calibration of the HP limiters (Item
2)
1
must be 460 bar.
2
During this operation, there will be a
large drop in the engine speed to about
500 ÷ 600 r.p.m.-1.
MB After checking the HP, adjust the DR
valve (Item 1) to a value of less than
MA 20 bar from the HP (Item 2).
ADJUSTING THE HP LIMITERS:
Series A4VG 71 DA pump
• Remove the lead seal A.

• Remove plug B.
• Unscrew the locknut D.
• Turn the screw E to increase the pressure.
• Replace the plug and attach a new lead seal to the adjustment.
B
2
C D
20-04-M146EN (11/01/2012)
17
A6VM MOTOR ADJUSTMENT
A. MINIMUM DISPLACEMENT CONTROL (MAX. SPEED):
• The test is carried out with the vehicle on a flat surface, at max. engine speed and in forward
gear.
• Connect two 600 bar range manometers as indicated in the diagram. At max. vehicle speed both
20
pressures must be the same. This means that, taking into account the ratio of the area of the
command cylinder, the motor is switched to minimum displacement.
• For an effective speed test (check the technical specifications of the vehicle).
This adjustment (Item 1) is done on the test bench by the manufacturer; it is essential
that it is not changed except with the prior authorisation of head office.
High pressure
1
Adjusting the start
of switching regulation
(Item 1) MINIMUM DISPLACEMENT

ADJUSTING SCREW (by screwing in
the screw the swashplate is moved
downwards. In this way it increases the Switching pressure
displacement and reduces the speed).
B. START OF REGULATION CONTROL
• When the vehicle is at max. speed, gradually press the brakes to raise the HP (the inching valve
must be bypassed).
• Note the two pressures. When the HP reaches 260 ÷ 280 bar, the switching pressure will drop
and the HP will continue to increase up to the calibration value of the DR valve.
• The start of adjustment of the switching can be calibrated by means of the adjustment screw on
the motor.
C. MAX. DISPLACEMENT: (MAX TRACTION FORCE)
• To carry out this adjustment, the vehicle must b e locked (brakes applied).
The test is carried out at max. engine speed in forward gear.
• The switching pressures(on the large section side of the command cylinder) must be near zero bar.
If necessary, adjust the adjustment screw (screw in to increase the switching pressure or screw
out to decrease it).
• A traction force test (on a hook) must be carried out (for the required results, see the User
Maintenance manual).
(11/01/2012) 20-04-M146EN
18
FAULT FINDING
PUMP / MOTOR
Inlet pressure A4VG “S” pump Inlet tube Oil tank filter
20
Type of oil
Measuring point Direction
of rotation Oil
temperature
Cause
Gear change
Supply pressure A4VG “G” pump A6VM MOTOR

Auxiliary pump
Measuring point
Boost valve Wear
Supply pressure Wear
Oil heat exchanger temperature Washing valve
Cause
Bypass valve
Oil temperature
Number of revolutions
Pump- engine connection (joint)
Control
pressure “X1/X2” pump A4VG
A6VM MOTOR
Throttles
Measuring point Control tubing
Regulation valve DA/inching/ splitter valve
Inlet pressure
Supply pressure Pressure cutoff
Electrodistributor/magnet
Cause
High pressure “MA/MB” pump A4VG A6VM MOTOR

HP-DR valves Not locked
Measuring point Joint
Pressure cutoff
Movement of distribution plate Brake
Inlet pressure Wear Wear/oil blow-by
Supply pressure
Oil heat exchanger temperature Oil temperature
Cause
Gear change
I.C. engine
Min/max number of revolutions

Diesel filter
Air filter
Power
20-04-M146EN (11/01/2012)
19
VEHICLE
The engine turns A4VG PUMP

The vehicle does not stop
20
Electrodistributor
Start of regulation
Cause
Mechanical zero
Vehicle movement is delayed A4VG PUMP

Throttles
Inlet pressure
Cause
Control pressure
Start of adjustment
Inching
Heavy overload
of the engine A4VG PUMP A6VM MOTOR
Start of
DR valve regulation
Wear Tilt angle
Movement of
Cause distribution plate
I.C. engine
Injection pump
Fuel filter
Insufficient
traction force A4VG PUMP VEHICLE A6VM MOTOR
Start of
Movement of regulation
distribution plate Wheel
diameter Control tubing
Pressure cutoff X1/X2
Control pressure Magnet
Cause Tilt angle
I.C. engine
Max. transfer
speed not
reached A4VG PUMP VEHICLE A6VM MOTOR
Control Start of
pressure Transmission regulation
Inching Tyres Magnet
Tilt angle
Cause Adjusting the
CC screw
I.C. engine
(11/01/2012) 20-04-M146EN
20
20
MANITOU A4VG--DA / A6VM--DA HYDROSTATIC TRANSMISSION ADJUSTMENT CARD

DATA OF TEST : TYPE OF VEHICLE : TYPE OF HYDROSTATIC PUMP :
20-04-M146EN
NAME OF DEALER : SERIAL NO. : PUMP SERIAL No. :
NAME OF ENGINEER : NUMBER OF HOURS : TYPE OF HYDROSTATIC MOTOR :
MOTOR SERIAL No. :
ENGINE SPEED r.p.m.-1 :

1 minimum: ..... 2 max no load: ....... 3 max on load hydraulically: ........... 4 start of regulation:...... 5 end of regulation 400b : .. 6 max on load fwd. gear: ......
HYDROSTATIC PUMP HYDRAULIC MOTOR

CONTROL HIGH PRESSURE
TRUCK SITUATION + GEAR PRESSURE HP CASING TROLLEY STATUS
BOOST INLET PUMP HIGH PRESSURE
tests/adjustments SELECTOR ENGINE SPEED WASHING +
PRESSURE FORWARD REVERSE FORWARD REVERSE DEPRESSION
CARRIED OUT POSITION PRESSURE PRESSURE CYLINDER
GEAR SELECTOR
GEAR GEAR GEAR GEAR HP COMMAND

POSITION
MINIMUM
ADJUSTING THE
NEUTRAL
BOOST PRESSURE OFF LOAD,
MAX.
IN MOTION,
FORWARD START OF REGULATION FORWARD GEAR,
NO LOAD GEAR MAX. ENGINE
ADJUSTING MAX.
SPEED
THE START OF START OF REGULATION
REVERSE FORWARD GEAR,
REGULATION
GEAR MAX. IN MOTION AT THE
MOMENT OF MAX.
FORWARD ENGINE SPEED
ON LOAD MAX.
GEAR SWITCHING
ADJUSTING THE
HIGH PRESSURE HP
RAISING THE RIGHT REVERSE FORWARD GEAR,
MAX.
CUT OFF VALVE FORWARD ON LOAD, MAX.
ENGINE SPEED
ON LOAD FORWARD
MAX.
ADJUSTING THE AGEAR
RIGHT CUT OFF TYPE OF OIL
VALVE REVERSE
MAX.
GEAR TEMPERATURE OF OIL ................................. °C
FORWARD END OF
ON LOAD GEAR REGULATION MAX. NO LOAD SPEED:
CHECKING END OF
REGULATION REVERSE END OF ................................km/h
GEAR REGULATION
TRACTION FORCE .........................................kg
(11/01/2012)
ON LOAD
FORWARD
ADJUSTING THE MAX.
GEAR
INCHING VALVE
TRANSMISSION REMOVAL
20
page
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
HYDROSTATIC TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(25/05/2011) 20-06-M146EN
2
Transmission removal
20
GENERAL INFORMATION
Position the vehicle on a horizontal surface, support it on the stabilisers to ensure maximum
stability and safety, turn off the engine.
- Forklift truck.
20-06-M146EN (25/05/2011)
3
HYDROSTATIC TRANSMISSION REMOVAL
Obtain receptacles of sufficient size for the quantity of oil to

be collected and place it under the drain plug (Item 1) of the
1 hydraulic oil tank.
Remove the plug (Item 1) and leave the oil to run out.
20
To speed up draining of the tank, remove the filler plug
(Item 2).
Unscrew the screws (Item 3) and remove the brackets

(Item 4) holding the cardan shaft (Item 5) to the front axle.
5
Unscrew the screws (Item 3) and remove the brackets

(Item 4) holding the cardan shaft (Item 5) to the rear axle.
Remove the cardan shaft (Item 5) from the vehicle.
3
5
(25/05/2011) 20-06-M146EN
4
Disconnect all the tubes of the hydraulic oil system and inlet, the hydrostatic pump (Item 6),
the services pump (Item 7) and the hydraulic motor (Item 8), taking care to mark the tubes and
attachments with a paint brush before removing them, to ensure they are correctly replaced.
Plug all the hydraulic orifices of the hydrostatic motor and pump to prevent impurities
from contaminating the hydraulic system.
20
Remove the transmission oil filter (Item 9) from the

9 hydrostatic pump (Item 6) to gain access to remove one of
6
the two screws holding the pump.
20-06-M146EN (25/05/2011)
5
6
Secure the pumps with belts or ropes (Item 10) to an
overhead crane, passing them through the central hole in
the fifth wheel.
Remove the 2 screws (Item 11) attaching the pump (Item 6)
to the motor.
11
10
20
Support the pumps (Item 6 and 7) on a forklift truck and
move them away from the vehicle.
6
Unscrew the screws (Item 12) and remove the washers

(Item 13 and 14) to remove the hydrostatic pump (Item 6)
6 from the services pump (Item 7).
14
13
12
Unscrew the screws (Item 15) attaching the hydrostatic

motor (Item 8).
15
(25/05/2011) 20-06-M146EN
6
Place a trolley under the motor (Item 8) and remove the

motor from the front axle gearbox until it is not resting on
the trolley.
Withdraw it from under the vehicle.
8
20
20-06-M146EN (25/05/2011)
TRANSMISSION REFIT
20
page
HYDROSTATIC TRANSMISSION REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(26/05/2011) 20-07-M146EN
2
Transmission refit
20
GENERAL INFORMATION
Position the vehicle on a horizontal surface, support it on the stabilisers to ensure maximum
stability and safety, turn off the engine.
- Forklift truck.
20-07-M146EN (26/05/2011)
3
Transmission refit
HYDROSTATIC TRANSMISSION REFIT
Position the motor (Item 1) under the vehicle with a trolley.

Fit the motor (Item 1) to the front axle gearbox.
20
Screw in the screws (Item 2) that fix the hydrostatic motor
(Item 1) to the front axle gearbox.
Carefully clean the surface (Item A) of the hydrostatic pump

(Item 4) with a cloth and apply a layer of “Motorseals”
4
sealant (working time 15 minutes).
5
Refit the service pumps (Item 3) to the hydrostatic pump
3 (Item 4) inserting the seal (Item 5) and screwing the screws
and washers on again (Item 6 - 7 - 8).
A
Use a tightening torque of 87 Nm.
6
7
8
Support the pumps (Items 3 and 4) on a forklift truck and

position them under them vehicle.
4
(26/05/2011) 20-07-M146EN
4
Transmission refit
4
Secure the pumps with straps or ropes (Item 9) to an
overhead crane, passing them through the central hole in
the thrust ring.
Lift the pump unit and position it on the motor, screwing in
the 2 screws (Item 10), using a tightening torque of 250
10
Nm, to fix the hydrostatic pump (Item 4) to the motor.
9
20
Replace and fit the transmission oil filter (Item 11) on the
11 pump (Item 4).
4
Carefully wash and dry all the tubes in the hydraulic oil and inlet system, refit the tubes to
the service pumps (Item 3) on the hydrostatic pump (Item 4) and the hydraulic motor (Item 1),
taking care to a reposition them correctly following the marks made with a paint brush during
removal.
Tighten the screws (Item 12) using a tightening torque of 87 Nm.
12
12
3
1
20-07-M146EN (26/05/2011)
5
Transmission refit
Refit the cardan shaft (Item 13) to the rear axle, repositioning
the clamps (Item 14) and screwing in the screws (Item 15).
15
13
14
20
Refit the cardan shaft (Item 13) to the front axle, repositioning
the clamps (Item 14) and screwing in the screws (Item 15).
13
15
14
Screw the plug (Item 16) back into the hydraulic oil tank.
16
Fill the tank with hydraulic oil (see “LUBRICANTS” manual

for the type and quantity).
The oil level is correct when it is between the upper and lower
oil indicator marks (Item 17) located under the stepladder.
17
(26/05/2011) 20-07-M146EN
6
Transmission refit
Bleed the hydraulic transmission system and screw the plug

(Item 18) back in.
18
15
20
20-07-M146EN (26/05/2011)
SPECIFIC TRANSMISSION TOOLING
20
page
BASIC GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(13/12/2011) 20-09-M146EN
2
Specific transmission tooling
BASIC GEARBOX
Standard
7 7 7
7
3 4 6
20
2 4 5 6
Maniscopic
8 8
Hydromatik Kit – Assembly 2 - Pump A 4 VG - DA / Engine A 6 VM - DA
49 49 49 51 51 51 51 51 52
8x100
12x150 14x150
54
53-1
55 58
53 53 30x200 48
55 58
14x150 14x150
50 50 50 50 50 50
16x150 18x150
ø20 (S) ø8 (L) ø6 (L)
Flexible tube (Bypass valve TH7) Nipple (Valve with flexible hose TH7)
50
x1
14
56
14x150
57
14x150
14
x1
50
20-09-M146EN (13/12/2011)
3
Ref Number Description QT.
1 549 671 Basic gearbox 1
2 549 882 Manometer 1/9 bar 1
20
5 549 885 Manometer 0/400 bar 1
6 549 886 Manometer 0/600 bar 2
7 549 887 Flexible tube 4
8 549 888 Flexible tube for MANISCOPIC 2
9 549 889 Attachment for manometer 7
48 209 572 HYDROMATIK kit 1
49 58 181 Attachment for manometer 8x100 3
50 58 197 O-ring dia. 8 6
53-1 199 175 Attachment for manometer 18x150 1
54 173 568 Connector ø 20 1
55 165 711 Adaptor M/F - dia.8L + M8x100 2
58 706 653 Adaptor M/F - dia.6L + M8x100 2
By-pass valve TH7
56 191 000 Flexible tube 1
57 491 632 Connector (M14x150) 1
(13/12/2011) 20-09-M146EN
4
20
20-09-M146EN (13/12/2011)
AXLE
- AXLE REMOVAL
- AXLE REFIT
30
M
R
- COMPONENTS CONTROLS ADJUSTMENT (Dana M0212S20 axle)

AXLE REMOVAL
30
page
FRONT AXLE AND HYDROSTATIC MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . 3
REAR AXLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(09/05/2011) 30-06-M146EN
2
Axle removal
FRONT AND REAR AXLES, AND HYDROSTATIC MOTOR

REMOVAL
30
GENERAL INFORMATION
Position the truck on a horizontal surface and level it (frame parallel to the front axle).
Support the stabilizers to ensure maximum stability and safety, bringing it to the necessary height
to remove the wheels and stop the IC engine.
30-06-M146EN (09/05/2011)
3
Axle removal
FRONT AXLE AND HYDROSTATIC MOTOR
30
REMOVAL
Unscrew all the nuts (Item 1) and remove the 2 front tyres
(Item 2).
1
Unscrew the flange fixing screws (Item 3) on the cardan

shaft and disconnect the shaft.
Disconnect the tube (Item 4) (on the left side of the axle)
associated with operation of the steering.
Disconnect the tube (Item 5) (on the right side of the axle)
Disconnect the 2 tubes (Item 6).
Disconnect the electrical connection (Item 7).
5
7
6
6
(09/05/2011) 30-06-M146EN
4
Axle removal
Disconnect the 2 tubes (Item 8 and 9) associated with

operation of the road brakes and parking brake.
Disconnect the electrical connection (Item 10) of the wheel
8 10 alignment sensor.
Unscrew the 8 connecting screws (Item 11) of the 4 flanges

30
(Item 12), located on both sides of the hydrostatic motor

11
and disconnect both the tubes (Item 13 and 14).
Disconnect the hydraulic pipes (Item 15 and 16).
13
12
15
17 Disconnect the tubes from the “T” connector (Item 17) and
disconnect the electrical connection from the connector.
11
14
12
16
Secure the front axle and hydrostatic motor to an overhead

crane or hoist adequate for the weight to be lifted.
Unscrew the 4 screws (Item 18) that fix the axle to the left
levelling jack.
18
30-06-M146EN (09/05/2011)
5
Axle removal
Unscrew the 4 screws (Item 19) that fix the axle to the right
levelling jack.
19
Unscrew the screws (Item 20) that fix the front axle to the
30
front side frame.
20
Unscrew the screws (Item 21) that fix the front axle to the
rear side frame.
Remove the front axle and hydrostatic motor.
Plug all the hydraulic orifices of the hydrostatic motor

21
and axle to prevent impurities from contaminating
the hydraulic system.
(09/05/2011) 30-06-M146EN
6
Axle removal
REAR AXLE REMOVAL

30
Unscrew all the nuts (Item 1) and remove the 2 rear tyres
(Item 2).
Unscrew the fixing screws (Item 3) of the cardan shaft flange

(Item 4) and disconnect the shaft.
Disconnect the tube (Item 5) (on the left side of the axle)
5
Disconnect the tube (Item 6) (on the right side of the axle)
30-06-M146EN (09/05/2011)
7
Axle removal
Disconnect the electrical connection (Item 7) of the brake

light.
Disconnect the tube (Item 8) associated with the road
9
brakes.
Disconnect the electrical connection (Item 9) of the wheel
alignment sensor.
8
30
Secure the rear axle to an overhead crane or hoist adequate
for the weight to be lifted.
Unscrew the screws fixing the rear axle to the front side
frame (Item 10), taking care to mark the bracket and frame
for correct refitting.
10
Unscrew the screws fixing the rear axle to the front side
frame (Item 11), taking care to mark the bracket and frame
Remove the rear axle.
Plug all the hydraulic orifices of the axle to ensure

that no impurities can contaminate the hydraulic
system.
11
(09/05/2011) 30-06-M146EN
8
Axle removal
30
30-06-M146EN (09/05/2011)
AXLE REFIT
30
page
REAR AXLE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FRONT AXLE AND HYDROSTATIC MOTOR REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(09/05/2011) 30-07-M146EN
2
Axle refit
FRONT AND REAR AXLES, AND THE HYDROSTATIC

MOTOR REFIT
30
GENERAL INFORMATION
Position the truck on a horizontal surface and level it (frame parallel to the front axle).
Support the stabilizers to ensure maximum stability and safety, bringing it to the necessary height
to remove the wheels and stop the IC engine.
30-07-M146EN (09/05/2011)
3
Axle refit
REAR AXLE REFIT
30
Bring the rear axle into correspondence with its original
positional and hold it steady.
Connect the axle to the front side frame by means of the
screws (Item 1).
Connect the axle to the rear side frame by means of the

screws (Item 2).
Before connecting it, ensure that the reference

(Item 3) punched on the frame corresponds with the
reference (Item 4) of the bracket.
3
(09/05/2011) 30-07-M146EN
4
Axle refit
Reconnect the electrical connection (Item 5) of the brake

light.
Reconnect the tube (Item 6) associated with operation of
7
the road brakes.
Reconnect the electrical connection (Item 7) of the wheel
alignment sensor.
6
Reconnect the tube (Item 8) (on the left side of the axle)
30
Reconnect the tube (Item 9) (on the left side of the axle)
Reconnect the cardan shaft (Item 10) in its predefined

position using loctite 270 to lock the screws.
9
10
Refit the 2 rear tyres (Item 11) using a tightening torque for
the nuts (Item 12) of 740 Nm.
12
11
30-07-M146EN (09/05/2011)
5
Axle refit
FRONT AXLE AND HYDROSTATIC MOTOR REFIT
30
Bring the rear axle and hydrostatic motor into correspondence
with their original position and hold them steady.
Connect the axle to the frame using the screws (Item 1)
1
on the front side.
Connect the axle to the frame using the screws (Item 2)

on the rear side.
Connect the right levelling jack to the axle by means of the

screws (Item 3).
(09/05/2011) 30-07-M146EN
6
Axle refit
Connect the left levelling jack to the axle by means of the

screws (Item 4).
Refit the 4 flanges (Item 5) located on both sides of the

30
hydrostatic motor, screw in the 8 screws (Item 6) and

6
reconnect the 2 tubes (Item 7 and 8).
Reconnect the hydraulic pipes (Item 9 and 10).
7
11 Reconnect the tubes to the “T” connector (Item 11) and

reconnect the electrical connection to the connector itself.
6
10
Reconnect the 2 tubes (Item 12 and 13) associated with

operation of the road and parking brakes.
12 14 Reconnect the electrical connection (Item 14) of the wheel
alignment sensor.
13
30-07-M146EN (09/05/2011)
7
Axle refit
Reconnect the tube (Item 15) (on the right side of the axle)
Reconnect the 2 tubes (Item 16).
Reconnect the electrical connection (Item 17).
15
17
16
16
Reconnect the tubes (Item 18) (on the left side of the axle)
30
Reconnect the cardan shaft in its predefined position, using
loctite 270 to lock the flange screws (Item 19).
18
19
Refit the 2 front tyres (Item 20) using a tightening torque for
the nuts (Item 21) of 740 Nm.
Before returning the truck to service, remember to

check the efficiency of the brakes and, if necessary,
21 bleed the system.
20
(09/05/2011) 30-07-M146EN
8
Axle refit
30
30-07-M146EN (09/05/2011)
BRAKE
- BRAKE CONTROL AND ADJUSTMENT
- BRAKE SPECIFIC TOOLING
40
BRAKE CONTROL AND ADJUSTMENT
page
40
PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PROCEDURE FOR BLEEDING THE BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DIAGRAM OF BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SETTING THE TRUCK AND INCHING PARAMETERS MRT EURO 3 PRIVILEGE SAUER
DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– EQUIPMENT REQUIRED FOR SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– INSTRUCTIONS FOR MAKING THE SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . 7
– INSTRUCTIONS FOR CALIBRATING THE INCHING PEDAL . . . . . . . . . . . . . . . . . 9
SETTING THE TRUCK AND INCHING PARAMETERS MRT EURO 3 PRIVILEGE
REXROTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
(14/07/2011) 40-04-M146EN
2
Brake control and adjustment
BLEEDING THE BRAKES AND ADJUSTING INCHING

40
Position the truck on a horizontal surface and stop the IC engine.
- Bleeding device.
40-04-M146EN (14/07/2011)
3
PROCEDURE FOR BLEEDING THE BRAKES
Disconnect the drain tube (Item 1) from the brake fluid

reservoir and insert a water tight plug.
Fill the brake fluid reservoir completely.
Connect the brake bleeding device (Item 2) to the tank S

(see “Diagram of brake system”), located on the dashboard.
40
Slacken the 2 bleed screws (Item 3) located on the rear axle
and connect the transparent tubes.
Pressurise the brake bleeding device and wait until all the
air has passed through the transparent tubes.
Retighten the 2 bleed screws (Item 3) on the rear axle.
Repeat the above procedure for the front axle.
Also ensure that the stroke of the brake pump is normal.
If it is not, adjust the brakes on both axles
3
(see procedure in the section REMOVING THE AXLES).
- When the brake bleeding procedure has ended, reconnect
the hydraulic pipe (Item 1) to the drain manifold.
(14/07/2011) 40-04-M146EN
4
40
40-04-M146EN (14/07/2011)
5
DIAGRAM OF BRAKE SYSTEM
BRAKE BLEEDING DEVICE

2 bar
MC
PF
B A
1 2
T P VSLR
S.
R. CR
P.I.
40
VCLR
RCFP
A B FDAV
B FDAR
A P T
VBP P VFP
B
A
S MA
MB
E V.D.
VBPA
V.D. C.R.
PS
BLEEDING THE BRAKES ON STANDS

G
R T
B
200 bar
175 bar
a
X2
FDAR FDAV
A L P
VBP
X1
I.D.
b
R T2
T1
PI
VBPA D.F. F.A. F.R.
R.
M
BLEEDING THE BRAKES
ON STANDS
(14/07/2011) 40-04-M146EN
6
40
40-04-M146EN (14/07/2011)
7

SAUER DANFOSS
EQUIPMENT REQUIRED FOR SETTING
Connecting cable for diagnostic unit socket.

Connecting cable for diagnostic unit socket/computer.
Computer with the “PLUS+1 GUIDE Service Tool” program
installed.
INSTRUCTIONS FOR MAKING THE SETTINGS
2
Open the fuse box (Item 1) of the ADM diagnostic unit
1
inside the cabin (behind the driver’s seat), using the two
pushbutton catches (Item 2).
2
40
Connect the connector (Item 3) to the diagnostic socket on
the diagnostic unit.
Connect the other end of the cable connected to the

diagnostic socket on the diagnostic unit (Item 4) to the
USB cable intended for the port on the laptop computer
(Item 5).
(14/07/2011) 40-04-M146EN
8
Switch on the laptop computer and launch the program by

clicking on the “PLUS+1 GUIDE Service Tool” icon (Item 6).
Turn the ignition key (avoiding starting the engine) of the

fork lift truck and turn it to position “1” (Item 7).
7
40
Check that the “Connect” (Item 8) command (shown in

green) appears on the program screen (at the bottom).
When the “Confirm” window appears, confirm by selecting
the “Yes” pushbutton (Item 9).
If the previous operation is not to be checked (connection to

the fork lift truck) click on the “Communication”, “Settings”,
“CG150” commands in succession and then “Enable”
(Item 10).
10
40-04-M146EN (14/07/2011)
9
Then click on the “File”, “Open” commands in succession

and select the file “101076602_S0168_D0001” (with
extension *.P1D) (Item 11).
Confirm the choice by clicking on “Open” and wait for the
11
data to load.
After loading the data, select the “Allparameter V157”

command (Item 12) (on the left of the window).
Then click the “Parameter” and “File Import” commands
13 in succession. Select the file “10107602_S0168_P0001
FINAL TESTING CENACCHI 28 NOVEMBER.xml” for MRT
Standard models, or the file “10107602_S0168_P0001
40
12 FINAL TESTING MACHINE FOR GERMANY.xml” for MRT TUV
models (Item 13).
Confirm the choice by clicking on “Open” and wait for the
data to load.
Click the “Parameter” and “Download” (Item 14) commands

in succession to save the parameters in the diagnostic
unit.
14
INSTRUCTIONS FOR CALIBRATING THE INCHING PEDAL
From the menu, select the “Parameter Function”, “Inputs”,

“Inching”, “Set Defaults” commands in succession
(Item 15).
15
(14/07/2011) 40-04-M146EN
10
Check that the brake pedal (Item 16) is fully raised.
16
Select the command “1” of the item “Calibrate Inch

Potentiometer” (Item 17).
Confirm the choice by clicking on “Download Parameters”
(Item 18) and wait for the data to load.
Select the command “0” of the item “Calibrate Inch
Potentiometer” (Item 17).
40
18 17
Confirm the choice by clicking on “Download Parameters”
(Item 18) and wait for the data to load.
From the menu, select the “Log Function”, “Calibration”,

“Pedal Data” (Item 19) commands in succession.
19
Press the “Start Logging” pushbutton (at the top of the

program), press the brake pedal fully down (Item 16), and
wait for about three seconds unit calibration is complete
(visible from the green icon on the screen).
Refer back to the “All Parameter V157” diagram (Item 12).
20 Confirm the choice by clicking on “Download Parameters”
and wait for the parameters to be saved (Item 20).
16
40-04-M146EN (14/07/2011)
11
From the menu, select the “Log Function”, “System”,

“Electrical”, commands in succession (Item 21).
21 With the brake pedal fully raised, check that the value
displayed in the inching pedal window (Item 22) is between
450 and 550 mV.
22
With the brake pedal fully depressed, check that the value
displayed in the inching pedal window inching (Item 22) is
21 between 4400 and 4700 mV.
If the values displayed are not within the ranges
40
indicated above, adjust the mechanics of the inching
potentiometer on the brake pedal. If when pressing the
22 brake pedal the values displayed do not change, check the
electrical connections to the inching potentiometer.
(14/07/2011) 40-04-M146EN
12

REXROTH
ADJUSTING THE INCHING CLEARANCE ON REXROTH
PUMP
Remove the protective cap (Item 1) on the inching adjustment

1 screw.
Ensure that the initial measurement of the screw (Item 2)

40
2
is 16 mm.
Unscrew the locknut (Item 3) on the adjustment screw.
To inhibit the inching function, tighten the screw

3
completely (Item 2).
40-04-M146EN (14/07/2011)
SPECIFIC BRAKE TOOLING
page
40
HYDRAULIC BRAKE BREATHER VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PARKING BRAKE BREATHER VALVE WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(13/12/2011) 40-09-M146EN
2
Specific brake tooling
HYDRAULIC BRAKE BREATHER VALVE
Breather valve complete with components necessary

for venting hydraulic brake systems for all Manitou
products
40
MANITOU part no.
Hhydraulic brake breather valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554019
Spare parts:
Maximum manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
Minimum manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
Membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
Brake pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914
40-09-M146EN (13/12/2011)
BOOM
- BOOM CONTROL AND ADJUSTMENT
- BOOM REMOVAL
- BOOM REFIT
50
BOOM CONTROL AND ADJUSTMENT
page

FEET ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– ARM FEET Ist EXTENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– ARM FEET IInd EXTENSION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
50
– ARM FEET IIIrd EXTENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ARM CHAINS ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(09/05/2011) 50-04-M146EN
2
Boom control and adjustment
PENTAGONAL TELESCOPIC ARM ADJUSTMENT

50
Position the truck on a horizontal surface, support the stabilisers to ensure maximum stability and
safety (do not stop the engine).
If the arm has been removed, use a hydraulic power unit, connecting two tubes to the breather
cylinder.
Execute the command to retract the arm to the end of the breather cylinder stroke.
50-04-M146EN (09/05/2011)
3
FEET ADJUSTMENT
ARM FEET Ist EXTENSION ADJUSTMENT
From the rear to the front of the Ist extension arm, screw on the adjusting nuts (Item 1) to the end
of the thread and then unscrew them about half a turn anticlockwise before tightening the lateral
nuts (Item 2).
To secure the feet to the brackets, the nuts (Item 1) must be screwed on (without tightening
them).
Tighten the nuts (Item 2) (keeping the grub screws fixed) and the screws (Item 3) that fix the foot-
mounting brackets at the side to the outer arms to a torque of 100 Nm.
Check the correct operation of the arm by extending and retracting it.
If the arm is jerky, unscrew all the grub screws (Item 1) another half turn.
Check that no oil has been lost from the area behind the arm (extension actuator valve).
WARNING: the grub screws are sensitive to the slightest movement, therefore only tighten
them when the play between the arms has been eliminated.
2 2
1 1
50
2 2
1 2
1 3 1 1
2
3
3
2 2
1 2 2
1 1
1 1
3
1 2
2
2
2
2
2
1 1
1 1
3 3
1 3 2
2
2
1 1 1 1 1
1
2 1 3
1 2 2 2 2
(09/05/2011) 50-04-M146EN
4
ARM FEET IInd EXTENSION ADJUSTMENT
From the back of the IInd extension arm to the front of the Ist extension arm, screw in the adjusting
grub screws (Item 1) to the end of their thread and then unscrew them about half a turn anticlockwise
before tightening the lateral nuts (Item 2).
them).
Tighten the nuts (Item 2) (keeping the grub screws fixed) and the screws (Item 3) that fix the
foot-mounting brackets at the side to the outer arms to a torque of 100 Nm.
2
2
1 1
1
2 1
2
50
3
3
1 1 1 2
3 1 1
2
2 2
1
2 2 1
2 1 1
1 2
1
2 2 1 3
2 2
50-04-M146EN (09/05/2011)
5
ARM FEET IIIrd EXTENSION ADJUSTMENT
From the back of the IIIrd extension arm to the front of the IInd extension arm, screw in the
adjusting grub screws (Item 1) to the end of their thread and then unscrew them about half a turn
anticlockwise before tightening the lateral nuts (Item 2).
them).
Tighten the nuts (Item 2) (keeping the grub screws fixed) and the screws (Item 3) that fix the
foot-mounting brackets at the side to the outer arms to a torque of 100 Nm.
1
1
2
2 2 2
2
1 1 1 1
50
3 2
3 3
1
2 1
2
2 2
1
1 3
1 1
2
2
3
2
3 1 2
2 1
2 1 2
1
2 1
1 1
1 2
2 2 1 3
2
(09/05/2011) 50-04-M146EN
6
ARM CHAINS ADJUSTMENT
Pretension the internal chains by screwing down the nuts on

the pull rods.
Note the values in the table below (the measurements may
differ by 20-30 mm):
90/95
mm 2 internal chains, 90/95 mm.
70/75 mm 1 internal chain, 70/75 mm.

50
Pretension the external chains by screwing down the nuts

on the pull rods.
Note the values in the table below (the measurements may
differ by 20-30 mm):
4 external chains, 90/95 mm.
90/95 mm
2 external chains, 70/75 mm.
70/75 mm
50-04-M146EN (09/05/2011)
7
Then:
Fully extend the telescopic arm in a horizontal position to check the tension in the external chains
and possibly retension them.
Ensure that the chains remain under tension (keep the arm extension lever pressed for a few
seconds).
Measure the distance between the lower chain side and the arm with a gauge or ruler.
If the values are less than those in the table below, adjust the chains.
For correct adjustment of the internal chains, fully retract the arm extensions and check that each
rests perfectly on the mechanical shoulders provided.
Arm IInd extension Arm Ist extension

Minimum Minimum
H2 80 mm H1 80 mm
MRT measurement MRT measurement
1850-2150 Maximum 1850-2150 Maximum
H2 100 mm H1 100 mm
measurement measurement
Minimum Minimum
H2 116 mm H1 59 mm
MRT 2540 MRT 2540
Maximum Maximum
H2 136 mm H1 79 mm
50
H1
H2
(09/05/2011) 50-04-M146EN
8
50
50-04-M146EN (09/05/2011)
BOOM REMOVAL
pages
TELESCOPIC BOOM REMOVAL FROM THE TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
COMPLETE TELESCOPIC BOOM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– HYDRAULIC AND ELECTRICAL SYSTEMS REMOVAL OF THE BOOM . . . . . . . . . . 7
– ACTUATORS REMOVAL FROM THE BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– I, II AND III BOOM REMOVAL FROM THE EXTERNAL BOOM . . . . . . . . . . . . . . . . 18
– IInd AND IIIrd EXTENSION REMOVAL FROM THE Ist EXTENSION BOOM . . . . . . . 20
– Ist EXTENSION BOOM REMOVAL FROM THE IInd EXTENSION BOOM . . . . . . . . . 23
(29/03/2011) 50-06-M146EN
2
Boom removal
PENTAGONAL TELESCOPIC BOOM REMOVAL

50
GENERAL INFORMATION
Position the truck on a horizontal surface, support the stabilisers to ensure maximum stability and
safety (do not stop the engine).
50-06-M146EN (29/03/2011)
3
Boom removal
TELESCOPIC BOOM REMOVAL FROM THE TRUCK
Activate the boom lift command and raise the boom above
the profile of the cabin (Item 1), to give easy access to the
lifting actuator hinge pin on the rod-boom side from both
sides.
1
Secure the boom to an overhead crane or hoist through the

appropriate eyelets (Item 2) in the top of the boom itself.
2 2
Secure the lifting actuator to a support.
50
Unscrew the locking screw (Item 3) and withdraw the lifting
actuator hinge pin on the rod-boom side (Item 4).
3
Rest the lifting actuator on the turret, placing a wooden beam

under it (Item 5), and retract the rod with the command in
the cabin.
Lower the telescopic boom to an almost horizontal position

with the overhead crane or hoist used.
Switch off the engine.

5
(29/03/2011) 50-06-M146EN
4
Boom removal
Turn the ignition key to position

“I” (ignition key switch on the
dashboard) and carry out all
movements possible with the
commands to release the
residual pressure in the hydraulic
system.
OK OK
Turn off the ignition key and disconnect the battery

terminals.
Remove all the clamps (Item 6 and 7) of the hydraulic tubes
6 and electric cables in the upper rear part of the boom,
6 6 6
making sure that after the operation they are all completely
8 disconnected from each other.
6 Disconnect the connector on the chain safety microswitch
cable (Item 8).
50
Working on the appropriate bush, disconnect the plug-electric

wiring (Item 9) in the top of the boom, if present.
7
9
7
7
7 7
Disconnect the hydraulic pipes supplying the boom (Item 10)

taking care to make a corresponding mark for correct
refitting.
10 10
10 10
10
10
10
50-06-M146EN (29/03/2011)
5
Boom removal
To avoid losing oil from the hydraulic system, plug all the
11
feed through connectors on the boom with water tight plugs
11
11 (Item 11).
11 11
11 11
Remove the raising limit microswitch of the boom (Item 12)

with its mounting (Item 13) located at the upper end of the
13
12 turret, but without disconnecting the electrical connections.
50
Disconnect connector “X2” (Item 14) of the safety system.
14
Using the overhead crane or hoist, raise or lower the boom

very slowly (a few degrees), to find the balance point between
the anchorage force of the boom to the overhead crane
and the reaction of the compensating actuator, so that the
16
15
weight of the boom does not rest entirely on the pin hinging
the boom to the turret.
17
Unscrew the screws and lock nut (Item 15 and 16)

and withdraw the pin (Item 17) hinging the boom to the
turret.
(29/03/2011) 50-06-M146EN
6
Boom removal
With the help of the overhead crane or hoist, pull the boom
very slowly and very carefully a few centimetres towards the
rear of the truck so that the hinge pin of the compensating
cylinder projects from the outline of the turret.
During this operation, try to keep the boom nearly horizontal,
and be very careful not to make sharp movements and avoid
damaging other components of the truck with the boom (only
partially disconnected).
Remove the screws and lock nut (Item 18 and 19) and
withdraw the hinge pin (Item 20) of the compensation
cylinder with the possible help of an extractor.
18
20
50
19
With the help of the overhead crane or hoist, remove the

boom from the base of the turret.
50-06-M146EN (29/03/2011)
7
Boom removal
COMPLETE TELESCOPIC BOOM REMOVAL

1
HYDRAULIC AND ELECTRICAL SYSTEMS REMOVAL OF
THE BOOM
1
After supporting the telescopic boom on two trestles in a

horizontal position, disconnect the hydraulic pipes (Item 1)
from the valve block on the traverse cylinder and mark them
50
Disconnect the hydraulic pipes (Item 2) from the quick

connectors (Item 3) on the left at the top of the boom and
mark them for correct refitting.
3
Disconnect the pipe from the quick connector on the right
side of the top of the boom and mark it for correct refitting.
2 3
Disconnect the winder cable of the “M.S.S.” from the ring

(Item 4) on the Ist extension.
(29/03/2011) 50-06-M146EN
8
Boom removal
Remove the winder (Item 5) of the “M.S.S.” with its bracket

(Item 6) in the left rear of the external boom.
Disconnect the electrical water tight connections of the

9
microswitches on the chain attachment points in the top
front of the boom and remove the cable clamps (Item 7).
Remove the microswitch brackets (Item 8) and their
7 9 counterparts (Item 9), in the top front part of the boom.
9
8
8
7
50
Open the box for the socket card frame and disconnect the
electrical cables from the socket (Item 10).
10
10
12 Withdraw the electric cables from the box (Item 11) and free
them from their clips (Item 12).
11
12
50-06-M146EN (29/03/2011)
9
Boom removal
Release the electric cables and hydraulic pipes from their

protective sheaths (Item 13) and withdraw the hydraulic pipes
through the upper hole in the top of the boom (Item 14).
14
13
In the passages between the pipe-carrier tubing and tube

supporting chains, release the electric cables from their
15
15 15 clips (Item 15).
15
15
50
Release the hydraulic pipes from the IIIrd extension chain
support tubing (Item 16) removing the locking collar
(Item 17 - 18).
17
16
18
Disconnect the third pipe-carrier chain (Item 19) in the rear

part of the tubing (Item 20).
19
20
(29/03/2011) 50-06-M146EN
10
Boom removal
Withdraw the electric cables (Item 21) for the card frame
and the hydraulic pipes (Item 22) from the chain-carrier
tubing (Item 23).
21
22 23
Remove the tubing (Item 24) from the IIIrd extension boom.
24
50
Remove the locking collars (Item 25) of the elbow connectors

25
(Item 26 and 27) from the fixing plate (Item 28) on the IInd
extension chain-carrier tubing.
28
26
27
29 30
Disconnect the iron tubes (Item 26 and 27) from the
30 30
hydraulic pipes (Item 29 and 30) inside the third tube-carrier
chain; disconnect the iron tubes (Item 26 and 27) from the
29
hydraulic pipes (Item 31) inside the IInd extension chain-
carrier tubing.
32
During this operation, mark the hydraulic pipes for correct
32
refitting.
31
31 31 Withdraw the electric cables (Item 32) from the third tube-
carrier chain to the quick connector.
31 31
50-06-M146EN (29/03/2011)
11
Boom removal
Remove the third tube-carrier chain (Item 33) from the chain-
33
carrier tubing (Item 34) by removing the appropriate screws
35 (Item 35).
34
Remove the second tube-carrier chain (Item 36) in the rear

of the chain-carrier tubing (Item 37).
36
37
50
Withdraw the electric cables and hydraulic pipes from the
chain-carrier tubing (Item 38).
38
Remove the chain-carrier tubing (Item 39) from the IInd

extension boom.
39
(29/03/2011) 50-06-M146EN
12
Boom removal
Withdraw the electric cables (Item 40) from the second tube-
40 carrier chain to the quick connector.
40

(Item 42 and 43) from the fixing plate on the Ist extension
chain-carrier tubing (Item 44).
45
45 45 45
45 Disconnect the iron tubes (Item 42 and 43) from the
hydraulic pipes (Item 45) inside the second tube-carrier
chain; disconnect the iron tubes (Item 42 and 43) from the
hydraulic pipes (Item 46) inside the Ist extension chain-
41
44 carrier tubing.
50
46
refitting.
43 42
Remove the second tube-carrier chain (Item 47) from the

chain-carrier tubing (Item 48) by removing the appropriate
screws (Item 49).
47
49
48
Release from its clamps the cable (Item 50) for the
microswitch on the single equaliser arm boom attaching the
chain to the boom Ist extension.
50
50-06-M146EN (29/03/2011)
13
Boom removal
Remove the first tube-carrier chain (Item 51) in the rear of

the chain-carrier tubing (Item 52).
51
52
Withdraw the electric cables, the cable for the microswitch

of the chain attachment on the single balance boom and the
hydraulic pipes from the chain-carrier tubing (Item 53).
53
50
Remove the chain-carrier tubing (Item 54) from the Ist
extension boom.
54
Withdraw the electric cables (Item 55) from the first tube-
carrier chain to the quick connector. Release from its clips
the cables (Item 56 and 57) for the microswitches of the
56 chain attachments on the equalisers.
57
55 55
(29/03/2011) 50-06-M146EN
14
Boom removal

(Item 59 and 60) from the fixing plate (Item 61) on the
62 62 external boom chain-carrier tubing.
62 62 62
58 Disconnect the iron tubes (Item 59 and 60) from the hydraulic
pipes (Item 62) inside the first tube-carrier chain; disconnect
the iron tubes (Item 59 and 60) from the hydraulic pipes
(Item 63) inside the external boom chain-carrier tubing.
61
60 59 refitting.
63
Remove the first tube-carrier chain (Item 64) from the chain-
carrier tubing (Item 65) by removing the appropriate screws
(Item 66).
64
66
65 66
50
Release the hydraulic pipes and electric cables from the

external boom by removing the clamps (Item 67).
67
67
Withdraw the hydraulic pipes and electric cables from the

chain-carrier tubing.
50-06-M146EN (29/03/2011)
15
Boom removal
Remove the multi-way plug (Item 68) for the plate basket
(Item 69).
69
Remove the plate (Item 69) for the electric socket in the
right rear of the external boom.
68
Remove the collar (Item 70) and remove the hydraulic pipes
70
connecting to the extension cylinder (Item 71 and 72).
50
72 71
Remove the hydraulic pipes in sequence (Item A - B - C - D -

E - F - G) from the feed-through connectors.
Mark the pipes for correct refitting.
G
D E
F
B C
A
Remove the chain-carrier tubing (Item 73) on the right side

73
of the external boom.
(29/03/2011) 50-06-M146EN
16
Boom removal
Remove the feed through connectors in the drilled tongue in

the rear of the external boom.
ACTUATORS REMOVAL FROM THE BOOM
Secure the traverse cylinder (Item 1) to the overhead crane

3 or hoist.
Unscrew the screws (Item 2) locking the traverse cylinder
2 hinge pin of the IIIrd extension boom.
Withdraw the pin (Item 3) hinging the traverse cylinder to the

1
50
IIIrd extension boom.

Remove the traverse cylinder (Item 1) from the base of the
IIIrd extension boom.
With the boom extended by about 25÷30 cm, unscrew the

locknuts and nuts on the tie rods for the boom extending
4
chains (Item 4 and 5) until they are against the split pins.
5
Unscrew the locknuts and nuts (Item 6) of the tie rods of the
IInd extension boom retracting chains until they are against
the split pins.
50-06-M146EN (29/03/2011)
17
Boom removal
Unscrew the locknuts and nuts (Item 7) on the tie rod of the
IIIrd extension boom retracting chain until they are against
the split pins.
Remove the screws (Item 8) locking the extension cylinder

hinge pins to the Ist extension boom.
8
8
50
With the help of an extractor, withdraw the extension cylinder
hinge pins (Item 9) on the Ist extension boom.
10 Remove the circlip (Item 10) and withdraw the hinge pin
(Item 11) between the extension cylinder and external
boom.
11
(29/03/2011) 50-06-M146EN
18
Boom removal
With the help of an overhead crane or hoist, remove the

boom extension cylinder.
I, II AND III BOOM REMOVAL FROM THE EXTERNAL

1
1 1 BOOM
Be careful to mark all the feet with their shims that

are removed from the telescopic boom for correct
refitting.
Remove the rear runners fixed to the Ist extension with their
50
shims (Item 1).
At the top front of the boom, release the 6 chains for

2 extending the arms, removing the equalisers (Item 2) from
2 3
3 their tie rods (Item 3).
2
3
Remove the pulley (Item 4) in the upper front part of the IInd
extension boom by removing the pin (Item 5).
5
50-06-M146EN (29/03/2011)
19
Boom removal
Remove the pulley (Item 6) in the upper front part of the Ist
extension boom by removing the pin (Item 7).
6
Remove the runner (Item 8) for the sliding of the extension

cylinder and disconnect the IInd extension boom the combs
9 9
(Item 9) attaching the retracting chains of the IInd extension
(Item 10).
9 9
50
10 10
Remove the pulley (Item 11) in the top of the Ist extension
boom.
With the help of an overhead crane or hoist, extend the Ist

extension boom of the external boom by about 20÷30 cm.
11 11
Remove the front upper lateral runners attached to the

external boom (Item 12) with their shims.
12
12
(29/03/2011) 50-06-M146EN
20
Boom removal
Raise the Ist extension boom with the help of an overhead

crane or hoist and remove the lower front runners (Item 13)
of the external boom with their shims.
13
13
With the help of an overhead crane or hoist, withdraw the

Ist, IInd and IIIrd extension booms from the external boom.
50
Remove the two split pins (Item 14) and unscrew the nuts
and locknuts completely (Item 15), release the chains for
retracting the IInd extension boom in the lower front part of
the external boom.
15
15
14
14
IInd AND IIIrd EXTENSION REMOVAL FROM THE Ist

EXTENSION BOOM
1
Release the Ist retraction chain (Item 1) of the IIIrd extension

boom in the rear part of the arms.
50-06-M146EN (29/03/2011)
21
Boom removal
Remove the comb from the chain (Item 2).
Slacken the grub screws of the rear lateral runners (Item 3)

with their shims fixed to the IInd extension boom.
3 3
3 3
50
Remove the upper rear runners (Item 4) fixed to the IInd
4 4
extension boom.
Withdraw the chain from the base of the pulley (Item 5).
(29/03/2011) 50-06-M146EN
22
Boom removal
Remove the front fixing clutches of the retracting chain

of the IIIrd extension by means of the appropriate screws
6 6
(Item 6) and extract the chain by pulling it towards the quick
connector.
6 6
Remove the front lateral and upper runners (Item 7)

7 with their shims fixed to the Ist extension boom.
7
50
Remove the front lateral and lower runners (Item 8)

with their shims fixed to the Ist extension boom.
8
8
Pass the four chains (Item 9) for extending the IInd extension
boom inside the opening in the upper front part of the Ist
extension boom (Item 10), and extend it fully on the IInd
9
9
10 10 extension boom.
9
9
Tie the chains to the IInd extension boom.
50-06-M146EN (29/03/2011)
23
Boom removal
With the help of an overhead crane or hoist, withdraw

the IInd and IIIrd extension booms from the Ist extension
boom keeping the chains resting on the upper part well
stretched.
Ist EXTENSION BOOM REMOVAL FROM THE IInd

EXTENSION BOOM
1 Remove the pulley (Item 1), in the rear of the IInd

extension boom.
50
Extend the IIIrd extension boom by 20÷30 cm from the IInd
extension boom and remove the lateral runners (Item 2) with
their shims fixed to the IIIrd extension boom at the rear.
Remove the front and upper lateral runners (Item 3)

with their shims fixed to the IInd extension boom.
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24
Boom removal
Raise the IIIrd extension boom in the front with the help of
an overhead crane or hoist to remove the lower front runners
(Item 4) with their shims fixed to the IInd extension boom.
Tie the chains (Item 5) to the IIIrd extension boom.
5
50
With the help of an overhead crane or hoist, withdraw the

IIIrd extension boom from the IInd extension boom keeping
the chains resting on the top well stretched, which could be
fitted.
Remove the upper fixing combs in the front of the four

extension chains (Item 6) of the IInd extension boom.
6 6
50-06-M146EN (29/03/2011)
25
Boom removal
Remove the fixing tie rods (Item 7) for the extension chains
of the IInd extension boom, withdrawing them from the holes
7
in the tail of the IInd extension boom.
Remove the fixing tie rods (Item 8) for the chains for
extending the IIIrd extension boom, extracting it through the
appropriate holes in the tail of the IIIrd extension boom.
50
Disconnect the two combs fixing the upper chain (Item 9)
from each other by removing the pair of single equalisers
(Item 10).
9
9
10
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Boom removal
50
50-06-M146EN (29/03/2011)
BOOM REFIT
page
PRELIMINARY OPERATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMPLETE TELESCOPIC BOOM REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
– PREASSEMBLY OF EXTERNAL BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– PREASSEMBLY OF BOOM Ist EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– INSERT BOOM Ist EXTENSION INTO EXTERNAL BOOM . . . . . . . . . . . . . . . . . . . 12
– PREASSEMBLY OF THE IInd EXTENSION BOOM. . . . . . . . . . . . . . . . . . . . . . . . 14
– INSERT THE BOOM IInd EXTENSION INTO THE BOOM Ist EXTENSION . . . . . . . . 17
– PREASSEMBLING THE BOOM IIIrd EXTENSION . . . . . . . . . . . . . . . . . . . . . . . . 21
– FIT THE TRAVERSE JACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
– FIT THE EXTENSION JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
– FIT THE QUICK CONNECTOR TO THE HEAD OF THE BOOM . . . . . . . . . . . . . . . . 33
TELESCOPIC BOOM REFIT TO THE VEHICLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Boom refit
PENTAGONAL TELESCOPIC BOOM REFIT

50
PRELIMINARY OPERATIONS
Prepare the framework, checking that the holes are correctly tapped; eliminate burrs from the
bushes for the pins, rub down any weld splash around the runner housings.
and safety.
50-07-M146EN (05/05/2011)
3
Boom refit
COMPLETE TELESCOPIC BOOM REFIT
PREASSEMBLY OF EXTERNAL BOOM
Lubricate the internal walls of the external arm with grease

(see “Lubricants” table in the User and Maintenance
manual).
Then stretch the chains (Item 1) for retracting the IInd

extension boom over them.
50
1 1
Fit the tie rods (Item 2) with their combs at the front end of
3
the chain (Item 3).
6 4 5
Insert the fixing tie rods (Item 4) into their holes in the lower
front of the external boom; for each tie rod fit 2 washers, one
cylindrical and one conical and screw on the nut and locknut
(Item 5) before inserting the safety split pin (Item 6).
(05/05/2011) 50-07-M146EN
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Boom refit
Fit the combs (Item 7) to the rear end of the chain (Item 8)
and stretch the chain towards the end of the external
boom.
8
8
Fit 2 equalisers supporting the external chain tie rods

(Item 9), on the upper wall of the external boom.
9
50
Keeping the boom head on, preassemble on the front walls of the external boom:
- on the right side, runner adjustment grub screws (Item 10) several split washers and locknuts
(Item 11 and 12) and runner fixing screws (Item 13);
- on the left side, runner adjustment grub screws (Item 10) with locknuts (Item 12) and runner
fixing screws with split washers (Item 11 and 13);
- on the upper side, runner adjustment grub screws (Item 10) with locknuts (Item 12);
- on the lower side, runner adjustment grub screws (Item 10), several split washers and locknuts
(Item 11 and 12).
10 10
12 12 12
12
12
13 13 12
10 11 10
11
10 11 11 10
11 11
13
12
11 11
10 12
13
13 11 12
12 10 11 10 10 11 11
10
11 10 13
10 12 12 12 12
50-07-M146EN (05/05/2011)
5
Boom refit
Fit the feed through connectors in the drilled rib in the rear
part of the external boom.
Fit the tubular chain carrier (Item 14) on the right side of the
external boom.
50
14
In all the tubular chain carriers fit edge protector

seals to the rear (Item 15) and front (Item 16) ends
to prevent breakage of the hydraulic pipes.
15
15
15
16
16
(05/05/2011) 50-07-M146EN
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Boom refit
23 22 21
Fit the traverse command hydraulic pipes (Item G and F)
20 19 18 17
to the feed through connectors (Item 17 and 18).
Fit the extension command hydraulic pipes (Item E and D)
D E
F G
Fit the optional command hydraulic pipes (Item C and B)
Fit the hydraulic drain tube (Item A) to the bulkhead
A B C
feedthrough (Item 23)
Mark all the tubes with the corresponding number.
Fit the electric socket plate (Item 24) in the rear right part of
the external arm.
Connect the multipin electric plug (Item 25) of the platform
24 cable to the plate (Item 24).
50
25
Insert the chain-carrier tube (Item 14):

26
- the cable for the platform socket (Item 26), keeping it to
the outside of the tube;
G 27 - the wiring for the 3 chain fault microswitches (Item 27)
F
26
to the outer boom.
C
B
A
14
Insert the hydraulic tubes (Item G - F - C - B - A), previously

attached to the feedthrough couplings, inside the chain-
carrier tube (Item 14) in sequence.
14
G
A B F
C
50-07-M146EN (05/05/2011)
7
Boom refit
Attach the hydraulic tubes (Item G - F - C - B - A) and the

electric cables (Item 26 and 27) to the outer boom with the
appropriate clips (Item 28).
Tie the electric cables to the hydraulic tube.
28 28
Fit the first tube-carrier chain (Item 29) to the chain-carrier

tube (Item 14) using the appropriate screws (Item 30).
30
30
29
50
14
Tie (Item 31) the electric cable for the pair of microswitches
directly to the wall of the boom.
Insert the cable for connection to the single microswitch
31
(Item 32) into the tube-carrier chain of the outer boom.
32
Prepare the hydraulic tubes then insert them into the tube-
carrier chain (Item 29) numbering them on the back (E - G =
traverse; C - B = optional; A = drainage).
29
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8
Boom refit
35
Connect elbow connectors (Item 33) to the tubes (Item 34)
inside the tubing (Item 14) and then to the tubes (Item 35)
B C
G F inside the chain (Item 29) following the sequence from the
A
36 inside of the boom to the outside, alternating the long and
short couplings.
Fix the couplings with the collars (Item 36) to the chain-
carrier tubing (Item 14).
In the passages between the chain-carrier tubing tube-carrier
14 chains, secure the electric cables to the hydraulic tubes with
33
34
straps.
PREASSEMBLY OF BOOM Ist EXTENSION
Lubricate the internal walls of the boom Ist extension with

grease (see “Lubricants” table in the User and Maintenance
manual) then stretch over the chain (Item 1) for retracting
the boom IIIrd extension.
50
7
Preassemble the internal chain tie rod for retracting the IIIrd
2
extension: fit the tie rod with combs (Item 2) built-into the
fixing for the tie rod (Item 3); screw a nut and locknut (Item 4
and 5) onto the tie rod until the safety split pin (Item 6) can
3 be inserted.
4
Fit the preassembled tie rod (Item 7) to the front end of the
inner chain (Item 1) and stretch the chain towards the front
1
of the external boom.
50-07-M146EN (05/05/2011)
9
Boom refit
Fit the pulleys (Item 8) into the rear part of the boom Ist
extension, locking the pin (Item 9) with the appropriate
11
screw and nut (Item 10 and 11).
9
Grease the pulley spindle (see “Lubricants” table in the User
and Maintenance manual).
8 10
Preassemble on the external walls in front of the Ist extension:

- on the right, foot adjustment grub screws (Item 12) several split washers and locknuts (Item 13
and 14) and foot fixing screws with split washer (Item 15 and 13);
- on the left, foot adjustment grub screws (Item 12 and locknuts (Item 14) and foot fixing screws
with split washer (Item 15 and 13);
- on the top, foot adjustment grub screws (Item 12) several split washers and locknuts (Item 13
and 14) foot fixing screws with split washer (Item 15 and 13).
50
14 15 15
14 12 14
13 13 15
13
12
12 13
13 14 12
13 13
15 13
14
13
15 12
13
14
14 12
12 14 14
13 13
13 14
12 13 12 13
13 12
15
13 12 14 12
14 13
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Boom refit
Behind the boom Ist extension, preassemble to the inner walls:

- on the right and left, foot adjustment grub screws (Item 12) several split washers and locknuts
(Item 13 and 14) and foot fixing screws with split washer (Item 15 and 13);
- on the top, foot adjustment grub screws (Item 12) several split washers and locknuts (Item 13
and 14) foot fixing screws with split washer (Item 15 and 13).
13 14 14 13
13 12
12
13 13
12 15
14 12 14 14 12
12
13
15 15
13 13
13 13
13
12 14
14 12 12 14
12
12
15
13 14 12
14 13
50
Fit the chain-carrier tube (Item 16) to the boom Ist extension,
fixing it at the front with the appropriate screws (Item 17).
17
16
Fit the second tube-carrier chain (Item 18) to the chain-

carrier tubing (Item 16), fixing it with the appropriate screws
(Item 19).
19
18
16
50-07-M146EN (05/05/2011)
11
Boom refit
Prepare the hydraulic tubes then insert them into the tube-
carrier chain (Item 18) numbering them on the back (E - G =
18
22 Connect the elbow couplings (Item 20) to the tubes (Item 21)
inside the tubing (Item 16) and then to the tubes (Item 22)
g
a b c
e inside the chain (Item 18) following the sequence from the
23 inside to the outside of the boom, alternating the short and
long couplings.
Fix the couplings with the collars (Item 23) to the chain-
carrier tubing (Item 16).
50
16 chains, secure the electric cables to the hydraulic tubes with
20
21
straps.
Preassemble the feet (Item 24) and fit them afterwards to

the bottom of the boom Ist extension.
24
24
Then tape them with rubberised paper (Item 25) so that they
do not fall from the tubing.
25
(05/05/2011) 50-07-M146EN
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Boom refit
INSERT BOOM Ist EXTENSION INTO EXTERNAL BOOM
With a hoist or overhead crane, lift the boom Ist extension

1 2 (Item 1) and insert it into the external boom (Item 2), leaving
it projecting by 30-40 cm.
6 5 Prepare the feet (Item 3) on their own mountings (Item 4).

Note: the feet and mountings are of two different sizes.
3
3
3 3 When assembled, the smallest are positioned on the top of
the boom and the largest on the bottom.
50
4
4
Fit at the front between the external boom and Ist extension the preassembled lower and lateral
feet (Item 5).
Only screw in the screws fixing the foot mountings (Item 7), located on the outer boom.
50-07-M146EN (05/05/2011)
13
Boom refit
Fit the preassembled upper and lower feet (Item 6) at the front between the external boom and Ist
extension.
Only screw in the screws fixing the foot mountings (Item 7), located on the outer boom.
7 7
6
6
Fully insert the Ist extension into the external boom.

Prepare the feet (Item 8) and upper rear foot mounting plate (Item 9), then the rear side feet plus
their mountings (Item 10 and 11).
8 12 13
50
8 11
10
Fit the plate with the preassembled feet (Item 12) on the upper rear side of the boom Ist extension.
Screw in the two screws (Item 14) to secure the plate (Item 9).
Fit the preassembled feet and side mountings (Item 13) at the rear of the boom Ist extension.
Screw in the screws (Item 15) to secure the mountings (Item 11).
12 12 12
14 15 14
14
13 15
15 15
13
14
Adjust all the feet of the boom Ist extension.

50-04 Boom control and adjustment.
(05/05/2011) 50-07-M146EN
14
Boom refit
After connecting them, insert the electric cables and

hydraulic tubes of the external boom tube carrier chain into
the Ist extension tubing.
Fix the tube carrier chain (Item 16) of the boom external to
the tubing of the Ist extension with the appropriate screws
(Item 17).
17
16
PREASSEMBLY OF THE IInd EXTENSION BOOM
Lubricate with grease (see “Lubricants” table in the User

and Maintenance manual) the internal walls of the boom
IInd extension.
50
In front of the boom IInd extension, preassemble on the outer walls:

- on the right, feet adjustment grub screws (Item 1) plus split washers and locknuts (Item 2 and 3)
and feet fixing with split washers (Item 4 and 2);
- on the left, feet adjustment grub screws (Item 1) and locknuts (Item 3) and feet fixing screws with
split washers (Item 4 and 3);
- on the top, feet adjustment grub screws (Item 1) plus split washers and locknuts (Item 2 and 3)
and feet fixing screws with split washers (Item 4 and 2).
3 2
3 1 3
2
2 4
1 2
1 3 1
2
4 2
3
2 2 2
1
4 1
2
3 2
3 1
3 3 1
3
1 2
2 1 1
2 2 3
2
2 3 2 4
1
2 3 3
50-07-M146EN (05/05/2011)
15
Boom refit
2 1
2
Behind the boom IInd extension, preassemble on the internal
2 walls:
3 - on the right and left, feet adjustment grub screws (Item 1)
3 1
plus split washers and locknuts (Item 2 and 3) and feet
2 1 2
2 1 fixing screws with split washers (Item 5 and 2);
2
1
3 - on the top, feet adjustment grub screws (Item 1) plus split
3 3
5 5 washers and locknuts (Item 2 and 3) and feet fixing screws
5
2 2 with split washers (Item 5 and 2).
1 1
3 3
Stretch externally the 4 extension chains of the boom Ist

extension (Item 6) on the boom IInd extension.
Assemble the chains with the combs (Item 7) and then fix
6
6
them to the walls with the screws (Item 8), tightening them
from the inside.
7 Finally tape the chains to the walls of the IInd extension.
7
50
8
8 8 8
8 8 8 8
Assemble the fixing combs (Item 9) in front of the 4 extension

chains (Item 6).
9 9
9
9
(05/05/2011) 50-07-M146EN
16
Boom refit
Fit the chain carrier tubing (Item 10) to the boom Ist
extension, fixing it at the front with the appropriate screws
(Item 11).
11
10
Fit the second tube carrier chain (Item 12) on the chain
carrier tubing (Item 10), fixing it with the appropriate screws
(Item 13).
13
12
50
10
Prepare the hydraulic tubes then insert them into the tube
carrier chain (Item 12) numbering them at the back (E - G =
12
16
Connect the elbow couplings (Item 14) to the tubes (Item 15)
e g inside the tubing (Item 10) and then to the tubes (Item 16)
c
a b inside the chain (Item 12) following the sequence from the
17
inside to the outside of the boom.
Fix the couplings with the collars (Item 17) to the chain
carrier tubing.
chains, secure the electric cables to the hydraulic tubes with
14 straps.
15
50-07-M146EN (05/05/2011)
17
Boom refit
Preassemble the feet and fit them behind the bottom of the
boom IInd extension, then tape them with rubberised paper
so they do not fall from the tubing.
INSERT THE BOOM IInd EXTENSION INTO THE BOOM

Ist EXTENSION
1 With a hoist or overhead crane, lift the boom IInd extension

(Item 1) and insert it into the boom Ist extension, leaving it
projecting 30-40 cm.
50
1
7 5
2
2 Prepare the feet (Item 2) on their own mountings (Item 3).
2 2 Note: the feet and mountings are of two different sizes.
When assembled, the smallest are positioned on the top of
3
3
(05/05/2011) 50-07-M146EN
18
Boom refit
4 4 4 Extend the 4 chains (Item 4) in front from the boom IInd

4
extension to the boom Ist extension.
4
Fit the preassembled lower side feet (Item 5) in front between the boom Ist extension and the
boom IInd extension.
Screw in only the fixing the feet mounting (Item 6), located on the external boom.
50
5 5
6
Fit the preassembled upper side feet (Item 7) in front between the boom Ist extension and the
boom IInd extension.
Screw in only the fixing the feet mounting (Item 6), located on the external boom.
6
6
7
7
50-07-M146EN (05/05/2011)
19
Boom refit
10 Prepare the feet (Item 8) and the upper rear foot mounting
plate (Item 9).
8 8
Fit the plate with the preassembled feet (Item 10) to the
10 10 boom IInd extension, on the rear top side.
10 Screw in the screws (Item 11) to fix the plate.
Screw in the screws (Item 12) to fix the rear side foot
mountings.
12
11
12
50
Adjust all the feet of boom IInd extension.
(05/05/2011) 50-07-M146EN
20
Boom refit
After connecting the tubes as previously shown, insert the electric cables and hydraulic tubes of
the Ist extension tube carrier chain, into the IInd extension tubing.
Fix the tube carrier chain of the Ist extension (Item 13) to the tubing of the IInd extension with the
appropriate screws.
13
50
50-07-M146EN (05/05/2011)
21
Boom refit
4 4 PREASSEMBLING THE BOOM IIIrd EXTENSION

1 1
Stretch the 2 extension chains of the IInd boom (Item 1)

externally onto the boom IIIrd extension.
Assemble the chains with their combs (Item 2) and then fix
2
them to the walls with their screws, tightening them from
the inside (Item 3).
Finally, tape the chains to the wall of the extension
(Item 4).
Assemble their fixing combs (Item 5) in front of the 2

extension chains (Item 1).
Lock the 2 combs (Item 5) to their equalisers (Item 6), with
the appropriate screws and nuts.
Lock the pivot to the head of the boom.
5 5
5 5
50
6
Behind the boom IIIrd extension, preassemble on the internal

7
8
7
8 8
8 walls:
9 9 9
9 - on the right and left, foot adjustment grub screws (Item 7)
9
7 7 8
plus split washers and locknuts (Item 8 and 9) and foot
7
8 8 8
fixing screws with split washers (Item 10 and 8);
8
10
- on the top, foot adjustment grub screws (Item 7) plus split
10 7
9 7 8
washers and locknuts (Item 8 and 9) and foot fixing screws
8 9
with split washers (Item 10 and 8).
Preassemble the feet (Item 11) and fit them at the back to
11
the bottom and side of the boom IIIrd extension.
Then tape them with rubberised paper (Item 12) so they do
not fall off the tubing.
11
12
11 11
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Boom refit
With a hoist or overhead crane, lift the boom IIIrd extension

(Item 13) and insert it into the boom IInd extension, leaving
it projecting 30-40 cm.
13
18 16 Prepare the feet (Item 14) on their mountings (Item 15).

Note: the feet and mountings are of two different sizes.
14
14 When assembled, the smallest are positioned on the top of
14 14
50
15
15
Fit the lower side feet (Item 16) at the front between the boom IInd extension and boom IInd extension.
Screw in only the foot mounting fixing screws (Item 17), on the external boom.
Fit the upper side feet (Item 18) at the front between the boom IInd extension and boom IIIrd
extension.
Screw in only the foot mounting fixing screws (Item 17), on the external boom.
17
17
18
17 17
18
17
16
17
50-07-M146EN (05/05/2011)
23
Boom refit
21 Prepare the feet (Item 19) and the rear upper foot mounting
plate (Item 20).
19 19
20
Fit on the boom IInd extension, on the upper rear side, the
plate with the preassembled feet (Item 21).
21 21 21
Screw in the screws (Item 22) to fix the plate.
Screw in the screws (Item 23) to fix the rear side feet
mountings.
Adjust all the feet of the boom IIIrd extension.

22
23
50
23
Fully close the IIIrd extension.
(05/05/2011) 50-07-M146EN
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Boom refit
Prepare the pulley (Item 24) for sliding the single internal chain (Item 25), with its spindle (Item 26)
and the 2 crescent washers (Item 27) that lock the spindle.
24
27 27
26 24
28
27
27
25
31 Fit the pulley (Item 24) with its spindle (Item 26) in their
seatings in the back of the IIIrd extension, keeping the 2
50
30
chamfers (Item 28) of the spindle facing upwards.
29 29 Lock the spindle (Item 26) with the 2 crescent washers
29 29 (Item 27) screwing them on with the appropriate screws
27 (Item 29).
27
Apply loctite blue 243 before tightening.
35
35 Tighten the screws (Item 29) using a tightening torque of
34 34 70 Nm.
25 Slide the single internal chain (Item 25) into the pulley
32 32 (Item 24) and fix its combs (Item 30) into the lower wall
of the IIIrd extension, in its seating, with the appropriate
screws (Item 31).
In the rear part of the IInd extension, slide the 2 internal

chains (Item 32) into the pulleys (Item 33) of the Ist
extension, position the combs (Item 34) of the chains on
the lower walls of the IInd extension, in its seating, fixing
33 them with the appropriate screws (Item 35).
33
32
32
50-07-M146EN (05/05/2011)
25
Boom refit
Prepare the square foot (Item 36).

36
Then support the mounting (Item 37) for the square foot over
the combs (Item 34) and fix it with the appropriate screws
(Item 38).
39 36
Now fit the square foot (Item 36) to the mounting fixing
39
it with the appropriate screws (Item 39).
38 38
50
34 34
38 38
37
Insert the electric cables and hydraulic tubes of the IInd

extension tube carrier chain, into the IIIrd extension tubing.
Fix the IInd extension tube carrier chain to the IIIrd extension
tubing with the appropriate screws (Item 40).
40
(05/05/2011) 50-07-M146EN
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Boom refit
FIT THE TRAVERSE JACK
Check that the valve block is correctly mounted on the

traverse cylinder (Item 1).
With the help of an overhead crane or hoist insert the
traverse cylinder (Item 1) into the seating in the boom IIIrd
1 extension.
Insert the hinge pin (Item 3) into the traverse cylinder (Item 1)
and lock it with the appropriate screw (Item 2).
Grease the traverse cylinder hinge pin (see “Lubricants
3 table” in the User and Maintenance manual).
2
50
Fit the box (Item 4) for the platform socket on the left side
4
of the head.
Connect the electric cables to the multi-pin socket on the
platform (Item 5).
5
6 Tie (Item 6) the electric cable to the left side of the head of
the boom IIIrd extension.
4
6
50-07-M146EN (05/05/2011)
27
Boom refit
Protect the electric cables socket and the hydraulic tubes for
the platform with a sheath (Item 8) then position the hydraulic
tubes on the chain carrier tubing with the appropriate collar
(Item 7) leaving them free for sliding and orientation.
Insert the tubes into the head of the boom through the hole
at the top (Item 9).
50
Fit the hydraulic couplings at 90° with the rapid couplings (male) (Item 10 and 11) on the left and
(female) (Item 12) on the right of the head of the boom. Fit their plug carrier.
Connect the hydraulic tubes (Item E and G) to the valve block (Item 13) on the traverse cylinder.
Insert the tubes for the options (Item B and C) in the hole in the top of the head of the boom and
connect them to the quick connectors (Item 10 and 11) on the left of the head of the boom.
Insert the drainage tube (Item A) in the hole in the top of the head of the boom and connect it to
the quick connectoron the right side of the head of the boom (Item 12).
11
12 13 E C
12
11
10
10
A B
(05/05/2011) 50-07-M146EN
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Boom refit
Tie (Item 14) the electric cable assembly to the sheath

protecting the traverse command tubes, optional and
drainage.
14
14
14
Fit the pulley (Item 15) in the upper front part of the boom IInd
extension, locking the spindle (Item 16) with the appropriate
screw (Item 17).
17
Lubricate the pulley spindle with grease (see “Lubricants
15
table” in the User and Maintenance manual).
16
50
Fit the pulley (Item 18) in the upper front part of the boom Ist
extension, locking the spindle (Item 19) with the appropriate
18 screw (Item 20).
Lubricate the pulley spindle with grease (see “Lubricants
table” in the User and Maintenance manual).
18
20
19
Slide the 6 chains for extending the booms onto the pulleys.
Fix the appropriate equalisers (Item 21) to the combs of the
21
4 chains.
21
50-07-M146EN (05/05/2011)
29
Boom refit
Insert the single tie rod of the 2 chains into the appropriate
hole in the Ist extension (Item 22) and lock it with its nut
(Item 23) and locknut (Item 24).
27
Fix the single tie rod (Item 25) in the bilanciere (Item 26)
23 22
of the 2 chains with the appropriate bolts and nut (Item 27
and 28).
24 26 25
28
Insert the two tie rods (Item 29) of the 4 chains into the
double equalisers (Item 30) on the external boom and lock
30
them with their shims (Item 31), nuts and locknuts (Item 32
and 33).
33 32 31 29
50
Fix the 2 tie rods in the equalisers of the 4 chains with the
34 appropriate bolts and nuts (Item 34 and 35).
Tighten all the bolts of the equalisers and tie rods of the
6 chains.
34
35
Fit the crescent washers (Item 36) for the microswitches.
36
36
36
(05/05/2011) 50-07-M146EN
30
Boom refit
FIT THE EXTENSION JACK
Clean the bushes of the boom extension cylinder.

Check that the rollers (Item 1) and guide (Item 2) are fitted
correctly on the extension cylinder.
2
Check that the valve block (Item 3) is fitted correctly on the

3
extension cylinder.
50
Fit 2 eccentric bushes (Item 4) on the rod side of the

extension cylinder (one on each side), with the mounting
holes (Item 5) facing outwards.
4
5
With the help of an overhead crane or hoist, insert the

extension cylinder (Item 6) into the boom keeping the valve
block (Item 3) facing downwards.
50-07-M146EN (05/05/2011)
31
Boom refit
Centre the holes in the bushes in the boom Ist extension with
the spindle seats on the liner of the extension cylinder.
Insert both the pins (Item 7) for hinging between the

extension cylinder and the boom Ist extension, keeping both
the holes (Item 8) perpendicular to the pin.
8
50
8
Fix the pins (Item 7) with the screws (Item 9) to the cylinder.
Insert the screws upwards and lock them with the nuts
(Item 10).
9 9
10 10
Centre the holes in the boom Ist extension with the seats of
the pins on the liner of the extension cylinder.
(05/05/2011) 50-07-M146EN
32
Boom refit
Screw 2 grub screws (Item 11) onto the cylinder rod to lock
the eccentric bushes.
Insert the pin (Item 12) for hinging between the extension
cylinder and the external boom and fix it with circlips
(Item 13), one on each side.
N.B. If necessary, raise the extension cylinder with the help

11 11
of an overhead crane or hoist to centre the hinge hole with
the external boom.
12
Lubricate the extension cylinder pin with grease (see
“Lubricants” table in the User and Maintenance manual).
13
50
14 From the feedthrough connectors in the external boom, fit

the hydraulic extension command tubes (Item E and D) to
14 the extension cylinder and secure them with the collars
(Item 14 and 15).
d e
15
50-07-M146EN (05/05/2011)
33
Boom refit
FIT THE QUICK CONNECTOR TO THE HEAD OF THE BOOM
With the help of an overhead crane or hoist, insert the quick

connector (Item 1) in the head of the boom.
2
Insert the pin (Item 2) for hinging with the head of the boom
3
and fix it with the screws (Item 3).
Insert the pin (Item 2) for hinging with the rod of the traverse
cylinder (Item 4) and lock it with the ring (Item 5).
4
50
Preassemble the 3 chain fault microswitches (Item 6) to the
6 mountings (Item 7 and 8).
Fix the microswitches to the boom with the appropriate

9 screws (Item 9).
9
(05/05/2011) 50-07-M146EN
34
Boom refit
Adjust the distance between the microswitches and the

crescent washer with the appropriate screw to about
1 mm.
Connect the IInd and IIIrd extension chain microswitches

and if necessary secure the cables.
50
10 Fit the “M.S.S.” winder (Item 10) in the front left part of the
external boom.
Fix the “M.S.S.” winder cable to the ring (Item 11) in the
11 boom Ist extension.
The “M.S.S.” safety system must be calibrated by

authorised Manitou personnel.
Extend the boom fully and lubricate the outer walls with
grease (See User and Maintenance table).
50-07-M146EN (05/05/2011)
35
Boom refit
2
TELESCOPIC BOOM REFIT TO THE VEHICLE
Arrange the turret of the vehicle with the lifting cylinder

(Item 1) and compensating cylinder (Item 2) in the positions
indicated.
With the help of an overhead crane or hoist, hook the boom

into the appropriate eyebolts and position it on the vehicle
in the appropriate slot in the turret.
50
Carry out centring between the compensation jack rod
eyebolt and the corresponding bush on the boom (Item 3).
3
Insert the compensation jack hinge pin (Item 4) into the

boom screw in the locking screw (Item 5).
(05/05/2011) 50-07-M146EN
36
Boom refit
Working with an overhead crane or hoist, centre the bushes

in the turret with the bush in the boom to fit the pin hinging
the boom to the turret.
Insert the pin (Item 6) hinging the boom to the turret, after
coating it with grease, and screw in the locking screw
7 (Item 7).
Working with overhead crane or hoist, lower the telescopic

boom to centre the eyebolt of the lifting jack with the
appropriate bushes in the lower part of the boom (Item 8).
8
50
Insert the pin hinging the boom raising jack (Item 9) and fit
the pin locking screw (Item 10).
9
10
Reconnect safety system connector “X2” (Item 11).

11
50-07-M146EN (05/05/2011)
37
Boom refit
Refit the limit microswitch for raising the boom (Item 12)
with its mounting (Item 13) situated at the upper end of the
13 12 turret.
Replace the binding of the electric cables inside the turret.
Reconnect the hydraulic tubes supplying the boom (Item 14)

taking care that the tubes correspond.
14
14
14
50
14
14
14
14
Working on the appropriate bush, connect the electrical plug-

wiring (Item 15) in the rear part of the boom, if present.
16
15
16
16
16 16 16
Connect the connector for the cable chain safety

microswitches (Item 17).
Replace the fixings of the hydraulic tubes and electric cables
18
18 in the upper rear part of the boom (Item 16 and 18).
18 18 18
17 Reconnect the terminals to the battery.
Check correct operation of the limit microswitches (Item 12)

for raising the boom.
(05/05/2011) 50-07-M146EN
38
Boom refit
Before using the vehicle, grease the feet of the telescopic boom as follows:
- fully extend the telescopic boom.
- using a brush, apply a layer of grease (see “PACKING TABLE” in the User and Maintenance
manual) to the sides of the telescopic boom.
- actuate the telescopic boom several times to distribute the grease evenly.
- remove excess grease.
GREAS E
GREA S E
GREAS E
50
GREAS E
GREAS E
GREAS E
50-07-M146EN (05/05/2011)
HYDRAULICS
- HYDRAULIC SCHEMATIC DIAGRAMS
- HYDRAULIC COMPONENTS LOCATION
- HYDRAULIC CONTROL AND ADJUSTMENT
- HYDRAULIC COMPONENTS REMOVAL
- HYDRAULIC COMPONENTS REFIT
- HYDRAULIC SPECIFIC TOOLING
70
HYDRAULIC SCHEMATIC DIAGRAMS
page
DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH SAUER TRANSMISSION

– LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
– DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH REXROTH TRANSMISSION
– LEGEND . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
– DIAGRAM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B9
70
(23/11/2011) 70-02-M146EN
A2
Hydraulic schematic diagrams
70
70-02-M146EN (23/11/2011)
A3
LEGEND FOR DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH SAUER TRANSMISSION

Position on the
Ref Description Characteristics (Optional)
diagram
A ACCUMULATOR C18
C.1 FRONT RIGHT STABILISER RAISING-LOWERING CYLINDER G2
C.2 FRONT LEFT STABILISER EXTENSION CYLINDER K2
C.3 FRONT RIGHT STABILISER EXTENSION CYLINDER G2
C.4 FRONT LEFT STABILISER RAISING LOWERING CYLINDER M2
C.5 FRONT RIGHT STABILISER RAISING LOWERING CYLINDER G13
C.6 REAR LEFT STABILISER EXTENSION CYLINDER K13
C.7 REAR RIGHT STABILISER EXTENSION CYLINDER I12
C.8 REAR LEFT STABILISER RAISING LOWERING CYLINDER K13
C.R. HYDRAULIC COLLECTOR G35
C.S.P. CONTROLLED SAFETY VALVE A18 / A22
D DANFOSS DISTRIBUTOR C27
D.F. FLOW SPLITTER K17
EV(S1) DANFOSS RAISING ELECTROVALVE SLIDER 100 LT. E20
EV(S2) ELECTROVALVE DANFOSS EXTENSION SLIDER 100 LT. E21 / E22
EV(S3) DANFOSS ROTATION ELECTROVALVE SLIDER 40 LT. E23
EV(S4) DANFOSS TRAVERSING ELECTROVALVE SLIDER 100 LT. E24
EV(S5) ELECTROVALVE OPTIONAL DANFOSS SLIDER 65 LT. E25 / E26
EV(S8) PARKING BRAKE ELECTROVALVE I35
EV(S9) GENERAL ELECTROVALVE STABILISERS G15
EV(S10) EMERGENCY ELECTROVALVE HYDRAULIC SYSTEM EXCLUSION G20
EV(S11) ELECTROVALVE FRONT RIGHT BEAM C7
EV(S12) ELECTROVALVE FRONT LEFT BEAM C9
EV(S13) ELECTROVALVE REAR LEFT BEAM C10
EV(S14) ELECTROVALVE REAR RIGHT BEAM C12
EV(S15) ELECTROVALVE RETRACT/EXTEND STABILISERS E7
70
EV(S16) ELECTROVALVE FRONT RIGHT STABILISER C8
EV(S17) ELECTROVALVE FRONT LEFT STABILISER C10
EV(S18) ELECTROVALVE REAR LEFT STABILISER C11
EV(S19) ELECTROVALVE REAR RIGHT STABILISER C13
EV(S21) FORWARD ELECTROVALVE O28 / O29
EV(S22) REVERSE ELECTROVALVE O26
EV(S23) ELECTROVALVE REAR AXLE UNLOCKING I30
EV(S24) ELECTROVALVE CRAB STEERING K36
EV(S25) ELECTROVALVE CONCENTRIC STEERING K34
EV(S26) ELECTROVALVE REAR AXLE UNLOCKING K30
EV(S27) ELECTROVALVE FAST GEAR A33
EV(S28) ELECTROVALVE SLOW GEAR A34
EV(S35) ELECTROVALVE LEVELLING CONTROL 1 I6 / I7
EV(S36) ELECTROVALVE LEVELLING CONTROL 2 K6 / K7
EV(S40) ELECTROVALVE ENGINE DISPLACEMENT REDUCTION Q25 / Q36
F.A. SUCTION FILTER S13
F.D.A.R. REAR DISK BRAKES I38 / M37
F.D.A.V. FRONT DISK BRAKES I31 / K31
F.M. FLOW FILTER O15
F.R. EXHAUST FILTER S20
G.E.S. ELECTROVALVE STABILISER UNIT E12
I.D. HYDRAULIC STEERING K20
L.P. PRESSURE LIMITING VALVE G15
M.C. BRAKE PUMP C37
M.I. VARIABLE DISPLACEMENT ENGINE S39
(23/11/2011) 70-02-M146EN
A4
LEGEND FOR DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH SAUER TRANSMISSION

Position on the
diagram
M.R.T. TURRET ROTATION MOTOR A30
M.V. FAN MOTOR I23
P TRIPLE GEAR PUMP O14
P.E. ELECTRIC PUMP M20
P.F. BRAKE PEDAL C35
P.I. HYDROSTATIC PUMP S26
R OIL TANK S11
RAD. RADIATOR S33
R.C.F.P. PARKING BRAKE VALVE I35 / I36
S OIL TANK E39
V.A. ACCESSORY CYLINDER A27 OPTIONAL
V.B. LOCK AND MOVEMENT CONTROL VALVE C30
V.B.P REAR AXLE LOCKING VALVE I28 / K28
V.B.P.A. REAR AXLE LOCKING CYLINDER K29 / M29
V.C. COMPENSATING CYLINDER A25
V.C.L.R. SLOW SPEED CONTROL CYLINDER I37 / I38
V.D. STEERING CYLINDER K31 / K39
V.F.P. PARKING BRAKE CONTROL CYLINDER K37
V.I. TRAVERSE CYLINDER A24
V.L. LIFTING CYLINDER A20
V.L.1. RIGHT LIFTING CYLINDER K2
V.L.2. LEFT LIFTING CYLINDER I2
V.S.L.R. SLOW SPEED SELECTOR VALVE A32
V.T.I. Ist EXTENSION CYLINDER A21
70
70-02-M146EN (23/11/2011)
A5
DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH SAUER TRANSMISSION
1 2 3 4 5 6 7 8 9 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
V.L. V.I. V.C.

V.T.I V.A.
EV(S27)
EV(S28)
A VSLR A
M.R.T.
C.S.P. B A
1 2
C.S.P. R T P
350bar 350bar 350bar
A 0.7L
C A B A B A B A B 300bar
MC C
270bar 260bar
D
PF
EV(S16)
EV(S12)
EV(S11)
EV(S17)
EV(S13)
EV(S14)
EV(S19)
EV(S18)
EV(S15) C2 100bar V.B. 100bar C1
270bar
T
E G.E.S. E
P T S.
EV(S1) EV(S2) EV(S3) EV(S4) EV(S5) V2 C3 V1
C.5
C.1 EV EV
(S9) (S10)
G G
CR
L.P. 220bar
C.3
C.7
V.L.2 EV
(S35) L R
I I
200bar
RCFP VCLR
A P A B
FDAV EV
B T B
EV (S8) FDAR
M.V. VBP (S23) P T
A A
V.L.1 EV VFP
(S36) I.D. V.D.
P
175bar
T VBPA V.D.
70
C.6 175bar
K C.2 EV EV K
0.8mm (S25) (S24)
L B B
EV
C.8 VBP A (S26)
D.F. 4bar
FDAV
C.4 VBPA FDAR
M M
3 bar
P.E.
M14 M6 1 2
P R1
R2
11.2cc
C2 C1
O
F.M. O
27cc
EV EV L2 M4 M3 N
(S22) (S21) A
M8 L1 L2 MA
27cc A XB XA M1
F0OB F0OA 480bar
max.
450bar 34bar disp.
Q 350bar Q
480bar
M5
CW 450bar
EV
(S40) (M5) X3
M4 B
M7
B M2
S L3 L4 MB L1
P.I. max 3 bar
M.I.
S
F.R.
143,5 psi
RAD. S
F.A.
R.
(23/11/2011) 70-02-M146EN
A6
70
70-02-M146EN (23/11/2011)
B7
LEGEND FOR DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH REXROTH TRANSMISSION

Position on the
diagram
A ACCUMULATOR C18
C.1 FRONT RIGHT STABILISER RAISING-LOWERING CYLINDER G2
C.2 FRONT LEFT STABILISER EXTENSION CYLINDER K2
C.3 FRONT RIGHT STABILISER EXTENSION CYLINDER G2
C.4 FRONT LEFT STABILISER RAISING LOWERING CYLINDER M2
C.5 FRONT RIGHT STABILISER RAISING LOWERING CYLINDER G13
C.6 REAR LEFT STABILISER EXTENSION CYLINDER K13
C.7 REAR RIGHT STABILISER EXTENSION CYLINDER I12
C.8 REAR LEFT STABILISER RAISING LOWERING CYLINDER K13
C.R. HYDRAULIC COLLECTOR G35
C.S.P. CONTROLLED SAFETY VALVE A18 / A22
D DANFOSS DISTRIBUTOR C27
D.F. FLOW SPLITTER K17
EV(S1) DANFOSS RAISING ELECTROVALVE SLIDER 100 LT. E20
EV(S2) ELECTROVALVE DANFOSS SLIDER EXTENSION 100 LT. E21 / E22
EV(S3) DANFOSS ROTATION ELECTROVALVE SLIDER 40 LT. E23
EV(S4) DANFOSS TRAVERSING ELECTROVALVE SLIDER 100 LT. E24
EV(S5) ELECTROVALVE DANFOSS OPTIONAL SLIDER 65 LT. E25 / E26
EV(S8) PARKING BRAKE ELECTROVALVE I34 / I35
EV(S9) GENERAL ELECTROVALVE STABILISERS G15
EV(S10) EMERGENCY ELECTROVALVE HYDRAULIC SYSTEM EXCLUSION G20
EV(S11) ELECTROVALVE FRONT RIGHT BEAM C7
EV(S12) ELECTROVALVE FRONT LEFT BEAM C9
EV(S13) ELECTROVALVE REAR LEFT BEAM C10
EV(S14) ELECTROVALVE REAR RIGHT BEAM C12
EV(S15) ELECTROVALVE RETRACT/EXTEND STABILISERS E7
70
EV(S16) ELECTROVALVE FRONT RIGHT STABILISER C8
EV(S17) ELECTROVALVE FRONT LEFT STABILISER C10
EV(S18) ELECTROVALVE REAR LEFT STABILISER C11
EV(S19) ELECTROVALVE REAR RIGHT STABILISER C13
EV(S21) FORWARD ELECTROVALVE O29 / O30
EV(S22) REVERSE ELECTROVALVE O28 / O29
EV(S23) ELECTROVALVE REAR AXLE UNLOCKING I30
EV(S24) ELECTROVALVE CRAB STEERING K36
EV(S25) ELECTROVALVE CONCENTRIC STEERING K34
EV(S26) ELECTROVALVE REAR AXLE UNLOCKING K30
EV(S27) ELECTROVALVE FAST GEAR A33
EV(S28) ELECTROVALVE SLOW GEAR A34
EV(S35) ELECTROVALVE LEVELLING CONTROL 1 I6 / I7
EV(S36) ELECTROVALVE LEVELLING CONTROL 2 K6 / K7
F.A. SUCTION FILTER S13
F.D.A.R. REAR DISK BRAKES I38 / M38
F.D.A.V. FRONT DISK BRAKES I31 / K31
F.M. FLOW FILTER O15
F.R. EXHAUST FILTER S20
G.E.S. ELECTROVALVE STABILISER UNIT E12
I.D. HYDRAULIC STEERING K20
L.P. PRESSURE LIMITING VALVE G15
M I.C. ENGINE Q26
M.C. BRAKE PUMP C37
M.I. VARIABLE DISPLACEMENT ENGINE Q35
(23/11/2011) 70-02-M146EN
B8
LEGEND FOR DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH REXROTH TRANSMISSION

Position on the
diagram
M.R.T. TURRET ROTATION MOTOR A30
M.V. FAN MOTOR I23
P TRIPLE GEAR PUMP O14
P.E. ELECTRIC PUMP M20
P.F. BRAKE PEDAL C35
P.I. HYDROSTATIC PUMP Q27
R OIL TANK S11
RAD. RADIATOR S37
R.C.F.P. PARKING BRAKE VALVE I35 / I36
S OIL TANK E39
V.A. ACCESSORY CYLINDER A27 OPTIONAL
V.B. LOCK AND MOVEMENT CONTROL VALVE C30
V.B.P REAR AXLE LOCKING VALVE I28 / K28
V.B.P.A. REAR AXLE LOCKING CYLINDER K29 / M29
V.C. COMPENSATING CYLINDER A25
V.C.L.R. SLOW SPEED CONTROL CYLINDER I37 / I38
V.D. STEERING CYLINDER K31 / K39
V.F.P. PARKING BRAKE CONTROL CYLINDER K37
V.I. TRAVERSE CYLINDER A24
V.L. LIFTING CYLINDER A20
V.L.1. RIGHT LIFTING CYLINDER K2
V.L.2. LEFT LIFTING CYLINDER I2
V.S.L.R. SLOW SPEED SELECTOR VALVE A32
V.T.I. Ist EXTENSION CYLINDER A21
70
70-02-M146EN (23/11/2011)
B9
DIAGRAM OF TRUCK HYDRAULIC SYSTEM WITH REXROTH TRANSMISSION
1 2 3 4 5 6 7 8 9 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
V.L. V.I. V.C.

V.T.I V.A.
EV(S27)
EV(S28)
A VSLR A
M.R.T.
C.S.P. B A
1 2
C.S.P. R T P
350bar 350bar 350bar
A 0.7L
C 300bar
MC C
A B A B A B A B 270bar 260bar
D
PF
EV(S16)
EV(S12)
EV(S11)
EV(S17)
EV(S13)
EV(S14)
EV(S19)
EV(S18)
EV(S15) C2 100bar V.B. 100bar C1
270bar
T
E G.E.S. E
P T S.
EV(S1) EV(S2) EV(S3) EV(S4) EV(S5) V2 C3 V1
C.5
C.1 EV EV
(S9) (S10)
G G
CR
L.P. 220bar
C.3
C.7
V.L.2 EV
(S35) L R
I I
200bar
RCFP VCLR
A P A B
FDAV EV FDAR
B T B
EV (S8)
M.V. VBP (S23) P T
A A
V.L.1 EV VFP
(S36) I.D. V.D.
P
175bar
T VBPA V.D.
70
C.6 175bar
K C.2 EV EV K
(S25) (S24)
L
0.8mm
B B
EV
C.8 VBP A (S26)
D.F. 4bar
FDAV
C.4 FDAR
VBPA
M M
P.E.
P 3 bar
EV EV
(S22) (S21) T A
11.2cc
b a
O
F.M. R T1 T2 Ps Fa Fe MB
3 bar O
27cc
450bar B
27cc
M. 450bar 35bar 440bar
A
X1 X2 G S
M.I.
Q P.I. MA
X1 X2 B Q
S
F.R. RAD. S
F.A.
R.
(23/11/2011) 70-02-M146EN
B10
70
70-02-M146EN (23/11/2011)
HYDRAULIC COMPONENTS LOCATION
page
LEGEND - HYDRAULIC COMPONENTS LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– DIAGRAM 1 - HYDRAULIC COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . 5
– DIAGRAM 5 - CONNECTORS ON THE HYDRAULIC COLLECTOR LOCATION . . . . . 9
70
(31/08/2011) 70-03-M146EN
2
Hydraulic components location
70
70-03-M146EN (31/08/2011)
3
LEGEND - POSITION OF HYDRAULIC COMPONENTS

Shown on
Ref Description
diagram no.
A ACCUMULATOR 3
C.1 FRONT RIGHT STABILISER RAISING-LOWERING CYLINDER 1
C.2 FRONT LEFT STABILISER EXTENSION CYLINDER 1
C.3 FRONT RIGHT STABILISER EXTENSION CYLINDER 1
C.4 FRONT LEFT STABILISER RAISING LOWERING CYLINDER 1
C.5 FRONT RIGHT STABILISER RAISING LOWERING CYLINDER 1
C.6 REAR LEFT STABILISER EXTENSION CYLINDER 1
C.7 REAR RIGHT STABILISER EXTENSION CYLINDER 1
C.8 REAR LEFT STABILISER RAISING LOWERING CYLINDER 1
C.R. HYDRAULIC COLLECTOR 2
D DANFOSS DISTRIBUTOR 3
D.F. FLOW SPLITTER 4
EV(S1) DANFOSS RAISING ELECTROVALVE SLIDER 100 LT. 3
EV(S2) ELECTROVALVE DANFOSS SLIDER EXTENSION 100 LT. 3
EV(S3) DANFOSS ROTATION ELECTROVALVE SLIDER 40 LT. 3
EV(S4) DANFOSS TRAVERSING ELECTROVALVE SLIDER 100 LT. 3
EV(S5) ELECTROVALVE DANFOSS OPTIONAL SLIDER 65 LT. 3
EV(S8) PARKING BRAKE ELECTROVALVE 4
EV(S9) GENERAL ELECTROVALVE STABILISERS 4
EV(S10) EMERGENCY ELECTROVALVE HYDRAULIC SYSTEM EXCLUSION 4
EV(S11) ELECTROVALVE FRONT RIGHT BEAM 4
EV(S12) ELECTROVALVE FRONT LEFT BEAM 4
EV(S13) ELECTROVALVE REAR LEFT BEAM 4
EV(S14) ELECTROVALVE REAR RIGHT BEAM 4
EV(S15) ELECTROVALVE RETRACT/EXTEND STABILISERS 4
EV(S16) ELECTROVALVE FRONT RIGHT STABILISER 4
70
EV(S17) ELECTROVALVE FRONT LEFT STABILISER 4
EV(S18) ELECTROVALVE REAR LEFT STABILISER 4
EV(S19) ELECTROVALVE REAR RIGHT STABILISER 4
EV(S21) FORWARD ELECTROVALVE 3
EV(S22) REVERSE ELECTROVALVE 3
EV(S23) ELECTROVALVE REAR AXLE UNLOCKING 1
EV(S24) ELECTROVALVE CRAB STEERING 4
EV(S25) ELECTROVALVE CONCENTRIC STEERING 4
EV(S26) ELECTROVALVE REAR AXLE UNLOCKING 1
EV(S27) ELECTROVALVE FAST GEAR 4
EV(S28) ELECTROVALVE SLOW GEAR 4
EV(S35) ELECTROVALVE LEVELLING CONTROL 1 4
EV(S36) ELECTROVALVE LEVELLING CONTROL 2 4
F.A. SUCTION FILTER 2
F.M. FLOW FILTER 2
F.R. EXHAUST FILTER 2
G.E.S. ELECTROVALVE STABILISER UNIT 4
I.D. HYDRAULIC STEERING 2
L.P. PRESSURE LIMITING VALVE 4
M.C. BRAKE PUMP 2
M.I. VARIABLE DISPLACEMENT ENGINE 3
M.R.T. TURRET ROTATION MOTOR 2
M.V. FAN MOTOR 2
P TRIPLE GEAR PUMP 3
P.E. ELECTRIC PUMP 2
(31/08/2011) 70-03-M146EN
4
LEGEND - POSITION OF HYDRAULIC COMPONENTS

Shown on
Ref Description
diagram no.
P.I. HYDROSTATIC PUMP 3
R OIL TANK 2
S OIL TANK 2
V.B. LOCK AND MOVEMENT CONTROL VALVE 2
V.B.P REAR AXLE LOCKING VALVE 1
V.B.P.A. REAR AXLE LOCKING CYLINDER 1
V.C. COMPENSATING CYLINDER 1
V.D. STEERING CYLINDER 3
V.I. TRAVERSE CYLINDER 1
V.L. LIFTING CYLINDER 1
V.L.1. RIGHT LIFTING CYLINDER 1
V.L.2. LEFT LIFTING CYLINDER 1
V.S.L.R. SLOW SPEED SELECTOR VALVE 4
V.T.I. Ist EXTENSION CYLINDER 1
70
70-03-M146EN (31/08/2011)
5
DIAGRAM 1 - HYDRAULIC COMPONENTS LOCATION
VI
C2 VL2
VL
C4
VTI C1
EV(S23)
VBP C3
VBPA
70
C8
C6
VL1
VC
EV(S26)
VBP
VBPA
C5
C7
(31/08/2011) 70-03-M146EN
6
MC
S
ID
FR
MRT
PE
CR
70
VB
FM
MV
FA
70-03-M146EN (31/08/2011)
7
EV(S5)
EV(S4)
EV(S3)
EV(S2)
EV(S1)
VD A
EV(S21)
EV(S22)
PI
70
VD
P
MI
VD
VD
(31/08/2011) 70-03-M146EN
8
GES
EV(S9)
LP
EV(S15)
EV(S16)
EV(S17)
EV(S24) EV(S18)
EV(S19)
EV(S25) EV(S35)
EV(S11)
EV(S12)
EV(S13) EV(S36)
EV(S14)
EV(S8)
70
EV(S28)
EV(S27)
EV(S10) DF
GES
VSLR
70-03-M146EN (31/08/2011)
9
DIAGRAM 5 - CONNECTORS ON HYDRAULIC MANIFOLD LOCATION
1 - Outlet
2 - Outlet
Front part of the 3 - VSLR valve (B)
vehicle 9 4 - Vacuum
5 - VLSR valve (A)
6 - Vacuum
7 - Front axle brakes, inching
16 17 8 - Rear axle brakes
9 - Vacuum
10 - Hydrostatic booster pump (G)
11 - Vacuum
12 - Power steering (R), steering (P)
8 13 - Power steering (L), front axle (left wheel)
10 14 - Rotation lower side (V1)
15 - Rotation upper side (V2)
16 - Electrovalve S10 (P), electrovalve S9 (P),
2 distributor (P)
11 17 - Priority valve DF
Left Right
Upper part coupling
coupling of manifold
70
7
1
15
6
3
14
12
4
5
13
(31/08/2011) 70-03-M146EN
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70
70-03-M146EN (31/08/2011)
HYDRAULIC CONTROL AND ADJUSTMENT
page
PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– JIB MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– STABILISER MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– MOVEMENT OF COMPENSATING CYLINDER ON BASEPLATE SIDE. . . . . . . . . . . 6
– FAN MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– BOOST PUMP ON THE HYDROSTATIC TRANSMISSION (SAUER) . . . . . . . . . . . . 7
70
– BOOST PUMP ON THE HYDROSTATIC TRANSMISSION (REXROTH) . . . . . . . . . . 7
GENERAL RULES FOR REMOVING THE JACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
COMPLETE ROD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PISTON AND CLOSING RING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
PISTON SEALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
CLOSING RING SEAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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2
Hydraulic control and adjustment
page
APPLICATION OF THREADLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
LIFTING JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
TRAVERSE CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
COMPENSATION JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
EXTENSION JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TELESCOPIC STABILISER JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
70
STABILISER INCLINATION JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
REAR AXLE LOCKING JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LEVELLING JACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
– REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
– REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
TURRET ROTATION BRAKE ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
– MRT 1850 / 2150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
– MRT 2540 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
70-04-M146EN (16/06/2011)
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70
(16/06/2011) 70-04-M146EN
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70
GENERAL INFORMATION
To check the pressures, a suitable manometer must be used, the oil must be at a temperature of
about 60°, the engine must be at maximum revolutions for all the tests except for the rotation test
which must be carried out at minimum revolutions.
Position the vehicle on a horizontal surface and rotate the turret to 180°.
- Manometer (600 bar).
70-04-M146EN (16/06/2011)
5
PRESSURE TEST
1
JIB MOVEMENTS
Pump P1: Carry out the test at the pressure socket (Item 1),
depending on the model, and use the valve in the distributor
to adjust the pressure.
Pressure test Value Adjustment

Power steering 175 bar max. Danfoss pressure limiter in the body of the power steering
Raising 275 ÷ 280 bar Main limiter of Danfoss distributor
Lowering 275 ÷ 280 bar Main limiter of Danfoss distributor
Extending 275 ÷ 280 bar Main limiter of Danfoss distributor
Retracting 275 ÷ 280 bar Pre-adjusted anti-shock valve
Right rotation (at min. engine revolutions) 100 ÷ 110 bar Pressure limiter on motor supply block
Left rotation (at min. engine revolutions) 100 ÷ 110 bar Pressure limiter on motor supply block
Optional 1 270 bar Main limiter of Danfoss distributor
Optional 2 270 bar Main limiter of Danfoss distributor
Compensation (rod side) 250 ÷ 270 bar Pre-adjusted anti-shock valve
Danfoss 5 part distributor
70
OPTIONAL
TRAVERSING
ROTATION
EXTENSION
LIFTING
(16/06/2011) 70-04-M146EN
6
STABILISER MOVEMENTS
Pump P2: Carry out the tests at the pressure socket

2
(Item 2).

Stabiliser circuit 220 bar Valve located on the stabiliser electrovalve unit
To adjust the pressure in the stabiliser circuit, use the valve

(Item 3) located on the stabiliser electrovalve unit.
3
70
MOVEMENT OF COMPENSATING CYLINDER ON BASEPLATE

SIDE
To carry out the compensation pressure test on the baseplate

side:
- connect the manometer (Item 4) in the position shown;
- fully raise the jib;
- fully extend the traverse jack;
4
- accelerate the engine to maximum revolutions and lower
the jib.
The pressure must reach 300 bar during the descent.
70-04-M146EN (16/06/2011)
7
FAN MOTOR
Pump P3: Carry out the tests at the pressure socket (Item 1)
depending on the model

Adjustment of the speed as a function of the pressure is automatic
Cooling fan 70 bar
and is regulated by a valve inside the fan motor
The fan is the suction type.
BOOST PUMP ON THE HYDROSTATIC TRANSMISSION

(SAUER)

1
(Item 1).
647039EN - SAUER H1 45/53 pump
70
BOOST PUMP ON THE HYDROSTATIC TRANSMISSION
(REXROTH)

(Item 1).
647030EN - REXROTH A4VG pump

Parking brake
Power assisted braking
30 / 35 bar On the boost pressure limiter
Speed change command (slow and fast)
Rear axle lock
(16/06/2011) 70-04-M146EN
8
GENERAL RULES FOR REMOVING THE JACKS
COMPLETE ROD
1 2
REMOVAL
Put the jack in a vice fitted with jaw protector and, compress
the jack gently to avoid deforming the body.
Unlock the closing ring (Item 1) with a pin wench, in case of
difficulty in unlocking the ring, pleased refer to the paragraph
“REMOVAL” in the section “Application of threadlock”.
Fully unscrew the closing ring (Item 1) and extract the
complete rod from the body of the jack.
NOTE FOR VERY LONG JACKS:
Pull out the rod as maximum of 200 mm, unscrew the closing
ring (Item 1) half a turn (turn gradually, without jerking).
Pull out the rod about 2500 mm, support the rod (Item 3) by
the end to avoid forces on the closing ring.
Continue to unscrew the closing ring, if the force is too great,
3
raise and then lower the rod to reduce the friction.
Never force when unscrewing as there is a risk of

seizure.
TEST
Remove grease and clean the inside of the jack.
Visually check that the body of the jack is free from scratches,
5 burrs, oxidation etc.
1
70
REFIT
Apply hydraulic oil to the piston seals with a brush and refit
the complete rod in the body of the jack (Item 2).
Be careful not to damage the seals (Item 4) when they pass
through the threads in the body of the jack, apply hydraulic
oil to the external seals of the closing ring.
4 4 Apply Loctite threadlock 222 (See section “Applying
threadlock”) to the closing ring (Item 5).
Screw in the ring, lock with a pin wrench and torque wrench
to the torque indicated in the table (Item 6), turn the rod one
6 turn to position the seals.
Nm NOTE:
450 It is advisable to test the jack hydraulically before refitting
400
to the vehicle.
350
Extend and retract the rod several times.
300
250
200
150
100
50
0 M
M40 M50 M60 M70 M80 M90 M100
70-04-M146EN (16/06/2011)
9
PISTON AND CLOSING RING
REMOVAL
Place the rod in a vice with jaw protectors tighten to prevent
5
3 4 2 rotation of the unit.
1
6 Unlock the nut (Item 1) and unscrew it completely with a
polygonal wrench or, depending on the version, remove the
pin screw (Item 2) with a hexagonal wrench.
Remove the piston (Item 3) by pulling it by hand or, depending

on the version, unscrewing the piston (Item 4) with a pin
wrench.
5
4
6
Remove the ring (Item 5) by sliding it along the rod.
70
5
TEST
Using a comparator (Item 7), check the straightness of the
7 rod over its whole length.
Check that the rod is not chipped, corroded or scratched.
(16/06/2011) 70-04-M146EN
10
REFIT
Refit the ring (Item 5) on the rod (Item 6) and reattach the
piston (Item 3) to the rod.
8 Screw on and lock the nut (Item 1) with a polygonal wrench

Nm
and torque wrench to the torque indicated in the table
1400 (Item 8) or, depending on the version, screw the piston
1200 (Item 3) back on with a pin wrench (see tightening torque
1000 (Item 8)) and lock it with a pin screw (Item 2).
800 NOTE:
600 The pin screw must be fitted using loctite 243, see section
400 “Applying threadlock”.
200
Tightening torque of the screw = 20 Nm.
0 M
Strike with a chisel to spread the metal on the screw.
M20 M30 M40 M50 M60 M70
1 1 PISTON SEALS
70
NOTE:
Never use sharp tools (screwdrivers, blades, etc.) for fitting
4 and removing the seals.
It is advisable to work on clean benches, free from swarf.
REMOVAL
Remove the seals (Item 1-2-3) from the piston (Item 4
2
or 5).
Be careful to avoid damaging the edges and grooves.
TEST
3 Remove grease and clean the piston.
Check that the grooves and surfaces are smooth and free
from scratches.
The grooves must not contain foreign bodies.
5
REFIT
Position the seals after fitting them to the piston (Item 4
or 5).
To fit the external seals (Item 1 and 3), open them enough
2 to be able to insert them in the grooves without breaking
them.
The internal seal (Item 2) must be fitted by hand.
70-04-M146EN (16/06/2011)
11
1 2 CLOSING RING SEALS

3
NOTE:
Never use sharp tools (screwdrivers, blades, etc.) for fitting
and removing the seals.
It is advisable to work on clean benches, free from swarf.
REMOVAL
4
Remove the seals from the closing ring.
5
Be careful to avoid damaging the edges and grooves.
TEST
Remove grease and clean the closing ring.
Check that the grooves and surfaces are smooth and free
from scratches.
The grooves must not contain foreign bodies.
5 Fit the ring over the rod by sliding it all the way along.
The play must not be excessive, but it must never be locked
rigidly to the ring.
REFIT
Position the seals after fitting (Item 1-2-3-4-5).
6 The lips of the seal must be orientated towards the pressure
side.
To fit the seal to the rod (Item 5), insert it into the groove by
holding it with your thumb or a punch (Item 6) without any
sharp edges.
Press the seal into the groove with the other hand or with a
70
7
smooth punch (Item 7). If the seal is very strong, this can
be reduced by immersing it in a bath of hydraulic oil at a
temperature of 50 °C.
5
Position the oil scraper (Item 4) using a pad and a mallet.
Fit the O-rings (Item 2 and 3) and the anti-extrusion seal
(Item 1) by hand.
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APPLICATION OF THREADLOCK
CHARACTERISTICS
Loctite 222 light threadlock
Application to the threads of the closing ring.

Without Activator
Time of workability 10 - 30 min.
Curing time 3 - 6 hours
(Jack under pressure)
With Loctite Activator N
Shear resistance 1,5 - 4 N/mm2
Loctite 243 medium threadlock
Application to M8 screws for locking the pistons.

Without Activator
With Loctite Activator N
70
Shear resistance 5 - 7,5 N/mm2
REMOVAL
If components fitted with threadlock cannot be unlocked using standard tools, it is advisable to
heat the bonded area to temperature T = 250 °C preferably using a hot air gun instead of a blow
torch.
NOTE:
If the temperature is close to 0 °C, it is advisable, when fitting, to use a Loctite activator to reduce
the curing time.
70-04-M146EN (16/06/2011)
13
LIFTING JACK
Tools required:
- 1 hook wrench (for rings)
- 1 4 mm Allen key
10
11 4
6
9
7
9
8
5
3
14
15
14
16
12
13
1
REMOVAL
70
Unscrew the head (Item 1) with a hook wrench after working on the edge of the liner riveted in the
groove in the seat of the cylinder head.
Withdraw the liner, rod assembly (Item 2) + cylinder head (Item 1 and 3) + piston (Item 4 from the
jack).
Remove the Allen screw (Item 5) (4 mm Allen key) from the piston.
WARNING screw locked with loctite (see section “Application of threadlock”).
Unscrew the piston (Item 4) of the jack using a hook wrench.
Remove the piston (Item 4), spacer (Item 6) and cylinder head (Item 1 and 3) from the rod.
Remove the seals (Item 7 and 8) and piston guide rings (Item 9).
Remove the seals (Item 10-11-12-13), guide rings (Item 14) and cylinder head seals (Item 15
and 16).
Check the condition of the valve seat and spring, replace the seals and components if
necessary.
WARNING in the direction of refitting.
REFIT
Reverse operation to removal.
Note: Remember that the outside edge of the liner must be riveted in one of the grooved seats on
the cylinder head.
The Allen screws must be fitted using loctite thread lock.
Spread hydraulic oil on the seals.
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TRAVERSE CYLINDER
Tools required:
- 1 4 mm Allen key
10
8 6
9
1
11 4
12
11
13
REMOVAL
70
Withdraw the rod assembly (Item 2) + piston (Item 3) from the jack liner.
Remove the Allen screws (Item 4) (4 mm Allen key) from the piston.
Remove the piston (Item 3) of the jack and the head (Item 1) from the rod.
Remove the piston seals (Item 5 and 6) and guide rings (Item 7).
Remove the seals (Item 8-9-10), guide rings (Item 11) and head gaskets (Item 12-13).
necessary.
REFIT
the cylinder head.
70-04-M146EN (16/06/2011)
15
COMPENSATION JACK
Tools required:
- 1 4 mm Allen key
7
5
7
10 6
8
9
1 4
11
12
11
13
REMOVAL
70
Remove the seals (Item 8-9-10), guide rings (Item 11) and head gaskets (Item 12 and 13).
Replace the seals and components if necessary.
REFIT
the cylinder head.
(16/06/2011) 70-04-M146EN
16
EXTENSION JACK
Tools required:
- 1 4 mm Allen key
12
1 9
8
13 10
14 11
13
15
4
5
7
6 5
7
3
REMOVAL
70
Remove the sealing ring (Item 8) and take out the spacer (Item 9).
necessary.
REFIT
the cylinder head.
70-04-M146EN (16/06/2011)
17
TELESCOPIC STABILISER JACK
Tools required:
- 1 4 mm socket wrench
7
9 5
8 7
12 3
10
11
6
1
13
15
13
14 4
REMOVAL
70
Remove the sealing ring (Item 8) and take out the spacer (Item 9).
REFIT
the cylinder head.
(16/06/2011) 70-04-M146EN
18
STABILISER INCLINATION JACK
Tools required:
- 1 4 mm Allen key
10
3
8
4
5 11
2
13
7
11
6
12
REMOVAL
70
necessary.
REFIT
the cylinder head.
70-04-M146EN (16/06/2011)
19
REAR AXLE LOCKING JACK
4
1
7
5
REMOVAL
70
Withdraw the rod (Item 1) from the jack liner.
Remove the seal (Item 2), anti-extrusion seals (Item 3 and 4) and cylinder (Item 7) guide rings
(Item 5).
REFIT
Note: Spread hydraulic oil on the seals.
(16/06/2011) 70-04-M146EN
20
LEVELLING JACK
Tools required:
- 1 4 mm Allen key
5 4
6
2
4
12
10
11
10
9
7
8
REMOVAL
70
Unscrew the jack piston (Item 3) using an Allen key, remove the jack piston (Item 3) and the head
(Item 1) from the rod.
Remove the seal (Item 5) and the gas-tight piston seals (Item 6), remove the seals (Item 7-8-9),
guide rings (Item 10) and head gaskets (Item 11 and 12).
necessary.
REFIT
the cylinder head.
When refitting the gas-tight seal assembly (Item 6) “Do not allow the cuts in the anti-extrusion
seals to coincide” (separate them by one third of the circumference).
70-04-M146EN (16/06/2011)
21
TURRET ROTATION BRAKE ADJUSTMENT

MRT 1850 / 2150
Turn the valve cock (clockwise) until the valve is closed (Photo 01).
Then, to obtain the correct adjustment, turn the cock (anticlockwise) by 2 turns (Photo 02).
MRT 2540
Turn the valve cock (clockwise) until the valve is closed (Photo 01).
Then, to obtain the correct adjustment, turn the cock (anticlockwise) by 1 ¾ turns (Photo 02).
PHOTO 01 PHOTO 02
70
(16/06/2011) 70-04-M146EN
22
70
70-04-M146EN (16/06/2011)
HYDRAULIC COMPONENTS REMOVAL
page
HYDRAULIC OIL AND FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– STABILISER EXTENSION CYLINDERS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . 6
– STABILISER RAISING AND LOWERING CYLINDER REMOVAL . . . . . . . . . . . . . . . 8
– JIB RAISING CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– TRAVERSE CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
70
(04/07/2011) 70-06-M146EN
2
Hydraulic components removal
70
GENERAL INFORMATION
70-06-M146EN (04/07/2011)
3
HYDRAULIC OIL AND FUEL TANK REMOVAL
Obtain receptacles of adequate size for the quantity of

oil to be collected and position them under the drain plug
1 (Item 1).
Remove the plug (Item 1) and leave the oil to run out.
To speed up draining of the tank, remove the filler plug

(Item 2).
70
2
Remove the cover (Item 3), remove the 3 steps of the

stepladder (Item 4) and remove the front housing (Item 5).
3
4
5
(04/07/2011) 70-06-M146EN
4
Disconnect the fuel inlet and return tubes (Item 6) mounted

on the level indicator and undo the electrical connection
10 (Item 7) of the fuel level indicator.
11
Unscrew the oil breather screw (Item 8) and screw on an
8
eyelet to secure the tank to the overhead crane or hoist.
7 Disconnect the electrical socket (Item 9) and the mounting
9 (Item 10) on the tank and unscrew the clip (Item 11) that
supports the electric cables, from the frame.
6
Unscrew the oil return collector (Item 12) mounted on the

12
13 drain filter (Item 13), remove the relay box by unscrewing
the screws, (Item 14).
14
14
Unscrew the screws (Item 15) fixing the collector to the

frame and remove the vacuum indicator (Item 16).
70
15
16
24
Disconnect the hydraulic oil inlet pipes (Item 17, 18, 19,
20) mounted on the tank.
25 23
21
(Note: the pipe (Item 20) is only present in versions fitted
with air conditioning).
17 Disconnect the hydraulic inlet pipes (Item 21) on the
18 transmission oil filter (Item 22).
19
22 Disconnect the hydraulic oil return pipes (Item 23) from the
20
radiator, disconnect the rotation motor hydraulic drain pipe
(Item 24) and the hydraulic oil return pipe (Item 25) from the
hydrostatic pump.
70-06-M146EN (04/07/2011)
5
Unscrew the screws (Item 26) on the front of the tank.
26
26
Unscrew the screws (Item 27) on the back of the tank.
27
27
Unscrew the screw (Item 28) on the inside of the tank on

the frame.
70
Remove the tank
28
(04/07/2011) 70-06-M146EN
6
CYLINDERS REMOVAL
STABILISER EXTENSION CYLINDERS REMOVAL

Lower the stabilisers until it is possible to work on the pins
(Item 1).
1 Using the appropriate commands, extend the stabiliser
extension jib until it is possible to work on the pins
(Item 2).
If it is impossible to remove the arm, unscrew the locking

screw (Item 3) and the nut (Item 4), remove the pin (Item 5)
70
and take off the foot (Item 6).
4
5 6
Unscrew the screws (Item 7) and washers (Item 8) and

remove the valve protection plate (Item 9).
70-06-M146EN (04/07/2011)
7
If necessary, unscrew the screws (Item 10), remove the

12 valve (Item 11) on the base of the cylinder and disconnect
12
the two hydraulic supply pipes (Item 12) taking care to mark
them with a small brush before removing them to facilitate
refitting.
Close the orifices with suitable plugs to prevent any dirt from
entering.
10
11
Unscrew the locking screw (Item 13) and nut (Item 14) and
remove the pin (Item 15).
13
14
15
Unscrew the locking screw (Item 16), nut (Item 17) and
70
16
18
17
Withdraw the stabiliser extension cylinder (Item 19) from

the side of the bottom plate (Item 20).
19
20
(04/07/2011) 70-06-M146EN
8
STABILISER RAISING AND LOWERING CYLINDER

REMOVAL
1 To remove the front left or right rear tilt cylinder, it is necessary

3 to remove the mudguard to prevent accidental breakages.
2
With an overhead crane or hoist, hook the stabiliser jib on
the foot side, unscrew the locking screw (Item 1) and nut
(Item 2) and remove the pin (Item 3).
Lay down the stabiliser jib with the foot side (Item 4) on the
4 ground.
5
Remove the hydraulic pipes on the tilt stabiliser cylinder
valve and seal the orifices with suitable plugs to prevent any
70
7
dirt from entering.
6
Secure the cylinder to an overhead crane or hoist with a
suitable strap.
Unscrew the locking screw (Item 5) and nut (Item 6) and
Disconnect all the hydraulic pipes taking care to mark

refitting.
entering.
70-06-M146EN (04/07/2011)
9
8
Withdraw the cylinder (Item 8) from the base.
70
(04/07/2011) 70-06-M146EN
10
JIB RAISING CYLINDER REMOVAL
Activate the jib lift command and raise the jib above the
profile of the cabin (Item 1), to give easy access to the lifting
actuator hinge pin on the rod-jib side from both sides.
Secure the jib to an overhead crane or hoist through the

appropriate eyelets (Item 2) in the top of the jib itself.
70
2
2 Secure the lifting actuator to a support.
Unscrew the locking screw (Item 3) and withdraw the lifting

actuator hinge pin on the rod-jib side (Item 4).
70-06-M146EN (04/07/2011)
11
Rest the lifting actuator on the turret, placing a wooden beam

under it (Item 5), and retract the rod with the command in
the cabin.
Disconnect all the hydraulic pipes taking care to mark

refitting.
entering.
Unscrew the screw (Item 6) and nut (Item 7) and withdraw

the pin (Item 8) locking the lifting cylinder.
70
6
Remove the lifting cylinder (Item 9) using ropes and an

overhead crane.
(04/07/2011) 70-06-M146EN
12
TRAVERSE CYLINDER REMOVAL
Unscrew the bush (Item 1) locking the pin (Item 2).
4
Secure the rapid attachment (Item 3) to an overhead
crane.
70
Remove the pin (Item 2) from the rapid attachment (Item 3)

and the traverse cylinder (Item 4).
Mark the hydraulic pipes on the traverse cylinder valve and

disconnect them.
entering.
70-06-M146EN (04/07/2011)
13
Secure the traverse cylinder to a suitable jack.
Unscrew the screw (Item 6) and nut (Item 7) and remove the
7
pin (Item 5) to release the traverse cylinder (Item 4).
With the help of ropes, an overhead crane and jack, remove

the traverse cylinder (Item 4).
70
4
(04/07/2011) 70-06-M146EN
14
70
70-06-M146EN (04/07/2011)
HYDRAULIC COMPONENTS REFIT
page

CYLINDERS REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– TRAVERSE CYLINDER REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– JIB RAISING CYLINDER REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– STABILISER RAISING AND LOWERING CYLINDER REFIT . . . . . . . . . . . . . . . . . . 7
– STABILISER EXTENSION CYLINDERS REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . 9
OIL AND FUEL TANK REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
70
(10/05/2011) 70-07-M146EN
2
Hydraulic components refit
70
70-07-M146EN (10/05/2011)
3
CYLINDERS REFIT
1
TRAVERSE CYLINDER REFIT
With the help of ropes and an overhead crane, raise the

traverse cylinder (Item 1) and place it on a jack.
Hinge the traverse cylinder (Item 1) to the baseplate side.
70
1
Insert the traverse cylinder hinge pin (Item 2) into the hole
4 in the IIIrd jib extension.
Screw in the screw (Item 3) and lock nut (Item 4).
2
(10/05/2011) 70-07-M146EN
4
Reconnect the hydraulic pipes to the cylinder valve, taking

care to replace them correctly following the marks made
with the brush during the removal phase.
Observe the correct valve ports.
Insert the hinge pin (Item 6) and attach the rod of the traverse
1
cylinder (Item 1) to the rapid attachment (Item 5).
Lock the pin (Item 6) with the bush (Item 7).

70
70-07-M146EN (10/05/2011)
5
JIB RAISING CYLINDER REFIT
Using ropes and an overhead crane, replace the raising

cylinder (Item 1), on the truck.
1
Insert the raising cylinder locking pin (Item 2) into the

appropriate hole in the turret and lock it by screwing in the
70
screw (Item 3) and nut (Item 4).

(10/05/2011) 70-07-M146EN
6
Lift the raising cylinder (Item 1) from the turret (Item 5),
to permit the rod to be inserted into its housing on the jib.
Insert the raising cylinder hinge pin (Item 6), on the rod-jib
side, locking it with the screw (Item 7).
Remove the overhead crane or hoist from the eyelets (Item 8)

in the top of the jib itself.
70
8 8
Remove the lifting cylinder support.
70-07-M146EN (10/05/2011)
7
1
STABILISER RAISING AND LOWERING CYLINDER
REFIT
Replace the cylinder (Item 1) on the stabiliser jibs, using an

overhead crane or hoist with a suitable strap.
3
Insert the pin (Item 2) into the hole and lock it by screwing
the screw (Item 3) and nut (Item 4).
70
2
Refit all the hydraulic pipes on the stabiliser tilt cylinder
4
valve.
Replace the stabiliser jib on the foot side (Item 5). Using
an overhead crane or hoist, insert the pin (Item 6) locking it
with the screw (Item 7) and nut (Item 8).
7
You can now replace the mudguards corresponding to the
6
front left and rear right tilt cylinders.
8
(10/05/2011) 70-07-M146EN
8

70
70-07-M146EN (10/05/2011)
9
STABILISER EXTENSION CYLINDERS REFIT
1 Replace the stabiliser extension cylinder (Item 1) by inserting

2 it into the foot (Item 2) on the baseplate side.
Insert the pin (Item 3) into the appropriate hole locking it

with the screw (Item 4) and nut (Item 5).
70
4
3
5
Insert the pin (Item 6), locking it with the screw (Item 7) and
nut (Item 8).
8
6
(10/05/2011) 70-07-M146EN
10
Refit the valve (Item 9), that may have been previously
11 removed, on the bottom of the cylinder, with the screws
11
(Item 10) and reconnect the two hydraulic supply pipes
(Item 11) taking care to replace them correctly by following
the marks made with the brush while removing.
Observe the inlet ports.
10
9
Refit the valve protection plate (Item 12) with the screws
(Item 13) and washers (Item 14).
14
12
13
Refit the foot (Item 15), that may have been previously
removed, inserting the pin (Item 16) and locking it with the
70
screw (Item 17) and nut (Item 18).
17
18
16 15
70-07-M146EN (10/05/2011)
11
OIL AND FUEL TANK REFIT
Using an overhead crane, replace the tank on the truck,

screw in the screw (Item 1), on the inside of the tank to the
frame.
Screw in the screws (Item 2) at the back of the tank.
70
2
Screw in the screws (Item 3) at the front of the tank.
(10/05/2011) 70-07-M146EN
12
5
Reconnect the hydraulic oil return pipe (Item 4) from the
hydrostatic pump, the hydraulic rotation motor drain pipe
(Item 5) and the hydraulic oil return pipe (Item 6) from the
6
4 7 radiator.
Reconnect the hydraulic inlet tube (Item 7) to the transmission
9
oil filter (Item 8).
10
Reconnect the hydraulic oil inlet tubes (Item 9, 10, 11, 12)
8
11 fitted to the tank.
12 (Note: the tube (Item 12) is only present in versions fitted
with air conditioning).
Screw in the screws (Item 13) fixing the collector to the

chassis, refit the vacuum indicator (Item 14).
13
14
Refit the relay box by screwing in the screws (Item 15),

17
16 screw on the oil return collector (Item 16) to the discharge
70
filter (Item 17).
15
15
Reconnect the fuel inlet and return tubes (Item 18) mounted
on the level indicator and fasten the electrical connections
22
23 (Item 19) of the fuel level indicator.
Screw on the oil breather filter (Item 20) and remove the
20
19
forklift truck or hoist used to remove the tank.
21 Reconnect the electric sockets (Item 21) and the mounting
(Item 22) on the tank and screw on the clips (Item 23), that
18 support the electric cables on the chassis.
70-07-M146EN (10/05/2011)
13
Refit the front housing (Item 24), refit the 3 steps

(Item 25).
26 Refit the cover (Item 26).
25
25
24
25
Refit the drain plug (Item 27).
27
Fill the tank with 210 litres of hydraulic oil.
70
(10/05/2011) 70-07-M146EN
14
70
70-07-M146EN (10/05/2011)
HYDRAULIC SPECIFIC TOOLING
page
BASIC MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– FUNCTIONS : . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70
(13/12/2011) 70-09-M146EN
2
Hydraulic specific tooling
BASIC MANOMETER BOX
The box contains all the components required for

measuring pressures on all Manitou products.
1 2 3 3 4 5 5 6
70
8 7
Basic Manometer box .................................................................................549671
Consisting of:
1. 1 Manometer 1/9 bar ..............................................................549882

2. 1 Manometer 0/40 bar ............................................................549883
3. 2 Manometers 0/60 bar ..........................................................549884
4. 1 Manometer 0/400 bar ..........................................................549885
5. 2 Manometers 0/600 bar ........................................................549886
6. 4 Standard flexible tubes .........................................................549887
7. 2 Flexible tubes for Maniscopic ...............................................549888
8. 7 Manometer attachments .......................................................549889
70-09-M146EN (13/12/2011)
3
DIGITAL MANOMETER BOX
FUNCTIONS:
• Manometer Function: the display makes all the following

options possible:
- Inlet temperature and pressure to +/- 2 °C

- Maximum and minimum inlet pressure P1 (700 bar in
class 0.1)
- Maximum and minimum outlet pressure P2 (700 bar
in class 0.1)
- Differential pressure dP = P1-P
• Hold Function: the user can pause the display at any time
to take notes.
• Unit Function: the user can change the units of

measurement at any time (bar, PSI, kPa, mCe).
• Calibrate Function: used to offset the zero point.
• Loss test Function: for measuring pressure changes at a

predetermined time.
70
• Save Function: up to a maximum of 16,000 values can be
saved. The sampling frequency can be set.
• Zero Function: 2 sensors can be zeroed.
Digital Manometer box ...............................................................................662187
Consisting of:
1. 1 Mano dP digital Manometer HP 700 bar

2. 1 Flexible measuring tube DN2 1215/1620, L = 1,5 m, 630 bar
3. 2 Flexible measuring tubes DN2 1620/1620, L = 1,5 m, 630 bar
4. 2 Adapters for 1620 Manometer
(13/12/2011) 70-09-M146EN
4
70
70-09-M146EN (13/12/2011)
ELECTRICITY
- ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL COMPONENTS LOCATION
- ELECTRICAL CONTROL AND ADJUSTMENT
- ELECTRICAL TROUBLESHOOTING
- ELECTRICAL SPECIFIC TOOLING
80
ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS
page
EEPROM VERSIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TRUCK WITH FORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– TRUCK WITH FORKS ON TYRES OR STABILISERS . . . . . . . . . . . . . . . . . . . . . . 3
– TRUCK WITH FORKS ON TYRES OR STABILISERS IN OVERTURNED CONDITION. . . 4
TRUCK ON STABILISERS WITH PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
TRUCK WITH FIXED PLATFORM / ORH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– TRUCK ON STABILISERS WITH FIXED PLATFORM / ORH . . . . . . . . . . . . . . . . . 7
– TRUCK ON STABILISERS WITH FIXED PLATFORM / ORH IN OVERTURNED
CONDITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– TRUCK ON TYRES WITH FIXED PLATFORM / ORH IN OVERTURNED CONDITION . . 10
– TRUCK ON TYRES WITH FIXED PLATFORM / ORH . . . . . . . . . . . . . . . . . . . . . . 11
TRUCK WITH PENDULUM PLATFORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
80
– TRUCK ON TYRES WITH PENDULUM PLATFORM IN OVERTURNED CONDITION. . . 13
– TRUCK ON TYRES WITH PENDULUM PLATFORM . . . . . . . . . . . . . . . . . . . . . . . 14
– TRUCK ON STABILISERS WITH PENDULUM PLATFORM
IN OVERTURNED CONDITION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
– TRUCK ON STABILISERS WITH PENDULUM PLATFORM . . . . . . . . . . . . . . . . . . 17
TRUCK WITH RADIO CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
– TRUCK ON STABILISERS WITH RADIO CONTROL IN OVERTURNED CONDITION. 21
– TRUCK ON STABILISERS WITH RADIO CONTROL . . . . . . . . . . . . . . . . . . . . . . . 23
LAYOUT ON COMPONENT SIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
MEANING OF THE LEDS ON THE LOGIC CARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DESCRIPTION OF CONNECTORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
AXLE LOGIC CONFIGURATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
(13/12/2011) 80-01-M146EN
2 Electrical characteristics
and specifications
EEPROM
EEPROM VERSIONS
MRT 1850/2150: 3.23
MRT 2540 : 2.64

80
80-01-M146EN (13/12/2011)
Electrical characteristics 3
and specifications
TRUCK WITH FORKS
TRUCK WITH FORKS ON TYRES OR STABILISERS
MOVEMENT PERMITTED FROM THE CAB

TURRET WITHIN +/-15° TURRET BEYOND +/-15°
JIB WITHIN 55° JIB BEYOND 55° NOTES
JIB RETRACTED JIB EXTENDED
EXTENSION OF STABILISERS √
LOWERING OF STABILISERS √ √
ROTATION OF TURRET √ √
TRAVERSE UP √ √
TRAVERSE DOWN √ √
RAISING OF JIB √ √
LOWERING OF JIB √ √
RETRACTION OF JIB √ √
EXTENSION OF JIB √ √
OPTION 1 √ √
OPTION 2 √ √
LEVELLING OPERATES ON THE FRONT, WITH JIB < 3M
LOCK AXLE LOCKED (FLASHING LIGHT ON WITH TURRET ROTATED OR JIB > 55°)
WARNING: the MRT 2540 model cuts off rotation if the jib is > 55°, rotation only permitted within
+/- 5°.
WARNING: the stabilisers can only be raised if the turret is within +/-5°, the jib retracted and
positioned within 55°.
MOVEMENTS PERMITTED FROM THE CAB WITH ANTI-OVERTURNING PREVENTION KEY ACTIVATED
80
EXTENSION OF STABILISERS √ √
TRAVERSE UP √ √
OPTION 1 √ √
OPTION 2 √ √
WARNING: the platform exclusion key has no effect on the above operation.
WARNING: levelling must never be restored with the key.
(13/12/2011) 80-01-M146EN
and specifications
TRUCK WITH FORKS ON TYRES OR STABILISERS IN OVERTURNED CONDITION

EXTENSION OF STABILISERS
The turret can only be moved to the cen-
ROTATION OF TURRET √ √ tral position, if 1 of the 2 +/-5° proximity
sensors can be read
TRAVERSE UP
RAISING OF JIB
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √
OPTION 2
LEVELLING ONLY OPERATES WITH JIB ANGLE < 20° AND EXTENDED
EXTENSION OF STABILISERS √ √
80
TRAVERSE UP √ √
OPTION 1 √ √
OPTION 2 √ √
LEVELLING ONLY OPERATES WITH JIB ANGLE < 20° AND EXTENDED
WARNING: the platform exclusion key has no effect on the above operation.
80-01-M146EN (13/12/2011)
and specifications
TRUCK ON STABILISERS WITH PLATFORM

MOVEMENTS PERMITTED FROM PUSHBUTTON PANEL
JIB JIB JIB JIB
WITHIN H=3m WITHIN H=3m BEYOND H=3m BEYOND H=3m NOTES
JIB RETRACTED JIB EXTENDED JIB RETRACTED JIB EXTENDED
TURRET ROTATION √ √ √ √
TRAVERSE UP √ √ √ √
TRAVERSE DOWN √ √ √ √
RAISING OF JIB √ √ √ √
LOWERING OF JIB √ √ √ √
RETRACTION OF JIB √ √ √ √
EXTENSION OF JIB √ √ √ √
OPTION 1 √ √ √ √
OPTION 2 √ √ √ √
MOVEMENTS PERMITTED FROM THE PUSHBUTTON PANEL IN TRUCK OVERTURNED CONDITION

JIB JIB JIB JIB
The turret may only be moved the
to the central position, if 1 of the
2 +/-5° proximity sensors can be
read.
TRAVERSE UP
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √ √ √
80
OPTION 2
MOVEMENTS PERMITTED FROM THE PUSHBUTTON PANEL IN PLATFORM OVERLOAD CONDITION

JIB JIB JIB JIB
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JI
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
N.B. the data given in the abovementioned table are valid in any position of the turret.
(13/12/2011) 80-01-M146EN
and specifications
MOVEMENTS PERMITTED FROM THE PUSHBUTTON PANEL IN TRUCK OVERTURNED AND PLATFORM IN OVERLOAD CONDITION
JIB JIB JIB JIB
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
MOVEMENTS PERMITTED FROM THE PUSHBUTTON PANEL IN PLATFORM WITH DOOR OPEN CONDITION
JIB JIB JIB JIB
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
MOVEMENTS PERMITTED FROM THE PUSHBUTTON PANEL IN CONDITION TRUCK OVERTURNED AND PLATFORM WITH DOOR OPEN
80
JIB JIB JIB JIB

TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
80-01-M146EN (13/12/2011)
and specifications
TRUCK WITH FIXED PLATFORM / ORH
TRUCK ON STABILISERS WITH FIXED PLATFORM / ORH

JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
When the truck is stabilised, all
LOWERING OF JIB √
movements are speed limited
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
MOVEMENTS PERMITTED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
With the platform exclusion key
TRAVERSE UP √ √ √ √ activated all commands from
80
the pushbutton panel are lost,
TRAVERSE DOWN √ √ √ √ but if pressing the permission
RAISING OF JIB √ √ √ √ pushbutton on the vinco panel the
rescue key (permission from the
LOWERING OF JIB √ √ √ √ pushbutton panel is prioritised
on the key) and command from
RETRACTION OF JIB √ √ √ √ pushbutton panel is restored.
EXTENSION OF JIB This is because the person on the
√ √ √ √
platform must be able to stop a
OPTION 1 √ √ √ √ “dangerous” movement made by
the operator in the cabin
OPTION 2 √ √ √ √
(13/12/2011) 80-01-M146EN
and specifications
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB √
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
Controlled by the
OPTION 2
anti-overturning system
TRUCK ON STABILISERS WITH FIXED PLATFORM / ORH IN OVERTURNED CONDITION

JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
80
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
80-01-M146EN (13/12/2011)
and specifications
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION √ √ Only to return to the centre
TRAVERSE UP
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √ √ √
OPTION 2
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB √
80
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
(13/12/2011) 80-01-M146EN
and specifications
TRUCK ON TYRES WITH FIXED PLATFORM / ORH IN OVERTURNED CONDITION

JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION √ √ Only to return to the centre
TRAVERSE UP
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √
OPTION 2
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
80
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √ √ √
OPTION 2
80-01-M146EN (13/12/2011)
and specifications
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION √ √
TRAVERSE UP √ √
EXTENSION OF JIB
OPTION 1 √ √
OPTION 2 √ √
TRUCK ON TYRES WITH FIXED PLATFORM / ORH

JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
80
TRAVERSE UP √ √
EXTENSION OF JIB
OPTION 1 √ √
OPTION 2 √ √
(13/12/2011) 80-01-M146EN
and specifications
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TRAVERSE UP √ √
EXTENSION OF JIB
OPTION 1 √ √
OPTION 2 √ √
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TRAVERSE UP √ √
80
EXTENSION OF JIB
OPTION 1 √ √
OPTION 2 √ √
80-01-M146EN (13/12/2011)
and specifications
TRUCK WITH PENDULUM PLATFORM
TRUCK ON TYRES WITH PENDULUM PLATFORM IN OVERTURNED CONDITION

JIB JIB JIB JIB
RAISING Only with proximity sensor
√
THE STABILISERS on pendulum being read
LOWERING
√ √
THE STABILISERS
TURRET ROTATION +/- 6° then returns to centre
TRAVERSE UP √ √
TRAVERSE DOWN
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √
Controlled by the
OPTION 2
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
80
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √ √ √
Controlled by the
OPTION 2
(13/12/2011) 80-01-M146EN
and specifications
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TRAVERSE DOWN
EXTENSION OF JIB
OPTION 1 √ √ √ √
Controlled by the
OPTION 2
TRUCK ON TYRES WITH PENDULUM PLATFORM

JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
80
TURRET ROTATION √ √ Within +/- 5°
TRAVERSE DOWN
EXTENSION OF JIB
OPTION 1 √ √ √ √
OPTION 2
80-01-M146EN (13/12/2011)
and specifications
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TURRET ROTATION √ √ Within +/- 5°
TRAVERSE UP √ √
OPTION 1 √ √
OPTION 2 √ √
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TRAVERSE DOWN
80
EXTENSION OF JIB
OPTION 1 √ √ √ √
OPTION 2
(13/12/2011) 80-01-M146EN
and specifications
TRUCK ON STABILISERS WITH PENDULUM PLATFORM IN OVERTURNED CONDITION

JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
80
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √ √ √
OPTION 2
80-01-M146EN (13/12/2011)
and specifications
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
TRUCK ON STABILISERS WITH PENDULUM PLATFORM

JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
80
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
(13/12/2011) 80-01-M146EN
and specifications
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
OPTION 1 √ √ √ √
OPTION 2 √ √ √ √
JIB JIB JIB JIB
√
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
80
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
80-01-M146EN (13/12/2011)
and specifications
TRUCK WITH RADIO CONTROL

TRUCK ON STABILISERS: MOVEMENTS PERMITTED FROM THE CAB
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
Because considered
LOWERING OF JIB √
to be a platform
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
TRUCK ON TYRES: MOVEMENTS PERMITTED FROM THE CAB

JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TRAVERSE UP √ √
80
EXTENSION OF JIB
OPTION 1 √ √
OPTION 2 √ √
(13/12/2011) 80-01-M146EN
and specifications
TRUCK ON STABILISERS: MOVEMENTS PERMITTED FROM THE CAB WITH PLATFORM EXCLUSION KEY ACTIVATED
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
OPTION 1 √ √ √ √
OPTION 2 √ √ √ √
TRUCK ON STABILISERS: MOVEMENTS PERMITTED FROM THE CAB WITH EXCLUSION AND OVERTURNING KEY ACTIVATED
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
TURRET ROTATION
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB √
80
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
80-01-M146EN (13/12/2011)
and specifications
TRUCK ON STABILISERS WITH RADIO CONTROL IN OVERTURNED CONDITION

JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √ √
THE STABILISERS
The turret may only be moved
the to the central position,
TURRET ROTATION √ √ √
if 1 of the 2 +/-5° proximity
sensors can be read.
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √
THE STABILISERS
80
TRAVERSE UP
RAISING OF JIB
LOWERING OF JIB
EXTENSION OF JIB
OPTION 1 √ √ √ √
OPTION 2
(13/12/2011) 80-01-M146EN
and specifications
JIB JIB JIB JIB
RAISING
√
THE STABILISERS
LOWERING
√ √ √
THE STABILISERS
TURRET ROTATION √ √ √
TRAVERSE UP
TRAVERSE DOWN
RAISING OF JIB
LOWERING OF JIB √
RETRACTION OF JIB
EXTENSION OF JIB
OPTION 1
OPTION 2
80
80-01-M146EN (13/12/2011)
and specifications
TRUCK ON STABILISERS WITH RADIO CONTROL
MOVEMENTS PERMITTED FROM THE RADIO CONTROL PUSHBUTTON PANEL

JIB JIB JIB JIB
OPTION 1 √ √ √ √
Controlled by the
OPTION 2 √ √ √ √
MOVEMENTS PERMITTED FROM THE RADIO CONTROL PUSHBUTTON PANEL IN WITH TRUCK IN OVERTURNED CONDITION
JIB JIB JIB JIB
TRAVERSE UP
RAISING OF JIB
LOWERING OF JIB
EXTENSION OF JIB
80
OPTION 1 √ √ √ √
Controlled by the
OPTION 2
(13/12/2011) 80-01-M146EN
and specifications
80
80-01-M146EN (13/12/2011)
25
Electrical characteristics and specifications
LAYOUT ON COMPONENT SIDE
80
(13/12/2011) 80-01-M146EN
26
Electrical characteristics and specifications
80
80-01-M146EN (13/12/2011)
and specifications
MEANING OF THE LEDS ON THE LOGIC CARD

LED Name IN/
Description On Off
name Connector OUT
Does not read the cam Reads the cam
Proximity sensor no.1 for management of
DL1 JP1-16 limited rotation IN
(Signal from I 11)
400° 400°
Does not read the cam Reads the cam

Proximity sensor no.2 for management of
DL2 JP1-12 limited rotation IN
(Signal from I 50)
400° 400°
Power ON Power OFF

DL3 - Supply voltage IN
Rescue key. Rescue key.

activated not activated
DL4 JP3-6 Signal from rescue key IN
Platform not present Platform present

Platform signal present
DL5 JP4-10 (Activated by operating the pushbutton IN
panel on the box in the head of the jib)
Platform jib Platform jib

Pendulum platform signal (A+B or 3D) with lowered not lowered
jib lowered (permits the stabilisers to be
DL6 JP6-3 IN
raised)
(Signal from I 39)
Microswitch not operated Microswitch operated
JP3-8 Platform overload microswitch signal

DL7 IN
JP6-5 operated
80
Key Key
not in rest position in rest position
Platform operator microswitch
JP2-11
DL8 Is the input of any command from the plat- IN
JP4-6
form pushbutton panel N
Key Key
not in rest position in rest position
Microswitch key in cab
DL9 JP1-10 This is the input of any command from the IN
cab
N
Command active Command not active

Signal for retract or raise stabiliser com-
DL10 JP5-4 IN
mand
Command active Command not active

Signal for extend or lower stabilisers com-
DL11 JP3-3 IN
mand
(13/12/2011) 80-01-M146EN
and specifications

LED Name IN/
Description On Off
name Connector OUT
Rear axle free Rear axle locked
Proximity sensor for locking rear axle
DL12 JP3-5 (Signal from I 60 for jib up and I 7 for turret IN
rotation)
Jib below 3 m Jib above3 m

Proximity sensor for sensing the 3 m height
DL13 JP1-1 of the jib IN
(Signal from I 37) MR T 1
TURBO
850
MR T 18
50
T UR B O
Jib retracted Jib not retracted

Proximity sensor for reading jib fully retrac-
DL14 JP1-5 ted IN
(Signal from I 36)
Stabilisers on the ground Stabilisers not on the ground
DL15 JP3-2 Signal for stabilisers resting on the ground IN
Retracting Stabilisers locked or extended

Output for controlling stabilisers extend or
DL16 JP1-21 retract valve. Operates together with the OUT
main valve which is excited
Main valve enabled Main valve disabled
Output for controlling main valve for stabili-

DL17 JP5-1 OUT
sers, beams and levelling command
Truck half stabilised Truck not stabilised

Output going to the ant-overturning system
to indicate that the truck is stabilised (does
DL18 JP1-13 OUT
not distinguish whether the stabilisers are
fully extended or not)
Electrovalve energised Electrovalve not energised

80
This output activates the electrovalve to

DL19 JP6-2 OUT
switch the platform to pendulum
This output goes to the pushbutton panel to Microswitch or anti-

switch on the yellow indicator light and the Microswitch or anti- overturning
buzzer. overturning occurred not occurred
Indicates the condition of the overload
DL20 JP6-6 OUT
microswitch activated with a continuous 1
2
3 1
2
3
4
signal, while it indicates the condition of 5
4
5
anti-overturning has occurred by means of

an intermittent signal
Rear axle locked Rear axle
(flashing) not locked
Output for indication in cab (flashing) of rear
DL21 JP3-9 OUT
axle locked
Red lamp Red lamp

switched on on the off
pushbutton panel
Output used to activate the red lamp on the
DL22 JP6-1 OUT
pushbutton panel 1
2
3
2
1 3 4
4
5
5
80-01-M146EN (13/12/2011)
and specifications

Name Name IN/
Description On Off
LEDS Connector OUT
Emergency roof lamp Emergency roof lamp
not pressed pressed
Signal coming from the emergency lamp on S TOP S TOP
DL23 JP3-12 OUT
the platform. Normally closed
E ME R G E NC Y E ME R G E NC Y
Power supplied Power not supplied

Output that carries the supply to the Dan-
foss distributor.
DL24 JP1-9 OUT
Activated when the truck makes a physical
N
movement T T
P P
These 3 leds are associated with three re-

lays that manage the change of extension, Movements enabled from
Movements enabled by the
optional, traversing, rotation and raising the cab
platform or by radio control
movements of the platform or radio control
DL25
from the cab.
DL27 JP3-1 1
2
3 OUT
When the movements on the platform or on 4
DL28 5
the radio change, they are activated only if

I
all the conditions required by the platform 0

MR T
TURBO
or the radio control are present (including

the manoeuvre consent)
Optional enabled Optional disabled
This signal is activated when optional mo-
vement is enabled and the signal from the ROLLER ROLLER
DL26 -
key has a significant value to perform the OPTIONAL OPTIONAL
movement
Extension enabled Extension disabled

This signal is activated when extension
movement is enabled and the signal from
DL29 -
the key has a significant value to perform
the movement
Maximum height Maximum height

reached not reached
Proximity sensor for maximum jib elevation
DL30 JP1-22 IN
(Disables raising)
MAX
80
Key inserted Key removed
DL31 JP1-7 Safety exclusion key IN
Anti-overturning Anti-overturning
not occurred occurred
DL32 JP1-17 Anti-overturning signal IN
Pendulum platforms Normal platform
Selection between normal and pendulum

DL33 JP4-2 IN
platform
Radio control present Radio control not present

Radio control presence signal
DL34 JP1-8 (Activated with the “Radio control” pushbut- IN
ton on the “Stabilisers” control panel)
(13/12/2011) 80-01-M146EN
and specifications

LED Name IN/
Description On Off
name Connector OUT
Manoeuvre consent present Manoeuvre consent absent
Signal for consent for platform or radio
control manoeuvre
DL35 JP4-9 IN
(Obtained by pressing the red pushbutton
on the pushbutton panel key)
Presence of a man not Presence of a man simulated

simulated
Simulation of the presence of a man when
DL36 JP1-24 OUT
working from platform or radio control
DL37
- Input not used (must be off) OFF OFF
DL38
The Proximity sensor reads The Proximity sensor does not
Proximity sensor 1 to identify status of front the cam read the cam
of truck within 8°
DL39 JP2-4 IN
Is also used to reset the rotation together MR T 18
TURBO
50
MR T 18
TURBO
50
with centrcab1
8°

Proximity sensor 2 to identify status of front the cam read the cam
of truck within 8°
DL40 JP1-4 IN
Is also used to reset the rotation together MR T 18
TURBO
50
MR T 18
TURBO
50
with centrcab 2
8°
Levelling enables Levelling disabled
Output that enables the levelling function

DL41 JP5-5 OUT
or not
Truck Truck
in central position not in front position
Output that goes to the anti-overturning
DL42 JP5-2 system to indicate that the condition of the OUT
truck at the front is within 8°
850 50
MR T 1 MR T 18
TURB O TURBO
8°
80
DL43 - Unused free output (must be off) OFF OFF
This output simulates the input of the over- Overload microswitch Overload microswitch
load microswitch. not occurred occurred
It is only activated if with the down platform
DL44 -
signal (platform present) normally closed
signal of the overload microswitch not
present
Power supply to the platform Power supply to the platform

removed on
This output is used to supply the pushbut-
ton panel and the platform. The power
DL45 -
supply to the platform is removed when the
rescue key is turned on
Movements limited Movements not limited
This led indicates whether the truck is wor-

DL46 JP1-3 IN
king with limited or fast movement speed

Proximity 3 to identify that the status of the the cam read the cam
truck at the front is within 8°
DL48 JP1-6 IN
Also used to reset the rotation together with MR T 18
TURBO
50
MR T 18
TURBO
50
centrcab 3
8°
80-01-M146EN (13/12/2011)
and specifications
DESCRIPTION OF CONNECTORS
CONNECTOR JP1
Name Name IN/
Description
Connector LEDS OUT
JP1-1 DL13 Jib height 3 metres sensor IN
JP1-2 - Proportional extension input from cab IN
JP1-3 DL46 Tortoise speed IN
JP1-4 DL40 1/3 turret sensor in front position IN
JP1-5 DL14 Jib retracted sensor IN
JP1-6 DL48 Turret 3/3 sensor in front position IN
JP1-7 DL31 Exclusion key ssafety IN
JP1-8 DL34 Cab/radio control command selector IN
JP1-9 DL24 DANFOSS reel power supply OUT
JP1-10 DL29 Joystick microswitch in cab IN
JP1-11 - Proportional traverse input from cab IN
JP1-12 DL2 1/2 rotation sensor limited to 400° IN
JP1-13 DL18 Stabilisers supported from logic to MSS-3B6 OUT
JP1-14 - +12 V from battery
JP1-15 - Proportional raising input from cab IN
JP1-16 DL1 2/2 sensor rotation limited to 400° IN
JP1-17 DL32 Input from MSS-3B6 IN
JP1-18 - Not used
JP1-19 - Optional proportional input from cab IN
JP1-20 - Crushed microswitch man present simulation IN
JP1-21 DL16 Stabilisers retract/raise changeover electrovalve OUT
JP1-22 DL30 Jib fully raised microswitch IN
JP1-23 - Proportional rotation input from cab IN
JP1-24 DL36 Crushed microswitch man present in cab OUT
CONNECTOR JP2
Name Name IN/
Description
Connector LEDS OUT
JP2-1 - Permission from radio control IN
80
JP2-2
JP4-5 - Proportional traverse input from radio control IN
JP4-8
JP2-3 - Radio control power supply OUT
JP2-4 DL39 2/3 turret sensor in front position IN
JP2-5
- Proportional optional input from radio control IN
JP4-1
JP2-6
- Proportional raise input from radio control IN
JP4-11
JP2-7 - Ground
JP2-8 - Stop motor from radio control IN
JP2-9
- Proportional extension input from radio control IN
JP4-7
JP2-10 - Radio control power supply OUT
JP2-11
DL8 Radio control joystick switch IN
JP4-6
JP2-12
- Proportional rotation input from radio control IN
JP4-4
(13/12/2011) 80-01-M146EN
and specifications
CONNECTOR JP3
Name Name IN/
Description
Connector LEDS OUT
JP3-1 - DANFOSS traverse output OUT
JP3-2 DL15 Input to stabilisers supported logic IN
JP3-3 DL11 Input to stabilisers extended logic IN
JP3-4 - DANFOSS rotation output OUT
JP3-5 DL12 Input to rear axle locking logic IN
JP3-6 DL4 Platform rescue key input IN
JP3-7 - DANFOSS extension output OUT
JP3-8
DL7 Platform overload IN
JP6-5
JP3-9 DL21 Rear axle locked yellow indicator light OUT
JP3-10 - DANFOSS raising output OUT
JP3-11 - DANFOSS optional output OUT
JP3-12 DL23 Power saving power supply OUT
CONNECTOR JP4
Name Name IN/
Description
Connector LEDS OUT
JP4-1
- Proportional optional input from platform IN
JP2-5
JP4-2 DL33 Pendulum platform present input IN
JP4-3 - Power supply for platform pushbutton panel IN
JP4-4
- Proportional rotation input from platform IN
JP2-12
JP4-5
- Proportional traverse input from platform IN
JP2-2
JP4-6
DL8 Joystick microswitch on platform IN
JP2-11
JP4-7
- Proportional extension input from platform IN
JP2-9
JP4-8
- Proportional traverse input from platform IN
JP2-2
JP4-9 DL35 Manoeuvre permission from platform IN
JP4-10 DL5 Platform present input IN
80
JP4-11
- Proportional raising input from platform IN
JP2-6
JP4-12 - Motor stop from platform IN
80-01-M146EN (13/12/2011)
and specifications
CONNECTOR JP5
Name Name IN/
Description
Connector LEDS OUT
JP5-1 DL17 Main stabiliser electrovalve OUT
JP5-2 DL42 Turret in front position (output) OUT
JP5-3 - Ground
JP5-4 DL10 Retract stabilisers input signal IN
JP5-5 DL41 Power supply for levelling system OUT
JP5-6 - +12 V battery
CONNECTOR JP6
Name Name IN/
Description
Connector LEDS OUT
JP6-1 DL22 Red light on pushbutton panel OUT
JP6-2 DL19 Electrovalve for locking pendulum platform OUT
JP6-3 DL6 Pendulum platform supported on the truck IN
JP6-4 - +12 V battery
JP6-5 DL7 Platform overload IN
JP6-6 DL20 Yellow light on pushbutton panel OUT
80
(13/12/2011) 80-01-M146EN
and specifications
6 AXLE LOGIC CONFIGURATION
MR T 1742
WARNING: Before replacing the logic,
1 1 MR T 1850 check that the wiring numbered 1, 2, 3,
MR T 2150 4, 5, 6, inside the box complies with the
MR T 2540
fitting out of the truck.
1 1 MR T 1432
MR T 1542
MR T 1635
2 2
2 2
3 3
3 3
4 4
4 4
80
5
CR CR
CR ZL
6
ZL ZL
ZL RN
80-01-M146EN (13/12/2011)
ELECTRICAL SCHEMATIC DIAGRAMS
page
POSITION OF THE COMPONENTS ON THE DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . A3

FUSES AND RELAYS IN THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
FUSE BOX AND RELAYS ON TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
ELECTRICAL DIAGRAMS BY FUNCTION:

– 1 - ENGINE STARTING / COOLING FANS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A16
– 2 - HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A19
– 3 - SAUER DANFOSS TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A23
– 4 - PLATFORM/RADIO CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A28
– 5 - SAFETY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A32
– 6 - HEADLAMPS / INDICATOR LIGHTS / LIGHTING / SENSORS / PROXIMITY . . . A35
– 7 - CAN BUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A40
80
– 8 - OPTIONAL LIGHTING / CAR RADIO / WINDSCREEN WIPER . . . . . . . . . . . . . A44
– 9 - PNEUMATIC SEAT / 2a / 3a OUTPUT / OPTIONAL CONTINUOUS . . . . . . . . . A48
– 10 - HEATING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A52
(16/08/2011) 80-02-M146EN
A2
Electrical schematic diagrams
80
80-02-M146EN (16/08/2011)
A3
POSITION OF THE COMPONENTS ON THE DIAGRAMS

Diagram
Component Diagram 1 Diagram 2 Diagram 3 Diagram 4 Diagram 5 Diagram 6 Diagram 7 Diagram 8 Diagram 9
10
A1 √ √
A2 √
A4 √ √ √
A5 √
B1 √ √
B2 √
BMG √
BMP √
BS1 √
BS2 √
C1 √
C2 √
D1 √
D2 √
D3 √
D4 √
D5 √
D6 √
D7 √ √
D8 √ √ √
D9 √ √ √
D10 √
D11 √
D12 √
D13 √
D14 √
80
D16 √
D17 √
D18 √
D19 √
D20 √
D21 √
D22 √
D27 √
DL √
DM √ √ √ √
DOC √
E35 √
F1 √
F2 √ √
F3 √
F4 √ √ √ √
F5 √
(16/08/2011) 80-02-M146EN
A4
Diagram
10
F6 √ √ √
F7 √ √ √
F9 √
F10 √
F11 √
F12 √
F13 √
F14 √
F15 √ √
F16 √ √ √
F17 √ √
F18 √ √
F19 √
F20 √ √
F21 √
F22 √ √ √
F23 √ √ √ √ √ √ √
F24 √
F25 √
F26 √ √ √ √
F27 √
F28 √ √ √
F29 √ √
F30 √ √
F31 √ √
F32 √ √
F33 √
F34 √
80
F35 √
F36 √
F37 √
F38 √
F39 √
F40 √
F49 √
F50 √ √
F52 √
F53 √ √
F54 √ √
F55 √
F56 √
F57 √
F58 √
F59 √
80-02-M146EN (16/08/2011)
A5
Diagram
10
F60 √
F61 √
F62 √
F75 √ √
F76 √
FADX √
FASX √
FLA1 √
FLA2 √
FLB1 √
FLB2 √
FLP1 √
FLP2 √
FPDX √
FPSX √
G √ √
GF √
HL1 √ √ √ √ √
I1 √
I2 √
I3 √
I4 √
I5 √
I6 √
I7 √
I8 √
I9 √
I10 √ √
80
I11 √ √
I12 √
I14 √
I15 √
I16 √
I17 √
I18 √
I19 √
I20 √
I22 √ √ √
I24 √
I25 √
I26 √
I27 √
I28 √
I29 √
(16/08/2011) 80-02-M146EN
A6
Diagram
10
I30 √
I31 √
I34 √
I41 √ √
I43 √
I51 √ √ √
I52 √ √
I53 √
I54 √
I55 √
I56 √
I62 √
I63 √
I64 √
I65 √
I66 √
I69 √ √
I70 √
I71 √
I72 √ √
I73 √
I74 √
I76 √
I77 √
I78 √
I79 √
I80 √
80
I81 √
I101 √
I102 √
IS8 √
IS38 √
IS39 √
IS40 √
IS41 √
IS42 √
IS43 √
KEY √ √
L7 √
L19 √
L28 √
L29 √
L30 √
L31 √
80-02-M146EN (16/08/2011)
A7
Diagram
10
L32 √
L40 √
M1 √ √
M3 √ √
M4 √
M4C √
M5 √
M5C √
M6 √
M8 √
M9 √
M11 √
M12 √
M101 √
MA √
MC1 √
MC2 √
MC3 √
ML1 √
ML2 √
ML3 √
MP √
R1 √
R5 √
R6 √
R7 √
R8 √
80
R9 √
R10 √
R11 √
R12 √ √ √
R13 √ √ √
R14 √
R15 √ √
R16 √ √
R19 √
R20 √
R21 √
R22 √
R23 √
R24 √
R25 √
R26 √
R27 √ √
(16/08/2011) 80-02-M146EN
A8
Diagram
10
R28 √
R29 √
R30 √
R31 √
R32 √
R33 √
R34 √
R35 √ √
R37 √ √ √
R39 √
ROC √
S1 √ √ √
S2 √ √
S2TB √
S3 √ √
S3TB √
S4 √ √
S5 √ √
S8 √
S9 √
S10 √ √
S11 √
S12 √
S13 √
S14 √
S15 √
S16 √
80
S17 √
S18 √
S19 √
S21 √
S22 √
S23 √
S24 √
S25 √
S26 √
S27 √
S28 √
S35 √
S36 √
S37 √
S40 √
SQ √ √ √
STR1-1 √
80-02-M146EN (16/08/2011)
A9
Diagram
10
STR1-2 √ √ √ √
STR1-3 √ √
STR1-√ √
T1 √
X9 √ √ √ √ √ √
X12 √
X23 √
X26 √
X28 √
X29 √
X32 √
X33 √
X37 √ √ √ √
X38 √
X39 √
X40 √
X41 √ √
X42 √
X44-X45 √ √ √
X46 √
X47 √
X48 √
X52 √
X54 √
X55 √
X57 √ √
X73 √
80
X74 √
X75 √
X76 √
X96 √ √
X97 √
X99 √ √
X100 √
X101 √
X102 √
X103 √
X107 √
XA √ √
XAS √
XB √ √
XCD √
XD24 √
XD25 √
(16/08/2011) 80-02-M146EN
A10
Diagram
10
XDG √
XOC √
XPA √
80
80-02-M146EN (16/08/2011)
A11
FUSES AND RELAYS IN THE CAB

Ref Description
F1 Large mixing bucket power supply fuse (30A)
F2 Small mixing bucket power supply fuse (15A)
F3 Pneumatic seat power supply fuse (15A)
F4 Emergency pump + brake pressure switch + gear electrovalve power supply fuse (15A)
F5 Headlamp switch working at top of jib power supply fuse (15A)
F6 Stabiliser control panel power supply fuse (15A)
F7 Logic card / anti-overturn instrument power supply fuse (15A)
F8 Heating fan power supply fuse (10A)
F9 Headlamp dipping + acoustic warning power supply fuse (10A)
F10 Headlamp switch working in front of cab power supply fuse (10A)
F11 Headlamp switch working in rear of cab power supply fuse (10A)
F12 Power supply fuse downstream of economiser for platform (10A)
F13 Heater power supply fuse (20A)
F14 “30” emergency switch power supply fuse (10A)
F15 Fuse “30” car radio + connector provision for power supply (10A)
F16 Fuse Danfoss power supply from logic (10A)
F17 Chain breakage system relay power supply fuse (10A)
F18 Optional double triple output power supply fuse (10A)
F19 Power supply fuse rear windscreen wiper (10A)
F20 Power supply fuse hydraulic exclusion system (10A)
F21 Upper windscreen wiper power supply (10A)
F22 Manipulators power supply fuse (15A)
F23 Switch illumination power supply fuse (10A)
F24 Thermostat power supply fuse (7,5A)
F25 Steering Power supply fuse (7,5A)
F26 Gear change power supply fuse (7,5A)
F27 Indicator lights power supply fuse (7,5A)
F28 Power supply fuse tower alignment proximity sensor (7,5A)
F29 Power supply fuse upstream of economiser for platform (10A)
F30 Anti-overturn exclusion key power supply fuse (10A)
F31 Economiser excitation relay power supply fuse (7,5A)
F32 Car radio + antitheft power supply fuse (7,5A)
80
F33 Electronic transmission gearbox power supply fuse (20A)
F34 Mercedes Engine Diagnostics Fuse (10A)
F35 Window Winder Fuse (15A)
F36 Provision for rear window deicer fuse (20A)
F37 Rear windscreen wiper fuse (10A)
F38 Cigarette lighter “30” fuse (20A)
F39 Mercedes engine control unit “30” fuse (10A)
F40 Mercedes engine diagnostics Fuse (10A)
R1 Intermittence
R5 Relay Mercedes engine control unit
R6 Relay chain breakage system
R7 Double triple output switch power supply relay
R8 Cab aligned relay
R9 Door microswitch relay
R10 Forward gear relay
R11 Reverse gear relay
R12 Danfoss valve relay power supply
R13 Start permission relay
R14 Relay shut down transmission
(16/08/2011) 80-02-M146EN
A12
Ref Description
R15 Economiser excitation Relay
R16 Hydraulic system exclusion relay
R34 Slow/fast gear bistable relay
80
80-02-M146EN (16/08/2011)
A13
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
C
F10
F1
10
10
15
15
10
15
15
15
15
30
F11
F20
10
20
10
10
10
10
10
10
10
10
E
F30
F21
7.5
7.5
7.5
7.5
7.5
10
10
10
15
10
G
F31
F40
7.5
7.5
10
20
20
10
15
10
20
10
I
R1 R34
R5 R6 R7
80
M
R8 R9 R10
O
R11 R12 R13
R14 R15 R16
(16/08/2011) 80-02-M146EN
A14
FUSE BOX AND RELAYS ON TRUCK

Ref Description
D25 Diode 3A
D26 Diode 3A
D27 Diode 3A
F49 Reversing lights power supply fuse (7,5A)
F50 Fuse rear axle oscillation (7,5A)
F51 “15” auxiliary socket power supply fuse (10A)
F52 Main stabiliser relay power supply fuse (10A)
F53 Sidelights/reset gears Fuse (10A)
F54 Stop light relay power supply fuse (10A)
F55 “30” Mercedes engine control unit Power supply fuse (25A)
F56 Dipped headlights power supply fuse (15A)
F57 Main beam power supply fuse (15A)
F58 Fuel heater fuse (20A)
F59 Oil cooling fan 1 power supply fuse (25A)
F60 Oil cooling fan 2 power supply fuse (25A)
F61 Fuse Sidelights power supply (7,5A)
F62 Sidelights power supply fuse (7,5A)
F63 Sidelights “30” auxiliary socket power supply fuse (10A)
F64 Provision not connected
R19 Relay “15” under key
R20 Stop light relay
R21 Main beam relay
R22 Dipped beam relay
R23 Main stabiliser electrovalve relay
R24 Rear axle oscillation permission relay
R25 Fan 1 oil cooling relay
R26 Fan 2 oil cooling relay
R27 Engine starting relay
R28 Reversing light relay
R29 Front right stabiliser beam relay
R30 Rear left stabiliser beam relay
80
R31 Rear right stabiliser beam relay

R32 Front left stabiliser beam relay
R33 Rear axle oscillation relay
R37 Start command/lights relay
R39 Glow plug remote switch excitation
80-02-M146EN (16/08/2011)
A15
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
C R37 R19
E R20
R26
R27
G
R33
F60
F49
I
F61
F64
C1
K R39
D25 D32
80
M
(16/08/2011) 80-02-M146EN
A16
1 - ENGINE STARTING / COOLING FANS
COMPONENTS
B1 Battery 12V O4
C1 4 IN+ 4 OUT circuit O16
D2 Diode 3A E29
DM Gear change C40
F15 “30” radio/connector provision power supply fuse position (10A) C35
F23 Lighting switch power supply fuse (10A) C3
F26 Gear change power supply fuse (7,5A) C36
F28 Tower alignment proximity sensor power supply fuse (7,5A) C34
F29 Economiser power supply fuse platform economiser (10A) C26
F30 Anti overturn exclusion key power supply fuse (10a) C35
F31 Economiser excitation relay power supply fuse (7,5A) C28
F32 Car radio/anti theft power supply fuse (7,5A) C37
F39 Mercedes control unit fuse “30” (10A) C3
F50 Rear axle oscillation fuse (7,5A) C33
F55 Mercedes control unit power supply fuse “30” (25A) C41
F58 Fuel heater fuse (10A) C4
F59 Oil cooling fan 1 power supply fuse (25A) C18
F60 Oil cooling fan 2 power supply fuse (25A) C22
F75 Main fuse M4
G Alternator O13
I10 Platform exclusion key E34
I22 Emergency domed pushbutton G35
I73 Engine start permission with I10 activated G32
I76 1450 r.p.m. switch C31
KEY Starter panel K7
M1 Starter motor O8
M5 Oil cooling fan 1 K19
M6 Oil cooling fan 2 K22
M9 Diesel filter heater G3
80
R8 Cab aligned relay I25

R13 Start permission relay C24
R15 Economiser excitation Relay C28
R19 Relay “15” under key C15
R25 Fan 1 oil cooling relay C18
R26 Fan 2 oil cooling relay C21
R27 Engine starting relay O11
R35 Economiser remote switch C11
R37 Switch on lights command relay C8
R39 Glow plug remote switch relay I29
STR1-2 Instrument connector (STR1-2) Q30
X28 Connector provision for preheating relay O40
X29 Connectorand provision for preheating I41
X37 Antitheft connector E39
X44-X45 Check warning lights Q25
X47 Provision for air preheating O38
X48 Provision for air preheating O35
X57 Hydraulic oil temperature light K20
80-02-M146EN (16/08/2011)
A17
ELECTRICAL DIAGRAM “STARTING / COOLING FAN”
1 2 3 4 5 6 7 8 9 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 A
X3-6
R2.5
F60 25A
F29 10A
RN2.5
R2.5
RNnr.13
RB1.5
R2.5
F59 25A S4
RB1.5
RB1.5
M 2.5
F31
M2.5
R1.5
7.5A
RN4
F39 10A
F58 20A
F23 10A
RB1.5
R4
RNnr.13
CVnr.1
X3-A-B-C
C C
LN2.5
DM
V2.5
R2.5
R37
7.5A
7.5A
7.5A
F26 7.5A
R19 R26 R13 R15
F55 25A
R35 R25 I76
10A
10A
ZV
M4
AH
R4
M2.5
R2.5
N
M4
ZG 86 LS 86 ZV AC Mnr.3 1 +
F50
VB VB 30
F30
F28
F32
30 30 30 30 30 30
F15
86 86 86 86 86 10
0
X5-4
XM3-12
X21-33 1 0 1 2
RB1.5
R1.5
MV1.5
V
A1.5
R4nr.1
X13-A
X8-3
33
BV 85 N 85 N 85 NG 85 NG 85 N 85 N 85 1450
87 87a 87 87 87a 87 87a 87 87a 87 87a 87 87a
X4-36
X3-1
X4-39
X3-16
RpM 5 9 1 0 2
X1-33
X20-E
S4
LOKED
RN4
IGNITION/LIGHTS ECONOMIZER OIL OIL STARTING ECONOMIZER SWITCH
V2.5
LN2.5
LS
GZ1.5
BV
R10
CONTROL RELAY WITH KEY COOLING FAN EXCITATION
AC
REMOTE COOLING FAN CONSENT
N
REVERSE/FORWARD
CONTROL SWITCH “15” RELAY RELAY 1 RELAY 2 RELAY RELAY GEAR LEVEL
X4-5
X4-22
X21-19
R2.5
X20-I
X17-J
X20-G
E X21-1 E
XM4-1
19
I10
1
S1.5 XD2-8 XD2-2 X4-14

IN "+V" BEFORE ECONOMIZER JP6-4
X27-6 R2.5
X17-H
R2.5
X2-8
M GL MV1.5
X17-1
X1-1
X37
X13-14 X6-20
M2.5
S1.5
X27-5
IN "+V" BEFORE ECONOMIZER JP4-3
D2
X19-42
X19-38
X19-39
X19-36
X19-37
GZ
GZ
M9 M1.5 RN1.5 I73 R

XM1-1
1
X27-8
HEATER
GASOIL 3 N 2
PUMP
M1.5 CB1.5 M1.5 M1.5nr.2 M1.5nr.2 #% 3

N2.5
01
2 60 4
G X1-32
I22 EMERGENCY
BUTTON
ZVnr.1
+ 0
5 G
X17-I
X21-32 6'
ZV *%
32
X4-40 '6 6
M1.5nr.3 (1
7
64
8
RL

X29
A1.5
X4-37 M1.5
R8 1 PRE-HEATING CONNECTOR
V
R39
V 86 30 A
RB1.5
86 30
X1-2 X18-10 X17-11
M1.5
ZG
M1.5
I XM4-2 35 X27-15 I
P 0 1 23 10 5 6 8 7 3 4
SN X1-27 X18-16 X17-5
85 SN
NG
85 G*
LN2.5
G*
V2.5
N2.5
N2.5
XM2-13 X27-1
N
87 87a 87 87a 44
PRE-HEATING PRE-HEATING
X20-A-B-C-D
2 RELAY 1 RELAY
MV
1 2 X1-25 X18-14 X17-7 MR*
X27-3
LG
MR*
XM2-14
KEY 42
R2.5
MH*
START ENGINE X27-4
KEY
2 2
1 1
M5 M6 A*
X1-26 X18-15 X17-6
A*
OIL COOLING FAN 1 OIL COOLING FAN 2 XM2-15 43 X27-2
X21-31
X20-4
X4-8
X4-7
K K
X57
X17-A-B-C-D-E-F-G
X18-A-B-C-D X2-A-B-C-D X3-H-I-J HYDRAULIC OIL
X17-12
47 TEMPERATURE BULB
X1-31
31
F75 125A
80
XM1-10
XM4-7
XM2-9
M M
RNnr.13
N70
MBnr.3
N50
RNnr.13
RNnr.13
R25
10
11
12
13
14
15
16
18
17

ALTERNATOR
ZG
30 STARTING ENGINE
01 02 03 04 05 06 07 08 09 10 11 12 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
M1 X17-4 X20-2
G HR
O O
MV Nr°2
MB Nr°2
R1.5
SN Nr°1
12V
B1 R27
MVnr.1
MBnr.3
BATTERY
C1
HR
ZG
SN
LG
ZG 86 30
N
X48 X47 X28
X17-3 X20-11
(3) (4) (8) (2)

IN 1 IN 2 IN 3 IN 4 GLOW PLUGS GLOW PLUGS GLOW PLUGS
L1.5
M (1) 4 INPUT 4 OUTPUT
PRED. PRED. RELAY PRED.
2
CONNECTOR CONNECTOR
2
W
50 N CONNECTOR
N 85 CICUITS GND (6)
87 87a ZV
1
3
1
3
2
1
(10) VCC
IGNITION RELAY
L1.5
OUT1 OUT2 OUT3 OUT4

(11) (5) (9) (7)
X27-12
STR1-2
X20-J
INDICATOR CHECK INSTRUMENT CONNECTOR

VB
Q X44-X45 Q
X17-L
X18-I-J-K-L X2-I-J-K-L
48
X18-G-H X1-34
N10 L4 L1.5
46
X29-1 L4 L2.5 X5-1 X13-H L Nr3
X27-9 L4 L1.5 L1.5
JP5-3 NEGBATT XM4-3 XM3-6
X17-K X2-G-H L1.5
L2.5 JP2-7 NEGBATT
X27-11
.5
16
R 4
N
M
B1
R
R
S S
(16/08/2011) 80-02-M146EN
A18
80
80-02-M146EN (16/08/2011)
A19
2 - HYDRAULIC MOVEMENTS
COMPONENTS
Ref. Description Position on the diagram
A4 Anti overturning alarm buzzer Q26
D8 Diode 3A Q24
D9 Diode 3A Q25
D13 Diode 3A E10
D16 Diode 3A E7
D17 Diode 3A E8
D18 Diode 3A G11
D19 Diode 3A C32
D20 Diode 3A E32
D27 Diode 3A E24
F4 Fuse pump emergency/brake pressure/gear electrovalve (15A) C28
F6 Stabiliser control panel power supply fuse (15A) C22
F16 Danfoss logic power supply fuse (10A) C30
F20 Hydraulic system exclusion power supply fuse (10A) C23
F22 Key power supply fuse (15A) C2
F50 Rear axle power supply fuse (7,5A) C3
F52 Main stabiliser relay power supply fuse (10A) C26
HL1 Red lamp Q27
I11 Limited rotation proximity sensor 2 Q30
I22 Emergency domed pushbutton E21
I26 Stabiliser raised/lowered beam extend/retract switch O9/O10
I27 Beams/stabiliser selector switch O6
I28 Left front beam/stabiliser switch C21
I29 Front right beam/stabiliser switch C9
I30 Rear left beam/stabiliser switch C13
I31 Rear right beam/stabiliser switch C18
I41 Maximum raising microswitch Q29
I51 Anti-overturn exclusion key Overturning K23
I52 Limited rotation proximity sensor 1 Q34
80
I69 Levelling switch C6
I72 Optional exclusion switch G32
L28 Selected beam indicator light Q8
L29 Selected stabilisers indicator light Q10
L30 Beam extension/lowering stabiliser feet indicator light Q15
L31 Retract beams/raise stabiliser feet indicator light Q12
M3 Left side seat lever I36
M4 Right side seat lever C36
R12 Danfoss valve power supply relay G29
R16 Hydraulic system exclusion relay G22
R23 Main stabiliser electrovalve relay G25
R24 Rear axle oscillation permission relay O19
R29 Front right beam/stabiliser relay G7
R30 Rear left beam/stabiliser relay G10
R31 Rear right beam/stabiliser relay G15
R32 Front left beam/stabiliser relay G18
R33 Rear axle oscillation relay O15
S1 Danfoss lifting electrovalve M29
S2 Danfoss extension electrovalve M30
(16/08/2011) 80-02-M146EN
A20
COMPONENTS
S3 Danfoss rotation electrovalve M31
S4 Danfoss traverse electrovalve M32
S5 Danfoss optional electrovalve M33
S9 Main stabiliser electrovalve M26
S10 Hydraulic circuit exclusion electrovalve M21
S11 Front right beam electrovalve M10
S12 Front left beam electrovalve M20
S13 Rear left beam electrovalve M13
S14 Rear right beam electrovalve M17
S15 Stabiliser retract/raise electrovalve M14
S16 Front right stabiliser electrovalve M9
S17 Front left stabiliser electrovalve M18
S18 Rear left stabiliser electrovalve M12
S19 Rear right stabiliser electrovalve M16
S23 Unlock rear axle electrovalve Q18
S26 Unlock rear axle electrovalve Q20
S35 Levelling electrovalve 1 M7
S36 Levelling electrovalve 2 M11
SQ Door microswitch K20
X9 Anti overturn circuit O23
X52 Rotation potentiometer kit O26
X55 Stabiliser calliper configuration connector M6
XD24 Right man present joystick diode connector Q35
XD25 Left man present joystick diode connector Q36
80
80-02-M146EN (16/08/2011)
A21
ELECTRICAL DIAGRAM “HYDRAULIC MOVEMENTS”
1 2 3 4 5 6 7 8 9 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
N
4
N
M
X6-4 X14-29
R
RV
JP1-20 IN "PREUOM1"
X21-14 X2-6 X6-15 X13-19

HZ
14 JP5-1 OUT "GENSTA"
A X6-9 X14-5
A
AG1.5
JP1-9 OUT "DISTRDANF"
ML
M4
MV
MG
MS
N
N
N
X3-3
RIGHT ARM REST LEVER
AG1.5
RH
RN1.5
RH
VN
1
VN
10 1 10 1 10 1 10
M2.5
CL0.25
M2.5
M2.5
1 0 1 0 1 0 1 0 1 MICROSWITCH JOYSTICK
M4
RN4
M2.5
X6-38
C D19 CL0.25
2 MICROSWITCH JOYSTICK
C
F52 10A
F23 10A
F6 15A
F20 10A
XD3-8 X5-P
F16 10A
XD3-1 X11-T
15A
F50 7.5A
F22 15A
RVnr.1 HVnr.1 HV0.25

3 +12V AFTER MOVEMENT CONSENT SWITCH
I31
X14-36
I29 I30 I28
BR Nr°3
MH Nr°1
MR Nr°2
X1-30 BR Nr°3
F4
LEVELING 5 9 5 9 5 9 5 9
4
I69
RNnr.13
X14-17
RNnr.13
RNnr.13
FRONT RIGHT REAR LEFT REAR RIGHT X11-A
BRnr.2
BRnr.2
CV1.5
BRnr.2
FRONT
BRnr.2
RNnr.13
VN
HL
RN1.5
OUTRIGGER OUTRIGGER OUTRIGGER LEFT
RH
/BEAM SWITCH 5 PREDISPOSITION SIGNAL

/BEAM SWITCH /BEAM SWITCH
A1.5
HV1.5
OUTRIGGER
RN1.5nr.1
X3-17
X3-G
X1-29
/BEAM
X6-30
6
OUT "OUTLIV" JP5-5
SWITCH
X8-ee
X1-7
X14-24 X11-B
X1-5
X1-8
X3-6
X1-6
AB AB
29
30
IN "BRACAB" JP1-11 7 TILTING SIGNAL

X21-30
X11-bb
X14-2
VB
X21-29
VB
5
IN "SOLCAB" JP1-15 8 LIFTING SIGNAL
I22 X14-23 X11-C
X21-7
X21-8
X21-5
XD1-27
X19-9 9
X8-bb
D20
X1-6
E HV0.25
E
BRnr.2
XD3-7 XD3-2 X5-G X11-U
EMERGENCY BUTTON RVnr.1 HVnr.2
X7-T
MH
RVnr.1
MR
X19-8
D16 D17 11
D13
HZ
D27 12
HV0.25
ZG
X4-30
ZG
BRnr.3
CL0.25
ZG
X13-9 X11-cc X53-2
OUT "EVOPT" JP3-11 HV0.25
XD1-35
XD2-1
D18 XD2-7
JP1-24 OUT"PREUOM2" HV0.25
RVnr.1 X6-6 X14-28
RNnr.13
17
BN1.5
RN1.5
MG
R29
MV
R30 R32 R16 R23 R12
MS
R31
RV
ML
G G
RVnr.1
B
18
BL 30 BL 30 BL 30 BL 30 30 30 30 1 10
86 86 86 86 86 ZG 86 RVnr.1 86 1 0 19
20
21
I72 5 9 N
22 GND
N 85 N 85 N 85 N 85 N 85 N 85 N 85 OPTIONAL
EXCLUSION 23
BN
N
87 87a 87 87a 87 87a 87 87a 87 87a 87 87a 87 87a SWITCH
FRONT/RIGHT REAR/LEFT REAR/RIGHT FRONT/LEFT HYDRAULIC OUTRIGGER FEEDING DANFOSS 24
BR1.5
RV Nr°2
CN1.5
GR
CR
AG
CN
OUTRIGGER/BEAM OUTRIGGER/BEAM OUTRIGGER/BEAM
GL
VALVE RELAY
HL
LR
OUTRIGGER/BEAM CIRCUIT VALVE
C
RELAY RELAY RELAY RELAY RELAY B

EXCLUSION 25 +12V AFTER MOVEMENT CONSENT SWITCH
X19-3
I I
M3 LEFT ARM REST LEVER
JP3-10 OUT "EVSOL"
JP3-4 OUT "EVROT"
JP3-1 OUT "EVBRA"

OUT "EVSFI"
CL0.25
X21-3
X53-1
JP1-17
CL0.25
HN
OUT"EVRIE-STA" JP1-21 IN "ANTIRIB" 2 MICROSWITCH JOYSTICK
HV0.25
3
X14-1
X14-3
JP3-7
4
X7-S
X1-3
X2-7
MH
X6-14
5 OPTIONAL SIGNAL
X6-12
BV1.5
G
S
V
L
SQ 6
X19-33
X19-32
X11-dd
X19-31
X19-34
X19-35
X19-28
X19-29
X19-30
X13-4
X13-3
X6-34
X13-6
17
X11-D
X13-7
K K
X2-3
S
7
X4-34
ROTATION SIGNAL
SG
X21-17
8 TELESCOPE SIGNAL
4
HV1.5
X5-L
DOOR
X21-4
HB
BV1.5
MICRO
I51
HN
HV0.25
NR
BL
A
OUTRIGGERS
X19-21
X4-6
X19-12
CN1.5
CN1.5
CN1.5
CN1.5
X11-F
OUTRIGGERS
MR
GR
AG
11
CR
CN
MH
GL
HL
LR
BR1.5
VALVE
C
L
S
V
HB
COMPASS
CL
CONFIG.
12
S35 S16 S11 S36 S18 S13 S15 S19 S14 S17 S12 S10 S9 S1 S2 S3 S4 S5 HV0.25
X14-19
VN1.5
VN1.5
SAFETY
VN1.5
80
N SYSTEM
N
N
N
N
N
N
N
N
N
N
FRONT HYDRAULIC
2
FRONT LEVELING REAR LEFT REAR LEFT OUTRIGGERS REAR RIGHT REAR RIGHT FRONT LEFT FRONT LEFT EXCLUSION LIFTING TELESCOPE ROTATION TILTING CL0.25
LEVELING RIGHT CIRCUIT OPTIONAL 14 MICROSWITCH JOYSTICK
RIGHT OUTRIGGER RETRACTION OUTRIGGER BEAM VALVE OUTRIGGER BEAM VALVE KEY DANFOSS
N
OUTRIGGER BEAM VALVE 2 VALVE BEAM VALVE DANFOSS DANFOSS DANFOSS DANFOSS
M X55 1 VALVE
VALVE /RISING VALVE VALVE VALVE EXCLUSION
VALVE VALVE VALVE VALVE HV0.25 M
N
VALVE VALVE VALVE 15 +12V AFTER MOVEMENT CONSENT SWITCH
SG
HV0.25
IN "SFICAB" JP1-2
X8-H X6-11 X11-R 17
18
OUTRIGGERS RETR./EXT. BEAM REAR AXLE REAR AXLE
VN1.5
RG1.5
VN1.5
VN1.5
/BEAMS LOW./RISED. OSCILLATION

A1.5
OSCILLATION 19
SELECTION OUTRIG. RELAY
R33 R24
RB
RL
CONSENT RELAY
SWITCH
20
BS
BL
VALVE 3 4
N
B
S
1 7 8 10 10 BS 86 30 ZR 86 30
2 1 0 2
1 0 1 2 3 4 21
P N M L K J H V
R
X21-20
X21-37
N
3B6 U ROTATION
22 GND
ANTI-TILT CIRCUIT
O S
POTENTIOMETER KIT
23 O
I26 G F E D C B A T
20
I27
X6-36
5 9 1 7 2 8 9
6
24
85
X52
BRnr.2
NL
85
BRnr.2
N N
NR
A
RNnr.13
BL
87 87a 87 87a B
X9 25 +12V AFTER MOVEMENT CONSENT SWITCH
RG1.5
37
RG1.5
X11-G
X5-S
X4-27
RN1.5nr.1
X20-18
X14-26
I41
X2-11
L29
X4-29
NR
L31
X14-41 X6-25 X2-9
RB
RL
NL
L28 L30
RN1.5nr.1
MAXIMUM
1 1
A4
CH
1 1
HL1 RISING
X6-16
N
MICRO
RN
X6-17
X6-22
CV
X14-20 X11-E
CV
CL
CL
N
RG1.5
X4-28
N
RED
RG1.5
Q N Q
XD1-22
XD1-23
X14-18
LAMP
I11
V
I52
X13-18
ZL
D9
X13-17
X14-13
X13-12
2 2 2
2
S23 S26 LIMITED LIMITED
GH
D8
CV
ROTATION
PILOT/OUTRIG.
PILOT LIGHT
PILOT LIGHT
OUTRIGGER
ROTATION
PILOT/OUTRIG.
B B
SELECTED
SELECTED
SAFETY 2 PROXY 1 PROXY

N
X7-M
RETRACION
N
1
2
2
1
EXTENSION
BL
REAR AXLE REAR AXLE SYSTEM
N
IN "MANCAB" JP1-10
JP5-4
XD24 XD25
JP3-5
IN"CHI3B6" JP1-7
C A
N
C A
BEAMS
OSCILLATION OSCILLATION BUZZER

LOWER.
OUT"OUTCC" JP5-2
IN "OUTSTA" JP3-3
BEAMS
RISING
VALVE
IN "ROTCAB" JP1-23
VALVE
IN "ESCSAL" JP1-22
BEAMS
C A C A
1
2
2
XD1-31
XD1-30
IN "INSTA"
X4-43
B
IN "BLPOPOS"
X6-35
S S
(16/08/2011) 80-02-M146EN
A22
80
80-02-M146EN (16/08/2011)
A23
3 - SAUER DANFOSS TRANSMISSION
COMPONENTS
A4 Anti overturning alarm buzzer Q12
C2 4 IN+ 4 OUT circuit I12
D3 Diode 3A E17
D4 Diode 3A G17
D8 Diode 3A K17
D9 Diode 3A K17
D21 Diode 3A G17
D22 Diode 3A G17
DM Gear change C21
F4 Emergency/brake pressure/electrovalve gear pump fuse (15A) E4
F6 Stabiliser control panel power supply fuse (15A) E4
F22 Manipulators power supply fuse (15A) C4
F25 Steering fuse (7,5A) A4
F33 Danfoss electronic transmission control unit power supply fuse (20A) A4
F53 Position/reset gears lights fuse (10A) C4
HL1 Red lamp Q11
I1 Parking brake switch C9
I2 Slow/fast switch C37
I3 Gear change switch C6
I4 Switch Gear change reset C13
I24 Steering switch C33
I51 Anti overturn exclusion key I19
I55 Stop pressure switch G27
I81 Translation safety bypass switch G14
I102 Danfoss electronic transmission setting authorisation I31/I32
L40 Danfoss control unit alarm indicator light Q28
R5 Relay Mercedes engine control unit G29
80
R9 Door microswitch relay C28
R10 Forward gear relay C23
R11 Reverse gear relay C26
R14 Relay shut down transmission C17
R34 Slow/fast gear bistable relay G38
S8 Parking brake electrovalve Q10
S21 Forward electrovalve Q24
S22 Reverse electrovalve Q26
S24 Crab steering electrovalve Q30
S25 Concentric steering electrovalve Q32
S27 High speed electrovalve Q33
S28 Low speed electrovalve Q8
S40 Engine displacement reduction Q29
SQ Door microswitch C27
SRT1-2 Instrument connector (STR1-2) O7
STR1-3 Instrument connector (STR1-3) Q6
X9 Anti overturn circuit I24
X37 Antitheft connector G26
X44-X45 Check warning lights G3/G4
(16/08/2011) 80-02-M146EN
A24
COMPONENTS
X96 Connector for I18047 Q37
X97 Danfoss settings block Q39
X99 Bus ring closure J1939 Q13/S13
X102 Electronic brake pedal Q14
XA MC024-021 Danfoss control unit connectors/A1 Q16
XB MC024-021 Danfoss control unit connectors /B1 Q22
XPA Electronic accelerator pedal Q34/Q35
80
80-02-M146EN (16/08/2011)
A25
ELECTRICAL DIAGRAM “SAUER DANFOSS TRANSMISSION”
1 2 3 4 5 6 7 8 9 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 A
.3
R
4
LN
N
M
R
M2.5 F33 20A X4-3
M1.5 F25 7.5A X3-12

ZR1.5
M2.5 F22 15A X14-2 X7-T BV1.5 SQ
HV1.5
M2.5 F26 7.5A X3-16

ZVnr.1
C I3 ENGAGED
GEAR MICRO C
RN2.5
F53 10A X19-10 X21-15 X1-15
15
RNnr.13
RN GV
GMnr.1
RNnr.13
Cnr.1
X19-24
ZR1.5
ZR1.5
HSnr.1
F28 7.5A X3-4
R14 DM R10 R11 R9 I2
I1 I4 I24
VH
VM
ZV
GV
CB
VN
VN
M2.5
V
N
V
5 6 10 3 4 10 AN 86 30 + 86 30 SM 86 30 B1.5 86 30 4 8 3 7 10 3 4 10
1 0 1 0
F23 10A X3-6 1 0 2 2 1 0 1 0 2
NLnr.1
M4 ZV
RNnr.13
M2.5 F6 15A X3-G

PARKING 1 7 2 8 9 1 7 2 8 9 N 85 NV 85 NV 85 N 85
BRAKE 87 REVERSE 87a 87 87a STEERING SLOW/FAST
HV1.5 SWITCH 87a 87 87a 87
SWITCH 1 0 2 SWITCH SWITCH
GV
AN
/FORWARD 2 6 1 5 9 1 7 2 8 9
VMnr.1
DOOR MICRO
VMnr.1
FORWARD REVERSE
NV
BREAK GEAR
F4 GEAR
VMnr.1
GEAR
X4-11
15A
RNnr.13
SWITCH
VM
M2.5 RN1.5nr.1 MOVEMENT MOVEMENT
VN
VB
MOVEMENT
VG
BC
NLnr.1
BOX
AV
N
SM
ZR1.5
LEVER
N
RELAY RELAY RELAY RELAY
E VN X4-13 E
XM4-16
INDICATOR
CHECK X4-12
X8-H
X7-S
XD2-9
D3 XD2-3
GMnr.1
HV1.5
X3-18
X1-28
01 02 03 04 05 06 07 08 09 10 11 12 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
BY-PASS SAFETY
TRASLATION
XD2-10
D4 XD2-4
HSnr.1
RNnr.13
X108-D
X108-C
SWITCH
40
I81
VN
Cnr.1
XD3-6
D22 X6-22 X13-12
X21-40
XD3-4
VH
AN
1 10 AN
X4-19
X4-20
1 JP5-2
X37
0 OUT"OUTCC"
1
RN1.5nr.1
X4-10
(3) (4) (8) (2)
G G
RNnr.13
X14-10
IN 1 IN 2 IN 3 IN 4 XD3-5
D21 XD3-3
Cnr.1
2

X19-19
(1) W
R5
NR
BC
AV
5 9 #%
Cnr.1

N
(6) 01 3
R
GND
S
ZV
X8-gg
X8-hh
X44-X45 VN (10) VCC 60
I55
86 30 1 0 1 10 6 2 4
AN
ZVnr.1 4
N
+ 0
N
OUT1 OUT2 OUT3 OUT4
P
(11) (5) (9) (7) ZV 6'

R34
X4-28
*% 5
p
M N
F
'6
ANTI-TILT CIRCUIT
C2
NZ
SLOW-FAST
CH (1 6 N 85
I102 5 9
X108-E
64 GEAR RELAY
E
RNnr.13 X14-26 BRAKES 87 87a
4 INPUT 4 OUTPUT 3 8 5 1
RN
7 PRESSURE
N
A
BV1.5
3B6
CIRCUITS JP1-7 DANFOSS
VH
D
CH
SWITCH
K L
I51
BV
BH
BV
RZ
X6-10 IN"CHI3B6" MODE SWITCH
A
8 MERCEDES ABILITATION
RN1.5nr.1
C
X3-9
ENGINE
X4-18
X4-17
CONTROL
J
UNIT RELAY
I RNnr.13
I
H
A
XM4-15
Cnr.1
U
T
V
MANITOU
SAFETY
X3-5
VN1.5
VN1.5
X9
SYSTEM
EXCLUSION
X3-9
KEY
XM2-1

K
GH
XD1-31
D9 XD1-23
A
K

RNnr.13

ZL
XD1-30
D8 XD1-22
A
X5-S

VN

10
11
12
80
13 BH
14
M 15 M
16 RZ
17
18
INSTRUMENT CONNECTOR STR1-2
XM4-12
XM4-14
XM4-13
XM2-5
X1-16
X1-17
X1-24
X2-2 X8-cc
X2-5 X8-dd
O O
24
25
38
GM Nr°1
HS Nr°1
X18-19
L Nr°3
RN1.5
RN1.5
RN1.5
X18-6
X18-7

X6-35
GM
HS
NR
AH
NB
VH
AB
X4-43

M
M
G
R
V
L
M
L
RZnr.1
R
18
RNnr.13
X20-5
SR Nr°1
SH Nr°1
SR Nr°1
SB Nr°1
SB Nr°1
SV Nr°2
X20-9
X19-6 X20-6
CAN
NR
RN
28
RZ
VGnr.1
RZnr.1
V G
Lnr.3
LINE
X7-M
X17-9 X18-5
X21-22

RN
RN
BH
AB
11
X17-10 X18-2
11
10
4
2
10
2
8
7
6
X102
X19-15
VB
X19-5
MC024-021 DANFOSS CEN.BOX CONN./A1 MC024-021 DANFOSS CEN.BOX CONN./B1
12
1
2
1
12
1
INCHING
3 2
RED
X99 PEDAL
XA XB L40 8 7 6 5 4 3 2 8 7 6 5 4 3 2
LAMP
A4
NB
1 9
9
X96 1
AH
HL1 XPA 4 1
VB
BUS J1939 CLOSED RING

1 ELECTRONIC I18047 CONNECTOR X97
SH
10
RZ
GM
VM
BH
VH
1
2
ACCELERATOR MODE
Q S28 S8 S21 S22 ! S40 S24 S25 S27 4 SWITCH 1
DANFOSS
Q
1 KOhm 1/4W
3 2
N
N
N
N
N
SAUER DANFOSS ELECTRONIC TRASMISSION BOX
1 KOhm 1/2W
DIODI 1Amp.
N
SLOW PARKING FORWARD REVERSE 2 CRAB CONCENTRIC FAST GEAR

N
MOTOR
N
120 Ohm
N
GEAR BRAKE SAFETY GEAR GEAR DISPLACEMENT STEERING STEERING VALVE

VALVE SOLENOID SYSTEM SOLENOID SOLENOID VALVE VALVE
N
VALVE BUZZER VALVE VALVE SAUER
ELECTRONIC
STR1-3 BOX ALARM
DIODO 1Amp.
INSTRUMENT CONNECTOR X99a LAMP 1 KOhm 1/4W

CAN-BUS RING
S S
(16/08/2011) 80-02-M146EN
A26
80
80-02-M146EN (16/08/2011)
A27
80
(16/08/2011) 80-02-M146EN
A28
4 - PLATFORM / RADIO CONTROL
COMPONENTS
A1 Acoustic warning S24
A5 Emergency pump buzzer O16
B1 Battery 12V O5
B2 Battery 12V O3
D5 Diode 3A G33
D6 Diode 3A G32
D10 Diode 3A M9
D11 Diode 3A M15
D12 Diode 3A M16
D14 Diode 3A M16
DM Gear change C33
E35 Emergency pump remote switch coil O13/O14
F4 Emergency/brake pressure/electrovalve gear pump fuse (15A) C11
F7 Anti overturn instrument card logic power supply fuse (10A) C2
F12 Power supply fuse downstream of platform economiser (10A) C40
F17 Chain breakage circuit relay power supply fuse (10A) C3
F18 Optional-double/triple output fuse (10A) C36
F29 Power supply fuse platform economiser (10A) C4
F30 Anti overturn exclusion key power supply fuse (10A) C35
F31 Economiser excitation relay power supply fuse (7,5A) C21
F75 Main fuse M6
F76 Fuse emergency pump remote switch Q13
HL1 Red lamp Q9
I9 Emergency pump remote switch C12
I10 Platform exclusion key G35
I25 Tilt/aerial rotation jib/3D platform switch I35
I70 Radio control connector C35
80
KEY Starter panel E4

M1 Starter motor O8
MC1 Chain 1 microswitch K24
MC2 Chain breakage microswitch 2 I24
MC3 Chain breakage microswitch 3 I24
MP Emergency pump O15
R6 Relay chain breakage system G14
R15 Economiser excitation relay economiser C20
R27 Engine starting relay C38
R35 Economiser remote switch C16
R37 Switch on lights command relay G21
SRT1-2 Instrument connector (STR1-2) I4
X9 Anti overturn circuit G3
X37 Antitheft connector I28
X73 3D Platform rotation inclination K40
80-02-M146EN (16/08/2011)
A29
ELECTRICAL DIAGRAM “PLATFORM / RADIO CONTROL”
1 2 3 4 5 6 7 8 9 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
.3
N
R
LN
R16
A A
M2.5
M2.5
M2.5
M2.5
RB1.5
RB1.5
RB1.5
M2.5
M2.5
M4
F26
X3-A-B-C
7.5A
F30
F4
15A
F18
F12
F31
10A
10A
10A
7.5A
F17
ZVnr.1
F29
F23
RN1.
5nr.1
10A
10A
F7
10A
10A
X6-20 X13-14 X6-20 X13-14 X20-11 X17-3
GN2.5
X4-39
HN2.5
RNnr.13
X27-12
C C
M1.5
X3-5
MV1.5
X3-16
R1.5
BR
ZV
I70
M4
R13 I9 R15 DM R27
S4
RNnr.13
R35
AH
ZB1.5
X13-1
Mnr.3
5 6 10 30 + 5 6 10
AC 86 30 LS 86 Mnr.3 86 30 X14-15 X6-2 X8-P 1 0 2 ZG 86 30
SL
1 0 1 0
X15-B X16-B XA-J
X22-J
1 0 2
X70-13
RN1.5
CB1.5
X22-U
REVERSE
NLnr.1
AC
7 2
SM
1 8 9 1 7 2 8 9
ZV
/FORWARD
EMERCENCY BUTTON
85 N 85 85 GEAR N 85
C1.5
N N
CB1.5
N
RADIO
BR
EMERGENCY
REMOTE CONTROL
5 LEVER
N
6 CONTROL
REMOTE CONTROL
87 87a PUMP SWITCH 87 87 87a 87 87a
XD2-6 X4-12
CONSENT SWITCH
XD2-5 X4-13
CONSENT SWITCH
X3-6
X5-2
X4-5
X4-37
PREDISPOSITION
SWITCH
3 2
X4-4
STARTING CONSENT ECONOMIZER IGNITION RELAY
LS
ECONOMIZER
R10
L1.5
BV
MOUVEMENT
MOUVEMENT
RELAY REMOTE
E CONTROL SWITCH
EXCITATION RELAY E
X4-22
X14-32 X5-H
ZL
CR
ZL
S1.5
BASKET
+12V
+12V
M1.5
M1.5
RB1.5
KEY
X22-T
P01 23 JP4-9 IN "CONCES" JP1-8 IN "POSRAD"
10 5 6 8 7 3 4
JP4-2 IN "CEST23M"
X14-14 X6-30 X8-R
JP6-3 IN "SELCES"
M1.5nr.1
HN2.5
1 2
START
R2.5
ENGINE
KEY I10
NLnr.1
X14-8
SM
X5-3
D6
X6-8 X6-8
G D5
ZB
G
X108-L-M
R2.5
X13-8
P N M L K J H V
R6 R37 1
ZB
R
ZVnr.1
GN
X9 3B6 MZ N
HG
GNnr.1
GV
U
X3-H-I-J
X1-33
ZV
X21-33
HN1.5
X21-19
ANTI-TILT CIRCUIT ZB 86 30 X15-R ZG 86 30
CZ
CZ
X5-W
33
X5-V
S T
G F E D C B A
X15-D
X15-P
X15-T
X108-A-B
X51-2 X11-1
8 7 6 5 4 3 2 1 BASKET
XD2-11
XD2-12
X15-ff
X13-B EXCLUSION
G
KEY
X71-2
X71-1
X51-5
X37 ANTITHEFT
STR1-2
X16-R
BASKET PREDISPOSITION
INSTRUMENT CONNECTOR CONNECTOR
XM3-5
XM3-4
RNnr.13
X47-1
X5-J
X16-D
85 85
X16-P
GN2.5
BV
X16-T
19
MZ
X22-G
BASKET PREDISPOSITION - CHAINS MICROSWITCH
X22-D
AERIAL JIB - 3D BASKET

87 87a 87 87a I25
+12V SUPPLY PROXY

CHAIN
MC3
GZ1.5
BREAKING
X2-8
4 8 3 7 10
2 1 0
G
I 1 I
X3-7
X3-8
SYSTEM
YELLOW LAMP
XB-H
XB-A
XB-F
8 1
XA-K
RELAY BREAKING
2 CHAIN 7 6 5 4 3 2
X4-42
MICRO 3
X21-1
3
X20-I
X5-B
X5-A
BG
MC2 2 6 1 5 9
X70-18
X70-23
5 RNnr.13
X70-4
REMOTE
+12V
1
SN1.5
C1.5
X17-1
BREAKING CONTROL
N
X6-13
AERIAL JIB - 3D
X70-14
X2-A-B-C-D
6 CHAIN
X1-1
G2.5 ZB BASKET 2°/3° EXIT
X51-4
MICRO 2
X51-3
7 INCLIN/ROT SWITCH
GZ
G1.5
GZ
G1.5
X14-35
X14-34
8
4 MC1
X11-3
X11-2
XM1-1
X27-8
9
X14-2
X73
+VBAT JP1-14
BREAKING
+VBAT JP5-6
10 CHAIN C2.5
X13-D
X13-C
X14-27
MICRO 1 2
11 IN "CONCES" X22-N
12 JP2-1 SN2.5
GL 1
X22-R
X22-P
X47-2
K 13 X22-B K
+12V
RL AVAILABLE ONLY
14 JP2-6
FOR MRT A&K
15 IN "SOLCES"
ZB
MV RL GL
ACCELERATOR SWITCH
16
X15-gg
INCLINATION/ROTATION
AERIAL JIB - 3D BASKET
X4-26 XD1-28
X15-N
X3-9 N
IN "PRECES" JP4-10
17 CG
18 +12V X15-3 X16-3 XB-1 X70-21
SOLENOID VALVE
CONTROL
PREDISPOSITION
47
REMOTE
BV
BR2.5
X18-A-B-C-D
ELECTRONIC
X22-F
IN "BRACES" JP2-2 NG
JP6-1 OUT "MARINS"

IN"PENDOLO"
XM2-1
BN2.5
X16-N
X15-2 X16-2
X4-46
BASKET
XA-2 X70-22
BASKET PRESENCE
G1.5
IN "OPTCES" JP2-5 CG
X22-H
80
X20-A-B-C-D XD1-24 XD1-25
Xb-G
X5-4
HS UNLOCKED 3D BASKET VALVE

M F75 M
JP3-8
X17-A-B-C-D-E-F-G- RG X22-C X15-V X16-V XA-L X70-15
D11
D14
D12
X5-E XD1-26 IN "SFICES" JP2-9 GM
X70-24
OUT"MOVCES" JP6-2
+12V
X13-A
125A X22-M
MV
CZ
R25 IN "MANCES" JP2-11
MV RG GL
X13-10
S4
D10 X15-F X16-F XB-J X70-2

N50
VN
X14-33
CR
CR
IN "SOLCES" JP4-11
X2-10
PREDISPOSITION
S1.5
JP4-3 IN "+V" BEFORE ECONOMIZER BG
XD1-33
XD1-36
XD1-34
30 STARTING ENGINE OUT "P0SRAD" JP2-3 +12V X15-L X16-L XA-C X70-3
+12V
S1.5 SV
JP6-4 IN "+V" BEFORE ECONOMIZER IN "SFICES" JP4-7
X15-dd
X15-ee
X15-1
BG X22-A
X15-C
M1 OUT "P0SRAD" JP2-10
39
+12V
XD1-32
B2
X18-18
B1 ML X22-E ML X15-A X16-A XA-H X70-12

X20-J
IN "ROTCES" JP2-12 CL
IN "MANCES" JP4-6
X4-44
X15-G X16-G XA-D X70-8

X16-ee
A5 BN
X15-S
X15-W
O IN "OPTCES" JP4-1 O
X16-dd
X4-43
X16-C
X16-1
EMERGENCY PUMP SWITCH
X22-V HS X16-E XA-B X70-6

BR
12V BATTERY
12V BATTERY
LN
MP
CR IN "BRACES" JP4-5
E35
BASKET PRED. - START ENGINE
X16-S
X15-E X16-J XA-A X70-5
M
X17-L
XA-N
BASKET PREDISPOSITION GN
X7-M
X16-W
N IN "ROTCES" JP4-4
L1.5
M
XB-D
XA-E
XA-1
EMERG. EMERGENCY BUTTON

N
50 REMOTE CONTROL-JOYSTICK MOVEMENT X15-J

PUMU
X22-K
X70-16 XA-M
REMOTE
GH
Xa-F
EMERGENCY
EMERGENCY
RED ALARM LAMP

CONTROL +12V
AH
PUMP
SWITCH
C2.5
REMOTE CONTROL
BUZZER
X70-10
BASKET-JOYSTICK MOVEMENT
PUMP
START ENGINE
X15-aa X16-aa XB-C X70-20

X70-9
X70-1
F76
7.5A
N
X16-bb X70-19
HL1
+12V
RED SL +12V
IN "MICROSV" JP6-5
+12V
+12V
Q LAMP
X15-bb XB-B
Q
MICROSWITCH OVERLOAD BASKET
X18-I-J-K-L X2-I-J-K-L
48
N
X29-1 X18-J-H
L4
X2-G-H X13-H
L1.5
X22-S
BASKET PREDISPOSITION - GND
A1
46 REMOTE CONTROL X15-4 HORN
N10 SYSTEM GND
X5-1
N
X13-11
X13-F X16-4 Xb-2 X70-GND

S S
REMOTE X15-M Xa-G
X15-hh X16-hh Xb-E X70-7 Z
CONTROL +12V +12V BASKET PRED. - HORN
HORN Z
X16-M X70-11
16
X22-L
R
(16/08/2011) 80-02-M146EN
A30
80
80-02-M146EN (16/08/2011)
A31
80
(16/08/2011) 80-02-M146EN
A32
5 - SAFETY SYSTEM
COMPONENTS
A4 Anti-overturn buzzer Overturning Q12
D7 Diode 3A O24
D8 Diode 3A M12
D9 Diode 3A M11
F6 Stabiliser instrument panel power supply fuse (15A) C7
F7 Anti-overturn instrument logic card power supply fuse (15A) C3
F16 Danfoss logic power supply fuse (10A) K32
F53 Sidelights/reset gears fuse (10A) C5
F54 Stop lights relay power supply fuse (10A) C8
HL1 Red lamp Q11
I16 Rear right beam lowered E8
I17 Microswitch left beam lowered microswitch G8
I18 Front left beam lowered microswitch G8
I19 Front right beam lowered microswitch I8
I51 Anti overturn exclusion key M14
I62 Rear left stabiliser extended microswitch E4
I63 Rear right stabiliser extended microswitch G4
I64 Front right stabiliser extended microswitch K4
I65 Front left stabiliser extended microswitch M4
I77 Rear left stabiliser extended microswitch G4
I78 Rear right stabiliser extended microswitch I4
I79 Front right stabiliser extended microswitch I4
I80 Front left stabiliser extended microswitch K4
L7 Stabilisers supported indicator light Q9
L19 Stabilisers partially extended indicator light Q5
L32 Provision for danger lamp Q17
R12 Danfoss valve power supply relay M32
S1 Danfoss lifting electrovalve Q32
X9 Anti overturn circuit K15
80
X41 Winch behind jib microswitch M24

X74 Provision for connector Q19
80-02-M146EN (16/08/2011)
A33
ELECTRICAL DIAGRAM “SAFETY SYSTEM”
1 2 3 4 5 6 7 8 9 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 A
4
N
N
M
R
MAIN BOOM BALANCING

MS1 CYLINDER BOOM
SLIM021/XX ANGLE AND LENGHT
RN2.5
BOTTOM SIDE ROD SIDE BOTTOM SIDE
M2.5
M2.5
ROD SIDE
RN2.5
TRANSDUCER
C C
J4
CAN H
J5
CAN L
14 AI2 - IN-BOTTOM SIDE COMP CYL
+15V
+15V
+15V
13 AI0 - IN-BOTTOM SIDE MAIN CYL
1 +15V
GND
GND
3 GND
3 GND
OUT
3 GND
2 OUT
2 OUT
2 OUT
F53
F54
F7
15A
15A
10A
10A
F6
1 +V
AI3 - IN-ROD SIDE COMP CYL
AI1 - IN-ROD SIDE MAIN CYL
3
1
1
17 DI8 - OUTRIGGER DOWN
DI5 - OUTRIGGER OUT
DO3 - BOOM CLOSED

13 DI7 - OVERRIDE KEY
RV2.5
RN
10 DO4 - LOW SPEED

DO1 - LOW ANGLE
RN
DI6 - FRONT SIDE

VN
12 DI16 - ANGLE 55°

C1 C2
11 DO0 - CUT-OFF
M12 C3 C4
DI9 - BASKET
M
G
G
V
V
N
X20-15
B
L
CAN H
X20-1
CAN L
X3-G
X5-2
GND
16 +15V
GND
AI10
+VB
14 +VB
+VB
E E
RV1.5
10
11
15
18
12
8
8
7
7
9
2
5
1
6
2
9
RN
I16 X2A
EXTENDED
I62 LEFT REAR
OUTRIGGER
REAR RIGHT
LOWERED X2
BEAM MICRO
MICRO
X1A
RG
EXTENDED REAR LEFT 1 2 3 4 5 6

I77 LEFT REAR
OUTRIGGER
LOWERED
BEAM MICRO X1
MICRO
I17
B
SB
X19-4 X20-14
G G
EXTENDED
I63 RIGHT REAR
OUTRIGGER
MICRO
I18
SV
FRONT LEFT
EXTENDED LOWERED
I78 RIGHT REAR
OUTRIGGER
BEAM MICRO
MICRO
B
SB
FRONT RIGHT
LOWERED
BEAM MICRO
X19-1 X20-13
I I19 I
LV
SB
X19-27
EXTENDED
RIGHT
I79 FRONT
OUTRIGGER
MICRO
2
X6-9
SV
X14-5
X21-2
EXTENDED JP1-9 OUT"DISTRDANF"

RIGHT
I64 FRONT
OUTRIGGER
MICRO P R V B T N K G U E L A C D M J F H S
X2-1
K K
AG1.5
SR
X9 3B6
EXTENDED ANTI-TILT CIRCUIT
LEFT X6-21 X13-13
I80 FRONT
OUTRIGGER
LV
JP3-2 IN "STAUSC"
Lnr.1
BS
CB
CN
AH
ZB
CH
MICRO
Cnr.1
HG
VH
A
N
C
LR
RG
F16
10A
EXTENDED
LEFT
I65 FRONT
X14-12
X14-41
X14-26
X14-11
X14-25
X14-38
X14-10
X5-S
X14-8
OUTRIGGER
X5-R
BN1.5
X4-14
X13-E
MICRO
X4-45 X6-37
X3-10 X5-C
HG
80
A
X14-28
XD1-23
XD1-22
M X41 M
X21-13 X19-25
OUT"EVSOL" JP3-10
R12
IN"PRECES" JP4-10
OUT "SISTANTIR" JP1-13
IN"LIMSAL" JP1-1
OUT"OUTCC" JP5-2
OUT"SISTANTIR" JP1-3
JP1-7
IN"BLPOPOS JP3-5
IN "LIMSFILO" JP1-5
D9 D8 I51 BOOM BACK
HN
X14-28 X6-6
86 30
A
HOIST
IN"CHI3B6"
MICROSWITCH OUT"PREUOM2" JP1-24
HB RV Nr°1 RVnr.1
PREDISPOSITION
ZL
GH
Cnr.2
13
XD1-31
XD1-30
X2-4
X4-33
VN1.5
VN1.5
MANITOU N
SAFETY
SYSTEM 87 87a
X6-35
X4-43
EXCLUSION
XD1-21
FEEDING DANFOSS
CN1.5
KEY
X4-34
VALVE RELAY
O O
C
D7
X14-3
LV
X8-G
X6-34
X13-3
A4
X4-38
L19 L7 HL1
CN1.5
XD1-29
CN
CB
ZL
N
N
GH
Q 1 1 SAFETY
SYSTEM
Q
N BUZZER LIFTING
DANFOSS
VALVE
S1
N
X14-3 X6-12
2 2 IN"ANTIRIB" JP1-17
1
2
2
1
RED
LAMP
L32 X74
N
LEANED
N
N
PARTIALLY
EXTENDED OUTRIGGER PREDISPOSITION PREDISPOSITION
OUTRIGGER PILOT WARNING LAMP CONNECTOR
PILOT
S S
(16/08/2011) 80-02-M146EN
A34
80
80-02-M146EN (16/08/2011)
A35
6 - HEADLAMPS / INDICATOR LIGHTS / LIGHTING / SENSORS / PROXIMITY
COMPONENTS
A1 Acoustic warning M33
A2 Reverse gear horn Q40
D7 Diode 3A K29
DL Headlamp dipping C29
DM Gear change I40
F4 Fuse pump emergency/brake pressure/gear electrovalve (15A) C9
F9 Headlamp dipping and klaxon power supply fuse (10A) C25
F14 “30” emergency switch power supply fuse (10A) C34
F17 Chain breakage circuit relay power supply fuse (10A) C38
F23 Lighting Switches power supply fuse (10A) C7
F27 Direction indicator lights power supply fuse (7,5A) C33
F38 Fuse and “30” cigarette lighter (20A) C10
F49 Reversing lights relay power supply fuse (7,5A) C25
F54 Stop light relay power (10A) C15/C16
F56 Dipped headlamps power supply fuse (15A) I15
F57 Main beam headlamp power supply fuse (15A) I17
F61 Side lights power supply fuse (7,5A) I29
F62 Side lights power supply fuse (7,5A) I30
FADX Front right lamp Q25
FASX Front left lamp Q33/Q34
FPDX Front right lamp Q29
FPSX Rear left lamp Q29/Q30
G Alternator Q5
GF Rotating lamp M38
HL1 Red lamp Q7
I5 Stop circuit pressure switch M20
I6 Rear axle alignment proximity sensor Q13
I8 Front axle alignment proximity sensor Q11
80
I11 Limited rotation proximity sensor 2 I26
I12 Air filter M11
I14 Cab centred proximity sensor 1 Q19
I15 Tower alignment proximity sensor Q16
I41 Maximum raising microswitch G23
I43 Proximity sensor for speedometer Q12
I52 Limited rotation proximity sensor 1 I28
I53 Emergency arrows switch C35
I54 Rotating lamp switch C38
I71 Cab locked proximity sensor Q18
IS8 Roof light in cab M37
MA Horn microswitch M29
R1 Intermittence G33
R20 Stop light relay C22
R21 Main beam headlamps relay C17
R22 Dipped beam headlamps relay C14
(16/08/2011) 80-02-M146EN
A36
COMPONENTS
R28 Reversing light relay C24
R37 Switch on lights command relay C11
STR1-1 Instrument connector (STR1-1) K4
STR1-2 Instrument connector (STR1-2) G4
STR1-3 Instrument connector (STR1-3) M7
T1 Fuel float M19
X9 Anti overturn circuit O40
X23 Connector provided for indicator lights I13
X26 Trailer lights connector Q38
X37 Antitheft connector E40
X41 Winch behind jib microswitch M25
X44-X45 Check warning lights C5
X54 Hydraulic braking 2nd connector Q15
X57 Hydraulic oil temperature light O14
X96 Connector for I18047 Q8
X103 Intercooler fans oil filter pressure switch M14
XAS Cigarette lighter O17
XB MC024-021 connector/B1 control unit Danfoss I40
80
80-02-M146EN (16/08/2011)
A37
ELECTRICAL DIAGRAM “LIGHTS / INDICATOR LIGHTS / LIGHTING / SENSOR / PROXIMITY”
1 2 3 4 5 6 7 8 9 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
4
16
N
M
R
r.3
N
Ln
A A
M2.5
M2.5
M1.5
M1.5
R1.5
RN1.5
RN2.5
M2.5
R4
M4
M2.5
F27
F14
F17
F23
F49
F54
F26
F38
F28
7.5A
10A
7.5A
7.5A
7.5A
10A
15A
20A
F4
10A
10A
10A
F9
X44-X45
VG
CB
BR2.5
RV2.5
RV1.5
V
RNnr.13
INDICATOR
RNnr.13
X3-14
X3-13
CHECK
ZB1.5
X4-1
SN1.5
X3-16
R2.5
GH
L2.5
R37
L2.5
R22 R21 R13 R20 R28 DL LIGHTS SWITCH I53 I54
LN
C C
CB
VG
N
ZG 86 30 SV 86 30 SR 86 30 AC 86 30 RV 86 30 LS 86 30 1
X6-36
1 3 6 10
X3-6
01 02 03 04 05 06 07 08 09 10 11 12 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36
1 0
0 1
HRnr.1
BV 85 N 85 N 85 N 85 NB 85 N 85
HV 87a
87 87 87a 87 87a 87 87a 87 87a 87 87a ROTATING
BNnr.1
IGNITION/LIGHTS DIPPED DRIVING STARTING LAMP 5 9
BV
STOP LIGHT REVERSEWARD
HN1.5
L2.5
VN1.5
R1.5
X21-33
H CONTROL GZ1.5 SWITCH
X20-7
HEADLAMPS BEAMS CONSENT RELAY LIGHTS RELAY
N
AB1.5
X3-15
RELAY RELAY RELAY RELAY
X20-I
X21-1
4 2 5 7
CZ
HR
33
B WARNING
GR
GR
SG
L R L 56a 56b 58 30 49
X21-10
X18-7
LIGHTS
L
X21-9
X17-1
1
SWITCH
X1-33
X21-19
VN
X1-1
SN1.5
SG
LN
SR
SV
L
B1.5
Z
E ZG E
GZ
10
GZ
41
B
19
X1-10
N
X27-8
X1-9
XM1-1
X1-13
X2-8
N
RNnr.13 X37
SV 1
X4-24 #% 2
NG
01
SR 60 3
ZVnr.1 + 0
4
6'
RNnr.13 *% 5
ZV
X7-C
'6 6
X4-23
SVnr.1 (1
64 7
Lnr.2
X1-21
G 8 G
LVnr.1 R1
RN1.5nr.1
CG FLICKERING
SG
LIGHT
21
RN1.5nr.1
I41
VN1.5
STR1-2 INSTRUMENT CONNECTOR
HN1.5
X21-21
RN
LB
MG
N
N NG
N
31 R
F57 15A
F56 15A
ZV
HRnr.1
MAXIMUM
C
DM
B1.5
B1.5
V
H RISING B
X14-30
+
X14-31
XM1-3 1 0 2
SG
B
X14-13
BNnr.1 MICRO REVERSE
C A /FORWARD
HV C A X4-25 GEAR
VN1.5
LIMITED
HN1.5
RNnr.13 LIMITED LEVER
I11 ROTATION I52 ROTATION 1 0 2
IN "ESCSAL" JP1-22
IN "ROTLIN1" JP1-16
IN "ROTLIN1" JP1-16
F61
F62
CHnr.1
7.5A
7.5A
2 PROXY 1 PROXY
I X23 I
AC

C
C
A
VN
XM4-16
CZ PREDISPOSITION
B
B
GN
G
1 PILOT CONN.
X4-5
10
11 MN
MC024-021 DANFOSS CENTRAL BOX CONN./B1

12 NB
13
14 MRnr.1
XB
XM4-5
15 MN 1
16 2
17 CG
3
18
4
X21-12
X4-41
5
X1-20
K LS K
6
D7
X6-23
7
12
34
STR1-1 INSTRUMENT
CONNECTOR 1 RNnr.13
X4-33 XD1-21 XD1-29 X6-12 X14-3
JP1-17 IN "ANTIRIB"
8
9
2 Lnr.3
10
3 B
X1-38
X1-36
X1-37
X1-35
km/h 11
AB1.5
4 ABnr.1
X18-E X17-2
CB1.5
MA 12
X20-17
RPM x10 5 BRnr.1
XM1-6 X19-26
6 BN
45
IS8 GF
X19-16
X1-14
4/4 X10-H
A1
X1-19
120 XM1-4
X1-18
X1-12
X18-F
7 S
CH Nr°1
HORN
C Nr°2
U
S G F E D C B A T
R P N M L K J H V
3B6 ANTI-TILT CIRCUIT

8 ZVnr.3 C
XM4-6
80
100
C Nr°2
NB
9 ZB1.5
22
26
27
HEADLAMPS
10 T1 I5 X41
S
1/2 80 X7-M
X103 p
X19-11
11 GH ROTATING
X4-15
N
M 60 M
X18-4
CABIN
STOP LAMP
12 OIL FILTER
°C 40 p CIRCUIT
N
0
C
X18-13
PRESSURE
JP3-9 OUT "SPIAPBL"
hours 13 PRESSURE
SENSOR
NG
OPTIONAL
km 14 I12 SWITCH
HV
INTERCOOLER BOOM BACK X10-N
C
X17-13
N
FAN FUEL TANK N HOIST
AIR FILTER
X17-4
FLOAT MICROSWITCH
STR1-3
X8-4
p
X20-8
X6-5
INSTRUMENT
CONNECTOR X9
RNnr.13
BR2.5
X19-42
N2.5
N
X21-16
X21-18
JP2-4 IN "CENTRCAB2"
JP1-4 IN "CENTRCAB1"
X1-23 X21-23 X3-10 X5-K

1 ZB
23
JP1-6 IN "INP_FR1"
2
X1-4 X18-1
NG
N
3 ZN
X19-17
X21-18
X19-14
X18-11
X19-18
X20-16
X19-23
16
X20-12
1
1
2
X20-10
X20-3
4
O X57 O
X18-9
X6-19 X13-5
5 GHnr.1 X1-11 X21-11
XAS
TEMPERATURE
6 X4-32 11
LIGTHER
7 B
HYDRAULIC
X4-47
2 2
1 1
8 SVnr.1
9 Lnr.2
X19-20
BULB
X19-7
10 LVnr.1
OIL
X14-40
X14-16
X6-33
X14-7
X6-1
ABnr.1
Lnr.3
X96
AB
HN1.5
BH Nr°1
VN1.5
HN1.5
VN1.5
GN
CZ
FADX
LN
FPDX
CZ
I8 I6 I15 I14 I34 I74 A2
RV
RV
I43 I71
ZN
GN
MN
ZB
LN
GN
RV
AB
CZ
LN
AV
AN
CZ
G
NB
L
G
G
V
R
V
V
V
R
L
8 7 6 5 4 3 2
L
RV
9 1 RIGHT FRONT LIGHT RIGHT REAR LIGHT LEFT REAR LIGHT LEFT FRONT LIGHT
N
I18047 CONNECTOR
GH
Q POSITION
7 6 5 4 3 2 Q
REVERSE STOP TURN LIGHT LOW BEAM HIGH BEAM TURN LIGHT POSITION
R25 FRONT AXLE REAR AXLE TURRET LOW BEAM HIGH BEAM TURN LIGHT POSITION REVERSE STOP TURN LIGHT POSITION
3 2
1 KOhm 1/4W
PROXY FOR
N
ALIGNAMENT LOCKED CAB CENTRED CAB
FPSX
N
ALIGNAMENT CENTRED CAB CENTRED CAB
N
1 KOhm 1/2W
DIODI 1Amp.
ALIGNAMENT 8 1
N
G
N
N
N
N
HR PROXY TACHOMETER PROXY 4 1 PROXY 1 PROXY 2 PROXY 3 PROXY FASX REVERSE
N
ALTERNATOR PROXY TRAILER LIGHT CONNECTOR
GEAR
HL1 X54 X26
N
BUZZER
N
N
N
N
1Amp. 2° HYDRAULIC
RED BRAKE PRED.
LAMP CONN.
1 KOhm 1/4W I18047
S S
(16/08/2011) 80-02-M146EN
A38
80
80-02-M146EN (16/08/2011)
A39
80
(16/08/2011) 80-02-M146EN
A40
7 - CAN BUS
COMPONENTS
F34 Mercedes engine diagnostics fuse (10A) K23
F40 Mercedes engine diagnostics fuse (10A) K20
STR1-4 Instrument connector (STR1-4) E4/E5
X99 Bus ring closure J1939 O10
X100 Bus ring closure J1939 O19
XA Connector MC024-021/Danfoss control unit A1 Q35
XDG Main diagnostics connector I37
80
80-02-M146EN (16/08/2011)
A41
ELECTRICAL DIAGRAM “CAN BUS”
1 2 3 4 5 6 7 8 9 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
.3
R
16
4
A A
LN
M
RN1.5NR.6
1
C C
2
X8-V GENERAL DIAGNOSTIC
M
3
4
M 9 10 11 12 13 14 15 16
CAN BUS HIGH XM4-19 X8-T L 1 2 3 4 5 6 7 8
Lnr.3 5
NEG. FROM BATTERY
L 6
CAN BUS LOW XM4-21
X8-aa
E MLnr.1 ML
E
Lnr.3 XM1-2 7
NEG. FROM BATTERY
X17-8 X18-12 X1-22 X8-W
ZL

X27-13 36 8
ZL
X8-U
STR1-4
RNnr.3
9
INSTRUMENT CONNECTOR
10
Lnr.3 L
NEG. FROM BATTERY 11
X8-J
G POS. DIAGNOSTIC RNnr.3 HNnr.1 G

12
X8-M
HNnr.1
TX RS232 10 HB
13
X8-S
RX RS232 11 HB
14
Lnr.3
NEG. DIAGNOSTIC 12
15
XDG
R1.5 GENERAL DIAGNOSTIC CONN.
16
RN1.5nr.6
I I
R1.5
F34 10A
F40 10A
M2.5
R2.5
K K
80
M M
M
L
Lnr.3
M
L
M
O O
L
X100
BUS J1939
X99
11
10
CLOSED RING
2
BUS J1939
CLOSED RING
XA
2
MC024-021 DANFOSS
2
1
12
1
CENTRAL BOX CONN./A1
2
2
1
X99a
Q Q
X99a
S S
(16/08/2011) 80-02-M146EN
A42
80
80-02-M146EN (16/08/2011)
A43
80
(16/08/2011) 80-02-M146EN
A44
8 - OPTIONAL LIGHTING / CAR RADIO / WINDSCREEN WIPER
COMPONENTS
BS1 Right box M28
BS2 Left box M29/M30
F2 Small mixing bin fuse (15A) E21
F5 Working lights fuse on head of jib (15A) E31
F10 Power supply fuse working lights in front of cab (10A) E34
F11 Working lights behind cab power supply fuse (10A) E37
F15 Power supply fuse “30” radio/provision for connector (10A) E23
F19 Front windscreen wiper power supply fuse (10A) E15/E16
F21 Upper windscreen wiper power supply fuse (10A) E4
F23 Lighting Switches power supply fuse (10A) E32
F32 Car radio/antitheft power supply fuse (7,5A) E25
F35 Power supply fuse Window winder switch (15A) E24
F36 Rear window deicer fuse (20A) E39
F37 Rear windscreen wiper power supply fuse (10A) E10
FLA1 Front right working headlight O33/O34
FLA2 Front left working headlight O35
FLB1 Working light on head of jib_1 O30/O31
FLB2 Working light on head of jib_2 O32
FLP1 Rear left working light O36
FLP2 Rear left working light O37/O38
I56 Front windscreen wiper switch G15
I101 Window winder switch G27
IS38 Rear working light switch G36/G37
IS39 Rear window deicer switch G39
IS40 Upper windscreen wiper switch G3
IS41 Rear windscreen wiper switch G9
IS42 Jib head working light switch G31
IS43 Front working lights switch G34
M4C Rear windscreen wiper motor Q10
80
M5C Upper windscreen wiper motor Q4

M8 Front windscreen wiper motor Q14
M101 Window winder motor E27/E28
ML1 Upper windscreen wiper pump Q6
ML2 Rear windscreen wiper pump Q11/Q12
ML3 Front windscreen wiper pump Q17
S37 Rear window deicer O39
X38 Car radio power supply connector Q25
X39 Car radio boxes connector Q29
X46 Provisional power supply connector Q19/Q20
XCD Car radio with CD power supply connector Q22
80-02-M146EN (16/08/2011)
A45
ELECTRICAL DIAGRAM “OPTIONAL LIGHTING / CAR RADIO / WINDSCREEN WIPER”
1 2 3 4 5 6 7 8 9 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 A
.5
16
B1
4
N
M
R
R
C C
M2.5
M2.5
M2.5
M2.5
RB1.5
M2.5
M2.5
M2.5
R2.5
M2.5
M2.5
M4
F21
F37
20A
F15
F35
F19
F11
F32
F23
F10
10A
15A
10A
10A
15A
7.5A
10A
10A
F36
15A
10A
F2
10A
F5
RNnr.13
ZN1.5
Z1.5
RL
AR1.5
B2.5
R
M101
X6-30
X7-A X8-C
X7-B X8-D
X8-A
X8-B
X7-L X8-E
M
X3-11
X7-1 X8-1
E E
X11-bb
X7-F
X7-E
DOOR WINDOW
REGULATOR
X7-P
ZG1.5
ZG1.5
MOTOR
SL
IS40 IS41 I56 I101 IS42 IS43 IS38 IS39
3 7 4 8 10 3 7 4 8 10 3 7 4 8 10 3 4 10 1 10 1 10 1 10 1 10
X8-F
2 1 0 2 1 0 2 1 0 1 0 2 1 0 1 0 1 0 1 0
1 1 1
G DOOR WINDOW G
1 5 2 6 9 1 5 2 6 9 1 5 2 6 9 REGULATOR 1 7 2 8 9 5 9 5 9 5 9 5 9
X7-N
SWITCH HEAD BOOM WORKING WORKING LIGHTS WORKING LIGHTS REAR WINDOW
SH
BG
FRONT WINDSCREEN
SH
N
UPPER WINDSCREEN REAR WINDSCREEN DEFROSTER
N
WIPER SWITCH LIGHTS SWITCH FRONT SWITCH REAR SWITCH
WIPER SWITCH WIPER SWITCH SWITCH
X7-2
X10-A
I I
X7-R
X6-27
X4-36
X3-1
K K
BS1 BS2
80
M M
X7-G
X7-K
X7-H
X7-J
O O
ZG1.5
BG
SH
SL
FLB1 FLB2 FLA1 FLA2 FLP1 FLP2 S37

HEAD
DEFROSTER
M5C ML1 M4C ML2 M8 ML3
NGnr.1
RBnr.1
BOOM
RHnr.1
NBnr.1
SC WORKING
M M M M M M LIGHT_1
HEAD FRONT FRONT REAR REAR
REAR
BOOM RIGHT LEFT RIGHT LEFT
R1.5
N1.5
RL
WORKING WORKING WORKING WORKING WORKING
N
R
RL
R
AC
LIGHT_2 LIGHT LIGHT LIGHT LIGHT

UPPER UPPER REAR REAR FRONT FRONT
Q WINDSCREEN WINDSCREEN WINDSCREEN WINDSCREEN WINDSCREEN WINDSCREEN Q
MOTOR WASHER MOTOR WASHER MOTOR WASHER
PUMP PUMP PUMP
B 7 6 5 4 3 2 7 6 5 4 3 2 7 6 5 4 3 2
C A 8 1 8 1 8 1
X46 XCD X38 X39

POWER SUPPLY CAR RADIO CD POWER SUPPLY CAR RADIO POWER SUPPLY CAR RADIO SPEAKERS
PRESETTING CONN.
S S
(16/08/2011) 80-02-M146EN
A46
80
80-02-M146EN (16/08/2011)
A47
80
(16/08/2011) 80-02-M146EN
A48
9 - PNEUMATIC SEAT / 2a / 3a OUTPUT / OPTIONAL CONTINUOUS
COMPONENTS
BMG Large mixing bin O18
BMP Small mixing bin electrovalve O22
D1 Diode 3A O31
DOC Diode 3A Q27
F1 Large mixing bin power supply fuse (30A) C19
F2 Small mixing bin power supply fuse (15A) C18
F3 Pneumatic seat power supply fuse (15A) C16
F7 Logic card/anti-overturn instrument power supply fuse (15A) C4
F16 Danfoss logic power supply fuse (10A) C40
F18 Optional-double/triple output fuse (10A) C15
F20 Hydraulic system exclusion power supply fuse (10A) C3
F22 Lever power supply fuse (15A) C20
F23 Switch illumination power supply fuse (10A) C17
I7 Small mixing bin switch E21
I20 Optional potentiometer enabling switch E27
I22 Emergency domed pushbutton E2
I66 Double/triple output switch C13
I69 Levelling switch O3
I72 Optional exclusion switch K39
M3 Left side seat lever C31
M12 Pneumatic seat motor O6
R7 Double/triple output switch relay C7
R12 Danfoss valve power supply relay C39
R16 Hydraulic system exclusion relay C35
ROC Optional adjustment relay M28
S1 Danfoss lifting electrovalve Q35
S2 Danfoss extension electrovalve Q36
S2TB Double output jib head electrovalve O13
S3 Danfoss rotation electrovalve Q37
80
S3TB Triple output jib head electrovalve O11

S4 Danfoss traverse electrovalve Q38/Q39
S5 Danfoss optional electrovalve Q39/Q40
S10 Hydraulic circuit exclusion electrovalve Q33
SQ Door microswitch K20
X9 Anti overturn circuit K14
X40 Large mixing bucket connector M18/M19
X76 Connector provided for air conditioning K25
XOC Optional Adjustment card Q25/Q26
80-02-M146EN (16/08/2011)
A49
ELECTRICAL DIAGRAM “PNEUMATIC SEAT / 2a / 3a OUTPUT / OPTIONAL CONTINUOUS”
1 2 3 4 5 6 7 8 9 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
4
M
N
X3-6
A A
X4-16 X5-N X14-18 X14-5 X6-9
CV
JP1-10 IN "MANCAB" OUT"DISTRDANF" JP1-9
AG1.5
X4-6 X5-L X11-D
X6-30 X11-bb
F16 10A
X3-2
LEFT ARM
RNnr.13
REST LEVER
M2.5
M2.5
BN1.5
M3
MR1.5
RNnr.13
GN2.5
AR1.5
RNnr.13
C C
RNnr.13
M2.5
M2.5
HVnr.2
AR1.5
GN2.5
F20 10A
C2.5
C2.5
MH
F7 15A
CV
R7 I66 2
R16 R12
RV
F22 15A
F18 10A
F23 10A
15A
3
F2 15A
F1 30A
X6-7 4 8 3 7 10 1 10 1 7 2 8 10 4
ZB 86 30 1 MH 86 30 86 30
2 0 1 0 1 0
F3
5 OPTIONAL SIGNAL
RVnr.1
G2.5
RVnr.1
6
X3-17
HV1.5
M2.5
M2.5
M2.5
I22 8
M4
L6
9
MR
I7 I20
X5-2
2 6 1 5 9 5 9 5 6 9 10
11
LITTLE OPTIONAL
AR1.5nr.1
N 85 85 85
BN2.5
12 N
HR2.5
BV1.5
N
MR
DOUBLE TRIPLE
N
C2.5
N
BUCKET POTENTIOM.
X13-B
87 87a EXIT SWITCH SWITCH ENABLING 13 87 87a 87 87a

SW. 14
DOUBLE TRIPLE 15 HYDRAULIC
C2.5
FEEDING
CN1.5
RVnr.2
E EXIT SWITCH 16 CIRCUIT DANFOSS E
FEEDING EXCLUSION VALVE
17
RELAY
X3-L
18
19
20
21
22
23
24
X4-30
25
X14-8
X4-9
X6-4
X5-F
X5-D X4-21
G G
X5-M
JP3-11 OUT "EVOPT"

X14-29
X14-22
X5-C X4-48
G1.5
JP5-6 +VBAT
RV
MR
X14-42
G1.5
X72-1 X14-43
JP1-14 +VBAT
IN "PREUOM1" JP1-20
IN "OPTCAB" JP1-19
X11-W
B
X72-2
ZB
X13-9
X14-2
IN "PRECEST" JP4-10
RV Nr°2
X71-2
X71-1
G2.5
X11-cc
X7-T
I I
X3-K
X53-3
4
X22-D
X22-G
X2-7
X53-2
AR1.5
RNnr.13
ZB
17
B
SQ X76
X21-17
1 10
PRED.CON. 1 0
X15-N
DOOR COOLING
MICRO SYSTEM
HB
2
1
ZB
K K
BV1.5
I72
X19-21
P N M L K J H V 5 9
R
X43-2
X43-3
X16-N
X9 3B6 OPTIONAL
N
U
BN
BASKET PRESENCE
ANTI-TILT CIRCUIT EXCLUSION
X7-S
S SWITCH
G F E D C B A T
X70-24 Xb-G
+12V
REMOTE CONTROL
BV1.5
2°/3° EXIT SWITCH
HVnr.2
80
L6
L6
ROC
N
RVnr.1
M ZB 86 30 M
3 2
XD2-7
JP3-4 OUT "EVROT"
JP3-1 OUT "EVBRA"

JP3-10 OUT "EVSOL"
JP3-7 OUT "EVSFI"

4 1
BIG BUCKET
CONNECTOR X40
X53-1
X53-4
4 1
3 2 N 85
87 87a D1
OPTIONAL
HVnr.2
REGOLATION RELAY
L
S
V
X8-bb XD2-1
X10-C
X10-D
L6
L6
MR1.5
O O
BN2.5
HR2.5
HVnr.2
X10-2
X10-B
X11-dd
X13-7
X6-34
X13-4
X13-6
M12
X13-3
PNEUMATIC
SEAT MOTOR S3TB S2TB BMG
I69
OPTIONAL
N2.5
BMP
N2.5
N CV OPTIONAL REGOLATION
L6
ELECTRONIC BOX
RH
VN
RH
VN
HB
TRIPLE EXIT DOUBLE EXIT
CN1.5
CN1.5
CN1.5
CN1.5
CN1.5
BOOM HEAD BOOM HEAD
OPTIONAL
XOC
OPTIONAL
BN
M M
G
LITTLE BUCKET
L
V
SOLENOID VALVE CV
DOC
S10
BR Nr°3
BR Nr°3
S1 S2 S3 S4 S5
MH Nr°1
MR Nr°2
LEVELING SWITCH
N6
X10-E
OPTIONAL BIG BUCKET

OPTIONAL
N2.5
N
Q Q
N
N1.5
HYDRAULIC LIFTING TELESCOPE ROTATION TILTING OPTIONAL

CIRCUIT DANFOSS DANFOSS DANFOSS DANFOSS DANFOSS
EXCLUSION VALVE VALVE VALVE VALVE VALVE VALVE
S S
(16/08/2011) 80-02-M146EN
A50
80
80-02-M146EN (16/08/2011)
A51
80
(16/08/2011) 80-02-M146EN
A52
10 - HEATING
COMPONENTS
F13 Heating power supply fuse (20A) C8
F24 Thermostat power supply fuse (7,5A) C15
M11 Heating pump Q17
X12 Heating G5
X32 Thermostat G17
X33 Ambient thermostat I13
X42 Heating diagnostics connector G14
X75 Provision for heating timer Q8
X101 Provision for air conditioning power supply M13
X107 Provision for heating fan Q13
80
80-02-M146EN (16/08/2011)
A53
ELECTRICAL DIAGRAM “HEATING”

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
4
N
16
4
N
M
R
R
M2.5
R4
F24
F13
7.5A
20A
C
RB
V4
X3-F
X3-19
E
LBnr.1
LBnr.1
X42 X32
V1.5
X12
MB
RB
MB
RB
G
N
G
8 6 5 4 1 2
1
3
14
3
5
HEATING DIAGNOSTIC THERMOSTAT
4 5
G 7 10 12 9 1
HEATER DIAGNOSTIC
HRnr.2
MB
HRnr.2
N4
V4
H
X8-N
H MB
X33
AMBIENT THERMOSTAT
X6-24
K
80
G
M
1
X101
AIR CONDITIONING PREDISPOSITION
O
HRnr.2
HRnr.2
LBnr.1
RB
MB
MB
RB
V1.5
M11
N
G
V
11
10
2
9
M
1
1
12
Q
TIMER HEATING SYSTEM PREDISPOSITION X107
SWITCH HEATING FAN PREDISPOSITION
X75
N1.5
HEATER GASOIL PUMP
(16/08/2011) 80-02-M146EN
A54
80
80-02-M146EN (16/08/2011)
ELECTRICAL COMPONENTS LOCATION
page
ELECTRICAL COMPONENTS LOCATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
ELECTRICAL COMPONENTS LOCATION UP TO TRUCK 22725 - 758856
– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
– GROUNDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A8
ELECTRICAL COMPONENTS LOCATION FROM TRUCK 22756 - 758886
– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A11
– GROUNDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
80
(16/08/2011) 80-03-M146EN
A2
Electrical components location
ELECTRICAL COMPONENTS LOCATION
Position on the diagram

Ref Description
Right side of truck Left side of truck
X1 System isolating connectors K40
X2 System isolating connectors C31
X6 System isolating connectors E31
X9 Anti overturn circuit G40
X10 System isolating connectors I40
X13 System isolating connectors E37/E38
X14 System isolating connectors G37/G38
X15 System isolating connectors E37/E38
X18 System isolating connectors G16/G17
X19 System isolating connectors Q24
X22 Connector provided for radio control C35/C36
X27 System isolating connectors M27
XA Connector MC024-021/A1 Danfoss control unit C14
XB Connector MC024-021/B1 Danfoss control unit C15
XD1/XD2 System isolating connectors E29
XD3 System isolating connectors E30
XDG Main diagnostics connector E31
XM1 System isolating connectors A21
80

80-03-M146EN (16/08/2011)
A3
ELECTRICAL COMPONENTS LOCATION ON RIGHT SIDE OF TRUCK
1 2 3 4 5 6 7 8 9 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 A
XM4
XM2 XM3
XM1
C C
XA XB ADM2 CENTRAL BOX UNDER THE

MAIN DASHBOARD IN THE CABIN
CONNECTORS FOR THE OPTIONAL

CENTRAL BOXS IS OVER THE
ACCELERATOR PEDAL
E E
G G
MAIN DASHBOARD
X16
I I
K K
80
M M
X27
PLD CENTRAL BOX ON

O THE TOP OF THE ENGINE O
Q Q
S S
(16/08/2011) 80-03-M146EN
A4
ELECTRICAL COMPONENTS LOCATION ON LEFT SIDE OF TRUCK
1 2 3 4 5 6 7 8 9 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 A
X3 X2
C C
X22
X4 X5
X8 X6
X15
XD1 XDG
E XD2 E
X13
XD3
X14
G G
X18 X9
X10
X70
I I
Xa
Xb
X1
K X7 K
X11
80
M M
O O
Q Q
X19 X20 X21
S S
80-03-M146EN (16/08/2011)
A5
CONNECTORS UP TO TRUCK 22725 - 758856
Position on the
Type of wiring Ref Description diagrams Comments
Diagram 1 Diagram 2
Rear turret A1 Acoustic warning G19
Rear A2 Reverse gear horn K7
Rear turret A4 Anti overturning alarm buzzer I9
Cab A5 Emergency pump buzzer O35
Cab DL Headlamp dipping G15
Cab DM Gear change G17
Engine F75 Main fuse K19
Rear F76 Emergency pump remote switch fuse K20
Front FADX Front right lamp M28
Front FASX Front left lamp E28
Rear FPDX Front right lamp O4
Rear FPSX Rear left lighting E4
Engine G Alternator M17
Cab I1 Parking brake switch G29
Cab I2 Slow/fast switch G30
Front I3 Gear change switch I24
Cab I4 Gear change reset switch G29
Rear I5 Stop circuit pressure switch I7
Rear I6 Rear axle alignment proximity sensor I8
Cab I7 Small mixing bin switch E7
Front I8 Option I23
Cab I9 Rear axle alignment proximity sensor E28
Cab I10 Platform exclusion key K30
Rear turret I11 Limited rotation proximity sensor 2 I11
Rear I12 Slow/fast switch K10
Rear turret I14 Gear change reset switch I17
Rear turret I15 Tower alignment proximity sensor G15
Rear I16 Rear right beam lowered microswitch M4
Rear I17 Rear left beam lowered microswitch G3
Front I18 Front left beam lowered microswitch G29
80
Front I19 Front right beam lowered microswitch M30
Cab I20 Optional potentiometer enabling switch E8 Option
Cab I22 Emergency domed pushbutton G14
Cab I24 Steering switch I29
Cab I26 Stabiliser raised/lowered beam extend/retract switch G32 / G33
Cab I27 Beams/stabiliser selector switch I32 / I33
Cab I28 Front left beam/stabiliser switch G31
Cab I29 Front right beam/stabiliser switch G32
Cab I30 Rear left beam/stabiliser switch I31
Cab I31 Rear right beam/stabiliser switch I32
Rear turret I34 Cab centred proximity sensor 2 G17
Cab I35 Electric accelerator switch E29 Option
Rear turret I41 Maximum raising microswitch K3
Front I43 Proximity sensor for speedometer I24 Option
Cab I51 Anti overturn exclusion key K29
Cab I53 Emergency arrows switch C26
Cab I54 Rotating lamp switch I29
Cab I55 Stop pressure switch Q39
Cab I56 Front windscreen wiper switch E5
(16/08/2011) 80-03-M146EN
A6
Position on the
Diagram 1 Diagram 2
Rear I62 Rear left stabiliser extended microswitch G3
Rear I63 Rear right stabiliser extended microswitch M4
Front I64 Front right stabiliser extended microswitch M30
Front I65 Front left stabiliser extended microswitch G29
Cab I66 Double/triple output switch Option E4
Cab I68 Provision for heating fan switch O38 Option
Cab I69 Levelling switch G33 Option
Cab I70 Radio control connector E29
Rear turret I71 Cab locked proximity sensor G15
Cab I73 Engine start permission with I10 activated K31 / K32
Rear turret I74 Cab centred proximity sensor 3 I17
Cab I75 Engine revolutions memorisation switch E31 Option
Cab I76 1450 switch/min switch E30 Option
Rear I77 Rear left stabiliser extended microswitch E3
Cab I102 Danfoss electronic transmission setting authorisation O35 Option
Cab KEY Starter panel C33
Cab L7 Stabilisers supported indicator light O38 Option
Cab L19 Stabilisers partially extended indicator light O38 Option
Cab L28 Selected beam indicator light I34
Cab L29 Selected stabilisers indicator light I34
Cab L30 Beam extension/lowering stabiliser feet indicator light G34
Cab L31 Beams retracted/feet raised stabiliser indicator light G34
Cab L32 Provision for danger lamp Q38 Option
Cab L40 Danfoss control unit alarm indicator light E32
Engine M1 Starter motor M16
Driving position M3 Left side seat lever E20
Driving position M4 Right side seat lever G20
Front M5 Oil cooling fan 1 I26
80
Cab M8 Front windscreen wiper motor Q39

Engine M9 Diesel filter heater M17
Cab M10 Provision for heating fan O37 Option
Rear turret M11 Heating pump I12
Driving position M12 Pneumatic seat motor G19
Cab R35 Economiser remote switch O35
Rear turret S1 Danfoss lifting electrovalve I12
Rear turret S2 Danfoss extension electrovalve I11
Rear turret S3 Danfoss rotation electrovalve I11
Rear turret S4 Danfoss traverse electrovalve I10
Rear turret S5 Danfoss optional electrovalve I10
Front S8 Parking brake electrovalve I22
Front S9 Main stabiliser electrovalve K22
Front S10 Hydraulic circuit exclusion electrovalve E23
Front S11 Right front beam electrovalve K22
Front S12 Front left beam electrovalve K23
Front S13 Rear left beam electrovalve K23
Front S14 Rear right beam electrovalve K24
Front S15 Stabiliser retract/raise electrovalve K25
Front S16 Front right stabiliser electrovalve K25
80-03-M146EN (16/08/2011)
A7
Position on the
Diagram 1 Diagram 2
Front S17 Front left stabiliser electrovalve K25
Front S18 Rear left stabiliser electrovalve I25
Front S19 Rear right stabiliser electrovalve K22
Engine S21 Forward electrovalve K16
Engine S22 Reverse electrovalve K17
Rear S23 Unlock rear axle electrovalve G7
Front S24 Crab steering electrovalve K23
Front S25 Concentric steering electrovalve K23
Rear S26 Unlock rear axle electrovalve K7
Cab S27 High speed electrovalve O33
Cab S28 Low speed electrovalve O34
Front S35 Levelling electrovalve 1 K24 Option
Front S40 Engine displacement reduction K26
Cab SC System isolating connectors Q36 Option
Cab STR1-1 Instrument connector (STR1-1) C29
Cab STR1-4 Instrument connector (STR1-4) A28
Front T1 Fuel float G16
Cab X1 System isolating connectors O28
Cab X2 System isolating connectors Q27
Rear turret X5 System isolating connectors G12
Rear turret X9 Anti overturn circuit I8/I9
Cab X10 System isolating connectors Q22 Option
Driving position / Rear turret X11 System isolating connectors E13
Cab X12 Heating Q39
80
Platform X15 System isolating connectors E13
Platform X16 System isolating connectors K9
Engine / Rear X17 System isolating connectors K21
Rear X18 System isolating connectors G22
Front X19 System isolating connectors E21
Rear X20 System isolating connectors E21
Cab X23 Connector provided for indicator lights O35 Option
Front X24 Provisional power supply I30 Option
Rear X26 Trailer lights connector K7
Engine X27 System isolating connectors M18
Engine X28 Connector provision for preheating relay M19
Engine / Rear X29 Connector provided for preheating M20 / K8
Cab X32 Thermostat Q35
Cab X33 Ambient thermostat O38
Cab X34 System isolating connectors O35 Option
Cab X37 Antitheft connector O37
(16/08/2011) 80-03-M146EN
A8
Position on the
Diagram 1 Diagram 2
Cab X38 Car radio power supply connector I30
Cab X39 Car radio boxes connector I31 / I32
Cab X40 Large mixing bucket connector O35 Option
Cab X41 Microswitch behind right jib O35 Option
Cab X42 Heating diagnostics connector O36
O34 /
Cab X44-X45 Check warning lights
O35
Rear turret / Cabin X46 Provisional power supply connector I11 I29
Cab X47 Provision for air heating O37
Driving position X51 System isolating connectors G19
Driving position X52 Rotation potentiometer kit E19
Driving position X53 System isolating connectors E19
Front X54 Hydraulic braking 2nd connector I30 Option
Cab X55 Stabiliser calliper configuration connector O36 Option
Front X57 Hydraulic oil temperature light G16
Front X58 Optional connector kit for locking stabilisers I21 Option
Cab X75 Provision for heating timer Q35 Option
Cab X76 Connector provided for air conditioning Q35 Option
Cab X96 Connector for I18047 Q38
Cab X97 Sauer Danfoss setting blocks Q37
Cab X99 Bus ring closure J1939 O38
Cab X100 Bus ring closure J1939 Q39
Cab X101 Provision for air conditioning power supply Q35 Option
Cab X102 Electronic brake pedal O35
Engine / Cab X103 Intercooler fans oil filter pressure switch K16 O38
Cab XA MC024-021 Danfoss control unit connectors/A1 Q36
Rear turret XAC Provision for air conditioning connector I12
Cab XAS Cigarette lighter C25
Cab XB MC024-021 Danfoss control unit connectors /B1 Q37
XD System isolating connectors G11
XD3 System isolating connectors G12
80
XDG Main diagnostics connector G12

Cab XM1 System isolating connectors O39
Cab XPA Electronic accelerator pedal G17
GROUNDS UP TO TRUCK 22725 - 758856
Position on the
Diagram 1 Diagram 2
Front Ground Ground I22
Rear Ground Chassis ground I20
Rear turret Ground Chassis ground I13
Engine Ground Engine ground K18
Cab Ground Instrument panel ground Q36
80-03-M146EN (16/08/2011)
A9
DIAGRAM 1 UP TO TRUCK 22725 - 758856
1 2 3 4 5 6 7 8 9 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 Key: A
Front wiring
Rear wiring
Rear turret wiring

C C
Engine wiring
Rear steering wiring
Platform wiring
Connection between wiring

E X19 E
FUSE AND
RELAY BOX X20
X22 X11 S10
FPSX X21
X15
I77 FASX
ELECTRONIC T1 X53 X52 M3
X13
I62 BOX I80
X14
I17 I65
XD XDG X18
XD3 X57
M12 I18
AND RELAY BOX

G BOARD-FUSE G
INSTRUM.
X51 M4
X5
X6 I34
I15 I71 A1
S23 I14 I74
X9 A4 S5 S4 S3 S2 S1
X58
I52 M5
I11 XAC
M6
I X46 M11 I3 I
I5 I6 Ground I8
X24
I43
Ground
X54
Ground S8 S18
A2 X26 X29 I12 ELECTRIC F76 X17 S9 S17 S40

MANIFOLD
S11 S12 S13 S14 S15 S16
I41 S19 S24 S25 S35 S36
K K
S21 S22
X16
S26
X103 Ground F75
I16
80
M1 X28 X29
I63
M I19 M
I78 X27
I64
I79
G M9 FADX
FPDX
O O
Q Q
S S
(16/08/2011) 80-03-M146EN
A10
DIAGRAM 2 UP TO TRUCK 22725 - 758856
1 2 3 4 5 6 7 8 9 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 Key A
STR1-4 Cab wiring
I53
STR1-1
STR1-2
C KEY C
XAS
STR1-3
E E
I66 I56 I7 I20

I9 I70 I35 I76 I75 L40
I22
I69
EXTRA DL DM
G G
I1 I4 I2 I28 I29 I26 L30
L31
XPA
L28
I54 I24 I30 I31 I27
L29
I I
X46 X38 X39
K K
I73
I51 I10
80
M M
I102
A5 X99
X7
X44-X45 L19
X1 XM1
R35 X23 X42 X47 X48 L7
O XM2 O
X102 X103
X40 X33 XM3

S27 S28
X41 X34 X55 X37 M10 I68 XM4
X101 X100
X76 L32
I55
X32 X75 SC X43 X97 X96
M8
AND RELAY BOX

X3 X2
BOARD-FUSE
XA XB
INSTRUM.
Q X12 Q
X4
X10 Ground
X8
ELECTRIC
S MANIFOLD S
80-03-M146EN (16/08/2011)
A11
CONNECTORS FROM TRUCK 22756 - 758886
Position on the
Diagram 1 Diagram 2
Rear turret A1 Acoustic warning G19
Rear A2 Reverse gear horn K7
Rear turret A4 Anti overturning alarm buzzer I9
Cab A5 Emergency pump buzzer O35
Cab DL Headlamp dipping G15
Cab DM Gear change G17
Engine F75 Main fuse K19
Rear F76 Emergency pump remote switch fuse K20
Front FADX Front right lamp M28
Front FASX Front left lamp E28
Rear FPDX Front right lamp O4
Rear FPSX Rear left lighting E4
Engine G Alternator M17
Cab I1 Parking brake switch G29
Cab I2 Slow/fast switch G30
Front I3 Gear change switch I24
Cab I4 Gear change reset switch G29
Rear I5 Stop circuit pressure switch I7
Rear I6 Rear axle alignment proximity sensor I8
Cab I7 Small mixing bin switch E7
Front I8 Option I23
Cab I9 Rear axle alignment proximity sensor E28
Cab I10 Platform exclusion key K30
Rear I12 Slow/fast switch K10
Rear turret I14 Gear change reset switch I17
Rear turret I15 Tower alignment proximity sensor G15
Rear I16 Rear right beam lowered microswitch M4
Rear I17 Rear left beam lowered microswitch G3
Front I18 Front left beam lowered microswitch G29
80
Front I19 Front right beam lowered microswitch M30
Cab I20 Optional potentiometer enabling switch E8 Option
Cab I22 Emergency domed pushbutton G14
Cab I24 Steering switch I29
G32 /
Cab I26 Stabiliser raised/lowered beam extend/retract switch
G33
Cab I27 Beams/stabiliser selector switch I32 / I33
Cab I28 Front left beam/stabiliser switch G31
Cab I29 Front right beam/stabiliser switch G32
Cab I30 Rear left beam/stabiliser switch I31
Cab I31 Rear right beam/stabiliser switch I32
Rear turret I34 Cab centred proximity sensor 2 G17
Cab I35 Electric accelerator switch E29 Option
Rear turret I41 Maximum raising microswitch K3
Front I43 Proximity sensor for speedometer I24 Option
Cab I51 Anti overturn exclusion key K29
Cab I53 Emergency arrows switch C26
Cab I54 Rotating lamp switch I29
Cab I55 Stop pressure switch Q39
Cab I56 Front windscreen wiper switch E5
(16/08/2011) 80-03-M146EN
A12
Position on the
Diagram 1 Diagram 2
Rear I62 Rear left stabiliser extended microswitch G3
Cab I66 Double/triple output switch Option E4
Cab I68 Provision for heating fan switch O38 Option
Cab I69 Levelling switch G33 Option
Cab I70 Radio control connector E29
Rear turret I71 Cab locked proximity sensor G15
K31 /
Cab I73 Engine start permission with I10 activated
K32
Rear turret I74 Cab centred proximity sensor 3 I17
Cab I75 Engine revolutions memorisation switch E31 Option
Cab I76 1450 switch/min switch E30 Option
Rear I77 Rear left stabiliser extended microswitch E3
Cab I81 Replacing translation safety system switch I30
Cab I102 Danfoss electronic transmission setting authorisation O35 Option
Cab KEY Starter panel C33
Cab L7 Stabilisers supported indicator light O38 Option
Cab L19 Stabilisers partially extended indicator light O38 Option
Cab L28 Selected beam indicator light I34
Cab L29 Selected stabilisers indicator light I34
Cab L30 Beam extension/lowering stabiliser feet indicator light G34
Cab L31 Beams retracted/feet raised stabiliser indicator light G34
Cab L32 Provision for danger lamp Q38 Option
Cab L40 Danfoss control unit alarm indicator light E32
Engine M1 Starter motor M16
Driving position M3 Left side seat lever E20
Driving position M4 Right side seat lever G20
80

Cab M8 Front windscreen wiper motor Q39
Engine M9 Diesel filter heater M17
Cab M10 Provision for heating fan O37 Option
Rear turret M11 Heating pump I12
Driving position M12 Pneumatic seat motor G19
Cab R35 Economiser remote switch O35
Rear turret S1 Danfoss lifting electrovalve I12
Rear turret S2 Danfoss extension electrovalve I11
Rear turret S3 Danfoss rotation electrovalve I11
Rear turret S4 Danfoss traverse electrovalve I10
Rear turret S5 Danfoss optional electrovalve I10
Front S8 Parking brake electrovalve I22
Front S9 Main stabiliser electrovalve K22
Front S10 Hydraulic circuit exclusion electrovalve E23
Front S11 Right front beam electrovalve K22
Front S12 Front left beam electrovalve K23
Front S13 Rear left beam electrovalve K23
Front S14 Rear right beam electrovalve K24
Front S15 Stabiliser retract/raise electrovalve K25
80-03-M146EN (16/08/2011)
A13
Position on the
Diagram 1 Diagram 2
Front S16 Front right stabiliser electrovalve K25
Front S17 Front left stabiliser electrovalve K25
Front S18 Rear left stabiliser electrovalve I25
Front S19 Rear right stabiliser electrovalve K22
Engine S21 Forward electrovalve K16
Engine S22 Reverse electrovalve K17
Rear S23 Unlock rear axle electrovalve G7
Front S24 Crab steering electrovalve K23
Front S25 Concentric steering electrovalve K23
Rear S26 Unlock rear axle electrovalve K7
Cab S27 High speed electrovalve O33
Cab S28 Low speed electrovalve O34
Front S40 Engine displacement reduction K26
Cab SC System isolating connectors Q36 Option
Cab STR1-4 Instrument connector (STR1-4) A28
Front T1 Fuel float G16
Rear turret X9 Anti overturn circuit I8/I9
Driving position / Rear turret X11 System isolating connectors E13
80
Cab X12 Heating Q39
Platform X15 System isolating connectors E13
Platform X16 System isolating connectors K9
Engine / Rear X17 System isolating connectors K21
Rear X18 System isolating connectors G22
Front X19 System isolating connectors E21
Cab X23 Connector provided for indicator lights O35 Option
Front X24 Provisional power supply I30 Option
Rear X26 Trailer lights connector K7
Engine X27 System isolating connectors M18
Engine X28 Connector provision for preheating relay M19
Engine / Rear X29 Connector provided for preheating M20 / K8
Cab X32 Thermostat Q35
Cab X33 Ambient thermostat O38
Cab X34 System isolating connectors O35 Option
(16/08/2011) 80-03-M146EN
A14
Position on the
Diagram 1 Diagram 2
Cab X37 Antitheft connector O37
Cab X38 Car radio power supply connector I30
Cab X39 Car radio boxes connector I31 / I32
Cab X40 Large mixing bucket connector O35 Option
Cab X41 Microswitch behind right jib O35 Option
Cab X42 Heating diagnostics connector O36
O34 /
Cab X44-X45 Check warning lights
O35
Rear turret X46 Provisional power supply connector I11
Driving position X51 System isolating connectors G19
Driving position X52 Rotation potentiometer kit E19
Driving position X53 System isolating connectors E19
Front X54 Hydraulic braking 2nd connector I30 Option
Cab X55 Stabiliser calliper configuration connector O36 Option
Front X57 Hydraulic oil temperature light G16
Front X58 Optional connector kit for locking stabilisers I21 Option
Cab X76 Connector provided for air conditioning Q35 Option
Cab X96 Connector for I18047 Q38
Cab X97 Sauer Danfoss setting blocks Q37
Cab X99 Bus ring closure J1939 O38
Cab X100 Bus ring closure J1939 Q39
Cab X101 Provision for air conditioning power supply Q35 Option
Cab X102 Electronic brake pedal O35
Engine / Cab X103 Intercooler fans oil filter pressure switch K16 O38
Cab X107 Provision for heating timer Q35 Option
Cab XA MC024-021 Danfoss control unit connectors/A1 Q36
Rear turret XAC Provision for air conditioning connector I12
Cab XAS Cigarette lighter C25
Cab XB MC024-021 Danfoss control unit connectors/B1 Q37
80
Cab XCD Provisional power supply connector I29

XD System isolating connectors G11
XD3 System isolating connectors G12
XDG Main diagnostics connector G12
Cab XPA Electronic accelerator pedal G17
GROUNDS FROM TRUCK 22756 - 758886
Position on the
Diagram 1 Diagram 2
Front Ground Ground I22
Rear Ground Chassis ground I20
Rear turret Ground Chassis ground I13
Engine Ground Engine ground K18
Cab Ground Instrument panel ground Q36
80-03-M146EN (16/08/2011)
A15
DIAGRAM 1 FROM TRUCK 22756 - 758886
1 2 3 4 5 6 7 8 9 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 Key: A
Front wiring
Rear wiring
Rear turret wiring

C C
Engine wiring
Rear steering wiring
Platform wiring
Connection between wiring

E X19 E
FUSE AND
RELAY BOX X20
X22 X11 S10
FPSX X21
X15
I77 FASX
ELECTRONIC T1 X53 X52 M3
X13
I62 BOX I80
X14
I17 I65
XD XDG X18
XD3 X57
M12 I18
AND RELAY BOX

G BOARD-FUSE G
INSTRUM.
X51 M4
X5
X6 I34
I15 I71 A1
S23 I14 I74
X9 A4 S5 S4 S3 S2 S1
X58
I52 M5
I11 XAC
M6
I X46 M11 I3 I
I5 I6 Ground I8
X24
I43
Ground
X54
Ground S8 S18
A2 X26 X29 I12 ELECTRIC F76 X17 S9 S17 S40

MANIFOLD
S11 S12 S13 S14 S15 S16
I41 S19 S24 S25 S35 S36
K K
S21 S22
X16
S26
X103 Ground F75
I16
80
M1 X28 X29
I63
M I19 M
I78 X27
I64
I79
G M9 FADX
FPDX
O O
Q Q
S S
(16/08/2011) 80-03-M146EN
A16
DIAGRAM 2 FROM TRUCK 22756 - 758886
1 2 3 4 5 6 7 8 9 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
Key
A A
Cab wiring
STR1-4
I53
STR1-1
STR1-2
C KEY C
XAS
STR1-3
E E
I66 I56 I7 I20

I9 I70 I35 I76 I75 L40
I22
I69
EXTRA DL DM
G G
I1 I4 I2 I28 I29 I26 L30
L31
XPA
L28
I54 I24 I81 I30 I31 I27
L29
I I
XCD X38 X39
K K
I73
I51 I10
80
M M
I102
A5 X99
X7
X44-X45 L19
X1 XM1
R35 X23 X42 X47 X48 L7
O XM2 O
X102 X103
X40 X33 XM3

S27 S28
X41 X34 X55 X37 M10 I68 XM4
X101 X108 X100
X76 L32
I55
X32 X107 SC X43 X97 X96
M8
AND RELAY BOX

X3 X2
BOARD-FUSE
INSTRUM.
Q XA XB X12 Q
X4
X10
X8
Ground
ELECTRIC
S MANIFOLD S
80-03-M146EN (16/08/2011)
ELECTRICAL CONTROL AND ADJUSTMENT
page
PRINCIPLE OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– MANAGEMENT OF OPERATING CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
POSITIONING THE SENSORS ON THE TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
DESCRIPTION OF THE CONTROL PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
PROCEDURE FOR REPLACING AN ACCESSORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
PROCEDURE FOR ADJUSTING THE BRIGHTNESS OF THE DISPLAY. . . . . . . . . . . . . . . 6
PAGES OF THE DIAGNOSIS SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– SYSTEM DIAGNOSIS PAGE 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
80
– SYSTEM DIAGNOSIS PAGE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LIST OF ALARM CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
CALIBRATING THE CABLE WINDER 3B6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(06/07/2011) 80-04-M146EN
2
Electrical control and adjustment
PRINCIPLE OF OPERATION
MANAGEMENT OF OPERATING CONDITIONS
Pressure sensor Angle and extension sensor Truck information
Stabiliser information
Turret position information
Overhead platform information
Comparison between the values measured on the truck and the load tables saved
in the SLIM memory
80
Reading of the load conditions on the truck
80-04-M146EN (06/07/2011)
3
POSITIONING THE SENSORS ON THE TRUCK
Cable winder for measuring

the jib length and angle
2 length sensors
2 angle sensors
Pressure sensor to measure the load

conditions on the truck
2 sensors on the lifting cylinder
2 sensors on the compensating cylinder
Man-Machine Interface
Indicates whether the load
conditions and position of the truck
80
(06/07/2011) 80-04-M146EN
4
DESCRIPTION OF THE CONTROL PANEL
Identification symbols for the operating modes (automatic selections from the outside)
Letters relating to the indications supplied by the display
Indicator lights Green / Yellow / Graphic Display
Red indicating the working condition for displaying
(safety/alarm/blocking) working data
Icon representing the truck Identification symbols for the

4 Keys for setting and letters relating to the tools (manual selection on
geometrical data displayed the panel)
1 2 4
80
3 5 6 7
1 Jib length
2 Actual weight on the forks
3 Maximum permissible weight in the present position of the truck
4 Distance between the ground and load centre
5 Loading table selected according to the truck position and the chosen accessory
6 Distance between the centre of the truck and the mean point of the load
7 Jib angle
80-04-M146EN (06/07/2011)
5
PROCEDURE FOR REPLACING AN ACCESSORY
The choice of a loading table suitable for the accessory selected is the responsibility of
the driver.
1) On the truck stability information display, press the up arrow key several times to select the
loading table according to the list avaiable.
Forks
confirm
Tool available
A Forks
B Overhead platform ORH365kg
C Pendulum
D Overhead platform ORH700kg
E Winch 5T
F JIB 5T
G JIB PT600
H JIB PT1200
2) Press the key to confirm the choice.
If an overhead platform is attached to the truck, without having selected the relevant
80
loading table, the display will indicate “WARNING 4”. There are various types of overhead
platform.
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6
PROCEDURE FOR ADJUSTING THE BRIGHTNESS OF THE DISPLAY
1) Press the down arrow key

2) The contrast is changed automatically; then press the key to confirm the level of contrast
chosen
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80-04-M146EN (06/07/2011)
7
PAGES OF THE DIAGNOSIS SYSTEM
The pages of the diagnosis system make it possible to define problems in the 3B6 system.
To access these pages, press the key several times.
SYSTEM DIAGNOSIS PAGE 2
Number of
pages
• P: Differential pressure between the upper and lower chambers of the main cylinder expressed
in bar
• W: Weight lifted on the forks
• M: Maximum permissible load in the present position of the truck
• A: Jib Angle
• L: Jib Length
• R: Distance between the centre of the turret and the centre of the load (50 cm from the base
of the forks)
80
• P: Differential pressure between the upper and lower chambers of the lifting cylinder
• L: Pressure in the lifting cylinder chamber on the piston side
• H: Pressure in the lifting cylinder chamber on the rod side
• p: Differential pressure between the upper and lower chambers of the compensating cylinder
• l: Pressure in the chamber of the compensating cylinder on the piston side
• h: Pressure in the chamber of the compensating cylinder on the rod side
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8
A1 A2 A3
L1 L2 L3
•A1: Angle sensor information ASA 1A

•A2: Angle sensor information ASA 1B
•A3: Difference between angles ASA 1A and ASA 1B Max 0,5°
•L1: ASA 1A extended sensor information
•L2: ASA 1b extended sensor information
•L3: Difference between extension ASA 1A and ASA 1B Max 50 cm
Extension and angle sensor information referred to the truck
MRT 1850 MRT 2150 MRT 2540

L min. 5,5 L min. 6,2 L min. 7,2
L max. 16,4 L max. 19,4 L max. 23,3
A min. -2,8 A min. -1,9 A min. -3
A max. 79,7 A max. 78 A max. 80
80
ACT1A ACT1B
80-04-M146EN (06/07/2011)
9
Information expressed in bits (Not used)

Information expressed in bits (Not used)
80
Information in input from the various sensors ( * = 12v )
• INP 5: Stabiliser extended information
• INP 6: Front turret information
• INP 8: Stabilisers in support information
• INP 9: Information on presence of overhead platform
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10
Output information ( * = 12v )

• OUT 0: Locking information
• OUT 1: Lower jib at 3m
• OUT 3: Jib retracted
• OUT 4: Information to reduce the speed of movement (hair/tortoise)

80
System counter
System counter: This number changes continuously since it indicates whether the communication
between the winder and the display is operating correctly.
• A: Information in bits from the angle sensor ASA 1A (about 1800 bits with jib at 0°)
• L: Information in bits from the extension sensor ASA 1A (about 50 bits with the jib retracted)
80-04-M146EN (06/07/2011)
11
System counter
System counter: This number changes continuously since it indicates whether the communication
between the winder and the display is operating correctly.
• A: Information in bits from the ASA 1B extension sensor (about 1800 bits with jib at 0°)
• L: Information in bits from the ASA 1B extension sensor (about 973 bits with the jib
retracted)
80
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12
LIST OF ALARM CODES

Alarm
Description Operations to be carried out
codes
Switch off and restart
1 Memory data not consistent Ensure that the eprom is correctly seated in its socket
If the alarm persists, replace the Slim
Check on the page 4 of the diagnosis system that
the values are not marked “EE”
2 ASA 1A Angle sensor reading less than the minimum value Check the CAN BUS connection
Check correct operation of the sensor
Calibrate the system
3 ASA 1A Angle sensor reading greater than the maximum value Check the CAN BUS connection
4 ASA 1A extension sensor reading less than the minimum value Check the CAN BUS connection
5 ASA 1A extension sensor reading greater than the maximum value Check the CAN BUS connection
6 Value of the ASA 1A sensor less than the calibration value Check the CAN BUS connection
7 Value of extension sensor ASA 1B less than the calibration value Check the CAN BUS connection
Check on system diagnostic page 3 that the values
Reading of the pressure sensor in the lifting cylinder (piston side) are not marked “EE”
8
below the minimum Check the wiring of the 3B6 system
Check the sensor signals
Reading of the pressure sensor in the lifting cylinder (piston side) are not marked “EE”
80
9
above the maximum Check the wiring of the 3B6 system
Reading of the pressure sensor in the lifting cylinder (rod side) are not marked “EE”
10
below the minimum Check the wiring of the 3B6 system
Reading of the pressure sensor in the lifting cylinder (rod side) are not marked “EE”
11
greater than the maximum Check the wiring of the 3B6 system
Check that the sensor is connected correctly to the card
12 Internal error code ASA 1A CAN-BUS Check that the wiring of the 3B6 system is in good
condition
Check that the sensor is connected correctly to the card
13 Internal error code ASA 1B CAN-BUS Check that the wiring of the 3B6 system is in good
condition
Extend the telescopic element then check on page 8
that the output is no longer active.
14 Uncontrolled output blockage with telescopic element at rest
Check the condition of the wiring between output 3
(J5-4) and the electronics card (JP1-5)
Fully raise the jib then check on page 8 that output 4
is no longer active.
15 Uncontrolled blocked output of telescopic section less than 3m
80-04-M146EN (06/07/2011)
13
Alarm
codes
Retract and fully lower the telescopic element,
remove the load from the jib so that it is no longer
16 Uncontrolled blocked output Key Info CEC (load limiter) overloaded.
17 Uncontrolled blocked output of overhead platform Not used
Reading of the pressure sensor in the compensating cylinder (piston side) are not marked “EE”
18
less than the minimum Check the wiring of the 3B6 system
Check the sensor signals J5-14
Reading of the pressure sensor in the compensating cylinder (piston side) are not marked “EE”
19
Check the sensor signals J5-14
Reading of the pressure sensor in the compensating cylinder (rod side) are not marked “EE”
20
less than the minimum Check the wiring of the 3B6 system
Check sensor signals J5-6
Reading of the pressure sensor in the compensating cylinder (rod side) are not marked “EE”
21
Check sensor signals J5-6
Uncontrolled blocked output Check the battery voltage
22
Relay alarms WDO Switch off and restart
23 Not used
Uncontrolled blocked output
24
Extension of telescopic element
25
Retraction the telescopic element
26
Lowering the jib
27
Raising the Jib
Check on page 9 of the system diagnostics that the
28 Communication error CAN BUS ASA 1A bus system contactor advances constantly
Check CAN-BUS wiring
Check on page 9 of the system diagnostics that the
29 Communication error CAN BUS ASA 1B bus system contactor advances constantly
Check CAN-BUS wiring
80
30 Stabiliser extended end of stroke congruence alarm Check the inputs, card connections and sensors
31 Stabiliser extended mid stroke congruence alarm Check the inputs, card connections and sensors
Check the values ASA 1A and ASA 1B on page 4 of
32 Angle congruence alarm the system diagnostic
Calibrate the cable winder
Check the values ASA 1A and ASA 1B on page 4 of
33 Extension congruence alarm the system diagnostic
Calibrate the cable winder
Check on page 4 of the system diagnostic that the
values are not marked “EE”
34 Angle sensor reading ASA 1B less than minimum value Check the CAN BUS connection
35 Angle sensor reading ASA 1B greater than maximum value Check the CAN BUS connection
36 Extension sensor reading less than minimum value Check the CAN BUS connection
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Alarm
codes
37 Extension sensor reading greater than maximum value Check the CAN BUS connection
38 Frontal stroke congruence alarm Check the inputs, card connections and sensors
39 Not used
40 Not used
Switch off and restart.
Ensure that the Eprom is correctly seated in its
41 CRC Error on EPROM
socket
socket
socket
socket
45 Not used
46 Not used
47 Not used
48 Not used
49 Not used
50 Error in memory area
socket
socket
80

socket
socket
80-04-M146EN (06/07/2011)
15
CALIBRATING THE CABLE WINDER 3B6
• Open the cable winder door on the front of the jib with an Allen key.
Remove the electronics card from the cable winder and turn the white potentiometer gears
clockwise to the end of their stroke.
• Then turn each potentioimeter back (anticlockwise) one turn. 80

• Climb into the cab of the vehicle.
• Switch on.
• Support the machine on the stabilisers and in line with the chassis.
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16
• When the image shown above appears on the display, press the key
• When the image shown above appears on the display, press the key
• At this point the password setting page appears, press key several times to move the
asterisk placing it over the first 4, then with the arrow keys change the number 4
to number 2.
• Press the pushbutton again to access the second number.

80
• After setting the first level password (that is the type of vehicle) press key and then the
pushbutton
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17
• Using the arrows , search menu 12 transd min.
• Fully retract the telescopic element and lower the jib to the maximum then press the
key
• At this point you will have set the system minimum point.
• Now using search menu 13 transd max.
80
• Fully raise the jib and extend it as far as possible.
• Press the pushbutton and then
• At this point you will have set the system maximum point.
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• Now with the keys search menu 01 SAVED.
• Press the pushbutton and wait until DONE (finished) appears on the display.
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80-04-M146EN (06/07/2011)
ELECTRICAL TROUBLESHOOTING
page
SAUER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– SAUER TRANSMISSION FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– SAUER TRANSMISSION ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– INSTRUCTIONS FOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– UNIVERSAL CONNECTION TO THE DIAGNOSTIC TESTER
FOR ALL EBERSPÄCHER HEATERS VERSIONS “C”-“C COMPACT” -
AIRTRONIC AND HYDRONIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
– AIR HEATER FAULT CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
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Electrical troubleshooting
SAUER TRANSMISSION
SAUER TRANSMISSION FAULTS
Problem Check Remedy

Check the load pressure in M3. Replace the filter or add oil to the tank.
The pump does not come up to pressure.
Check the coupling between the pump Replace the pump shaft or sleeve if worn.
and the fuel.
Check the flow in the two reducers. If necessary, replace it.
The pump comes up to pressure but not in both
directions of travel.
Check errors from the instrument panel. See table of errors.
Check the pressure at points M1 M2 M3. Test and reverse or replace the maximum valve.
Check that the changeover selector valve Replace the valve and check that there
The pump has no thrust force or only moves on the engine is not blocked on one side. is no interference in the seating.
in one direction.
Check that the pressure drop across the Replace the filter.
filter at points M5 and M6 is not greater
than 2,2 bar.
Check the load pressure of the pump. Adjust the supply valve on the pump.
The truck movement is delayed in both
directions of travel Check whether the filter is clogged, making Replace the filter.
the check at points M5 M6 on the pump.
Check the load pressure drop in pump M3 Replace the pump because it is damaged.
between the zero and working position.
Check the oil level in the tank. Add oil.

Excessive heating of the oil in the transmission.
Check the type of oil used and the Change the oil or replace the filters if clogged.
cleanliness of the filter.
Check the efficiency of the radiator. Clean the radiator.
Check the Error. See error table.
Check that the working and load pressure Replace the pump because it is damaged.
of the pump are correct.
The truck does not reach its maximum speed.
Check that the motor is at minimum Check the stopping position of the motor
displacement, checking that there is displacement, start-point, regulator valve
80
pressure at point M3 of the motor and that and for obstructions in the controls.
there is no longer pressure at point M4.
80-08-M146EN (21/12/2011)
3
SAUER TRANSMISSION ERROR CODES
INDICATION No.:
ERROR:
Rapid flickering before

transmission code
Long flashes in tens
Single short flashes
Fault Description of fault Causes/remedies

11 (Not available with MC024-021). SAFE - Mode
15 Voltage error of battery or sensor. SAFE - Mode
19 Error in forward gear pump valve. SAFE - Mode
23 Error in reverse gear pump valve. SAFE - Mode
27 Error in motor valve. SAFE - Mode
31 Error in engine RPM. LIMITED - Mode
35 FNR short circuit error SAFE - Mode
39 Loss of inching sensor. LIMITED - Mode
43 (sliding actuation error) LIMITED - Mode
47 (method of sliding error) LIMITED - Mode
51 (Not available with MC024-021). LIMITED - Mode
Elimination of rupture pressure error (or parking brake error or brake
55 SAFE - Mode
80
light error)
59 Loss of cardan shaft revolution sensor (HST motor RPM error). LIMITED - Mode
70 (CAN error). LIMITED - Mode
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4
HEATING
INSTRUCTIONS FOR OPERATION
Order number: Manitou Code 711231
The fault diagnosis equipment can be used for all models of Eberspächer; AIRTRONIC and
HYDRONIC heaters, including versions “C”, “C compact” and “P” previously sold.
1 - Cancel memorised faults 6

2 - Cancel memorised faults
3 - Diagnosis request
4 - Reverse, faults F5 – F1, actual (AF)
5 - Forwards, actual fault (AF), F1 – F5
6 - Display
1 2 3 4 5
Shown on the display, after connection
= intermittent signalling
After pressing key “D” the display shows

80
= intermittent signalling, and after about 8 seconds
= no fault present, or
= actual fault (example: interruption of flame sensor), or
= diagnosis not possible (incorrect connection or heater not

switched on)
80-08-M146EN (21/12/2011)
5
• MEMORISATION OF FAULTS
The control unit can memorise up to 5 faults, read from the diagnosis equipment and then
displayed. The present fault is memorised in memory space F1. I faults previously memorised
migrate to F5. If all the memory spaces are full, memory space F5 will be overwritten.
• OVERHEATING
When 3 overheating events are noted in succession - fault 12/13 - the display shows AF 15
which means that the control unit is locked.
• TOO MANY STARTING ATTEMPTS
When the heater performs 10 starting attempts in succession - fault 52 - the display shows
AF 50; which means that the control unit is locked.
• CANCELLATION OF FAULT MEMORISATION AND UNLOCKING OF CONTROL UNIT
Simultaneously press the 2 keys “L” “L“ until the display shows:
The control unit is unlocked and memorised faults from F1 to F5 are deleted.
N.B. Il automatic lock not present in all control units.
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6
UNIVERSAL CONNECTION TO THE DIAGNOSTIC TESTER FOR ALL EBERSPÄCHER

HEATERS VERSIONS “C”-“C COMPACT” - AIRTRONIC AND HYDRONIC
Connect 3 cables to the 6-pin connector on the diagnostic equipment (see diagram):
a) pin 1 (brown wire) - to the negative

b) pin 5 (red wire) - to the positive
c) pin 3 (blue/white wire) - to the free blue/white wire in the cable harness (*)
(*) In versions where the blue/white wire is connected to the command device, disconnect this
wire from the command and connect it to pin 3.
N.B. There is no fault code signalling if the wire is connected both to the command device and pin
3 of the diagnostic equipment.
• SWITCH ON THE HEATER

After pressing key “D” the present fault, consisting of 2 digits, is shown on the diagnostic
tester display.
Blue-white (diagnostic)
Red
Brown
5
(negative)
Blue-white 3 1
Brown
Red + (positive)
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7
AIR HEATER FAULT CODES

000 Operation without faults. .....................
001 Over-voltage signalling. Warning of over-voltage problems, check the regulator.
002 Low voltage signalling. Warning of low voltage problems, charge the battery.
004 Warning of short circuit in fresh air output signal. Eliminate short circuit/overload.
005 Warning of short circuit in antitheft system. Eliminate short circuit/overload.
009 ADR switched off through D+ o force sensor. Check ADR connecting cables.
Check the regulator.
010 Switched off due to over-voltage.
Check the alternator.
Check regulator and battery.
011 Switched off due to low voltage.
Check the alternator.
012 Check for any obstructions in the fresh air inlet and warm,
Overheating - interruption to the fillerpump.
013 air outlet. Check the power supply to the filler pump and
Heat exchanger temperature too high.
014 overheating switch/sensor.
Excessive overheating. Eliminate the cause and unlock
015 Operation locked.
the control unit using the diagnostic equipment.
017 Overheating (2at warning threshold). Check the overheating sensor.
020 Interruption of glow plug. Check, and if necessary replace the glow plug and/or
glow plug resistance, check connecting cables and pins,
check connection to the glow plug relay.
021 Overload or short circuit at glow plug output. Check, and if necessary replace glow plug.
Glow plug relay defective.
022 Check, and if necessary replace glow plug relay.
Short circuit in glow plug relay.
023 Voltage regulator: break in coil connection. Check connecting cables and pins, check connection
024 Voltage regulator: short circuit in coil connection. to glow plug and replace voltage regulator if necessary.
025 Short circuit in output from diagnostic system. Check output connection from the diagnostic system.
Check engine revolutions, replace it if necessary.
029/030 Electric motor does not turn.
Check the engine revolutions variation relay and printed
031/032 Relay for varying engine revolutions not working.
circuit.
033 Irregularity in engine revolutions (outside tolerance).
Check connections to the electric motor.
035 Reduced power relay, breakage in the coil. Check / replace relay.
036 Reduced power relay, coil short circuit. Check cables and pins.
038 Interruption in vehicle fan control relay. Check cables and pins, check the relay and replace
039 Shortcircuit in vehicle fan control relay. if necessary.
043 Short circuit in output of external components/filler pump. Eliminate short circuit/overload.
047 Short circuit in filler pump Check and/or replace filler pump and
80
048 Interruption in filler pump. check filler pump and electrical supply.
The number of start attempts possible was exceeded.
Check fuel supply, exhaust pipe and inlet pipe. Check
050 Operation locked.
glow plug and replace if necessary
Unlock the control unit using the diagnostic equipment.
Recognising defective flame before ignition.
051 Check the flame sensor and replace if necessary.
Flame sensor defective.
Will not start. Check fuel supply, inlet pipes and exhaust gases; check
052
Safety time exceeded. glow plug and replace if necessary.
Interruption of flame: The heater is on (flame recognised) and flame interruption
053 in ignition phase (“power”) signal in one of the phases.
054 at “maximum” power Check fuel quantity/supply and number of engine
055 at “medium” power revolutions.
056 at “minimum” power If the fuel is OK, check and/or replace flame sensor.
057 Short circuit in flame sensor or reversed connection. Check the cable and pin to flame sensor.
058 Flame during washing. Check flame sensor.
Check temperature sensor connectors, check temperature
060 Interruption to temperature sensor.
sensor on printed circuit or control unit and the additional
061 Short circuit in temperature sensor.
one if necessary.
062 Interruption to command device. Check cables and pins to the command device and
063 Short circuit in command device. replace if necessary.
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064 Interruption of flame sensor. Check the connector on the flame sensor cable.
065 Short circuit in flame sensor. Check the flame sensor and replace if necessary,
071 Interruption to the overheating sensor. Check overheating sensor and replace if necessary
072 Short circuit in overheating sensor. Check cables and connections.
090 Occasional internal disturbance. Replace control unit.
091 External voltage disturbances. Eliminate the cause.
092/093
Control unit defective. Replace control unit.
094/097
096 Command unit (internal temperature measurement sensor defective). Replace control unit or use additional temperature sensor.
255 Fault memory deleted. ...................
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ELECTRICAL SPECIFIC TOOLING
page
DIAGNOSTICS CARRYING CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

OFFICE TROLLEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
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Electrical specific tooling
DIAGNOSTICS CARRYING CASE

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3
12
11
10
5
9
13
6 8
7
1
3 4
80
Diagnostics carrying case ...........................................................................746120
Consisting of:
1. 1 Power supply cable with cigarette lighter plug .........................745240

2. 1 Cable for red battery clips .....................................................745241
3. 1 Cable for black battery clips ..................................................745242
4. 1 Power supply cable ..............................................................745243
5. 1 Cable for laptop VCI ..............................................................745244
6. 1 Cable for Manitou OBD Diag ..................................................745245
7. 1 Cable for Manitou RC2 / RC4 Diag ........................................745246
8. 1 Standard mains cable CE L : 3m ............................................745247
9. 1 Power supply unit Diag 3G 60W .............................................745251
10. 1 Battery LI-ION 7,4V / 9,6AH ..................................................745367
11. 1 PAD (PC set for industrial use + carrying case)........................745438
12. 1 VCI (Vehicle Communication Interface / PAD)..........................745439
13. Steel pens (set of 3) ................................................................745368
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4
Docking station
Docking station (battery load) ....................................................................745236
OFFICE TROLLEY
80
Office trolley (trolley + station set) .............................................................745235
80-09-M146EN (13/12/2011)
FRAME - BODY
- CHASSIS COMPONENTS REMOVAL
- CHASSIS COMPONENTS REFIT
90
COMPONENTS REMOVAL FROM THE CHASSIS
page
CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– CAB HOUSING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– DISCONNECT THE CAB ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 5
– DISCONNECT THE CAB HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 6
– CAB REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
DISCONNECT THE CABIN AIR CONDITIONING (OPTIONAL) . . . . . . . . . . . . . . . . . . . . 9
TURRET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– DISCONNECT THE TURRET HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . 11
– TURRET SENSORS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– TURRET LIFTING CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– TURRET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
THRUST RING REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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Components removal from the chassis
CAB, TURRET AND THRUST RING REMOVAL
GENERAL INFORMATION
and safety.
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3
CAB REMOVAL
CAB HOUSING REMOVAL
Remove the bonnet (Item 1), the housing (Item 2) covering the logic box and the housing (Item 3)
protecting the heating tank.
3
2
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4
Remove the casing under the cab (Item 4), the housing (Item 5) protecting the power steering and
the distributor housing (Item 6).
6
4
7
Disconnect the rotating lamp and emergency lamp (Item 7
and 8) from the cab.
8
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5
DISCONNECT THE CAB ELECTRICAL SYSTEM
Disconnect all the logic box connectors.
Disconnect all the fuse box connectors.
Disconnect the feedthough electrical connectors under the

cab and disconnect the ground cable (Item 9).
Remove all the clips (Item 10) holding the cables and tubes
10
of the cab electrical and hydraulic systems.
10
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10
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6
Disconnect the MSS system display from the instrument

panel (Item 11).
11
DISCONNECT THE CAB HYDRAULIC SYSTEM
Mark, with a brush (Item 12), all the hydraulic system tubes
12 for correct refitting.
Disconnect the hydraulic pipes (Item 13) of the power

steering.
13
Disconnect the hydraulic pipes (Item 14) from the brake

pump.
90
14
14 14
14
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7
Disconnect the hydraulic pipe (Item 15) and the coil (Item 16)
of the slow/fast gear change electrovalve.
16
16
15
Remove the brake pump cables though the opening in the

power steering housing and remove them from underneath
the cab.
CAB REMOVAL
17
Fit the eyebolts (Item 17) to the cab and secure them to an
overhead crane with ropes and chains.
19 Remove the cable (Item 18) from the rotation locking pin
lever (Item 19) from inside the cab.
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8
20
21
Remove the plastic housing (Item 20), to gain access to

the nuts that lock the rear cab mountings, remove the mat
(Item 21) to gain access to the nut that locks the front left
cab mounting.
It may be necessary to remove or move the pipe (Item 22)
from the burner, or its bracket, to gain access to the nut that
locks the front right cab mounting.
22
Unscrew the nuts (Item 23) and remove the antivibration

mounts (Item 24).
23
23
24 24
Unscrew the screws (Item 25) and remove the antivibration

mounts (Item 26).
90
26
25
90-06-M146EN (08/06/2011)
9
Disconnect the diesel tubes (Item 27) from the heater on

the rear side of the mounting plate.
27
With the aid of ropes and an overhead crane, gently lift the
cab, make sure that no cables or hydraulic pipes are still
connected and then remove the cab from the truck.
1
2 DISCONNECT THE CABIN AIR CONDITIONING
(OPTIONAL)
3
If the cab has an air conditioning system, it must be

removed before removing the cab. Remove the rotating lamp
and emergency lamp (Item 1 and 2), remove the housing
(Item 3) of the air conditioning radiators and the rear right
duct (Item 4).
5
Connect an air conditioning degassing plant to the couplings
(Item 5).
5
90
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10
Disconnect the tubes (Item 6 and 7) from the air conditioning

radiator unit.
Remove the air conditioning unit (Item 8).
Remove the feedthrough connector (Item 9) associated with

this option.
Disconnect the negative ground (Item 10) of the additional

battery for the air conditioning.
90
10
The cab can now be removed.
“CAB REMOVAL” in this section.
90-06-M146EN (08/06/2011)
11
TURRET REMOVAL
DISCONNECT THE TURRET HYDRAULIC SYSTEM
Disconnect the diesel tube (Item 1) or if considered

necessary, remove the tank (Item 2).
Unscrew the screws and nuts (Item 3 and 4) and remove the
plate (Item 5) that locks the bundle of tubes (Item 6).
4
4
3
Unscrew the screws (Item 7) and remove the collars

(Item 8).
90
7 7
8
8
(08/06/2011) 90-06-M146EN
12
Remove the cylinder couplings (Item 9).
Disconnect the tubes (Item 10 and 11).
10
10
11
Disconnect all the hydraulic pipes from the distributor, being

careful to mark them with a brush before disconnecting
them, to facilitate refitting.
While the above operation is being performed, withdraw the

pipes from the slot in the turret.
90
90-06-M146EN (08/06/2011)
13
TURRET SENSORS REMOVAL
Unscrew the screws (Item 12) and remove the bracket

12
(Item 13) that supports the sensors (Item 14) that detect
rotation of the turret beyond 15°.
13
14 14 14
Unscrew the screw and nut (Item 15 and 16) and remove
the bracket (Item 17) that supports the thrust ring centring
15
sensor (Item 18).
16
18
17
Remove the presence of the thrust ring locking pin

microswitch (Item 19).
19
Unscrew the screw (Item 20) and remove the klaxon

(Item 21).
20
90
21
(08/06/2011) 90-06-M146EN
14
Remove the mounting (Item 22) and the maximum jib height
23
22
TURRET LIFTING CYLINDER REMOVAL
Unscrew the screw (Item 24) and nut (Item 25) and extract
the pin (Item 26) locking the lifting cylinder.
24
26
25
Remove the lifting cylinder (Item 27) with a rope and

overhead crane.
27
TURRET REMOVAL
Secure the turret to an overhead crane.

90
Unscrew the screws (Item 28), from both sides of the shaft
and remove the cardan shaft (Item 29) from under the
28 truck.
29
90-06-M146EN (08/06/2011)
15
Remove the bracket (Item 30) to release the silencer

(Item 31).
30
31
Remove the silencer (Item 32).
32
Unscrew the locknuts (Item 33) and nuts (Item 34).
33
34
Remove the nuts (Item 34) by unscrewing the screws

(Item 35) which can be reached through a hole under the
35 chassis.
90
Turn the truck by the angle necessary to be able to reach all

the screws one at a time through the hole.
(08/06/2011) 90-06-M146EN
16
Remove the turret (Item 36).
36
90
90-06-M146EN (08/06/2011)
17
THRUST RING REMOVAL

1 Unscrew the screws (Item 1) that lock the thrust ring
(Item 2).
3 Insert two eyebolts (Item 3) in the two holes in the thrust

2 ring (Item 2), aligned at about 180°.
Lift the thrust bring (Item 2) with an overhead crane.

90
(08/06/2011) 90-06-M146EN
18
90
90-06-M146EN (08/06/2011)
COMPONENTS REFIT ON THE CHASSIS
page
THRUST RING REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TURRET REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– REPOSITIONING THE TURRET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– LIFTING CYLINDER REFIT ON THE TURRET . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– TURRET SENSORS REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– RECONNECT THE TURRET HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . 9
CAB REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– REPOSITIONING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– RECONNECT THE CAB HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 14
– RECONNECT THE CAB ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . 15
– CAB HOUSING REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
CONNECT THE AIR CONDITIONING TO THE CAB (OPTIONAL) . . . . . . . . . . . . . . . . . . . 18
90
(09/06/2011) 90-07-M146EN
2
Components refit on the chassis
CAB, TURRET AND THRUST RING REFIT
GENERAL INFORMATION
and safety.
90
90-07-M146EN (09/06/2011)
3
THRUST RING REFIT
Carefully clean the seating on the truck, where the new

thrust ring will be fitted.
Clean up the threads in the holes for the thrust ring locking
screws with a tapping attachment (Item 1).
1
Check that the lower surface of the new thrust ring (Item 2)
is clean and, with the aid of an overhead crane, place the
thrust ring on the truck.
90
(09/06/2011) 90-07-M146EN
4
While placing the thrust ring on the truck, be careful to direct

the edges of the thrust ring, on which the grease nipples
3 (Item 3) are mounted, towards the right and left sides of the
base.
The thrust ring gear (Item 2) has 3 coloured reference teeth

2
(Item 4) that must mesh with the corresponding teeth of the
reduction gear (Item 5).
4
6 Remove the eyebolts from the thrust ring (Item 6).

2
Apply loctite thread lock to the screws (Item 7) and tighten

the screws to a torque of 346 Nm.
90
90-07-M146EN (09/06/2011)
5
The tightening sequence of the screws is crosswise with

respect to the centre of the thrust ring, that means tighten
one screw, then the one diametrically opposite, so that the
thrust ring is screwed evenly onto the base.
90
(09/06/2011) 90-07-M146EN
6
TURRET REFIT
REPOSITIONING THE TURRET
With the aid of ropes and an overhead crane, replace the

turret (Item 1) on the truck.
Refit the screws (Item 2) through the hole under the

chassis.
2 Turn the truck by the angle necessary to give access to all
the screw holes, one at a time, through the hole.
Screw on the nuts (Item 3) and locknuts (Item 4).

90
90-07-M146EN (09/06/2011)
7
Replace the silencer (Item 5).
Refit the bracket (Item 6) to lock the silencer (Item 5).
Remove the ropes and release the turret from the overhead
crane.
Refit the cardan shaft (Item 7) under the truck by screwing
in the screws (Item 8) from both sides.
LIFTING CYLINDER REFIT ON THE TURRET
Replace the lifting cylinder (Item 9), using ropes and an

90
overhead crane.
9
(09/06/2011) 90-07-M146EN
8
Insert the lifting cylinder locking pin (Item 10) in its seating
and lock it by screwing in the screw (Item 11) and nut
(Item 12).
12
10
11
TURRET SENSORS REFIT

14
Replace the mounting (Item 13) and the maximum jib height
13
Refit the klaxon (Item 15) by screwing in the screw

(Item 16).
16
15
Refit the thrust ring locking pin presence sensor “I71”

(Item 17).
90
17
90-07-M146EN (09/06/2011)
9
Fit the thrust ring centring sensor “I15” (Item 18) on the
bracket (Item 19) and lock it to the truck.
18
19
Refit the bracket (Item 20) that supports sensors “I14”

(Item 21), “I74” (Item 22) and “I34” (Item 23) that detect
rotation of the turret beyond 15° by screwing in the screws
24
(Item 24).
20
21 22 23
RECONNECT THE TURRET HYDRAULIC SYSTEM
Insert the hydraulic pipes into the slot in the turret.
Reconnect all the hydraulic pipes to the distributor, following

the marks made when removing them.
90
(09/06/2011) 90-07-M146EN
10
Reconnect the pipes (Item 25 and 26).
25
25
26
Refit the couplings (Item 27).
27
Refit the collars (Item 28) and screw in the screws

(Item 29).
29 29
28
28
Lock the bundle of pipes (Item 30) with the plate (Item 31)
by screwing in the screws and nuts (Item 32 and 33).
33
90
32
30
31
33
32
90-07-M146EN (09/06/2011)
11
Reconnect the fuel line (Item 34) to the tank (Item 35) or,
if it was necessary to remove the tank, replace it on the
truck.
35
34
90
(09/06/2011) 90-07-M146EN
12
CAB REFIT
REPOSITIONING THE CAB
With the aid of ropes and an overhead crane, replace the

cab on the truck.
Connect the heater fuel line (Item 1) from the rear of the
mounting plate.
Fit the antivibration mounts (Item 2) by screwing in the

screws (Item 3).
90
90-07-M146EN (09/06/2011)
13
Fit the antivibration mounts (Item 4) by screwing on the nuts

(Item 5).
5
5
4 4
Refit the burner tube (Item 6), or its bracket, which may
have been moved at the assembly stage, to reach the nuts
locking the front right cab mounting.
Refit the plastic housing (Item 7) and the mat (Item 8).
Reconnect the wire (Item 9) to the rotation locking pin lever

10 (Item 10) inside the cab.
90
(09/06/2011) 90-07-M146EN
14
Remove the eyebolts (Item 11) from the cab.
11
RECONNECT THE CAB HYDRAULIC SYSTEM
Insert the hydraulic braking system cables from under the

cab and through the opening in the power steering housing
and take them out to the front of the cab near the brake
pump.
Reconnect all the hydraulic pipes according to the marks

made with a paint brush when removing.
13 Reconnect the hydraulic pipe (Item 12) and coil (Item 13) of
12
13 the slow/fast gear change electrovalve.
Reconnect all the hydraulic pipes (Item 14) to the brake

pump.
90
Bleed the brakes:

14
40 - Brake control and adjustment
14 14
14
90-07-M146EN (09/06/2011)
15
Reconnect the hydraulic pipes (Item 15) to the power

steering.
15
RECONNECT THE CAB ELECTRICAL SYSTEM
Reconnect the MSS system display (Item 16) to the

instrument panel.
16
Reconnect the feed through electrical connectors under the

cab and reconnect the ground cable (Item 17).
17
Reconnect all the connectors to the fuse box.
X3 X2
90
X4 X5
X8 X6
XDG
XD
(09/06/2011) 90-07-M146EN
16
Reconnect all the connectors to the logic box.

X22
X15
X13
X14
Secure the cables and pipes of the cab electrical and

18 hydraulic system with clips (Item 18).
18
18
18
19 CAB HOUSING REFIT

20
Reconnect the rotating lamp and emergency lamp
(Item 19 and 20) to the cab.
90
90-07-M146EN (09/06/2011)
17
Refit the housing bay under the cab (Item 21), the power steering protective housing (Item 22)
and the distributor cover (Item 23).
21 23
22
Refit the heating tank protective housing (Item 24), the logic box cover (Item 25) and the bonnet
(Item 26).
24
25
90
26
(09/06/2011) 90-07-M146EN
18
CONNECT THE AIR CONDITIONING TO THE CAB

(OPTIONAL)
If air conditioning is fitted to the truck, it must be refitted

after fitting the cab. Reconnect the feedthrough connectors
(Item 1) for this option.
Refit the air conditioning system (Item 2).
Reconnect the pipes (Item 3 and 4) to the air conditioning

radiator unit.
3
7
8
Refit the air conditioning radiator housing (Item 5) and the
right rear duct (Item 6), refit the rotating lamp and emergency
5
lamp (Item 7 and 8).
90
90-07-M146EN (09/06/2011)
19
Reconnect the negative ground (Item 9) of the additional

battery for the air conditioning.
Connect, an air conditioning gassing plant to the appropriate

10 couplings (Item 10), and charge the system with the
10
appropriate gas.
110 - Options - Attachments
90
(09/06/2011) 90-07-M146EN
20
90
90-07-M146EN (09/06/2011)

MRT 1850,2150,2540 Euro 3 Repair Manual M146EN 04.2011

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MRT 1850,2150,2540 Euro 3 Repair Manual M146EN 04.2011

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REPAIR MANUAL

This document has been printed from my e doc

AXLE ASSEMBLY - AXLE

- GENERAL INSTRUCTIONS AND SAFETY

In order to reduce accident risks, ensure the following:

When you see the symbol:

Before any repair work:

1 - Position the machine on a level surface and lock the wheels.

RULES FOR MAINTENANCE

Before carrying out any work on components with an electrical

Before carrying out any welding work, disconnect the

A machine that is operating in a contaminated environment

Never wear clothing, jewellery or objects that may become

Always wear goggles, protective gloves and safety boots and

If maintenance work is carried out near to a movable object,

While replacing or draining oil or fuel, or other work with liquids,

When lifting or propping up a component of the machine, ensure

If a jack is used, ensure that it is used on a level, uniform

Ensure that there are no objects or instruments that could

Do not check for any missing items by using your hands.

- ENGINE COMPONENTS REFIT

- COMPONENTS CONTROLS (Motor OM 904 LA

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PREPARATION AND SAFETY INSTRUCTIONS

Connect an unlocking lever to the screw (Item 3), tilt the

1 2 After removing the belt as indicated above, the alternator

Slacken the 2 nuts (Item 3) locking the 2 clamps (Item 4),

Unscrew the 4 screws (Item 6) locking the alternator

Unscrew the 2 screws (Item 8), slacken the screws (Item 9)

Unscrew the 2 screws (Item 11).

Disconnect the electric cables (Item 12 and 13) connected

The alternator (Item 14) can now be removed.

STARTER MOTOR REMOVAL

Unscrew the 6 screws (Item 1) and remove the lower casing

Disconnect the electric cables (Item 3 and 4) connected to

Slacken the 2 nuts (Item 5) locking the 2 clamps (Item 6)

Unscrew the screws and washers (Item 8 and 9) and remove

Unscrew the 3 screws (Item 12) and remove the starter

Remove the starter motor (Item 11) by passing it through

ENGINE COOLING WATER PUMP REMOVAL

Only work on the cooling system if the temperature

Unscrew the 6 screws (Item 1) and remove the lower casing

Remove the protective casing (Item 3) by unscrewing the

Connect an unlocking lever to the screw (Item 5), turn the

Slacken the 2 clamps (Item 8) on the lower sleeve

Obtain receptacles of adequate size for the quantity of liquid

Slacken the 2 clamps (Item 10) on the upper coupling

Unscrew the 4 screws (Item 12) and remove the pulley

Disconnect the temperature sensor (Item 22) from the

Unscrew the screws (Item 23 and 24) securing the

Unscrew the 6 screws (Item 1) and remove the lower casing

Unscrew the 2 nuts (Item 3) and remove the 2 clamps

Unscrew the screws (Item 6 and 7) and remove the clip

Slacken the clamp (Item 9) and remove the coupling

Plug all the pipes to prevent foreign bodies from

Unscrew the 4 screws (Item 20) and remove the protective

Unscrew the screws (Item 22) holding the turbocharger.

Unscrew the 8 screws (Item 25) and remove the exhaust

Unscrew the nuts (Item 27) and remove the turbocharger

PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PREPARATION AND SAFETY INSTRUCTIONS

Refit the turbocharger (Item 1) to the exhaust manifold

Refit the exhaust manifold (Item 2) to the engine crankcase

Reconnect the inlet coupling (Item 5) to the engine and