Manitou MLT 845 MLT X 845 Service Manual-21315M320014

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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Contents
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
Group 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
00
GENERAL
- GENERAL INSTRUCTIONS AND SAFETY

NOTICE
- GENERAL CHARACTERISTICS
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(26/09/2012) 00-00-M209EN
2 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
PREAMBLE
This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
– Follow the instructions in the truck operating and maintenance manual.

 This manual should be found in all trucks.
– Please follow all safety instructions.
– Use the appropriate tools for any work to be performed.
– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
When you see this symbol:
It means: Warning! Be careful! Your safety, somebody else’s or the safety of the lift truck itself
is at risk.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
given in the safety manual are not exhaustive.
At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or
to the lift truck itself when you repair, service or drive it.
Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other
than those specified.
00-00-M209EN (26/09/2012)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 3
00
MAINTENANCE POSITION
2 4
5
100 0
60 130 140 15
125
70 80 90
1 3
Before any intervention:
1 - Place the machine on a flat surface and chock the wheels.

2 - Turn off the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.
(26/09/2012) 00-00-M209EN
00
RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.
Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.
Be careful not to burn yourself when touching hot liquids or parts

when operations have to be done before the machine has had
time to cool down.
1
Before carrying out any operation on an electrically powered
2 component, activate the battery cut-off.
If the telehandler does not have a battery isolating switch, disconnect
the battery terminals then gather them.
ECU b Before carrying out any welding operations, think of

disconnecting computers.
A machine operating in a contaminated environment should be

specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.
00-00-M209EN (26/09/2012)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 5
00
Never step on a part of the machine that has not been designed for it.
Never wear clothes, jewelry or objects that could get caught during
work and cause accidents.
Always wear protection glasses, gloves, safety shoes as well as any

other protection required for the work to be carried out.
When carrying out maintenance operations near a mobile object,

make sure it is securitized.
When changing, or draining oils or fuel, or any other operation with

liquids, solids, gases that are harmful to the environment, make
sure the necessary precautions are taken to avoid contaminating
the environment.
(26/09/2012) 00-00-M209EN
00
When lifting or shoring a component of the machine, make sure

the equipment used is suitable for at least the load for which it
is subjected by the component and that it meets the national
standards for lifting devices.
When using a jack, make sure it is used on a flat, uniform surface, is

sturdy enough to support the load, that its lifting capacity is sufficient
and that it is correctly placed and positioned under the machine.
Make sure no object or tool which could cause an accident is left

in the machine.
Never control any leaks using a hand.
max.
min.
MAX Never adjust a component to over the maximum capacity indicated

by the manufacturer.
MIN
00-00-M209EN (26/09/2012)
00
GENERAL CONTROL AND ADJUSTMENT
pages
STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(09/10/2012) 00-04-M209EN
2 GENERAL CONTROL AND ADJUSTMENT
00
STANDARD TIGHTENING TORQUES

Standard tightening torque to be used when not otherwise indicated in the removal and refitting
operations:
- The following tightening torques are given for hexagon head screws without flanges and
cylinder head hexagon socket screws.
- The torques are given for a friction coefficient μ = 0,20 corresponding to dry-fitted zinc-plated
fasteners and for torque tools having a ± 20 % class C tightening torque accuracy (equivalent
to pneumatic screwdrivers).
NF E 25-030-1 Screw / Nut connection :

Tightening torque in N•m (±20%)
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “fine” pitch Grade 8.8 Grade 10.9
M3 x 0,5 1 1,5 - - -
M4 x 0,7 2,4 3,5 - - -
M5 x 0,8 4,8 7,1 - - -
M6 x 1 8,2 12,1 - - -
M8 x 1,25 20 30 M8 x 1 22 32
M10 x 1,25 43 63
M10 x 1,5 40 59
M10 x 1 46 68
M12 x 1,5 74 108
M12 x 1,75 69 102
M12 x 1,25 78 115
M14 x 2 111 163 M14 x 1,5 123 181
M16 x 2 175 256 M16 x 1,5 190 279
M18 x 2,5 240 352 M18 x 1,5 279 410
M20 x 2,5 341 501 M20 x 1,5 391 574
M22 x 2,5 470 691 M22 x 1,5 531 780
M24 x 3 588 864 M24 x 2 659 967
M27 x 3 874 1284 M27 x 2 965 1418
M30 x 3,5 1181 1735 M30 x 2 1351 1984
M33 x 3,5 1614 2371 M33 x 2 1821 2674
M36 x 4 2068 3037 - - -
b For hexagon screws with flanges:

Apply an increased torque of +10%.
(Standard NF E 25-030-1)
b Where washers are used, the following coefficient is to be applied (FD E 25-502) :
- Smooth tapered washer (CL): +5%
- Spring (or Grower) washer without jaws (W) : +10%
- Conical, internal teeth (CDJ-JZC) : +15%
00-04-M209EN (09/10/2012)
ENGINE
10
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS
- ENGINE COMPONENTS LOCALIZATION
- ENGINE CONTROL AND ADJUSTEMENT
- ENGINE REMOVAL
- ENGINE REMOVAL
- ENGINE CHARACTERISTICS AND l647370EN

SPECIFICATIONS
(ENGINE OM 904 LA
- ENGINE CONTROL AND ADJUSTEMENT 120CV)
10
ENGINE CHARACTERISTICS AND SPECIFICATIONS
pages
ENGINE CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
ELECTRICAL SUPPLY AND PIN-OUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ELECTRONIC CONTROL MODULE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
ENGINE GROUND. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
(26/09/2012) 10-01-M209EN
ENGINE CHARACTERISTICS AND
2 SPECIFICATIONS
ENGINE CHARACTERISTICS
 4 cylinders
 Electrical management (ECU A19 in the engine and A24 in the cab)
10
 Direct injection by injector pump

 Without preheating (to -20°C, from -15°C the optional air heater is activated)
 Compression: 18
 395 kg dry, 416 kg lubricated
FUEL CIRCUIT
Key :
Rep. Désignation
1 (1) Fuel pump
2 (2) Fuel filter
3 (3) Fuel supply to injection pumps
4 (4) Fuel return pipework
5 (5) Injector assembly
6 (6) Injector supply
7 (7) Injection lines
8 (8) Discharge valve
9 (9) Fuel return
10 (10) Injection pumps
11 (11) Return to fuel return line
12 (12) Fuel pre-fi lter
13 (13) Fuel pump supply hose
14 (14) Fuel supply hose
15 (15) Fuel supply valves
16 (16) Tank return hose
17 (17) Fuel return valve
18 (18) By-pass valve
19 (19) Hand starting pump
20 (20) Fuel heat exchanger (OPT)
21 (21) Primary fuel fi lter
22 (22) Water separator
A (A) Fuel supply
B (B) Fuel return
C (C) High pressure fuel supply
D (D) High pressure fuel
10-01-M209EN (26/09/2012)
SPECIFICATIONS 3
Diagram:
5 6
10
7
5 8
9
10
4
10
3
11
2
19
1 12
15 A
20 B
18 C
17 14 D
13 16
21
22
4
T° 10
Y5 5
R3 2 10
B10 5
9
3 10
1 5 8
11 10
17 19 5
12
13 18
20 A
B
15 C
14 D
16
(26/09/2012) 10-01-M209EN
4 SPECIFICATIONS
ELECTRICAL SUPPLY AND PIN-OUT
MR2-55
2
B37
2
10
19
1
1
2
Y34 20
B36
54
1
1
33
B35
Y35
2
45
2
49
1
16
1
29
Y36 53 B15
4
2
3
9
1
21
Y37 44
2
B19
2
48
1
06
05
+
F44
12
08 G1
15
36
1
09
B10
4 11 -
2
3
1
B18
34
2
01
CAN H ISO11992
02
CAN L ISO11992
15 03
5
Gnd CAN
B34
39 Gnd CAN 04
4
MR2-16
26
1
B17 26
2
5
3
1 30
S38
MR2-PLD
INHIBED 2 25
1
S39
INHIBED 2 35
ADM2-12 1 5 8 9 11 13 14 15 ADM2-15
10
CAN H
GND CAN H
CAN L
6
ADM2
4
3
120 Ohm
ANA piste 1
ANA piste 2
Gnd CAN
CAN H
CAN L
2
GND
1
1 2 3 5 6 7 12 13 14 3 8 19 21 20 ADM2-21
10-01-M209EN (26/09/2012)
SPECIFICATIONS 5
Key :
Rep. Désignation
- Negative power supply
10
+ Positive power supply
MR2 ECU MR2-PLD in engine
ADM2 Module ADM2 in cab
B15 Turbo air pressure sensor (combined with B19)
B10 Fuel temperature sensor
B17 Engine oil pressure control sensor
B18 Coolant liquid temperature sensor
B19 Turbo air temperature sensor (combined with B15)
B34 Engine oil temperature sensor
B35 Oil level sensor
B36 Camshaft position sensor
B37 Crankshaft position sensor
S38 Engine start-up button (disabled)
S39 Engine stop button (disabled)
Y34 Injection pump electrovalve cylinder A
Y35 Injection pump electrovalve cylinder B
Y36 Injection pump electrovalve cylinder C
Y37 Injection pump electrovalve cylinder D
B15 / B19
Y34 B10
Y35
Y36
Y37
B17 / B34
B36
D
C
B
A
S38
S39
B37
B18
B35
(26/09/2012) 10-01-M209EN
6 SPECIFICATIONS
ELECTRONIC CONTROL MODULE
The MR2-PLD electronic control module (1) is the regulator and computer for the fuel circuit. The MR2-
PLD receives signals from the sensors to control the engine’s tuning and speed.
10
The electronic circuit is made up of the MR2-PLD, sensors on the engine and inputs from the whole of
the machine by the ADM2 (2) located in the cab. The MR2-PLD is the computer. The personalization
module is the computer software. The personalization module contains the performance curves.
The performance curves define the following characteristics of the engine:
• Engine power
• Torque curves
• Engine rate (RPM)
• Engine noise 1 MR2-55
• Exhaust and emissions MR
2 MR2-16
2
2
M
AD
ADM2-21
ADM2-15
ADM2-12
ENGINE GROUND
Ground Point
10-01-M209EN (26/09/2012)
10
ENGINE COMPONENTS LOCATION
pages
MERCEDES ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
(26/09/2012) 10-03-M209EN
2 ENGINE COMPONENTS LOCATION
MERCEDES ENGINE
10
Water pump
Oil filter
Alternator
MR2-PLD
Fuel pre-filter
Belt Fuel filter
Fuel pump
Oil filter
Turbocompressor
Alternator
Starter
10-03-M209EN (26/09/2012)
ENGINE COMPONENTS LOCATION 3
FUEL CIRCUIT
10
Filter
Fuel tank
Engine
Key :
Tank aspiration
Fuel injection system
Back to tank
(26/09/2012) 10-03-M209EN
4 ENGINE COMPONENTS LOCATION
10
10-03-M209EN (26/09/2012)
10
ENGINE CONTROL AND ADJUSTMENT
pages
ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– ENGINE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– FUEL CIRCUIT - 120CV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– ENGINE SILENTBLOCS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FUEL GAUGE ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ALTERNATOR/CRANKSHAFT DRIVE BELT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
ENGINE COMPONENTS REMOVAL AND REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
– PREPARATION AND SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– A - ALTERNATOR DRIVE BELT CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– B - ALTERNATOR REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– C - CHANGING THE OIL FILTER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– D - CHANGING THE FUEL FILTER AND FUEL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . 10
– E - WATER PUMP REMOVAL AND REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– F - REMOVAL AND REFIT OF STARTER MOTOR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
FAN DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
– GRAPH SHOWING FAN DRIVE OPERATING CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
(26/09/2012) 10-04-m209EN
2 ENGINE CONTROL AND ADJUSTMENT
ENGINE TIGHTENING TORQUES
ENGINE ASSEMBLY
10
6 daN.m ± 10%
2,4 daN.m ± 10%
FUEL CIRCUIT - 120CV
10-04-m209EN (26/09/2012)
ENGINE CONTROL AND ADJUSTMENT 3
ENGINE SILENTBLOCS
A-A
C
A
10
11 daN.m ± 10%
20
141
7 daN.m ± 10%
C
66
142
A
142
B-B
11 daN.m ± 10%
285 300
20
63
7 daN.m ± 10%
ENGINE ORIENTATION
427,5
FRONT MACHINE
C-C
713
713
122
4,7 daN.m ± 10% 4,7 daN.m ± 10%
154 165
226,5
B B
205 216
(26/09/2012) 10-04-m209EN
FUEL GAUGE ADJUSTMENT PROCEDURE
Prepare the fuel gauge by following the values given below.

10
Part will be removed

after adjusting B
A=205
45
ma
xi
B=
21
0
10-04-m209EN (26/09/2012)
ALTERNATOR/CRANKSHAFT DRIVE BELT ADJUSTMENT
b
ALTERNATOR/CRANKSHAFT DRIVE BELT TENSION ADJUSTMENT PROCEDURE
10
Refer to the instructions.
(26/09/2012) 10-04-m209EN
ENGINE COMPONENTS REMOVAL AND REFIT

10
8 9 1
1 6 4
3
7
Key :
1 - Alternator
2 - Starter
3 - Belt
4 - Fuel fi lter
5 - Oil fi lter
6 - Water pump
7 - Fuel pump
8 - PLD
9 - Turbocompressor
PREPARATION AND SAFETY INSTRUCTIONS
– Activate battery cut-out.

– Open I.C. engine cover.
– Use battery cut-out to deactivate power supply.
10-04-m209EN (26/09/2012)
10
A - ALTERNATOR DRIVE BELT CHANGE
REMOVAL
4
3 Remove the 6 screws (Item 3) and remove the engine protection

3 cover (Item 4).
3
3
Slacken the belt (Item 5) by loosening the tensioning idler pulley
3
(Item 6).
3 Remove the belt.
5
REFIT
Examine the belt. If any of the following conditions are present,

replace it with a new belt:
– Wear on the sides.
6 – Transverse cracks over several ribs.
– Detached ribs or missing material.
– Torn or frayed structural threads.
– Deposits on the bottom of the belt.
To refit, proceed in the opposite order to the removal.
(26/09/2012) 10-04-m209EN
10
B - ALTERNATOR REFIT
1
REMOVAL
Carry out operation A.

3
Disconnect the electrical terminals (Item 1) on the alternator

3 (Item 2).
2
Using a 13 mm spanner, remove the alternator fixing bolts
(Item 3).
Remove the alternator.
REFIT
10-04-m209EN (26/09/2012)
10
C - CHANGING THE OIL FILTER ASSEMBLY
REMOVAL
Remove the alternator fixing bolt (Item 1). Swivel the alternator.
1
Disconnect the combined oil pressure and temperature sensor

(Item 2).
Disconnect the oil pressure hose (Item 3).
Remove the bolts (Item 4) fixing the oil filter (Item 5) to the
engine block.
4
Oil filter removal.
3
REFIT
b
2 4
4
Refer to MR647370EN for ensuring correct engine oil level.
(26/09/2012) 10-04-m209EN
10
D - CHANGING THE FUEL FILTER AND FUEL PUMP

ASSEMBLY
REMOVAL
Move the switch to the “vidange” (empty) position (Item 1) and

1 put the fuel pre-filter in its “OFF” position.
Drain the fuel filter using the drain plug (Item 2). Disconnect
the fuel inlet and outlet hoses (Item 3), and remove the fuel line
(Item 4). Plug the three hoses to avoid any possible leakage.
Remove the fixing bolts (Item 5) from the fuel filter (Item 6) and
from the fuel pump (Item 7).
Fuel filter removal.
4 2
Fuel pump removal.
3
REFIT
6 To refit, proceed in the opposite order to the removal.

5
b Refer to the instructions
5
5 5
5
5
7
5
10-04-m209EN (26/09/2012)
10
2 E - WATER PUMP REMOVAL AND REFIT
REMOVAL
Remove the fixing bolts from the tensioning idler pulley (Item
1) and from the pulley (Item 2).
Remove the pulley.

1 Remove the tensioning idler pulley.
Remove the hoses (Item 3) from the pump (Item 4).
3 Remove the retaining screws (Item 5) from the water pump.
Water pump removal.
Remove the thermostat, e MR647370EN.

4 3
REFIT
Ensure correct engine coolant level.

5
5
5
5
5
5
5 4
5
5
(26/09/2012) 10-04-m209EN
10
F - REMOVAL AND REFIT OF STARTER MOTOR

2
REMOVAL
3 Remove the rear engine (Item 2) protective cover (Item 1), by

removing the six retaining bolts with a 13 mm spanner.
6
Disconnect the connector (Item 4) located on the starter motor
4 (Item 5).
Unscrew the fastening screws (Item 6).
REFIT
5
10-04-m209EN (26/09/2012)
FAN DRIVE
ROLE
10
The function of the FAN DRIVE is to regulate the temperature of the oil in the hydraulic circuit and the
temperature in the engine coolant circuit.
OPERATING PRINCIPLE
The FAN DRIVE fan is powered by a hydraulic motor.
The motor is controlled by a solenoid control valve and by a changeover valve.
The solenoid control valve operates by increasing or decreasing the rotational speed of the fan, depending
on data from four sources: the transmission oil heat sensor, the hydraulic lift oil temperature sensor, the
engine coolant temperature sensor and the engine air temperature sensor.
The changeover valve changes to direction of rotation of the fan, thus allowing a clearing cycle. When
the switch is activated, the fan rotates in the normal direction for 3 minutes and then in the reverse
direction for 3 seconds, then reverting to normal rotation. This cycle continues for as long as the switch
is activated.
Changeover valve
Hydraulic
motor
Fan
Solenoid control
valve
(26/09/2012) 10-04-m209EN
Description of the fan reversal hydraulic motor
Key :
1 - Hydraulic motor
10
2 2 - Fan direction of rotation solenoid valve

4 3 - Fan speed control valve
1
5 4 - Pressure port (P)
5 - Return to tank (R)
Hydraulic schematic of motor:

BRVI 14 cm3/tr
P
Y43 BRVI: Fan reversal control unit
1
T P: From pump
Y42
RF RF: Radiator
Y42: Fan Drive reversal valve
Y43: Fan Drive control valve
Engine SPU
computer computer
CAN
Regulation
connection
valve
Turbocharged air
temperature sensor
Engine temperature
sensor
Mercedes engine
TOR changeover
valve
Gear box oil thermo switch
Hydraulic oil temperature switch
10-04-m209EN (26/09/2012)
CONDITIONS DES ÉLÉMENTS LIÉS À LA RÉGULATION DE VENTILATION
Lorsque la température d’eau moteur augmente, le courant d’alimentation de l’électrovanne de

régulation diminue.
10
Lorsque la température d’air moteur augmente, le courant d’alimentation de l’électrovanne de régulation
diminue.
Lorsque le thermocontact d’huile de transmission passe au-dessus du seuil maximal, le contacteur est
activé, ce qui enclenche le ventilateur en vitesse maximale. Lorsqu’il passe sous le seuil minimal, le
contacteur est désactivé.
Lorsque le thermocontact d’huile hydraulique passe au-dessus du seuil maximal, le contacteur est activé,
ce qui enclenche le ventilateur en vitesse maximale. Lorsqu’il passe sous le seuil minimal, le contacteur
est désactivé.
Valeur de régime du ventilateur
Régime ventilateur en fonction de la température eau moteur

Température d’eau moteur (T°) Pression entrée moteur (Bar) Vitesse ventilateur (tr/min)
70 28 739
75 69 1468
80 108 1979
85 127 2213
90 146 2438
95 163 2643
100 173 2747
Régime ventilateur en fonction de la température air sural moteur

Température d’air sural moteur (T°) Pression entrée moteur (Bar) Vitesse ventilateur (tr/min)
38 31 939
41 65 1550
43 98 1984
48 150 2592
52 169 2790
Seuil de déclenchement thermocontact huile transmission

Mini Typique Maxi
Plage de température - 20°C 90°C 110°C
Seuil de déclenchement 90°C
Seuil de désactivation 84,6°C
Seuil de déclenchement thermocontact huile hydraulique

Mini Typique Maxi
Plage de température - 20°C 75°C 110°C
Seuil de déclenchement 89°C
Seuil de désactivation 69,5°C
Pour les seuils électriques en fonction de la température, e fiches électriques de la sonde de température
d’eau moteur, la sonde de température d’air moteur, la sonde de température huile hydraulique et la
sonde de température huile transmission.
(26/09/2012) 10-04-m209EN
Graph showing Fan Drive operating cycle
Speed
Vitesse Clearing cycle Voltage Pressure
Tension Pression
(Tr/min) (A) (Bar)
10
2790 1,35
179
2500
1,15
150
2000 1,00
100
1500
0,50
0,45
1000 50
0,225
500 15
0,00 10
206 207 208 209 210 211 212 213 214 215 216 217 Temps (s)
Key :
Control voltage
Changeover voltage
Fan circuit pressure
Fan speed
10-04-m209EN (26/09/2012)
10
ENGINE REMOVAL
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DISMANTLING ORDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
“HYDRAULIC MOTOR” REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REMOVAL COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
“ENGINE” REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
(26/09/2012) 10-06-M209EN
2 ENGINE REMOVAL
10
Key :
A - Engine assembly

Stabilize the machine on a horizontal floor.
Perform several maneuvers in forward gear and reverse gear (wheels straight) in order to free the
steering and tires of any stresses.
Turn the wheels towards the left to facilitate disassembly.
Pull boom up to half-height and make sure it is positioned correctly.
Deactivate battery power supply using a battery cut-off.
Specific tools:
– Pallet truck
– Lifting crane (minimum 1000 Kg)
10-06-M209EN (26/09/2012)
ENGINE REMOVAL 3
DISMANTLING ORDER
Stage 1 HYDRAULIC MOTOR REMOVAL
10
Stage 2 REMOVAL COOLER
Stage 3 REMOVAL I.C. ENGINE
(26/09/2012) 10-06-M209EN
4 ENGINE REMOVAL
10
“HYDRAULIC MOTOR” REMOVAL
e 70 “Hydraulic components removal”
10-06-M209EN (26/09/2012)
ENGINE REMOVAL 5
10
REMOVAL COOLER
1
Follow the “Hydraulic Motor Removal” procedure
2
3
Disconnect the oil reservoir return hose (Item 1) and the
transmission hose (Item 2), using a 36 mm spanner. The hydraulic
oil reservoir will empty.
Disconnect connector X246 (Item 3).
6 Hold the oil reservoir return hose (Item 4), the transmission hose
(Item 5) and the bypass hose (Item 6) in the air. Then fix them
to the engine bay.
5
4
Disconnect connector X247 (Item 7), then remove the two

8
retaining screws (Item 8) and move the radiator side cover (Item
9) forwards.
9
7
(26/09/2012) 10-06-M209EN
6 ENGINE REMOVAL
Retirer les 6 vis de fixation (Rep.10) du carter de la courroie

11 d’alternateur (Rep.11). Dépose du carter, dégager la partie avant
10
puis la partie arrière.
10
10 10
10
14 Débrancher le flexible de transmission boite (Rep.12) à l’arrière

15
du refroidisseur (Rep.13), ce flexible permet la vidange de la
cuve d’huile de transmission. Défaire le collier (Rep.14) de la
durit d’eau inférieure (Rep.15) du refroidisseur, cela permet la
13
vidange du liquide de refroidissement.
12
17 16 Retirer les colliers (Rep.16) de la durit d’eau supérieure (Rep.17)

et déposer la. Dévisser la fixation du collier (Rep.18). Retirer
18 les colliers (Rep.19) de la durit du vase d’expansion (Rep.20) et
16
19
déposer la.
19
20
Retirer le support du capot moteur arrière (Rep.21), dévisser les

quatre vis de fixation (Rep.22) à l’aide d’une clé de 13.
21
23
22
10-06-M209EN (26/09/2012)
ENGINE REMOVAL 7
Retirer les vis de fixation (Rep.26) du support du vérin de capot

moteur (Rep.27), dévisser les vis de fixations à l’aide d’une clé
26 de 13. Exécuter la même opération pour les supports avant et
arrière du capot moteur.
10
27
Retirer les deux cylindres blocs (Rep.28) du refroidisseur sous le

caisson moteur (Rep.29).
29
28
28
Dévisser les colliers (Rep.30) de fixation des durits (Rep.31) à l’aide

d’une clé de 13, puis les boulons (Rep.32) de la ligne d’entrée
d’air refroidisseur (Rep.33) à l’aide d’une clé de 17.
Dégager et la faire glisser vers l’arrière du caisson.
32
31 31
32
33
30 30
Dévisser le collier de fixation (Rep.34) de la ligne sortie d’air

34
35
refroidisseur / moteur (Rep.35) et de la durit (Rep.36) fixée sur
le refroidisseur (Rep.37).
36
37
(26/09/2012) 10-06-M209EN
8 ENGINE REMOVAL
Dévisser les deux vis de fixation (Rep.38) de la ligne de sortie

d’air refroidisseur / moteur (Rep.39) à l’aide d’une clé de 17.
Dévisser le collier (Rep.40) à l’aide d’une clé de 13.
39
10
38
40
Accrocher un anneau d’élingage (Rep.45) et faire basculer le

refroidisseur vers l’avant afin de le libérer des caoutchoucs.
45
Procéder à la dépose refroidisseur en le sortant à l’aide d’un palan.
Déposer le refroidisseur.
10-06-M209EN (26/09/2012)
ENGINE REMOVAL 9
10
“ENGINE” REMOVAL
3
4
Using a screwdriver (Item 1) remove the clip from the lower

1
heater hose (Item 2).
Undo the clip (Item 3) and remove the upper heater hose (Item 4).
Remove the hydraulic pump
Put the diesel fuel filter switch (Item 5) in its “OFF” position.
43 Put the tap (Item 6) in its “Vidange” (“Empty”) position.

42
41 Disconnect the supply (Item 7) and return (Item 8) hoses from

the fuel filter (Item 9), using a 22 mm spanner.
44
(26/09/2012) 10-06-M209EN
10 ENGINE REMOVAL
Empty the air conditioning circuit, then remove its hoses (Item
7) using a 27 mm spanner.
10
Remove the protective cover (Item 8) from the back of the

engine bay (Item 9), unscrewing the bolts (Item 10) with a 10
8 mm spanner.
10
Remove the air inlet hose (Item 11), unscrewing the three hose
clips (Item 12) with a 7 mm spanner.
12
13
11
Remove the four fixing bolts (Item 13) from the protective grille
13 (Item 14) between the compensator and the turbo, using a 13
14 mm spanner.
Remove the protective grille.
13
10-06-M209EN (26/09/2012)
ENGINE REMOVAL 11
Remove the hose clip (Item 15) from the compensator (Item 16)
using a 19 mm spanner.
15
10
16
Remove the four bolts (Item 17) connecting the compensator

(Item 18) to the turbocharger (Item 19) using a 15 mm spanner.
17 Remove the compensator.
17
19
18
20 Disconnect connector X249 (Item 20), located behind the alternator

(Item 21).
21
Disconnect the starter motor (Item 22).
22
(26/09/2012) 10-06-M209EN
12 ENGINE REMOVAL
Unplug the Mercedes engine ECU (Item 24) connector (Item 23).
24
10
23
Disconnect connector X207 (Item 25) from the compressor

(Item 26).
26
25
Remove the six bolts (Item 27) and remove the two half-rings
(Item 28) and their fixings (Item 29).
29 29
27
27
28 28
27 27
Remove the eight fixing bolts (Item 30) from the transmission
universal joint (Item 31).
31
30
10-06-M209EN (26/09/2012)
ENGINE REMOVAL 13
Undo the silentbloc engine mountings (Item 32) leaving the

engine (Item 33) free.
10
32 33
Fix hooks to the lifting points (Item 34) then raise the engine
(Item 35) using a hoist (Item 36).
36
34
34
35
Lower the engine on to a pallet.
(26/09/2012) 10-06-M209EN
14 ENGINE REMOVAL
10
10-06-M209EN (26/09/2012)
10
ENGINE REFIT
pages
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

ORDER OF REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
REFIT “I.C. ENGINE” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
REFIT COOLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
HYDRAULIC MOTOR REFIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
(26/09/2012) 10-07-M209EN
2 ENGINE REFIT
10
Key :
A - Ensemble caisson + motorisation

Stabilize the machine on a horizontal floor.
Perform several maneuvers in forward gear and reverse gear (wheels straight) in order to free the
steering and tires of any stresses.
Turn the wheels towards the left to make it easier to reassemble.
Pull boom up to half-height and make sure it is positioned correctly.
Deactivate battery power supply using a battery cut-off.
Specifi c tools:
– Pallet truck
– Lifting crane (minimum 1000 Kg)
10-07-M209EN (26/09/2012)
ENGINE REFIT 3
ORDER OF REASSEMBLY
Stage 1 REFIT I.C. ENGINE
10
Stage 2 REFIT COOLER
Stage 3 REFIT “HYDRAULIC MOTOR”
(26/09/2012) 10-07-M209EN
4 ENGINE REFIT
10
REFIT “I.C. ENGINE”
2
Locate the engine (Item 1) in the correct position and secure
the four silentbloc engine mountings (Item 2).
Position the universal joint (Item 3) and secure the eight bolts
(Item 4) using a 13 mm spanner.
3
Re-fit the rubber half-rings (Item 5) and their brackets (Item 6);
secure the six bolts (Item 7) using a 13 mm spanner.
6
6
7 5 7
5
7 7
10-07-M209EN (26/09/2012)
ENGINE REFIT 5
9 Re-fit the connector (Item 8) to the starter motor (Item 9) using

10
8
Re-connect connector X249 (Item 10) to the alternator (Item 11).
10
Reconnect the plug (Item 12) to the PLD (Item 13).

13
12
15
Connect connector X207 (Item 14) to the compressor (Item 15).
14
(26/09/2012) 10-07-M209EN
6 ENGINE REFIT
Fit the compensator (Item 16). Fix the four fixing bolts (Item 17)
behind the turbo (Item 18), without forgetting the protective
17 18
grille’s fitting lug (Item 19).
10
19
17
16
Fit the clamp (Item 20) between the compensator (Item 21) and
the exhaust system (Item 22).
22
20
21
Fit the compensator protective grille (Item 23); Tighten the four
23
bolts (Item 24) with a 13 mm spanner.
24
Re-fit the air intake hose (Item 25) between the filter and the
turbo; secure it with the three hose clips (Item 26) and tighten
with a 7 mm spanner.
26
25
26
10-07-M209EN (26/09/2012)
ENGINE REFIT 7
Connect the air conditioning hoses (Item 27), using a 27 mm

spanner.
Re-fill the air conditioning circuit.
10
27
27
Remove the plugs from the filter hoses and valves. Connect the
diesel fuel hoses (Item 28) in accordance with the markings (Item
29), using a 22 mm spanner.
29
28
28
30
Hydraulic pump re-fitting (Item 30).
e 70 “Refit hydraulic components”
Refit the rear engine bay cover (Item 31), using a 13 mm spanner
on its six bolts (Item 32).
32
32
31
(26/09/2012) 10-07-M209EN
8 ENGINE REFIT
10
REFIT COOLER
Place the cooling assembly (Item 1) in the engine bay (Item 2)

3 using a hoist (Item 3).
1 2
Refit the fuel filter (Item 4). Position it against the chassis (Item 5)
5
and then tighten the fixing bolts (Item 6) with a 15 mm spanner.
Open the fuel outlet thumbwheel (Item 7).
6 6
4
7
Position the radiator/engine air outlet line (Item 8), then fix the
9
clamps (Item 9) with a 17 mm spanner.
10-07-M209EN (26/09/2012)
ENGINE REFIT 9
Locate the radiator/engine air outlet hose (Item 10) in position,

14
then secure with the hose clip (Item 11) using a 13 mm spanner.
10
10
Locate the radiator/engine air input line (Item 12) in position, fix
the clamps (Item 13) using a 17 mm spanner and the hose clips
14 12
14
13 13
Position the radiator (Item 15) in the engine bay (Item 16). Feed
the overflow pipe through the hole (Item 17), taking care not to
kink the pipe.
16
15
17
Fix the radiator in position using its silentbloc mountings (Item

18); use a 17 mm spanner to tighten the bolts (Item 19).
18
19
18
19
(26/09/2012) 10-07-M209EN
10 ENGINE REFIT
Monter les supports du capot moteur (Rep.20) et le support

vérin, fixer les avec les vis (Rep.21) à l’aide d’une clé de 13.
22
10
29
21
Positionner le refroidisseur (Rep.22) et le capot moteur (Rep.23)

puis serrer les vis (Rep.24) à l’aide d’une clé de 13. Faire la même
24
24 opération pour la fixation sur le support arrière.
23
24
24
22
Enclencher le vérin (Rep.25) sur la rotule du capot moteur

(Rep.26), et fixer à l’aide du cache vérin (Rep.27).
27
26
10
25
28 29
Positionner la durit supérieure du vase d’expansion (Rep.28)
33
et serrer les colliers de fixation (Rep.29) à l’aide d’une clé de 7.
Positionner la durit inférieure du vase d’expansion (Rep.30) et
31
29
32 serrer les colliers (Rep.31) à l’aide d’une clé de 7.
Fixer le collier (Rep.32) sur le vase d’expansion (Rep.33).
31 30
10-07-M209EN (26/09/2012)
ENGINE REFIT 11
Brancher le flexible de transmission boite (Rep.34) à l’arrière du

36
refroidisseur (Rep.35) à l’aide d’une clé de 36. Emboiter la durit
37
d’eau inférieure (Rep.36) et serrer le collier (Rep.37) à l’aide d’une
clé de 7.
10
35
34
Positionner et fixer le carter moteur (Rep.38) avec les six vis

(Rep.39) à l’aide d’une clé de 13.
39
39
39
38
39 39
Positionner et fixer le carter latéral du refroidisseur (Rep.40) avec

les deux vis (Rep.41), n’oubliez pas de fixer les colliers (Rep.42)
41
42 à l’aide d’une clé de 13.
Brancher le connecteur X247 (Rep.43).
40
43
42
41
Fixer les flexibles de retour de bac à huile (Rep.44) et de transmission

(Rep.45) à l’aide d’une clé de 36.
44 Brancher le connecteur X246 (Rep.46). Tout en maintenant l’orifice
du flexible de fuite (Rep.47) le plus en l’air possible.
45
46
47 Faire le remplissage en huile transmission et en liquide de
refroidissement.
(26/09/2012) 10-07-M209EN
12 ENGINE REFIT
10
HYDRAULIC MOTOR REFIT
10-07-M209EN (26/09/2012)
OPTIONS - ATTACHMENTS
- AIR CONDITIONING OPTIONS
110
OPTION CLIMATISATION
pages
OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2

DESCRIPTION OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A4
LOCALISATION CLIMATISATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A5
ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . .A6
SECURITY MEASURES FOR THE MANIPULATION OF R134A . . . . . . . . . . . . . . . . . . . . . . . . . .A6
REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . .A6
LOADING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7
OPERATING CONTROL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A8
MONITORING ANTI-ICING SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A10
AIR CONDITIONING MONITORING FORM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A11
110
(26/09/2012) 110-M209A-EN
A2 OPTION CLIMATISATION
OPERATING PRINCIPLE
Electromagnetic
Embrayage
électromagnétique
clutch
Alternator
Alternateur
Compresseur
Compressor
Moteur
Engine
Low pressure
Circuit vapeur High pressure
Circuit vapeur
basse
steampression
circuit steam
haute circuit
pression
Air
External air
extérieur
Ventilateur
Axial fan
Axial
Condenser
Condenseur
Evacuation
Hot air
air chaud
discharge
FILTRE
Drier Filter
DESHYDRATEUR
Binary pressure
PRESSOSTAT
switch
BINARY
Air tiède
Warm air
VOYANT
Lamp
Filtres
Filter
Circuit liquide
High pressure
VENTILATEUR haute
liquidpression
circuit
Centrifugal fan
CENTRIFUGE
(Turbine)
(Turbine) DETENDEUR
Expansion valve
Circuit liquide
Low pressure
Basse
liquidpression
circuit
Evaporateur
Evaporator
THERMOSTAT
Thermostat
Ecoulement de of
Flow of the water
l'eau de condensation
condensation
110
Diffusion
Cold air
d'air froid
distribution
HABITACLE
CAB
110-M209A-EN (26/09/2012)
OPTION CLIMATISATION A3
DESCRIPTION OF OPERATION
The air conditioning system aims to reduce the atmospheric pressure in the cab interior by extracting
and dispersing the heat to the exterior.
This heat exchange is possible thanks to the use of a refrigerant fluid, R134a whose properties are to
obtain very low temperature at low pressures by dilating it and inversely high temperatures at average
pressure by compressing it.
The use of the properties of this fluid is done following the closed circuit cycle whose principle is:
Phase 1: compression
The R134a enters the compressor as a low pressure gas, where it is compressed. The compressor sends
the resulting high pressure, high temperature gas to the condenser.
Phase 2: condensation
The gas enters the condenser where, assisted by the fan, it transmits its heat to the outside air.
As it passes through the condenser it condenses back to a liquid state, maintaining high pressure and
heat. It is then filtered in a drier.
Phase 3: reducing
The R134a then enters the expansion valve, where it considerably loses pressure and temperature,
while remaining in a liquid state.
Phase 4: evaporation
The liquid R134a then passes through the evaporator where it absorbs heat from the cab and vaporizes,
maintaining low temperature and pressure.
As such, the cab interior air propelled by the fan motor cools down and looses its humidity when in
contact with the evaporator. The condensation of the air is then drained and evacuated to the outside
of the vehicle.
Both high and low pressure sections of the circuit are monitored by high pressure and low pressure
Pressostats mounted directly to the receiver dryer.
Its security operations are as follows:
 Complete stop of the air conditioning if the pressure is lower than 2 bars or greater than 27 bars.
110
(26/09/2012) 110-M209A-EN
DESCRIPTION OF COMPONENTS
The compressor
The compressor circulates the R134a through the circuit, drawing it in as a low pressure and low
temperature gas from the evaporator and sending it to the condenser as a high pressure, high
temperature gas.
The condenser
The condenser is a thermal exchanger that transmits the heat recuperated from the evaporator
to the outside air using the fan and causes the condensation of the fluid at high pressure.
The drier filter

The filter is the main protective component in the system. It ensures:
- Filtering any solid particles passing in the fluid that may damage the compressor or
obstruct the reduce valve, for example.
- Separates out any water from the gas and oil to protect all parts of the circuit from
corrosive substances and from any water freezing as it leaves the expansion valve.
- Acts as the storage tank for liquid refrigerant and a buffer tank for any pressure variations.
It contributes to the absorption of any differences in the pressures created by the
compressor.
The “binary” pressure switch

Fixed to the receiver dryer, the Pressostat is the system’s safety device that monitors pressure
variations. It protects the system against pressures that are too low as well as those that are too
high, directly controlling the compressor clutch.
- Action to prevent low pressures (< 2 bars) due for example to insufficient refrigerant
fluid, a leak or a plug forming upstream of the circuit.
- Action to prevent low pressures (> 27 bars) due to poor condenser cooling, an excess
of refrigerant fluid or a plug forming upstream of the circuit.
The reducing valve

The expansion valve is fitted at the entry to the evaporator. By expansion it drops the pressure
in the fluid and consequently its temperature. The resulting cold liquid can cool the air passing
through the evaporator. It controls the flow in such a way as to ensure that it is completely
vaporized when it leaves the evaporator.
The evaporator
The evaporator is a heat exchanger fitted with an expansion valve and a fan. The fan draws air
across the cold evaporator fins. As the air passes across the fins any damp in it condenses and the
air leaves the evaporator cooled. This heat exchange allows the liquid refrigerant to evaporate
at low pressure.
The anti-frost thermostat

The electric thermostat is connected to a sensor placed between two evaporator fins. Temperature
variations in the evaporator lead to variations in the resistance of the potentiometer in the pre-
set thermostat and this controls the compressor clutch relay.
110
110-M209A-EN (26/09/2012)
LOCALISATION CLIMATISATION
b
m
10
8
6 5

1
green/yellow
Evaporator purple red
orange yellow
Reducing valve
Air-conditioning control
Connector
1
8
*$
=5

HP Pressostat
$
1

Receiver-drier
Condenser
Air blowing control
1/4 turn heating control
- batt
+ batt
HP connector
Thermal
110
circuit-breaker
LP connector
Compressor
(26/09/2012) 110-M209A-EN
ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT
Carry out the assembly operations in a dry and dust free area. Use oil PAG ISO 100 SP 20 for the lubrication
of all seals and seal surfaces before assembly.
INTERNAL EXTERNAL
POSITION HOSE MODULE UNION THREAD
DIAMETER DIAMETER
Between compressor and condenser Module 8 10 mm 20,5 mm 3/4"-16 UNF
Between receiver drier and expansion Module 6 8 mm 18 mm 5/8"-18 UNF
valve
Between evaporator and compressor Module 10 13 mm 23,5 mm 7/8"-14 UNF
To evaporator:
– Tightening torque on Module 10: 25 Nm, 22 mm spanner and + 25/26 mm counter-spanner on
expansion valve.
– Tightening torque on Module 6: 16 Nm, 16/17 mm spanner and + 25/26 mm counter-spanner on
expansion valve.
SECURITY MEASURES FOR THE MANIPULATION OF R134a
1 - Individual protection: integral protection glasses and rubber gloves.
2 - First aid: After inspiration, breath in healthy air, give oxygen and do mouth-to-mouth resuscitation
according to the degree of emergency (medication contraindication). Consult a doctor. If it touches
the eyes, rinse thoroughly for 15 minutes and see a doctor. If it touches skin, rinse thoroughly and
take contaminated clothes off.
3 - Storage conditions: store the R134a in a hermetic place in a dry, cool and well ventilated area.
4 - Manipulation: only in ventilated areas.
5 - Measures to take in case of accident: wear an autonomous respiratory device in case of R134a
exposure to fire.
REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT
Refrigerant fluid: R134a

Load equipment: Load station
Quantity of fluide: 1000 gr ± 25 gr and 135ml PAG SP20 oil.
For filling the circuit with R134a, contact and air-conditioning specialist.
110
110-M209A-EN (26/09/2012)
LOADING METHOD
Before any manipulation of the load station, refer to the instruction booklet for the device.
First circuit fluid load (duration 56 min)
1 - Circuit station connection phase (about 1 minute).

2 - Fluid circuit evacuation phase (minimum duration 45 minutes).
 Reach the evacuation at the pressure of – 0.75 bar in 10 minutes maximum,
 Maintain the evacuation at the pressure of – 0.99 bar maximum for dehumidifying in 30 minutes
minimum,
 Checking leaks in 5 minutes minimum.
3 - Charging operation (maximum 10 minutes).
Fluid load after intervention (duration 90 min)
1 - Preparation phase (about 15 minutes).

 Connect the circuit station,
 Run the vehicle engine between 800 and 1200 rpm,
 At the same time set the heater fan to its maximum speed “II”,
 Turn the vehicle ignition off after 10 to 15 minutes.
2 - Recovery phase (15 minutes maximum),
Its aim is to recuperate and recycle the gas, oil and any impurities present in the circuit.
Launch the fluid recuperation cycle on the station.
3 - 3- to 4-minute waiting phase for any oil and humidity micro freezing to be recovered.
4 - Recovered oil drain phase (about 1 minute).
5 - Phases 1, 2 and 3 can be redone if a pressure forming is observed during phases 2 and 3.
6 - Fluid circuit evacuation phase (minimum duration 45 minutes).
 Reach the evacuation at the pressure of –0,75 bar in 10 minutes maximum,
 Maintain the evacuation at the pressure of – 0,99 bar maximum for dehumidifying in 30 minutes
minimum,
 Checking leaks in 5 minutes maximum.
7 - Charging phase (maximum 10 minutes).
Fluid make-up (duration 15 min) vehicle engine in operation
1 - Preparation phase (about 10 minutes).

 Connect up circuit station,
 Run vehicle engine at between 800 and 1200 rpm,
 At the same time set the heater fan to its maximum speed “II”.
2 - Additional charging phase (about 5 minutes).
b The R134a fluid, in free air is a colorless and odorless gas, heavier than air, that may be
dangerous for human beings in certain conditions. Always recuperate the refrigerant fluid
using the loading station.
110
(26/09/2012) 110-M209A-EN
OPERATING CONTROL
The following controls are carried out with the vehicle engine running.
1. Heating adjustments
Use the switch to set the heater fan to speed “II”.
Ensure the air-conditioning switch is in its “off” position.
Check the increase in temperature between the minimum hot position

and the maximum hot position.
110
110-M209A-EN (26/09/2012)
2. Air conditioning adjustments
• Raccorder la station de charge

• Mettre le moteur du véhicule en route
• Mettre en fonction la climatisation comme suit :
Select speed “I” for the air diffusion by the switch
Turn the air-conditioning control to maximum.
Using the manual control, adjust the temperature to the minimum warm
position.
– Open 2 air diffuser mouths.

– Adjust engine rpm to idling speed (about 800 rpm).
– Wait at least 5 minutes for circuit to stabilize.
– Check that LP and HP circuit pressure values between two compressor shut-downs are in between:
 0,5 bar and 2 bar in LP,
 6 bar and 20 bar in HP.
110
(26/09/2012) 110-M209A-EN
MONITORING ANTI-ICING SAFETY
– Connect charging station

– Turn vehicle engine on
– Switch on air conditioning as follows:
Select speed “I” for the air diffusion by the switch.
Turn the air-conditioning control to maximum.

The compressor activates, then the condenser fans 7 seconds later.
Using the manual control, adjust the temperature to the minimum

warm position.
– Close all air diffuser mouths.

– Adjust engine rpm to idling speed (about 800 rpm).
– Check that the LP and HP circuit pressures are between:
 0,5 bar and 2 bar in LP,
 6 bar and 20 bar in HP.
– Check that compressor shuts down after some minutes:
 LP ≥ 3 bar,
 HP ≤ 5 bar.
110
110-M209A-EN (26/09/2012)
AIR CONDITIONING MONITORING FORM
– Engine idling, fan speed at position “I”, air conditioning in operation and in minimum cold position.
– Check air exit temperature and note:
Temperature Pressures Compressor

Date Machine N°
External Mouth output BP HP shut-down
110
(26/09/2012) 110-M209A-EN
110
110-M209A-EN (26/09/2012)
TRANSMISSION
- TRANSMISSION SCHEMATIC DIAGRAMS
20
- TRANSMISSION CONTROL AND
ADJUSTEMENT
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT
- SPECIFIC TRANSMISSION TOOLING
- TRANSMISSION CONTROL AND l 647058EN

ADJUSTEMENT
(ANGLE GEAR BOX
15930-15932)
- TRANSMISSION CHARACTERISTICS AND l 647020EN

SPECIFICATIONS
(COMPACT PLUS
- TRANSMISSION CONTROL AND GEAR BOX)
ADJUSTEMENT
- TRANSMISSION SCHEMATIC DIAGRAMS
- TRANSMISSION TROUBLESHOOTING
- TRANSMISSION CHARACTERISTICS AND l 647030DE/EN

SPECIFICATIONS
(A4VG PUMP)
- TRANSMISSION CONTROL AND
ADJUSTEMENT l 647031DE/EN
- TRANSMISSION COMPONENTS SECTIONS (A6VM MOTOR)

AND DIAGRAMS
- TRANSMISSION CHARACTERISTICS AND l 647379EN
SPECIFICATIONS
(TRANSFER BOX
- TRANSMISSION CONTROL AND TYPE 357)
ADJUSTEMENT
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT

TRANSMISSION SCHEMATIC DIAGRAMS
20
pages
POWER FLOW DIAGRAM/GEAR RATIOS - MECHANICAL TRANSMISSION . . . . . . . . . . . . .3

POWER FLOW DIAGRAM/GEAR RATIOS - HYDROSTATIC TRANSMISSION . . . . . . . . . . . .4
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN FORWARD GEAR . . . . . . . . . .5
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN REVERSE GEAR . . . . . . . . . . . .6
(26/09/2012) 20-02-M209EN
2 TRANSMISSION SCHEMATIC DIAGRAMS
20
20-02-M209EN (26/09/2012)
TRANSMISSION SCHEMATIC DIAGRAMS 3
MLT 845-120 Serie 5-E3
POWER FLOW DIAGRAM/GEAR RATIOS - MECHANICAL TRANSMISSION
Front Drive Axle Rear drive axle
Clockwise
20
IC engine
Shuttle
Torque
converter
GEAR BOX
Angle gear
box
Transfer box
Forward gear
Gear Box Angle gear box Final drive: Z22/Z23 11/35

Front Drive Axle
Z1 24 teeth Z20 23 teeth Ratio hub reduction: Z25/(Z24+Z25) 1/6
Rear Drive Axle
Z2 27 teeth Z21 23 teeth Axle total: 1/19,09
Z3 24 teeth
Z4 27 teeth Front and rear axles Rapport de l’inverseur : Z2/Z4 1/1
Z5 35 teeth Z22 11 teeth I (Z1*Z8)/(Z5*Z12) 1/4,824
Z6 29 teeth Z23 35 teeth II (Z1*Z7)/(Z5*Z11) 1/2,998
Forward gear
Z7 18 teeth Z24 70 teeth III (Z1*Z6)/(Z5*Z10) 1/1,408
Z8 13 teeth Z25 14 teeth Gear Box IV (Z1*Z5)/(Z5*Z9) 1/0,792
Box ratios
Z9 19 teeth Z26 27 teeth I (Z3*Z8)/(Z5*Z12) 1/4,824
Z10 28 teeth II (Z3*Z7)/(Z5*Z11) 1/2,998
Reverse gear
Z11 37 teeth III (Z3*Z6)/(Z5*Z10) 1/1,408
Z12 43 teeth IV (Z3*Z5)/(Z5*Z9) 1/0,792
Z13 37 teeth
Z14 37 teeth Transfer box Rear axle train ratio Z13/Z14 1/1
Converter Torque multiplication: : 1,99 à 1990 rpm
Angle gear box Ratio : Z21/Z20 1/1
(26/09/2012) 20-02-M209EN
MLT 845-120 H Serie 4-E3
POWER FLOW DIAGRAM/GEAR RATIOS - HYDROSTATIC TRANSMISSION
Front Drive Axle Rear drive axle
Clockwise
IC engine
20
Transfer box
Forward gear
Front and rear axles Final drive: Z1/Z2 8/31

Front Drive Axle
Z1 8 teeth Ratio hub reduction: Z4/(Z3+Z4) 1/6
Rear Drive Axle
Z2 31 teeth Axle total: 1/23,25
Z3 70 teeth
Z4 14 teeth Number of ratios: 2
Z5 27 teeth Z8/Z9 34/55
Ratios:
Transfer box Z6/Z7 21/69
Maximum input torque: 740 N.m
Transfer box Maximum input revolutions: 5000 rpm
Z6 21 teeth
Z7 69 teeth
Z8 34 teeth
Z9 55 teeth
20-02-M209EN (26/09/2012)
TRANSMISSION SCHEMATIC DIAGRAMS 5
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN FORWARD GEAR

Key :
B L Suction pressure
RLF
X N
Boost pressure
High Pressure
MC Low Pressure
§ 70
P Control pressure
A
§ 70 Cooling pressure
Drainage pressure
20
Oil tank return
P T Ø1
TH7 § 70 See chapter “70 - hydraulics”
CAR A Accumulator
2 b.
BT Transfer box
CAR Non-return valve
M1 T EVPV Solenoid operated gear change valve

B U T2 Y
FDav Front brake
MH Y2
T1 FR Return filter
R Y3 PS Fa Fa1 Fe MB
Y1
B M Turbo IC engine
MC Master cylinder
MH Hydrostatic motor
M
N Level
b PH
A PH Hydrostatic pump
R Hydraulic tank
X1 X2 G MH S Fs MA
RAD Radiator
T G X1 X3 A TH7 TH7 valve
VPV Gear change cylinder
Y1 Reverse gear electrovalve (MH)
FDAV Y2 Forward gear electrovalve (PH)
BT Y3 Reverse gear electrovalve (PH)
Y4 Snail speed electrovalve (MH)
VPV
CAR
2 b.
A A B
0,7 L.
13 b. EVPV
P T
§ 70
§ 70
FR A
RAD
Forward Gear VA 4b
B V3
§ 70
V1 V2
2b 7,6b
10 μm abs T
300 L/mn
N
R
(26/09/2012) 20-02-M209EN
SCHEMATIC DIAGRAM HYDROSTATIC TRANSMISSION IN REVERSE GEAR

Key :
B L Suction pressure
RLF
X N
Boost pressure
High Pressure
MC Low Pressure
§ 70
P Control pressure
A
§ 70 Cooling pressure
Drainage pressure
20
Oil tank return

P T Ø1
TH7 § 70 See chapter “70 - hydraulics”
CAR A Accumulator
2 b.
BT Transfer box
CAR Non-return valve
M1 T EVPV Solenoid operated gear change valve

B U T2 Y
FDav Front brake
MH T1 Y2 FR Return filter
R Y3 PS Fa Fa1 Fe MB
Y1
B M Turbo IC engine
MC Master cylinder
MH Hydrostatic motor
M
N Level
Y4 PH
A PH Hydrostatic pump
R Hydraulic tank
X1 X2 G MH S Fs MA
RAD Radiator
T G X1 X3 A TH7 TH7 valve
VPV Gear change cylinder
Y1 Reverse gear electrovalve (MH)
FDAV Y2 Forward gear electrovalve (PH)
BT Y3 Reverse gear electrovalve (PH)
Y4 Snail speed electrovalve (MH)
VPV
CAR
2 b.
A A B
0,7 L.
13 b. EVPV
P T
§ 70
§ 70
FR A
RAD
Reverse Gear VA 4b
B V3
§ 70
V1 V2
2b 7,6b
10 μm abs T
300 L/mn
N
R
20-02-M209EN (26/09/2012)
TRANSMISSION CONTROL AND ADJUSTMENT
20
pages
TIGHTENING TORQUES, MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

TIGHTENING TORQUES, HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PRESSURE TAKE-OFF POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
– A4VG 71 DA PUMP PRESSURE MEASURING POINT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– A6VM SERIES 63 MOTOR PRESSURE MEASURING POINT . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TRANSMISSION CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– TRANSMISSION SETTING POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– PRE START-UP OR POST SERVICING CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– BOOSTER PRESSURE SETTING AND MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– PUMP MECHANICAL “0” SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– PUMP REGULATION START MONITORING AND SETTING . . . . . . . . . . . . . . . . . . . . . . . . . 11
– REGULATION END MONITORING AND SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– HP LIMITERS MONITORING AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– UNBLOCKING HP LIMITERS FOR TOWING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
– A6VM MOTOR REGULATION SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– A4VG-DA/A6VM-DA HYDROSTATIC TRANSMISSIONS SETTING FILE . . . . . . . . . . . . . . 16
(26/09/2012) 20-04-M209EN
TRANSMISSION CONTROL AND
2 ADJUSTMENT
Standard tightening torque to be used when no mention is made in the dismantling and re-assembly
instructions.
(*) – Tightening torques are given for black or zinc finish fasteners with light lubrication.
– Tightening torques are given for automatic slip and reset torque wrenches and direct read dial
torque wrenches.
– For more information, consult French Standard NF E25-030.
20
Tightening torque in Nm (*)

Thread Ø Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9
M3 0,54 0,76 1,16 1,7 2
M4 1,24 1,74 2,66 3,91 4,57
M5 2,47 3,46 5,2 7,7 9
M6 4,29 6 9,1 13,4 15,7
M8 10,4 14,6 22 32 38
M10 20 28 44 64 75
M12 35 49 76 111 130
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
M30 600 840 1280 1880 2200
20-04-M209EN (26/09/2012)
ADJUSTMENT 3
MLT 845-120 Serie 5-E3
TIGHTENING TORQUES, MECHANICAL TRANSMISSION

34 daN.m ± 10%
34 daN.m ± 10%
20
7 daN.m ± 10%
7 daN.m ± 10% 7 daN.m ± 10% 3,7 daN.m ± 10%
4,1 daN.m ± 10%
7 daN.m ± 10%
7 daN.m ± 10%
7 daN.m ± 10%
7 daN.m ± 10%
3,7 daN.m ± 10%
3 daN.m ± 10%
3,7 daN.m ± 10%
7 daN.m ± 10%
6 daN.m ± 10%
48 daN.m ± 10%
48 daN.m ± 10%
(26/09/2012) 20-04-M209EN
4 ADJUSTMENT
TIGHTENING TORQUES, HYDROSTATIC TRANSMISSION
34 daN.m ± 10%
34 daN.m ± 10%
20
48 daN.m ± 10%
3,7 daN.m ± 10%
48 daN.m ± 10%
3,7 daN.m ± 10%
3,7 daN.m ± 10%
48 daN.m ± 10%
48 daN.m ± 10%
20-04-M209EN (26/09/2012)
ADJUSTMENT 5
PRESSURE TAKE-OFF POINTS
A4VG 71 DA PUMP PRESSURE MEASURING POINT
Refer to “Manometer Box” catalogue Ref. 547037 for pressure take-off point connection and hosing kits.
20
PP-PH1 Control Pressure
take-off point
Casing Pressure
take-off point
PP-PH2 Control Pressure

take-off point
High Pressure pressure

take-off point
Booster Pressure
take-off point
Casing Pressure
take-off point
(26/09/2012) 20-04-M209EN
6 ADJUSTMENT
A6VM SERIES 63 MOTOR PRESSURE MEASURING POINT

20
PP-MH2 High Pressure pressurer

take-off point
PP-MH1 Switching Pressure Take-off point
20-04-M209EN (26/09/2012)
ADJUSTMENT 7
TRANSMISSION CONTROL AND ADJUSTMENT
TRANSMISSION SETTING POINTS
AVG 71 DA pump
DR Valve
20
HP Valve
Regulation valve
Regulation start
setting
Booster valve
Plate mechanical “0”

setting
HP valve
Port plate
adjustment eccentric
A6VM Series 63 motor
Regulation adjusting screw

Min capacity Stop screw
(do not detune)
Max capacity Stop screw

(do not detune)
(26/09/2012) 20-04-M209EN
8 ADJUSTMENT
PRE START-UP OR POST SERVICING CHECKS
• Check reservoir oil level.

• Check sealing of all connections and hosing pieces.
• Check solenoid valve electrical connections.
• Check circuit is topped up, and in some cases fill oil filter cartridge before fitting for full priming.
• Check control hosing piece connections.
• Connect up booster - control – HP - casing manometers.
20
Start-up
• Put all wheels on chocks for safety reasons.

• Turn over engine on starter without starting up so as to purge circuit.
• Check that booster pressure goes up to around 14 bars by turning over starter.
“Never start without booster pressure as it will risk damaging transmission”.
• Reconnect injection pump solenoid valve.

• Start engine and let it idle for some minutes.
• 30 bar booster pressure with 2 bar casing pressure.
Needle instability indicates air intake at suction (oil surface emulsion in reservoir and transmission
cavitation noise).
“Lever in neutral” in two HP circuit loops. Pressure is equal to booster pressure.
• Gradually accelerate to heat up circuit oil.

• When oil is at -50° à 60° - check engine speed.
- Idling speed,
- Max no-load engine speed,
20-04-M209EN (26/09/2012)
ADJUSTMENT 9
BOOSTER PRESSURE SETTING AND MONITORING
– A4VG 71 - 180 series pumps are fi tted with an adjustable limiter.

Tighten up screw to increase booster pressure.
20
(26/09/2012) 20-04-M209EN
10 ADJUSTMENT
PUMP MECHANICAL “0” SETTING

20
– Connect up two small-value (40 to 100 bar) manometers to the pressure take-off points.
– Check that the hand brake is released and that the machine is on chocks (wheels off the ground).
– Engine idling.
– Gear lever in neutral position.
– Undo “Mechanical 0” setting adjusting screw lock-nut (19 mm ring wrench).
– Gently turn screw (6 mm Allen key) clockwise to find the smallest HP variation.
– Make a mark opposite the wrench. Then turn anti-clockwise up to the point of varying HP in other
motion direction. Make a mark opposite the wrench.
– Then turn setting screw to the centre point between the two marks.
– Tighten up locknut.
Check setting:
– Disconnect the small-value manometers from HP so as to monitor using 600-bar manometers:
1) Use a rev counter to monitor the forward and reverse motion regulation start points.
Gently accelerate IC engine - selector in forward motion - until wheels start to turn. Note IC engine
speed of rotation.
Do same operation for reverse motion.
Compare the two IC engine rotation speeds: they should be identical.
2) Check HP and corresponding control pressures - wheels locked - selector in forward motion - gradually
accelerate IC engine up to maximum speed.
Note forward motion HP and control pressures.
Do the same operation for reverse motion: values should be identical.
20-04-M209EN (26/09/2012)
ADJUSTMENT 11
PUMP REGULATION START MONITORING AND SETTING
20
Regulation valve
Setting regulation start
Regulation start:
• Measure IC engine idling speed which should be approximately 930 rpm.

Regulation start should kick in at 1100 rpm for a pressure of 50 bar. To adjust this, turn the regulation
start setting screw located at regulation cartridge end :
– Tighten screw to delay advance start.
– Undo to advance advance start.
• Modifying the start point setting shifts the pump regulating curve.
The end of the “440 bar for a 1700 rpm engine speed” regulation must be systematically checked.
(See machine specifi cations).
• Checking the setting is identical to checking the “Mechanical O” – Point 2 setting.
(26/09/2012) 20-04-M209EN
12 ADJUSTMENT
REGULATION END MONITORING AND SETTING

20
Regulation end
Setting the pump regulation end point at 1700 rpm is done by turning the eccentric screw that varies
the port plate setting (shifting by rotation). This has the effect of increasing or reducing the reactive
forces on the inclinable plate.
b This setting is done on the workshop bench. There is no need for the setting to be retouched.
20-04-M209EN (26/09/2012)
ADJUSTMENT 13
HP LIMITERS MONITORING AND ADJUSTMENT
• HP limiter checking and setting is done with the machine on chocks (wheels off the ground) and
locked brakes.
If using the service brake it is necessary to keep the TH 7 valve slide coupled to the brake, or by using
a hosing connection to by-pass this.
Activate the parking brake in order to lock the transmission.
20
• Upgrade the DR valve - Item 1 - to monitor
the actual HP limiter rating value.
Tighten screw - Item 1 - by one turn.
The HP limiter rating should be 508 bar.
During this test the drop in engine speed
is very significant at 500 to 600 rpm.
After HP setting, set the DR valve to a value
10% lower than the HP settings.
HP limiter rating:
A4VG 71 - 180 DA series pump
• Remove seal A.
• Remove cap B.
• Undo lock-nut D.
• Turn screw E to increase pressure.
• Replace cap having made sure to put in a new seal.
UNBLOCKING HP LIMITERS FOR TOWING
• Operate the two HP limiters.

• Very gently lift off caps B without removing seals A.
• Undo nuts C by two turns maximum.
When towing operation is completed

• Retighten nuts C. B
• Replace caps B.
E
D
(26/09/2012)
C 20-04-M209EN
14 ADJUSTMENT
A6VM MOTOR REGULATION SETTING
A. MAXIMUM CAPACITY MONITORING (MAX SPEED):
• This is done under the following conditions: truck on chocks, engine speed at maximum,in forward
motion.
20
Key : 1
1 - HP Pressure
2 - Switching pressure
• Connect two 600-bar manometers as indicated below. At vehicle maximum speed, the two pressure
readings should be the same. This will mean that, taking account of the command cylinder surface
ratios, the engine is in small capacity mode.
• To verify this, the speed can be effectively checked, by working out the gearbox ratios from the
machine’s technical data.
20-04-M209EN (26/09/2012)
ADJUSTMENT 15
B. MONITORING REGULATION START:
• When the machine reaches maximum speed, apply the brakes gradually so as to raise the HP (the
TH7 shut-down valve should be previously by-passed).
• Make note of the two pressure readings. When HP reaches 200-250 bar, switching pressure drops
and HP continues to increase to a DR valve rated value (switching pressures are specified for the
type of equipment concerned in the Service Note).
20
• The 320/18 bar regulating starting point should be adjusted by the regulating screw.
Switching: 280 bars
Control pressure: 25 bar
C. MAXIMUM CAPACITY: (MAXIMUM TRACTION FORCE)
To carry out this setting procedure the machine should be in calibration mode (brakes locked).
Monitoring is done at IC engine maximum speed in forward motion.
Switching pressure (control cylinder large section end) should be around zero bars.
Set regulation screw as needed (tighten to increase switching pressure, unscrew to reduce switching
pressure).
Monitoring the traction force (at tow hook) should then be done (see Service Note for values).
(26/09/2012) 20-04-M209EN
20
16
A4VG-DA/A6VM-DA HYDROSTATIC TRANSMISSIONS SETTING FILE
CONTROL DATE : MACHINE TYPE : HYDRAULIC PUMP TYPE. :
20-04-M209EN
DEALER NAME : SERIAL NUMBER : PUMP SERIAL NUMBER :
NAME OF TECHNICIAN : HOUR NUMBER : HYDRAULIC MOTOR TYPE. :
ADJUSTMENT
MOTOR SERIAL NUMBER :
IC ENGINE SPEED IN RPM:

1 idling: ..... 2 max at no-load: .................... 3 max at hydraulic setting: 4 regulation start: ............................... 5 end regulation 400b: ............. 6 max at Forward Motion setting: ...
HYDROSTATIC PUMP HYDROSTATIC MOTOR

CONTROL PRESSURE HP PRESSURE

MACHINE PUMP
IC ENGINE BOOSTER CASING
SITUATION + monitoring / LEVER POSITION SUCTION CONTROL
SPEED PRESSURE FORWARD REVERSE PRESSURE MACHINE STATUS + HP
settings CARRIED OUT FRONT REAR VACUUM CYLINDER
MOTION MOTION LEVER POSITION PRESSURE
PRESSURE
IDLING
BOOSTER LIMITER
NEUTRAL
SETTING MAXIMUM
No load at max
Regulation start speed forward
FORWARD MOTION motion phase
NO-LOAD MAXIMUM
REGULATION
CARTRIDGE SETTING Regulation start Forward motion
REVERSE MOTION phase at max engine
MAXIMUM speed switching
moment
IN CALIBRATION FORWARD MOTION MAXIMUM

UPGRADED DR VALVE HP Forward motion at
LIMITER SETTING REVERSE MOTION MAXIMUM max engine speed
setting
IN CALIBRATION FORWARD MOTION Regulation end
REGULATION END POINT
MONITORING REVERSE MOTION Regulation end OIL TYPE:
FORWARD MOTION MAXIMUM OIL TEMPERATURE: ......................°C

IN CALIBRATION
DR VALVE SETTING
REVERSE MOTION MAXIMUM
MAXIMUM NO-LOAD MOVING SPEED:
IN CALIBRATION .......................Km/h
DEPRESSED BRAKE PEDAL FORWARD MOTION MAXIMUM
(26/09/2012)
TH7 SETTING FORCE AT TOW HOOK: ..............................Kg
TRANSMISSION REMOVAL
20
pages
MECHANICAL TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– ANGLE GEAR BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(24/10/2012) 20-06-M209EN
2 TRANSMISSION REMOVAL
MLT 845-120 Series 5-E3
MECHANICAL TRANSMISSION REMOVAL

20
B
A
Key:
A - Angle gear box

B - Gear box
• Stabilise the machine on a horizontal floor above a pit.

• Lift the boom to approximately 40°, so that the sling is above the angle gear box.
• Deactivate the battery power supply using a battery cut-off.
• Machine in neutral position.
Specific tools:
- Lifting crane (minimum 1 000 kg).

- Pulleys
20-06-M209EN (24/10/2012)
TRANSMISSION REMOVAL 3
ANGLE GEAR BOX
1 SECURING THE MACHINE
Attach a sling (Item 1) to the anchoring points on the boom.

2
Lift it so that the sling is above the angle gear box.
Install a pulley (Item 2) on the sling.
20
Place the two safety systems (Item 3) on the compensation
cylinders and operate the battery cut-out.
Remove the three pad cover plates (Item 4, 5 and 6) in the

6 boom shaft.
Remove the cap (Item 7).
Install a lifting ring (Item 8) on the angle gear box.

9
Install a sling (Item 9) on the angle gear box.
Secure the angle gear box with the pulley.

8
(24/10/2012) 20-06-M209EN
Remove the gear box/rear axle transmission cardan joint

(Item 10), two flanges (Item 11) and four screws on each side
10 (Item 12) using an 8 mm spanner.
12
11
12
12
11
12
20
14 Remove the engine/angle gear box transmission cardan joint

(Item 13) (four screws) (Item 14) using a 10 mm spanner.
13
14
14 Remove the plate and the clamp (Item 15) under the angle gear
box (two screws) using a 13 mm spanner.
15
Turn the angle gear box using a 19 mm spanner (Item 16).
Remove the six screws (Item 17) between the angle gear box
16 and the gear box using a 13 mm spanner.
17
20-06-M209EN (24/10/2012)
ANGLE GEAR BOX REMOVAL
Remove the four screws (Item 1) from the support bracket

1
20
1
Remove the support bracket (Item 3) from the angle gear box
(two screws) (Item 4) using a 19 mm spanner.
4 Release the support bracket (Item 3).

4
Remove the four retaining screws (Item 5) between the angle

gear box and the hydraulic pump using a 19 mm spanner.
Disconnect the connector X104/A from the hydraulic pump.
Disconnect/release the angle gear box (Item 6) from the hydraulic

pump (Item 7).
(24/10/2012) 20-06-M209EN
Remove the twelve retaining screws (Item 8) between the angle

gear box and the gear box using a 14 mm spanner.
8
8
8
8
8
8
20
Lower the angle gear box (Item 9), verifying that nothing touches
during lowering.
20-06-M209EN (24/10/2012)
GEAR BOX
SECURING THE MACHINE
e “SECURING THE MACHINE” procedure in the “ANGLE GEAR BOX” chapter, page 3.
20
GEAR BOX REMOVAL
1
2
Remove the gear box/front axle transmission cardan joint
3
4
3 (Item 1), two flanges (Item 2) and four screws on each side
(Item 3) using an 8 mm spanner.
2
3
Cut the clamp on the gear box (Item 4).
Place a container under the carriage.
Remove the hose (Item 4) using a 36 mm spanner.
Remove the hose (Item 6 and 7) using a 36 mm spanner.

7
(24/10/2012) 20-06-M209EN
Disconnect the four connectors X09 and X10 (Item 8), X08 and
X98 (Item 9) and mark them to make refitting them easier.
8 8
20
Remove the gear lever (one screw) (Item 10) using a 17 mm
b
spanner.
Machine in neutral position.
Disconnect the connector X01.

10 Secure the height of the gear lever so that lowering the gear
box is not disturbed.
Remove the twelve retaining screws (Item 11) between the

angle gear box and the gear box using a 14 mm spanner.
11
11
11
11
11
11
11
Install lifting rings (Item 12) on the gear box
12
12
88
20-06-M209EN (24/10/2012)
Install a sling (Item 13) on the gear box.
14 Install a pulley (Item 14) above the gear box.
Secure the gear box with the pulley.
13
20
Remove the two screws (Item 15) from the speed box support
bracket on the rated engine frame using a 19 mm spanner.
15
15
16
Remove the six retaining screws (Item 16) from the support
16
bracket (Item 17) on the rated cab gear box using a 19 mm
spanner
17
16 Remove the support bracket (Item 17).

16
16
16
Remove the flange (Item 18) using the 13 mm spanner.
18
(24/10/2012) 20-06-M209EN
Lower the gear box (Item 19), verifying that nothing touches
during lowering.
19
20
20-06-M209EN (24/10/2012)
TRANSMISSION REFIT
20
pages
MECHANICAL TRANSMISSION REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– ANGLE GEAR BOX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– GEAR BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(29/10/2012) 20-07-M209EN
2 TRANSMISSION REFIT
MECHANICAL TRANSMISSION REFIT

20
B
A
Key:
A - Angle gear box

B - Gear box

• Lift the boom to approximately 40°, so that the sling is above the angle gear box.
• Machine in neutral position.
Specific tools:
- Lifting crane (minimum 1 000 kg).

- Pulleys
- Adjustable tie rods
20-07-M209EN (29/10/2012)
TRANSMISSION REFIT 3
ANGLE GEAR BOX
ANGLE GEAR BOX REFIT

1
Install a lifting ring (Item 1) on the angle gear box.
Place the angle gear box under the carriage.
20
Install a sling (Item 2) on the angle gear box and install the pulley.
2
Lift the angle gear box using the pulley.
Align the angle gear box with the gear box then tighten the
twelve retaining screws (Item 3) using a 14 mm spanner.
3
3
3
3
3
3
Connect the hydraulic pump to the angle gear box then tighten
the four retaining screws (Item 4) using a 19 mm spanner.
Connect the connector X104/A to the hydraulic pump.
(29/10/2012) 20-07-M209EN
Fasten the support bracket (Item 4) to the frame with four screws
4
20
Fasten the support bracket (Item 6) to the pump with two screws
MACHINE REASSEMBLY
Turn the angle gear box using a 19 mm spanner (Item 1).

1
Fasten the six screws (Item 2) between the angle gear box and
b
the gear box using a 13 mm spanner.
2
Apply lock Loctite 243 on each screw.
20-07-M209EN (29/10/2012)
5 Fasten the plate and the clamp (Item 3) under the angle gear
box (two screws) using a 13 mm spanner.
4
5
5
Fasten the engine/angle gear box transmission cardan joint
b
(Item 4) (four screws) (Item 5) using a 10 mm spanner.
20
3
Position and fasten the transmission cardan joint (Item 6), two
flanges (Item 7) and four screws (Item 8) on each side using an
6
b
8 mm spanner.
8
7
8
8
7
8
Position and fasten the plates (Items 9, 10 and 11) in the boom
9 shaft.
11
10
Remove the pulley (Item 12) and the sling (Item 13).
Remove the two safety systems (Item 14).

13
Turn the current back on by means of the battery cut-out.
12
Top up with hydraulic oil.
14
(29/10/2012) 20-07-M209EN
GEAR BOX
GEAR BOX REMOVAL

2 2
Install the lifting rings (Item 1) on the gear box.

Place the angle gear box under the carriage.
1 Install the tie rods (Item 2) on the gear box and install a pulley.
1
20
Lift the gear box using the pulley and align the gear box with
the angle gear box.
Fasten the gear box to the rated engine frame (two screws)
Fasten the support bracket (Item 4) to the gear box and the
5
rated cab frame (six screws) (Item 5) using a 19 mm spanner.
5
5
5
5
5
Align the gear box with the angle gear box, then tighten the
twelve retaining screws (Item 6) using a 14 mm spanner.
6
6
6
6
6
6
20-07-M209EN (29/10/2012)
Reposition the flange (Item 7) using the 13 mm spanner.
20
Remove the tie rods and the pulley (Item 8) from the gear box.
Fasten the hose (Item 9 and 10) using the 36 mm spanner.

9
10
Fasten the hose (Item 11) using the 36 mm spanner.
11
(29/10/2012) 20-07-M209EN
Connect the four connectors X09 and X10 (Item 12), X08 and
X98 (Item 13) by following the markings.
13
12 12
20
13
Refit the gear lever to the gear box (one screw) (Item 14) using
b
a 17 mm spanner.
Machine in neutral position.
Connect the connector X01 to the gear lever.

14
Position and fasten the transmission cardan joint (Item 15), two
15
flanges (Item 16) and four screws (Item 17) on each side using
16
b
an 8 mm spanner.
18 17
17
16
17
Put the clamps on the hoses (Item 18).
MACHINE REASSEMBLY
e “MACHINE REASSEMBLY” procedure in the “ANGLE GEAR BOX” chapter, page 4.
20-07-M209EN (29/10/2012)
SPECIFIC TRANSMISSION TOOLING
20
pages
BASIC BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(26/09/2012) 20-09-M209EN
2 SPECIFIC TRANSMISSION TOOLING
BASIC BOX
Standard
7 7 7
7
3 4 6
4
20
2 5 6
Maniscopic
8 8
ydromatik kit - 2nd Assembly - A 4 VG - DA Pump/A 6 VM - DA Motor
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)
Connection (TH7 valve hosing connection

Hosing piece (TH7 valve by-pass) piece)
05
x1
14
56
14x150
57
14x150
14
x1
50
20-09-M209EN (26/09/2012)
SPECIFIC TRANSMISSION TOOLING 3
Rep. Numéro Désignation QTE
1 549 671 Basic box 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 Hose 4
8 549 888 Hose for MANISCOPIC 2
9 549 889 Manometer port 7
48 209 572 HYDROMATIK kit 1
49 58 181 8 x 100 manometer take-off point 3
50 58 197 ø 8 O-ring seal 6
53-1 199 175 18 x 150 manometer take-off point 1
54 173 568 ø 20 connection 1
55 165 711 ø8L + M8 x 100 M/F connection adapter 2
58 706 653 ø6L + M8 x 100 M/F connection adapter 2
TH7 valve by-pass
56 191 000 Hose 1
57 491 632 (M14 x 150) connection 1
(26/09/2012) 20-09-M209EN
4 SPECIFIC TRANSMISSION TOOLING
20
20-09-M209EN (26/09/2012)
AXLE
- AXLE CONTROL AND ADJUSTEMENT
- AXLE CHARACTERISTICS AND l 547983EN
30
SPECIFICATIONS
(AXLE 212)
- SPECIFIC AXLE TOOLS
AXLE CONTROL AND ADJUSTMENT
30
pages
TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(10/10/2012) 30-04-M209EN
2 AXLE CONTROL AND ADJUSTMENT
TIGHTENING TORQUE
AXLE
34 daN.m ± 10%
34 daN.m ± 10%
63 daN.m ± 15%
63 daN.m ± 15%
30
63 daN.m ± 15%
48 daN.m ± 10%
48 daN.m ± 10% 63 daN.m ± 15%
30-04-M209EN (10/10/2012)
AXLE CONTROL AND ADJUSTMENT 3
Standard tightening torque to be used when no mention is made in the dismantling and re-assembly
instructions.
(*) – Tightening torques are given for black or zinc finish fasteners with light lubrication.
– Tightening torques are given for automatic slip and reset torque wrenches and direct read dial
torque wrenches.
– For more information, consult French Standard NF E25-030.
Tightening torque in Nm (*)

Thread Ø Class 5.6 Class 5.8 Class 8.8 Class 10.9 Class 12.9
M3 0,54 0,76 1,16 1,7 2
30
M4 1,24 1,74 2,66 3,91 4,57
M5 2,47 3,46 5,2 7,7 9
M6 4,29 6 9,1 13,4 15,7
M8 10,4 14,6 22 32 38
M10 20 28 44 64 75
M12 35 49 76 111 130
M14 57 79 121 178 209
M16 88 124 189 278 325
M18 122 171 261 384 449
M20 173 243 370 544 637
M22 238 334 509 748 875
M24 298 418 637 936 1095
M27 442 619 944 1386 1622
M30 600 840 1280 1880 2200
(10/10/2012) 30-04-M209EN
4 AXLE CONTROL AND ADJUSTMENT
30
30-04-M209EN (10/10/2012)
BRAKE
- BRAKE CHARACTERISTICS AND

SPECIFICATIONS
- BRAKE COMPONENTS LOCATION e 70 - HYDRAULICS

- BRAKE CONTROL AND ADJUSTEMENT
- SPECIFIC BRAKE TOOLS
40
BRAKE CHARACTERISTICS AND SPECIFICATIONS
pages
40
SERVICE BRAKE / PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
(26/09/2012) 40-01-M209EN
BRAKE CHARACTERISTICS AND
2 SPECIFICATIONS
40
40-01-M209EN (26/09/2012)
SPECIFICATIONS 3
SERVICE BRAKE / PARKING BRAKE
MAX
L.H.M S8 214 B SHELL brake fluid
S
Y
Hydrostatic pump Main pump
M
Master cylinder ø31.75 mm b a

R T1 T2 PS Fa Fa1 Fe MB B
Cubic capacity: 30.9 cm3 P1 Power supply unit
B
Oil 35b
ret
Oil urn U
sup
ply Accumulator
M
45±5b
PH 0,7l
P2 T 13b
A
26
4 S Fs MA
X1 X2 G MH
0,5b
Accumulator
0,7l
13b
40
ACCORDING TO
TRANSMISSION
TYPE
Tank
Braking ratio: ø1
264/89 = 2,96 Hand brake control switch
3 1
Hand brake control + battery

solenoid valve white
2
Oil back brake disc:

Negative hand brake operation:
Number of discs per wheel 4 P
Epicyclic reducer R = 1/6 - Si P = 0b -> Braking axle

Braking surface per disc side 146,85 cm2 - Si P > 15b -> Non-braking axle
Total braking area (front axle only) 2350 cm2
Pressure of use advised 70 to 80 bar
Friction material WELLMAN N°266
Dynamic friction coefficient 0,115
Static friction coefficient 0,095
Make DANA
Disc diameter 201,5 mm
Disc thickness 4,75 - 4,85 mm
Scope of action 88 mm
Number of receiver cylinders 1
Slave cylinder surface 41,88 cm2
Wear compensation Auto
Track width 26,75 mm
SERVICE BRAKE (Front axle) PARKING BRAKE (Front axle)
(26/09/2012) 40-01-M209EN
4 SPECIFICATIONS
40
40-01-M209EN (26/09/2012)
BRAKE CONTROL AND ADJUSTMENT
pages
40
MLT 845 SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– SETTING BRAKE PEDAL HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MLT 845 H SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
– SETTING BRAKE PEDAL HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
PARKING BRAKE (CABLE OPERATED BRAKE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
– HAND BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(26/09/2012) 40-04-M209EN
2 BRAKE CONTROL AND ADJUSTMENT
MLT 845 SERVICE BRAKE
SETTING BRAKE PEDAL HEIGHT
1) - BRAKE PEDAL
– Adjust the height of the brake pedal (A) to 95 mm in relation to the cab floor (without carpet) using
the stop (B).
– Tighten the locknut E.
– Adjust the brake pedal free play (A) (3 to 4 mm play) by turning the push rod (C)
– Tighten the locknut (D).
2) - TRANSMISSION CUT-OFF SWITCH
– Pedal at rest (touching the stop (B)).
– Move the switch mounted on its bracket (F) so that it is resting on the brake pedal arm (A), ensuring
40
41 mm free play. Pre-tighten the switch support fixing screws.
– Adjust the position of the switch (F) so that the transmission cut-off is activated when the pedal is
85 mm above the cab floor (see diagram).
B
E
F
C Pedal in rest position
A
D
41
±3
Pedal free play
3 - 4 mm
95 mm
85 mm
Pedal at start of
transmission cut-off
position
40-04-M209EN (26/09/2012)
BRAKE CONTROL AND ADJUSTMENT 3
MLT 845 H SERVICE BRAKE
SETTING BRAKE PEDAL HEIGHT
Fig. 1
TH
7
– Use screw A to adjust the height of the inching-brake

A
pedal (1) above the cab floor without mats.
B
– Tighten the lock-nut B.
1
119.5 mm
FIG 1
40
C Fig. 2
TH
7
Pushrod
2
– Adjust the TH7 pushrod so that C = 10.5 mm (brake
3 pedal in rest position)
– Turn the screw (2) to move the push-rod in to obtain
D
4 the clearance C.
1
– Tighten the counter-nut (Rep. 3).
5
Rest
– Screw the stud (4) so that clearance D = 15 mm.
– Position the master cylinder rod in contact with the stud.
FIG 2
TH 6
Fig. 3
7
3 – Press the brake pedal (1) to the point of switch cut-off

2 (end of rod)
– Adjust the screw (2) on the tab (6)
1
Rest
Pedal at the start

83,5 mm
of the transmission
cut-off position
FIG 3
(26/09/2012) 40-04-M209EN
4 BRAKE CONTROL AND ADJUSTMENT
PARKING BRAKE (CABLE OPERATED BRAKE)
HAND BRAKE CABLE ADJUSTMENT
Fit the cable to the hand brake and in the cab, ensuring a 455 mm gap at the axle end.
= =
455 mm
40
m
0m
47
40-04-M209EN (26/09/2012)
SPECIFIC BRAKE TOOLING
pages
40
PURGEUR FREINS HYDRAULIQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(26/09/2012) 40-09-M209EN
2 SPECIFIC BRAKE TOOLING
HYDRAULIC BRAKE BLEED KIT
Bleed valve supplied with all the components required for

bleeding the hydraulic brake circuits of all Manitou products.
40
MANITOU Reference
Hydraulic brake bleed kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 554019
Spare parts:
Top manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
Bottom manometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
Membrane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
Hose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914
40-09-M209EN (26/09/2012)
BOOM
- BOOM CHARACTERISTICS AND

SPECIFICATIONS
- BOOM COMPONENTS LOCATION
- BOOM CONTROL AND ADJUSTEMENT
- BOOM REMOVAL
- BOOM REFIT
50
BOOM CHARACTERISTICS AND SPECIFICATIONS
pages
DUPLEX (MLT 8 MÈTRES) :. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
50
(05/11/2012) 50-01-M209EN
BOOM CHARACTERISTICS AND
2 SPECIFICATIONS
DUPLEX (7 METRE MLT):
Consists of 2 components:
– 1 fixed
– 1 mobile (T1)
Machines equipped with a Duplex boom:
– MLT 845-120 H
– MLT 845-120
Boom weight:
– Approx. 2 050 kg
T1
50
Mobile component (T1):
– Weight: Approx. 600 Kg

– Centre of gravity: G
50-01-M209EN (05/11/2012)
BOOM COMPONENTS LOCATION
pages
COMPONENT CODE INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

LOCATIONS OF THE MAIN COMPONENTS OF THE 8M BOOM . . . . . . . . . . . . . . . . . . . . . . . .2
50
(05/11/2012) 50-03-M209EN
2 BOOM COMPONENTS LOCATION
COMPONENT CODE INDEX
Item Designation
CSP Piloted safety valve
T1 Telescope 1
VI Tilt cylinder
VT Telescoping cylinder
LOCATIONS OF THE MAIN COMPONENTS OF THE 8M BOOM
VI
(A)
(B)
V2
V1
CSP
VT
50
CSP
V2
V1
V2 (A)
V1 (B)
VI
VT
CSP
T1
CSP Boom foot
50-03-M209EN (05/11/2012)
BOOM CONTROL AND ADJUSTMENT
pages
DUPLEX BOOM COMPONENT DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– T2 TELESCOPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– TELESCOPE CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
50
DUPLEX BOOM COMPONENTS REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
– RECOMMENDATIONS FOR WEDGE ASSEMBLY AND GREASING AREAS . . . . . . . . . . . 8
(31/10/2012) 50-04-M209EN
2 BOOM CONTROL AND ADJUSTMENT
DUPLEX BOOM COMPONENT DISMANTLING

50
• Stabilise the machine on a horizontal floor.

• Fully retract the telescope.
• If an attachment is mounted on the carriage, remove it.
• Position the boom on an axle stand in order to keep it horizontal.
• Decompress all hydraulic elements.
Specific tools:
– Lifting crane (minimum 700 kg).

– Pulleys + slings
– Trestles
50-04-M209EN (31/10/2012)
BOOM CONTROL AND ADJUSTMENT 3
T2 TELESCOPE REMOVAL
1
Unscrew and remove the two rear covers (Item 1 and 2) attached
to the frame (eight screws) using a 5 mm hexagonal spanner.
50
Identify and unscrew the two hoses (Item 3) using a 30 mm
3
4 (Item 4) and 36 mm spanner.
Put the caps on the hoses, couplings and hydraulic tubes.
Place a wedge (Item 5) under the telescope cylinder.
7 Remove the circlips (Item 6) from the telescope cylinder.
Remove the telescope cylinder pin (Item 7).

5
(31/10/2012) 50-04-M209EN
Strap and remove the boom in halves (Item 8).

8
12
Remove the two screws (Item 9) from the high and low blades.
12
10
Remove two halves of the plate frame (Item 10) (two screws)
9 10 (Item 11) using a 10 mm spanner (two nuts) (Item 12) using
a 19 mm spanner.
50
11
9
Identify then remove the six left/right/upper slide pads (Item 13)

using a 19 mm spanner and a 6 mm hexagonal spanner.
13 13
88
13
13
15
i
Hold/secure the boom at the centre of gravity (Item 14) “BOOM
CHARACTERISTICS AND SPECIFICATIONS” using a strap (Item 15)
and a lifting system (pulley).
14
50-04-M209EN (31/10/2012)
Identify then remove the two lower slide pads (Item 16) using
a 19 mm spanner and a 6 mm hexagonal spanner.
16 16
Identify and unscrew the six hoses

- (x2) tilting circuit (Item 17)
- (x2) circuit attachments (Item 18)
17 18
17
18
50
Extract then remove the boom (Item 19) using the pulley +
sling, on the trestles.
19
(31/10/2012) 50-04-M209EN
TELESCOPE CYLINDER REMOVAL
Remove the T2 telescope until the telescope cylinder pin

1
appears (Item 1).
50
to frame (eight screws) using a 5 mm hexagonal spanner.
Identify and unscrew the two hoses (Item 4) using a 30 mm and

(Item 5) a 36 mm spanner.
4
5
50-04-M209EN (31/10/2012)
Place a wedge (Item 6) under the telescope cylinder.
8
Remove the circlips (Item 7) from the telescope cylinder.

6
Remove the circlips (Item 9) from the telescope cylinder.
10
50
Strap and remove the cylinder by approximately two metres
(Item 11).
11
Hold/secure the cylinder at the centre of gravity (Item 12) using

a strap and a lifting system (pulley).
12
b The cylinder’s centre of gravity (Item 12) is approximately
2 m from the cylinder’s pin (Item 13). Move the strap
forwards/backwards until the cylinder is balanced.
13
(31/10/2012) 50-04-M209EN
Extract then remove the cylinder using the pulley + sling, on

the trestles.
b Remove the hoses (Item 14) in order to pass the cylinder

(Item 15) during extraction.
14 14
15
DUPLEX BOOM COMPONENTS REFIT

50
Carry out the reverse of the procedure described above.
b Comply with block assembly and greasing values described hereafter .
b Apply "Loctite 243 normal thread lock" to all nut/screw interfaces only on the inside
of the boom.
RECOMMENDATIONS FOR WEDGE ASSEMBLY AND GREASING AREAS
1 - Grease the tube slip faces in the specified areas, the grease spread is 0,2 Kg/m2.
2 - Grease the slip face of each slide pad before installation.
3 - Put in place in the order of: side slide pad then upper and lower slide pads.
4 - Finish adjusting the calibration system, at the upper part of the tubes by inserting slide pads while
complying with the operating clearances shown.
50-04-M209EN (31/10/2012)
BOOM REMOVAL
pages
DUPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– BOOM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
(30/10/2012) 50-06-M209EN
2 BOOM REMOVAL
DUPLEX BOOM
50

• Fully retract the telescope.
• If an attachment is mounted on the carriage, remove it.
• Position the boom on an axle stand in order to keep it horizontal.
• Decompress all hydraulic elements.
Whole boom weight ≈ 2 050 kg
Specific tools:
– Lifting crane (minimum 2 500 kg).

– Pulleys
– Axle stand
– Mallet
– Trestles
50-06-M209EN (30/10/2012)
BOOM REMOVAL 3
BOOM REMOVAL
Position the boom on an axle stand (Item 1).
to frame (eight screws) using a 5 mm hexagonal spanner.
50
Remove the rod swivel joint (Item 4).
Disconnect the connector X134 (Item 5).
6 Remove the two screws (Item 6) from the angle sensor (Item 7)
7
fastened to the frame using the 10 mm spanner.
6 Disconnect the connector X100 from the angle sensor.
(30/10/2012) 50-06-M209EN
4 BOOM REMOVAL
Fasten a strap to the boom attachment points (Item 8).
Hold/secure the boom (Item 9) using a strap (Item 10) and

a lifting system (pulley).

10
9
50
Remove the screws (Item 11) from the compensation cylinder pins
(Item 12) on each side of the machine using a 17 mm spanner.
11
12
Remove the pins from the compensation cylinder heads (Item 12).
Wedge the lifting cylinders (Item 13) to hold them in place.

15
14
Remove the two screws/nuts (Item 14) from the lifting cylinder
pins (Item 16) from each side of the machine using a 13 mm
16
spanner.
14
Remove the screws (Item 15) using a 13 mm spanner then
remove the two axles (Item 15).
Remove the pins from the lifting cylinder heads (Item 16).
13
50-06-M209EN (30/10/2012)
BOOM REMOVAL 5
Wedge the lifting (Item 17) and compensation (Item 18) cylinders
18
in a way that does not disrupt removing the boom.
17
Using the lifting system, lift the boom to get access to the hose
(Item 19).
19
Place a container under the carriage at the level of the rear hoses.
Identify and unscrew the four hoses using a 24 to 30 mm spanner.

21
21 - (x2) circuit attachments (Item 21)
20
20
50
22
Identify and unscrew the two hoses (Item 22) using a 30 mm
23 and (Item 23) a 36 mm spanner.
Remove the screw (Item 24) using a 27 mm spanner from the

25
boom base pivot pin (Item 25).
Remove the boom base pivot pin and the washers.

24
b Before removing the boom base pivot pin, place the

boom horizontally on the axle stand.
(30/10/2012) 50-06-M209EN
6 BOOM REMOVAL
Lift the boom (Item 26) using the pulley + strap (Item 27), then
26
place it on a flat surface.
27
50
50-06-M209EN (30/10/2012)
BOOM REFIT
pages
DUPLEX BOOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– BOOM REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
(30/10/2012) 50-07-M209EN
2 BOOM REFIT
DUPLEX BOOM
50

Specific tools:
– Lifting crane (minimum 2 500 kg).

– Pulleys
– Axle stand
– Mallet
– Trestles
50-07-M209EN (30/10/2012)
BOOM REFIT 3
BOOM REFIT
1
3 2 Using a lifting system (pulley) (Item 1), position the boom (Item 2)
on the carriage by aligning the boom base pivot pin (Item 3).
Greasing recommendations before pivot pin assembly:

- Fill the cells or pivot pin ring holes.
- Apply a fine film of grease on the pin surface.
4
Insert the pin (Item 4) and the washers (Item 6) in the boom base.
5 Attach the pin to the boom base by tightening the screw (Item 5)
50
6
Greasing recommendations before pivot pin assembly:

9
- Fill the cells or pivot pin ring holes.
10
- Apply a fine film of grease on the pin surface.
8
Insert the pins (Item 8) on the lifting cylinder heads on each
12
11
10 side of the machine.
Insert the pins (Item 9) then screw them using a 13 mm spanner.
Fasten the pins (Item 8) with the screws/nuts (Item 10) using
a 13 mm spanner.
Insert the pins (Item 11) in the compensation cylinder heads,

then fasten them by tightening the screws (Item 11) using a
27 mm spanner.
(30/10/2012) 50-07-M209EN
4 BOOM REFIT
Connect the four hoses using the 24 and 30 mm spanner.

- (x2) circuit attachments (Item 14)
14
14
13
13
15
Screw the two screws (Item 15) to the angle sensor (Item 16)
16 on the frame using a 10 mm spanner.
15
Connect the connector X100 to the angle sensor.
50
Refit the rod swivel joint (Item 17).

19 22
20 23
Connect the connectors X134 (Item 18).
Connect the two hoses (Item 19) using a 30 mm (Item 20) and
17 a 36 mm spanner.
18
Replace and screw the rear covers (Item 21 and 22) (eight screws)
21
Remove the rings from the boom.
22
Test the machine: retract/extend all cylinders to end of travel
in order to fill them with hydraulic oil.
50-07-M209EN (30/10/2012)
HYDRAULICS
- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS
- HYDRAULIC SCHEMATIC DIAGRAMS
- HYDRAULIC COMPONENTS LOCATION
- HYDRAULIC CONTROL AND ADJUSTEMENT
- HYDRAULIC COMPONENTS REMOVAL
- HYDRAULIC COMPONENTS REFIT
- HYDRAULIC SPECIFIC TOOLING
70
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
HYDRAULIC COMPONENT SHEETS
– STEERING PUMP / STEERING UNIT OSPC 200 LS

– COUNTERBALANCE VALVE
– BOOM SUSPENSION ELECTROVALVE (OPTION)
– ACCUMULATOR UNIT
– POWER ASSISTED BRAKE MASTER CYLINDER
– DISTRIBUTOR SX 14 S (INLET ELEMENT)
70
– DISTRIBUTOR SX 14 S (TILTING ELEMENT)
– DISTRIBUTOR SX 14 S (TELESCOPING ELEMENTS - ATTACHMENT)
– DISTRIBUTOR SX 14 S (LIFTING ELEMENT)
– DISTRIBUTOR SX 14 S (CLOSING ELEMENT)
– TILTING CUT-OFF VALVE (VCI)
– STEERING SELECTOR
– PUMP CASAPPA MVP60
– HYDRAULIC PUMP A10VO EK1
(10/10/2012) 70-01-M209EN
2 SPECIFICATIONS
Values indicative only

70
70-01-M209EN (10/10/2012)
HYDRAULIC CHARACTERISTICS
AND SPECIFICATIONS 1
STEERING PUMP/DIRECTIONAL BLOCK OSPC 200 LS

Values for information purposes only.
T
P
Role:
L
- Direct and dose the flow in order to supply the steering
R circuit.
- It is a rotating valve.
LS
R L
140b
1 - Secondary relief valve.
2 - Pump valve.
1 3 - Main pressure relief valve.
70
200 cm³/tr
LS 200b -P : Pressure.
-T : Return to tank.
-R : Exit towards the right side.
-L : Exit towards the left side.
- LS : Pilot line.
T P
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
(03/09/2008) F70-3-0003EN
2 AND SPECIFICATIONS

R L
When the driver turns the steering wheel towards the right, he passes
the flowrate from P to R and sends pilot pressure towards the divisor
to get priority.
LS
T P
R L
When there is an impact on a wheel, the pressure increases in the line.

This pressure opens the valve which enables the resulting pressure to
be evacuated and therefore protects the hydraulic and mechanical
steering components.
LS
T P
R L
70
When the wheels are locked to a maximum, the steering circuit

increases in pressure, the LS line activates the relief valve and enables
flow to the tank.
LS
T P
What use do the two valves that are located opposite each other on the top part of the diagram have?
What is the maximum pressure permitted in the steering circuit?
What is the LS line, without actions, connected to on the steering wheel?
F70-3-0003EN (03/09/2008)
COUNTER BALANCE VALVE d1

Role :
- Insulates the cylinder in case of hose breakage.
V1 - Cylinder movement requires the starting of the I.C. engine.
- Limits max. pressure due to impacts.
V2
70
C1 C2
1 3
1 - Temporization screws.
2 2 - By-pass valve.
3 - Slide with max. adjustment screw.
4 4 - Non-return valve.
V1 V2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(03/09/2008) F70-3-0008EN
C1 C2
V1 V2
Return control during cylinder descent.
C1 C2
V1 V2
70
When a position is secured, no component is able to exert sufficient pressure to open the valve.
Only a pressure peak due to an impact can open it.
C1 C2
V1 V2
When the cylinder is pushed, the supply (no-return valve to pass) and return are free.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0008EN (03/09/2008)
What is the valve opening pressure on the diagram?
What happens when the non-return valve starts to leak?
70
If the temporization screw is either screwed or unscrewed, what effect does it have on movement?
(03/09/2008) F70-3-0008EN
70
F70-3-0008EN (03/09/2008)
BOOM SUSPENSION ELECTROVALVE (OPTION)

PX
V1
V2
C2 PX PX2 C1
EV(S1)
AC
EV(S2)
70
V2 V1 T
Maximum pressure (bar)
Maximum flowrate (L/min) 150
Nota :
(08/10/2012) F70-3-0017EN
70
F70-3-0017EN (08/10/2012)
SPECIFICATIONS 1
ACCUMULATOR BLOCK
1 - Role:
Provides a reserve of pressurized oil fir:
- Power assisted braking.

- Control valve control (depending on machine).
2 - Description:
70
P1/P2 : Pressure port
WV : Circuit selector
DM : Pressure reducer
T : Tank return
DB : Pressure relief valve (45 bar)
RV : Non-return valve
SBO : Membrane accumulator
U : Service port
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(08/10/2012) F70-3-0023EN
2 SPECIFICATIONS
3 - Operation:
Unit is supplied via P1.
Pressure reduced to 35 bar by pressure reducer, then

pressure stored in accumulator.
70
If the pressure reducer jams the pressure relief valve

opens (45 bar) to protect all components on exit U.
4 - Fill in the table below:
P1 P2 U Commentary
10 b 270 b
50 b 0b
10 b 20 b Accumulator empty
45 b
35 b
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0023EN (08/10/2012)
SPECIFICATIONS 1
MASTER CYLINDER WITH ASSISTANCE

1 - Part :
- To send the pressure fluid in order to push the brake

pistion that will stop the wheels.
- To add the mechanical force (pedal) and the hydraulic

force in order to help the driver.
2 - Description :
70
P- Assistance pressure
L- Pilot pressure (LS line)
N- Return to the tank line
B- Brake pressure
R- LHM tank
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(08/10/2012) F70-3-0027EN
2 SPECIFICATIONS
3 - Working :
Phase 1 (no action)
The pressure from the accumulator block arrives on P. The ball stops the oil.
Due to the fact that we do not use the brake, L is connected to N. Thus, the LS line is connected to the
return tank.
Phase 2 (the driver starts the action)

70
When the driver begins to push on the brake pedal, all components are in contact. In this case, the LS
line is cut (L).
The master cylinder is ready to send the pressure toward the brake with the assistance.
Phase 3 (during the action)
When the driver pushes completely the brake pedal, the piston moves and the ball does not stop the
oil. In this case, the pressure is sent to help the driver.
In the same time, the master cylinder sends a pilot pressure toward the flow divider to have the priority
on braking.
F70-3-0027EN (08/10/2012)
SPECIFICATIONS 3

4 - Exercises :
- What is the maximum assistance pressure ?

_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
- What is the maximum pilot pressure?

_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
- What is the maximum pilot pressure?

_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
70
- For each connector of the master cylinder, indicate the component name with which it is connected.
P _________________________________________________________________________________
L _________________________________________________________________________________
N___________________________________________________________________________________
B___________________________________________________________________________________
R___________________________________________________________________________________
(08/10/2012) F70-3-0027EN
4 SPECIFICATIONS
70
F70-3-0027EN (08/10/2012)
HYDRAULIC SPECIFICATIONS AND
CHARACTERISTICS 1
SX 14 S DISTRIBUTOR (INLET)
Function:
- Divide the hydraulic flow, giving priority to steering.
- Limit maximum pressure.
- Reduce the LS pressure to zero when the control stick is

returned to the neutral position.
- Cut off hydraulic movements.
MA
1 2 3 4
VCI
70
5
M LS D b B1 A1 b B2 A2 B3 A3 B4 A4 b B5 A5 D
DLS
1
b b
Tdd VS
VRP
2 LS
a a b
T B A T B T T B
T T
EI
EE EA(O) ET EA EL EF
a a a Pr Tpr
3 4
1 - Priority Valve.
2 - Movement cut-off valve.
3 - Flow controller and filter.
4 - Pressure limiter.
5 - Non-Return Valve.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(08/10/2012) F70-3-0037EN
2 CHARACTERISTICS
M LS D
DLS Hydraulic pressure arrives at P.
- The flow divider valve enables priority to be given to the steering

system when there is stand-by pressure equal to the spring. When
P the orbitrol is not called for the pressure moves the slide and
applies the stand-by pressure from the pump to the valveblock
Tdd VS modules.
- The LS limiter enables the maximum circuit pressure to be limited

LS
by limiting the pump pilot pressure. It pre-empts the action of
the pump DR slide and reduces rippling.
T
T EE
- The regulator allows the LS pressure to fall to 0 when the control
stick returns to neutral.
M LS D
- The VS enables all hydraulic movements to be cut off, directing
DLS the divider pilot flow to the tank.
P
70
Tdd VS
LS
T
T EE
What is the function of the non-return valve?
How is the main pressure limited?
What is the exact calibration of the maximum pressure relief valve?
F70-3-0037EN (08/10/2012)
SPECIFICATIONS 1
SX 14 S DISTRIBUTOR (TILT)
Function:
- Direct the hydraulic flow to the receiver.
- Limit impact pressure.
- Enables all movement to be stopped.
MA
1 2 3 4
VCI
70
1 2
DLS
b b
Tdd VS
VRP
a a b
LS
T B A T B T T B
T T
EI
a a a Pr Tpr
3 4
1 - Valve slide.
2 - Pressure balance.
3 - Pressure spike relief valve.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(08/10/2012) F70-3-0038EN
2 SPECIFICATIONS
b B1 A1
- The hydraulic pressure arrives at the entry module with pump

stand-by pressure.
- The Pressure balance ensures communication between the main

pressure line through the valveblock to the receiver feed.
- It takes the receiver pressure and communicates it to the pump.
- There is a priority between the receiver feed and pressure

information transmission to avoid any rapid pressure increase
as a result of a delay in slide opening relative to pump control.
T B A T
EI
a
Hydraulic control
(At “rest”)
b B1 A1 b B1 A1
70
T B A T T B A T
EI EI
a a
Hydraulic control Hydraulic control
(Setting “a”) (Setting “b”)
F70-3-0038EN (08/10/2012)
CHARACTERISTICS 1
SX 14 S DISTRIBUTOR (TELESCOPING - ACCESSORY)

EA
ET
Function:
- Direct the hydraulic flow to the receiver.
- Limit impact pressure.
- Enables all movement to be stopped.
EA
ET
MA
70
1 2 3 4
VCI
1 1
DLS
b b
Tdd VS
VRP
a a b
LS
T B A T B T T B
T T
EI
a a a Pr Tpr
3 2 2
1 - Valve slide.
2 - Pressure balance.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(09/10/2012) F70-3-0039EN
2 CHARACTERISTICS
Operating principles of the electro-hydraulic controller:
Pressure reduced
Pr by SPU
Valve slide
TPr
B3 A3 B4 A4
- The hydraulic pressure arrives at the entry module
with pump stand-by pressure.
b b - The Pressure balance ensures communication between

the main pressure line through the valveblock to the
receiver feed.
- It takes the receiver pressure and communicates it

to the pump.
a a
- There is a priority between the receiver feed and
pressure information transmission to avoid any rapid
70
B T pressure increase as a result of a delay in slide opening

relative to pump control.
ET EA
Electro-hydraulic controller (“Rest” state)
B3 A3 B4 A4 B3 A3 B4 A4
b b b b
a a a a
B T B T
ET EA ET EA
Electro-hydraulic controller (Setting “a”) Electro-hydraulic controller (Setting “b”)
F70-3-0039EN (09/10/2012)
CHARACTERISTICS 1
SX 14 S DISTRIBUTOR (ELEVATION)
Function:
– Direct the hydraulic flow to the receiver.
– Limit impact pressure.
– Enables all movement to be stopped.
– Regulates pilot pressure as per machine overload.
MA
70
1 2 3 4
VCI
1
DLS
b b
Tdd VS
VRP
a a b
LS
T B A T B T T B
T T
EI
a a a Pr Tpr
2 3
1. Distribution slide (includes the pilot regulation valve VRP).
2. Pressure spike relief valve.
3. Pressure balance.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(09/10/2012) F70-3-0040EN
2 CHARACTERISTICS
Operating principles of the electro-hydraulic controller and VRP:
Jet at control valve inlet for descent

control
Hydraulic
controller Control Valve
Pr
Valve slide
Pressure reduced
TPr by SPU
The descent control is mixed, i.e. the hydraulic controller directly controls the slide in normal operation.
The pressure relief valve, on the other hand, can reduce the slide pilot pressure if the operator wishes
to reduce the flow sent to descent and thus the rate of descent.
Current/pressure reduction curve, VRP:

70
F70-3-0040EN (09/10/2012)
CHARACTERISTICS 3
b B5 A5
VRP
b
– The hydraulic pressure arrives at the entry module with pump

T B stand-by pressure.
EL – The Pressure balance ensures communication between the main

a pressure line through the valveblock to the receiver feed.
Electro-hydraulic controller
(“Rest” state) – It takes the receiver pressure and communicates it to the pump.
– There is a priority between the receiver feed and pressure

b B5 A5 information transmission to avoid any rapid pressure increase
as a result of a delay in slide opening relative to pump control.
70
VRP
b
T B
EL
a
Electro-hydraulic controller
(Setting “b”)
(09/10/2012) F70-3-0040EN
4 CHARACTERISTICS
70
F70-3-0040EN (09/10/2012)
CHARACTERISTICS 1
SX 14 S DISTRIBUTOR (CLOSING)
Function:
– It contains a flushing valve whose function is to prevent

pressure spikes arising from the premature closing of
the main slide of one of the valveblock components
before the pump has returned to low.
T3
MA
Pr
r
Tp
70
1 2 3 4
VCI
DLS
1
b b
Tdd VS
VRP
a a b
LS
T B A T B T T B
T T
EI
a a a Pr Tpr
1 - Flushing Valve.
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(09/10/2012) F70-3-0041EN
2 CHARACTERISTICS
– The hydraulic pressure arrives at the entry module with pump

stand-by pressure.
EF
Pr Tpr
70
F70-3-0041EN (09/10/2012)
CHARACTERISTICS 1
TILT CUT-OFF VALVE (VCI)

Function:
– To authorize or not crowding, taking into account

machine overload and machine software.
– When powered, 35 bar pressure is applied to each side

of the slide, giving rise to no crowding movement.
– When unpowered, pressure can be applied to one side

or the other thus enabling movement.
Maximum pressure (bar) 35
Maximum flowrate (L/min) 19
MA
70
1
1 2 3 4
VCI
DLS
b b
Tdd VS
VRP
a a b
LS
T B A T B T T B
T T
EI
a a a Pr Tpr
1 - Crowding Cut-Off Valve (VCI)
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(09/10/2012) F70-3-0042EN
2 CHARACTERISTICS
70
F70-3-0042EN (09/10/2012)
CHARACTERISTICS 1
STEERING SELECTOR
T Function:
– Allows the selection of 3 steering modes, depending

on the steering alignment switch position
(See instructions).
A
B
P
A B T 2
3 1
3 2 1
AV AR
SD 3 2 1
P
70
Position of steering selector switch:
1 - Front and rear wheels face opposite directions (circle).

2 - Front wheels steer (road mode).
3 - Front and rear drive wheels in the same direction (crab steering).
Nominal pressure (bar) 250

Nominal flowrate (liters/minute) 45
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(29/01/2012) F70-3-0042EN
2 CHARACTERISTICS
70
F70-3-0042EN (29/01/2012)
CHARACTERISTICS 1
CASAPPA MVP 60 PUMP
1
2
3
3 1
5 7
70
6
4
7
X B
1. PEC (Pressure Electronic Control).
2. Hydraulic flow regulator.
P
3. Maximum displacement regulator.
4. Minimum displacement regulator.
5. High Pressure (B). 1 M
60 cm3/tr
6. Suction pressure (S).
7. LS (X) line coupling. Includes fi lter and flow
limiter.
8. Oil tank return.
S
2
(09/10/2012) F70-3-0047EN
2 CHARACTERISTICS
SECTION VIEW
DESCRIPTION
70
– LS spring : 17 b
X B
– Pressure limiter : 315 b
P
Key :
1 M
1. PEC (Pressure Electronic Control).
2. Hydraulic fl ow regulator.
315b
17b
S
2
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0047EN (09/10/2012)
CHARACTERISTICS 3
FLOW ADJUSTMENT
Keeping stand-by pressure of 17 bar.
Delta P = p(B) - p(X)
Delta P generated by weak fl ow passing through the control block pressure compensator (Ref 1).
If the Delta P increases, the pump’s displacement decreases.
Example: Hydraulic control (Setting “b”)
M LS D b B1 A1
Delta P
D
100b X B
DLS
119b
P
M P 1
Delta P
119b
Tdd VS 17 bar
5l/min
100b
17b LS
S A
70
T B T
T
T EE EI
a
Notes : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(09/10/2012) F70-3-0047EN
4 CHARACTERISTICS
70
F70-3-0047EN (09/10/2012)
HYDRAULIC PUMP A10VO EK1

Regulator DFR
Proportional
electrovalve EK 1
Pump A10VO
CROSS-SECTION OF PROPORTIONAL ELECTROVALVE EK 1 AND PUMP A10VO
70
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(23/05/2012) F70-3-0059EN
Description
Arrival of distributor signal
Flow regulator FR
Flow regulator DR
Proportional electrovalve
70
Control cylinder
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0059EN (23/05/2012)
Flow of fluids
Position of machine in stop mode or:
Governing fault
Governing deactivated
70
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(23/05/2012) F70-3-0059EN
Flow of fluids
Small displacement position 60%
70
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
F70-3-0059EN (23/05/2012)
Flow of fluids
Large displacement position 100%
70
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(23/05/2012) F70-3-0059EN
70
F70-3-0059EN (23/05/2012)
HYDRAULIC SCHEMATIC DIAGRAMS
pages
MLT 845-120 H SERIES 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MLT 845-120 SERIES 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
70
(08/10/2012) 70-02-M209EN
2 HYDRAULIC SCHEMATIC DIAGRAMS
70
70-02-M209EN (08/10/2012)
HYDRAULIC SCHEMATIC DIAGRAMS 3
MLT 845-120 H Series 4-E3
KEY
HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
A ACCUMULATOR K20
BT TRANSFER GEAR BOX Q12
CA SUCTION STRAINER I21
CAR NON-RETURN VALVE Q18/M16
CSP SAFETY VALVE COUNTERBALANCE C20/C29/C37/C41
D 6 COMPONENT DISTRIBUTOR I36
EE INLET COMPONENT K26
EI TILTING COMPONENT K29
ET TELESCOPING COMPONENT K31
EA ATTACHMENT COMPONENT K32
EL LIFTING COMPONENT K34
EF CLOSING COMPONENT K36
D3 3 POSITION STEERING DISTRIBUTOR C12
Position 1: short steering
Position 2: front wheel steering
Position 3: crab steering
EVPV GEAR CHANGE ELECTROVALVE S14
EVSE(O) 5 COMPONENT ELECTROVALVE (OPTION)
EVTF(O) BOOM HEAD ELECTROVALVE (O)(OPTION) C35
FDAV FRONT DISC BRAKE Q3
FEMS EMS HEAD FILTER M22
70
FR RETURN FILTER G17
M ENGINE 1104D-E44 TA O21
Idle speed 930 rpm (+20/0)
Nominal speed laden 2,200 rpm
Full speed unladen 2,400 rpm
MA MANIPULATOR M26/Q28
MER REVERSIBLE MOTOR FAN (FAN DRIVE) A6
MC MASTER CYLINDER G5
MH HYDROSTATIC MOTOR M6
N LEVEL I16
P HYDRAULIC PUMP I20
PAAV FRONT ATTACHMENT PLUG A31
PAAV(O) FRONT ATTACHMENT PLUG (OPTION) A36
PCR PUMPCOOLER CIRCUIT (FAN) G17
PD STEERING PUMP C10
PH HYDROSTATIC PUMP O20
PP PRESSURE PORT I26
PRES PRESSURE SWITCH M32/M36
PRF(O) LEAKAGE RETURN PLUG (OPTION) A17
R HYDRAULIC TANKS I22
(08/10/2012) 70-02-M209EN
HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
RAD RADIATOR K22/K23
RLF BRAKE FLUID TANK G4
RFV(O) FAN COOLER (OPTION) E17
R3V(O) 3 - WAY VALVE (OPTION) A32
TH7 MANIPULATOR TH7 I7
VAFM HAND BRAKE VALVE K3
VC COMPENSATION CYLINDER A26/C26 90x45 c320
VCI TILTING CONTROL CUT-OFF VALVE M36
VDAR REAR STEERING CYLINDER Q22
VDAV FRONT STEERING CYLINDER Q4
VI TILTING CYLINDER A20 150x75 c385
VIP-VC COMPENSATION CYLINDER BASE INSULATION VALVE E22
VIT-VC COMPENSATION CYLINDER HEAD INSULATION VALVE C23
VL LIFTING CYLINDER A38/A40 110x70 c845
VPV GEAR CHANGE CYLINDER Q13
VS SAFETY VALVE K26
VT TELESCOPE CYLINDER A28 80x60 c3150
VVT(O) CARRIAGE LOCKING CYLINDER (OPTION) A31 60x45 c183
NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine speed.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1 000 rpm.
70
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
70-02-M209EN (08/10/2012)
HYDRAULIC DIAGRAM
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 2 1
MER AR
VI C4
A AV PRF(O) A
3 2 1 VC VT PAAV VL VL
AB T
R3V(O) 1
C3
C1 C2 PAAV(O)
3 2 1
CSP 110b 315b
VVT(O) C1 C2
190b D3 2 3
14.5cm3/tr P
VIT-VC
R L V1 V2 VC C2
EVTF(O)
C1 P1 P2
PD 200b 200b A B 335b CSP
C C1 C2 C1 C2 C
200b 350b 200b 350b
200 cm3/tr
A B
CSP CSP
LS 140b 190b V1 V2 V1 V2
RFV(O) VIP-VC V1 V2
2b °C
T P
M
125L / mn
E E
B XL N
RLF PCR
G G
19 cm3/tr
X
MC Ø1
T P FR A
P VA 4b
B V3
V2 B
TH7 V1
2b 7,6b
A PP
10 μm abs T
300 L/mn
63 cm3/tr M M LS D b B1 A1 B2 A2 B3 A3 b B4 A4
P D
I L L1 L2 125 μm CA I
N 100 L/mn DLS
b b
R
P
Tdd VS
23
a a b bar
70
14V LS
270 T T B A T T B T B
K T EE bar K
3 1 190 280 EI 200 280
bar bar bar ET EA bar EL EF
VAFM RAD RAD a a Pr Tpr
2
A Gicleur Ø 0.8 mm
0,7 L.
Ajout Gicleur
13 b.
CAR FEMS
2 b.
10 μm
4b 4b
M 2 1 PRES 2 1 M
PRES 3
A
3
A
M1 T
MA P T 1
B U T2 Y
MH T1
VCI
2
R b a PS Fa Fa1 Fe MB
a 1 2 3 4
B
M
O b O
PH
A
X1 X2 G MH S Fs MA
T G X1 X3 A
MA
ES.AR
Accessoire
0.5b CAR VDAR Descente
FDAV VDAV Déversement
ES.AV
Q BT Q
VPV
Télescopage
A B Cavage Levage
EVPV
P T
S S
(08/10/2012) 70-02-M209EN
KEY
HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
AC ACCUMULATOR G37 RLF BRAKE FLUID TANK A6
BA FEED BLOCK + ACCUMULATOR C19 R3VD (O) DOUBLE 3 - WAY VALVE E27
BH HYDRAULIC UNIT S14 SC CIRCUIT SELECTOR E11
CA SUCTION STRAINER Q10 SCFR(O) CIRCUIT SELECTOR (TRAILER BRAKE OPTION) G7
E20/K24/K29/ VAFM HAND BRAKE VALVE I9
CSP COUNTERBALANCE VALVE
K33/K37
VAFR(O) TRAILER BRAKE VALVE (OPTION) G10
D 6 COMPONENT DISTRIBUTOR O31
VAI(O) INSULATION VALVE (OPTION) C32
EE INLET COMPONENT Q21
VASF BOOM SUSPENSION VALVE I36/I41
EI TILTING COMPONENT Q24
EV (S1) ELECTROVALVE (SOLENOID 1) G36/G41
ET TELESCOPING COMPONENT Q26
EV (S2) ELECTROVALVE (SOLENOID 2) G33/G38
EA ATTACHMENT COMPONENT Q28
VC COMPENSATION CYLINDER E26/G26 90x45 c320
EL LIFTING COMPONENT Q30
VCI TILTING CONTROL CUT-OFF VALVE O23
EF CLOSING COMPONENT Q31
VCHAR(O) REAR HYDRAULIC TOW-HITCH CYLINDER (OPTION) A26 50x30 c350
D3 3 POSITION STEERING DISTRIBUTOR C12
VDAR REAR STEERING CYLINDER K14
POSITION 1: SHORT STEERING
VDAV FRONT STEERING CYLINDER K7
POSITION 2: FRONT WHEEL STEERING
VI TILTING CYLINDER E21 150x75 c385
POSITION 3: STEERINGCRAB
VIP-VC COMPENSATION CYLINDER BASE INSULATION VALVE G22
EVTF(O) BOOM HEAD ELECTROVALVE (OPTION) C28
VIT-VC COMPENSATION CYLINDER HEAD INSULATION VALVE G23
FDAR REAR DISC BRAKE K13
VL LIFTING CYLINDER I29/I31/E36/E40 110x70 c845
FDAV FRONT DISC BRAKE K6
VS SAFETY VALVE Q22
FEMS EMS HEAD FILTER C21
VT TELESCOPE CYLINDER I26 80x60 c3150
70
FR RETURN FILTER Q12/Q13

VVT(O) CARRIAGE LOCKING CYLINDER (OPTION) A32 60x45 c183
M ENGINE 1104D-E44 TA Q6
IDLE SPEED 930 rpm (+20/0) NOTE: 1- The calibration pressures of the main relief valves, on the inlet sections, are given for maximum engine speed.
NOMINAL SPEED LADEN 2,200 rpm 2- The calibration pressures of the secondary relief valves are at an engine speed of 1 000 rpm.
FULL SPEED UNLADEN 2,360 rpm 3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
MA MANIPULATOR I20/O37
MER ENGINE FANREVERSIBLE (FAN DRIVE) M4
MC MASTER CYLINDER C7
N LEVEL S5
P HYDRAULIC PUMP Q9
PAAR(O) REAR ATTACHMENT PLUG (OPTION) C25
PAAV FRONT ATTACHMENT PLUG A30
PAAV(O) FRONT ATTACHMENT PLUG (OPTION) A28
PD STEERING PUMP C14
PFR(O) TRAILER BRAKE COUPLING (OPTION) I21/M11
PP PRESSURE PORT O20
PCR COOLING CIRCUIT PUMP FAN
PR(O) COOLING PUMP (OPTION) Q5
PRES PRESSURE SWITCH G35/S30/M28
RF COOLER Q3/Q4
RFV(O) FAN COOLER (OPTION)) O6
70-02-M209EN (08/10/2012)
HYDRAULIC DIAGRAM
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
2
3 1
A A
AV AR VCHAR(O) PAAV(O) PAAV VVT(O)
B L 3 2 1
RLF N
A B T P1
35b BA
3 2 1 U C4
PAAR(O) C2
C MC D3 2 3 C
0,7 L. C1 C3
P P 13 bar EVTF(O) VAI(O)
45±5B
R L P2 T FEMS
10μm 1
200b 200b PD
P1 P2
Ø 349
OPTION SUSPENSION DE FLÈCHE
200 cm3/tr A1
VI
SC B
VC VL
E V2 V1 A B1 VL E
LS 140b R3VD(O)
C C1 C2
OPTION FREINAGE REMORQUE
T P CSP 110b 315b
E E1
V1 VIT-VC PRES
SCFR(O) C VC
V1 V2
1 2
3
A B C1 C2 C1 C2
V2 PX EV(S1) PX EV(S1)
T P
G AC AC G
A B CLAPET PARACHUTE CLAPET PARACHUTE
Y
VAFR(O) VIP-VC EV(S2) EV(S2)
B N 320b+15/0
AC 320b+15/0
VEM VEM
30b
PFR(O) 30b+6/0 1.5 L 30b+6/0
VASF VASF
T V1 V2 T V1 V2
Gicleur
I Ø1 P T I
MA VT VL VL
3 1
VAFM
2
4 3 2 1
CSP
V1 C1
70
K C1 C2 K
C1 C2 C1 C2
CSP 335b CSP 200b 350b 200b 350b CSP V2
70b
C2
M
FD-AV VD-AV VD-AR FD-AR V1 V2 V1 V2
PRF(O)
MER 190b
V1 V2 PRES
ES.AR
ES.AV
1 2
3
4b
M M
A
190b
14.5cm3/tr
2
1 VCI
2b °C
RFV(O)
M
125L/mn P
O X B M LS D b B1 A1 B2 A2 B3 A3 b B4 A4 O
P PP D
DLS
b b
M
60 cm3/tr MA
RF RF FR FR P Accessoire
2b 2b Tdd VS
2 23 Descente
a a b bar Déversement
PR 14V
BOITE MECANIQUE 19cm3/tr M 10μm 10μm LS
Q 1 S B A
Q
270 T T T T B T B
T bar 190 280 200 280
bar bar bar bar EF Télescopage
EE EI ET EA EL
a a Pr Tpr
Gicleur Ø 0.8 mm
4b Cavage Levage
125 μm CA Ajout Gicleur
N absolu 100 L/mn
1 2
3
PRES
A
BH
S S
(08/10/2012) 70-02-M209EN
70
70-02-M209EN (08/10/2012)
HYDRAULIC COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
– 1 – MAIN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– 2 – HYDRAULIC LIFTING CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– 3 – HYDRAULIC BOOM CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– 4 – BOOM COMPENSATION HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– 5 – STEERING HYDRAULIC CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
70
(26/09/2012) 70-03-M209EN
HYDRAULIC COMPONENTS
2 LOCATION
KEY
1 - Main 4 - Boom supply compensation

2 - Lifting 5 - Steering
3 - Boom
Representation on circuit Electric code

Item Designation equivalence
1 2 3 4 5
A ACCUMULATOR √
BA FEED BLOCK + ACCUMULATOR √
CA SUCTION STRAINER √
CSP COUNTERBALANCE VALVE (VI) √
CSP COUNTERBALANCE VALVE (VL) √
CSP COUNTERBALANCE VALVE (VT) √
D 7 COMPONENT DISTRIBUTOR √ √ √ √
D3 3 POSITION STEERING DISTRIBUTOR √
FEMS EMS HEAD FILTER √
FR RETURN FILTER √
MA MANIPULATOR √
N LEVEL √
P HYDRAULIC PUMP √
PAAV FRONT ATTACHMENT PLUG √
PD STEERING PUMP √
PP PRESSURE PORT √
70
R HYDRAULIC TANK √
SC CIRCUIT SELECTOR √
VCI TILTING CONTROL CUT-OFF VALVE √
VC COMPENSATION CYLINDER √
VI TILTING CYLINDER √
VIP-VC COMPENSATION CYLINDER BASE INSULATION VALVE √
VIT-VC COMPENSATION CYLINDER HEAD INSULATION VALVE √
VL LIFTING CYLINDER √
VT TELESCOPE CYLINDER √
70-03-M209EN (26/09/2012)
LOCATION 3
HYDRAULIC CIRCUITS
1 – MAIN HYDRAULIC CIRCUIT
D
FR
CA
70
MA
3 4
P
2
1
T
VCI
Tdd PP
D
M
Pr DLS
Tpr
P1
T
FEMS
BA
(26/09/2012) 70-03-M209EN
4 LOCATION
FR
CA
70
MA
4
2
3
P T VCI
1
Tdd
D
M
Pr DLS
S
Tpr
LS
T
D P
FEMS
70-03-M209EN (26/09/2012)
LOCATION 5
2 – HYDRAULIC LIFTING CIRCUIT

CSP
CSP
VL
VL
70
(26/09/2012) 70-03-M209EN
6 LOCATION
3 – HYDRAULIC BOOM CIRCUIT

PAAV
VT
CSP
VI
CSP
70
70-03-M209EN (26/09/2012)
LOCATION 7
4 – BOOM COMPENSATION HYDRAULIC CIRCUIT

VIP-VC
VIT-VC
VC
VC
70
(26/09/2012) 70-03-M209EN
8 LOCATION
5 – STEERING HYDRAULIC CIRCUIT
PD
D3
Tdd
D M
DLS
D
SC
70
PD
D3
Tdd
D M
DLS
70-03-M209EN (26/09/2012)
HYDRAULIC CONTROL AND ADJUSTMENT
pages
PRESSURE TAKE-OFF POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– VALUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– LOCALIZATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SX14 S CONTROL BLOCK CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
DANGEROUS MOVEMENTS CUT-OFF OPERATING PRINCIPLES. . . . . . . . . . . . . . . . . . . . . . .5
REMOVAL OF SX 14 S DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
– 1 - SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– 2 – TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
70
– 3 - ESSENTIAL RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– 4 - REMOVAL AND RE-FITTING OF THE SX 14 S UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– 5 - SX 14 S UNIT REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– 6 - SPECIFIC TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
(26/09/2012) 70-04-M209EN
2 HYDRAULIC CONTROL AND ADJUSTMENT
PRESSURE TAKE-OFF POINTS
VALUES
N° of pressure Values (bars)

Machine
ports Typical
PP-1 270
LOCALIZATION
PP-1
70

70-04-M209EN (26/09/2012)
HYDRAULIC CONTROL AND ADJUSTMENT 3
SX14 S CONTROL BLOCK CONTROL LOGIC

The JSM sends information about the direction and proportional amount for rollers 1 and 2 to the SPU
computer. The computer turns the information into PWM control of the 4 coils for accessory and boom
movements.
JSM X56 SPU
1
X36 2
+12V (APC)
ATTACHEMENT (S1)
3
1
BOOM HEAD VALVE GND
4
2
3 5
12
4 SAFETY VALVE GROUD
5 6
11 6 BOOM LOWERING VALVE GROUD
10 7
9 MICRO RELAIS SUPLY
8
7 X36 8
ANALOG SENSOR ANGLE 2
9
10
11
EASY CONNECT SYSTEM
MOVENTS FORCING
X56
12
ROLLER 1 1
13 8
IN TIMER ECU +12V APC 14
14 7
ATTACHEMENT (S2) 20
13
15
TRANSMISION CUT 19
16 26
HYDRAULIC MOVENTS INHIBITION
17
SEAT MICROSWITCH (NO)
18
JSM ROLLER 1
19
20
GROUD
21
+12Vdc
22
OIL FLOW CONTINUOUS
23
PARKING BRAKE INFO
24
25
26
GROUD
X57 1
CAN H
2
CAN L
3
SPU +APC
4
SPU +APC
5
EV. SENS+ TELECOPE
6
BOOM LOWERING PROP. VALVE
7
SAFETY VALVE
8
+12V APC
9
+12V APC
10
11
12
BP1 ev TDF
13
14
70
GEAR INFO
15
16
ANALOG SENSOR (N.O.) BOOM RETRACTION X57
JSM ROLLER 2
17
TRANSMISSION CUT 1
18 10
18
19
26 9
ATTACHM. LOCK
20 17
FAN PROP. VALVE 25
21 34
22
GEAR INFO
23
ANALOG SENSOR (N.F.) BOOM RETRACTION
24
ROLLER 2
25
FAN PROP. VALVE
26
27
28
CAN GND
29
TELECOPIC BOOM PROP. OUT
30
FAN INVERSION
31
ANALOG SENSORS GND
32
VCI VALVE
33
OIL FLOW CONTINUOUS SIGN. LAMP
34
GROUD
X87
1
2
3
4
12
5
6 11
10
9
8
7
Y7 Y6 Y8 Y9
HYDRAULIC
DISTRIBUTOR GND
(26/09/2012) 70-04-M209EN
Rexroth SX 14 S control
block
JSM
70
5
100 0
60 130 140 1 5
125
70 80 90
SPU
70-04-M209EN (26/09/2012)
DANGEROUS MOVEMENTS CUT-OFF OPERATING PRINCIPLES
Movement cut-off is activated by the VRP/SPU or VCI at 105% gauge signal.

If gauge signal exceeds 112%, the VS also cuts out.
(These figures can change, depending on the jib angle)
VS cut-out occurs 7% after proportional cut-out, to cater for the eventuality of the SPU taking longer to
carry out a proportional cut-out. The VS will then cut out all movements at 112%.
P T
MA
4 3 2 1 PRES
1 2
3
4b
A
1 2
1 VCI
M LS D b B1 A1 B2 A2 B3 A3 b B4 A4
D
DLS
b b
70
2 P
Tdd VS
23
a a b bar
14V
LS
B A
270 T T T T B T B
T bar 190 280 200 280
bar bar bar bar EF
EE EI ET EA EL
a a Pr Tpr
3 4b
1 2
3
PRES
A
1 - Tilt cut-out valve (VCI).

2 - Movement cut-out valve (VS).
3 - Control Regulation Valve (VRP).
(26/09/2012) 70-04-M209EN
REMOVAL OF SX 14 S DISTRIBUTOR
5
100 0
60 130 140 15
125
70 80 90
70
1 – SAFETY INSTRUCTIONS
Safety instructions and important notices which you must closely observe are shown in this chapter
in the following way:
b Instructions to be scrupulously followed to guarantee your safety and avoid the risk of damage
to the telehandler in the course of maintenance operations.
70-04-M209EN (26/09/2012)
2 – TROUBLESHOOTING
b Before carrying out any of the fault-finding procedures to detect the cause of the breakdown
or before removing the distribution unit, it is essential to first carry out an examination of the
machine’s hydraulic circuit in order to eliminate any breakdown resulting from causes external
to the SX 14 S distributor unit.
Faults arising from malfunction of receivers linked to the distribution unit.
Results noted Probable causes Additional checks Solutions

Lack of power at all - LS Limiter defective Measure pressure (see - Change the LS limiter
receivers unit specifications) (cf. § 5.1)
- LS limiter out of - Adjust
adjustment
Lack of power at just one - Secondary suppression - Reset to design pressure
receiver limiter out of (see unit specifications)
adjustment
- Secondary limiter stuck - Change the secondary
open (return to tank) limiter (cf. § 5.5)
Lack of speed in one or For SX 14 S fitted with Change the body +
all movements “open center” inlet: piston assembly
“Open center” piston
stuck in position P
towards T
Lack of speed in one - Incorrect slide Manual control: - If movement is
movement movement measure slide movement. incorrect, change the
- Adjustable hydraulicDirect electrical control: body + slide assembly.
control stop out of check the coil resistance If the resistance is
70
adjustment (R: 2.5 Ohm at 25°C) incorrect change the
- Individual pressure coil.
balance stuck - Adjust
- Change the body
+ pressure balance
assembly
Failure to maintain - Load hold check valve - Change the body +
pressure faulty valve assembly
- Excessive play between - Change the body + slide
the body and the slide assembly
Steering abnormally hard Flow divider poorly - Regulating piston - Change regulation sub-
adjusted sliding freely assembly (cf. § 5.3)
- Regulating piston stuck - Change body +
regulation assembly (cf.
§ 5.7 et 5.3)
Excessive delay in Flow Divider regulation Change the filter
response to steering piston filter clogged
(26/09/2012) 70-04-M209EN

Clamps faulty (SX14S - Output coil defective - Check coil resistance (R: If resistance is incorrect,
fitted on loading shovel) - Output ball valve 6 Ohm at 20°C) change the coil.
malfunction Change the ball valve
- 2 way valve defective Change the 2 way valve
Simultaneous movement - Individual balance jet - Remove and clean
fault blocked the individual balance
(cf. § 5.7)
- Individual pressure - Change the body
balance stuck + pressure balance
assembly
- LS line leak - Change the LS flow
regulator (cf. § 5.2)
Faults manifesting as machine malfunction.

Diesel engine remains - Flow regulator blocked - Change the flow regulator
under load after slides - Regulator filter blocked (cf. § 5.2)
returned to neutral - Change the filter
Defects manifesting as malfunction of distribution unit controls.

Coupling fault - Mechanical defect - Check coil resistance (R: - Change the
70
- Defective coil 16.5 Ohm at 20°C) latchmechanical

- If resistance is incorrect,
change the coil
Increased effort to use Distribution unit tie bolts Check tightening torque Loosen and adjust to
controls or lack of return too tight tightening torque 42 ±
b
10% Nm.
Before
commencing free
the distribution
unit from its fixing
Slide unions worn out points
Change the slide
connectors (cf. § 5.6)
70-04-M209EN (26/09/2012)
Faults found upon visual inspection.

Slide oil leaks Defective slide seals Change slide connectors
(cf. § 5.6)
Oil leaks at limiters and Defective seals Remove the limiter or
stoppers stopper and change the
seals
Oil leaks between Defective seals between Remove distribution
modules modules modules and change
seals (cf. § 5.7)
Hydraulic controller oil - Defective seal between Change the seal
leaks unit and housing
- Defective adjustable
stop nut seal
Damaged joystick control Change the bellow
bellows
3 – ESSENTIAL RULES
GENERAL NOTES CONCERNING CONNECTING UP THE DISTRIBUTION UNIT
– When the unit is removed seal all openings immediately to avoid any possible contamination to the
hydraulic circuit.
– When re-fitting the unit, remove the plastic stoppers from openings and pipes just before making
70
connections.
– Do not tighten unions to a torque greater than that shown in the assembly instructions.
– Whenever work is done, check the quality of the oil and the level of filtration.
– The use of PTFE, hemp or sealing compound is forbidden.
– Pipework and unions must be under no mechanical strain.
(26/09/2012) 70-04-M209EN
4 – REMOVAL AND RE-FITTING OF THE SX 14 S UNIT
4.1 GENERAL GUIDANCE
b Before removing the SX 14 S distribution unit it is essential to fully clean the unit and its
surroundings. (Do not apply the output from a pressure washer directly to the unit).
It is essential that the hydraulic circuit is kept clean of all dirt or foreign objects. Use plastic
plugs on openings and pipes as soon as they are removed.
Wear protective clothing and use correct equipment to avoid any accident, particularly with
the fluid.
Use the lifting eye-bolts and appropriate maintenance equipment.
Place all the machine’s receivers attached to the distribution unit in their rest positions
(resting on the ground, at the bottom of their movement etc.) to avoid any accident arising
from unplanned movements as a result of disconnecting the hydraulic circuit.
With the machine stopped, release all stored pressure by moving the distribution slides.
4.2 REMOVAL OF THE SX 14 S UNIT
e HYDRAULIC COMPONENTS REMOVAL

– Attach a vacuum pump to the tank to limit the escape of oil when unions are unfastened.
– Insert the plastic plugs immediately after disconnecting the pipes from the unit.
– Take care to catch any oil spills in an appropriate container.
– Unscrew the fixing bolts and remove the distribution unit.
4.3 RE-FITTING THE SX 14 S UNIT

70
e HYDRAULIC COMPONENTS REMOVAL

– Ensure mating faces are perfectly clean.
– Check the mating surface of the unit with the machine for flatness (tolerance 0.5 mm).
– Check the condition of all the seals on the pipework unions.
– If the unit has been stored for an extended period, clean it.
– Offer the distribution unit up to the machine and secure it with bolts.
– Connect the pipework to the unit, in accordance with the connection diagram and the recommended
torque settings.
– Ensure that flexible hoses have clearance; they must not be twisted or rubbing on anything.
– When assembly is complete the machine can be put back into operation:
– Turn down the LS pressure limiter before starting up the machine.
– Keep one of the distributor lines activated after the hydraulic cylinder connected to it reaches
its end stop.
b On the distribution line in question, the value of the secondary pressure limiter must be greater
than that to be set with the LS limiter.
– Adjust the maximum pressure measured in M at the LS pressure limiter.

– Retighten the locknut on the adjusting screw to torque: 20 ± 10% Nm.
70-04-M209EN (26/09/2012)
5 – SX 14 S unit REPAIR PROCEDURES
5.1 CHANGING THE LS LIMITER
NOTE: It is not necessary to remove the distribution unit from
b
the machine to change the limiter.
With the machine stopped:
– Put all the machine’s receivers connected to the
distribution unit in their rest positions.
- With the machine stopped, release all stored pressure
by moving the distribution slides.
NOTE: Catch any leaked oil in an appropriate container.
On the inlet, unbolt the LS limiter (17 mm spanner).
Refitting: tightening torque: cf. § 6.
5.2 CHANGING THE FLOW REGULATOR
NOTE: It is not necessary to remove the distribution unit from
b
the machine to change the limiter.
– Put all the machine’s receivers connected to the
distribution unit in their rest positions.
70
- With the machine stopped, release all stored pressure
by moving the distribution slides.
NOTE: Catch any leaked oil in an appropriate container.
On the inlet, unbolt the LS limiter (22 mm spanner).
Filter removal and replacement
Using flat-nosed pliers, remove the filter from the regulator.
b
Filter
Take care not to damage the O-ring at the end of
the regulator.
(26/09/2012) 70-04-M209EN
5.3 DIS-ASSEMBLY OF FLOW DIVIDER REGULATION SUB-ASSEMBLY
b
NOTE: It is not necessary to remove the distribution unit from the machine to change the limiter.
– Put all the machine’s receivers connected to the distribution unit in their rest positions.
– With the machine stopped, release all stored pressure by moving the distribution slides.
NOTE:
– Attach a vacuum pump to the tank to limit the escape of oil
during this operation.
– Catch any leaked oil in an appropriate container.
– Remove the plug (12 mm Allen key)

– Remove the stop and the spring.
Selector kit
– Replace any defective parts.
Ball
– Replace the O-rings on the plugs.
O-rings
– Re-assembly is the reverse of dis-assembly.
Sealing
kit
70
Piston kit
Priority
flow divider
5.4 FLUSHING VALVE REMOVAL
NOTE: There is no need to remove the control block from the

telehandler for this operation.
b Telehandler switched off:

- Place all actuators connected to the control block
in their rest position.
- Release all stored pressure by moving the distribution
slides.
70-04-M209EN (26/09/2012)
– - On the outlet element, unscrew the flushing valve plug

Plug (12 mm Allen key).
O-ring
Re-fitting:
– Replace the plug O-ring.
Spring – Tightening torque: cf. § 6.
Shims – Remove: - the shim,

- the spring,
Piston - the ring,
- the piston.
T3
– Re-assembly is the reverse of dis-assembly.
5.5 SLIDE REMOVAL
NOTE: There is no need to remove the control block from

the telehandler for this operation.
b Telehandler switched off:

- Place all actuators connected to the control block
in their rest position.
- Release all stored pressure by moving the distribution
70
slides.
NOTE:
– Fit a vacuum pump to the fluid reservoir in order to limit
any possible oil leaks during this operation.
– Catch any oil leaks in an appropriate recipient.
– Remove the cover fixing screws (5 mm Allen key).
Reassembly: tightening torque: cf. § 6.
– Remove the cup and spring.

– Remove the O-ring from the cover.
– Extract the spool from the distribution element.
b
Re-fitting: Grease new seals when fitting.
Spool fitting direction.
(26/09/2012) 70-04-M209EN
5.6 DIS-ASSEMBLY AND RE-ASSEMBLY OF CONTROL BLOCK
Preliminary operations:
– Remove the control block from the telehandler (cf. § 4).
– Remove the 3 assembly nuts (13 mm socket).
Reassembly: tightening torque: cf. § 6.
– Remove the outlet (1).

– Separate the distribution units (2) from the inlet (3).
– Replace the O-rings between the distribution elements,
the input element and the output element.
– If the input element is to be replaced, remove the tie rods.
– Assembly is the opposite of dis-assembly, ensuring that
3
tie rods are torqued to the correct torque.
– Before commencing, ensure that mating faces on the
2 elements are clean.
1
Individual pressure compensator removal

70
– Unscrew the plug (7 mm Allen key).
– Remove the compensator piston.
– Clean the piston’s nozzle with compressed air.
– Check the condition of the bore in the body.
Re-assembly: replace the O-ring and the anti-extrusion ring

in the plug.
70-04-M209EN (26/09/2012)
Load hold check valve disassembly
– Unscrew the plug (5 mm Allen key).
– Remove the spring and the poppet.
– Visually inspect the parts for condition.
– If necessary, replace any defective parts.
Re-fitting:
– Replace the plug O-ring.
– Tightening torque: cf. § 6.
6 – SPECIFIC TIGHTENING TORQUE
Tightening torques given in Nm ±10%.
Ref. torque N.m

Inlet component:
1 LS pressure relief valve: 45
2 LS Flow regulator: 3,5
3 DLS/LS selector: 20
4 Priority valve seat: 10
5 Priority valve plug: 100
70
Distribution module
6 Non-Return Valve: 30 to 35
7 Balance plug: 60
8 Hydraulic Control Housing: 10
9 Return housing: 10
10 EMS module control piston: 10
11 EMS module: 15
Output module
12 Flushing valve plug: 100
13 Tie-bolt nuts: 42
(26/09/2012) 70-04-M209EN
100 N.m
12
42
N.m
T3
13
7 60 N.m
30-35 N.m
6
10 N.m 30-35 N.m 8
5 100 N.m 10 11
20 N.m 5 N.m
1 N.m
10 N.m 5 N.m
Loctite 542 3
4 10 N.m
1
45 N.m
20 N.m
20 N.m
Loctite 542
45 N.m 3,5 N.m
± 6 N.m ± 0,5 N.m
2
1 - Pressure limiter 8 - Hydraulic control housing

70
2 - Flow controller 9 - Return housing

3 - DLS/LS Selector 10 - EMS module control piston
4 - Priority valve seat 11 - EMS module
5 - Priority valve plug 12 - Flushing valve plug
6 - Non-return valve 13 - Tie-bolt nuts
7 - Balance plug
70-04-M209EN (26/09/2012)
HYDRAULIC COMPONENTS REMOVAL
pages
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– DISTRIBUTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70
(29/10/2012) 70-06-M209EN
2 HYDRAULIC COMPONENTS REMOVAL
DISTRIBUTOR
100 50
60 30 140 15
125
A
1
70 80 90
70
Key:
A - Distributor

• Lift the boom.
70-06-M209EN (29/10/2012)
HYDRAULIC COMPONENTS REMOVAL 3
DISTRIBUTOR REMOVAL
Place the two safety systems (Item 1) on the compensation

cylinders and operate the battery cut-out.
Remove the cover plate (Item 2) on the cab.

2
Place a container under the carriage at the level of the distributor.
70
Remove the T+hose (Item 4) using a 46 mm spanner.
4
3
8 7 8
Remove the four hoses (Item 7) using a 30 mm spanner, mark
7
them to make refitting them easier.
6 Remove the four hoses (Item 8) using a 36 mm spanner, mark

7
8
8 7
88
9 Remove the two hoses (Item 9) using a 19 mm spanner, mark
9
(29/10/2012) 70-06-M209EN
Disconnect the two connectors X29 (Item 10) and X35 (Item 11)
and mark them to make refitting them easier.
12
10
Remove the three hoses (Item 12) using a 19 mm spanner, mark

12

13
12
12
In the cab, remove the two cover plates (Item 14 and 15)
(six screws) using a 4 mm hexagonal spanner.
70
Disconnect the emergency stop connector (Item 16).

16
14
15
Remove the three hoses (Item 17) using a 19 mm spanner, mark

17
17
17
70-06-M209EN (29/10/2012)
HYDRAULIC COMPONENTS REMOVAL 5
Remove the hose (Item 18) using a 19 mm spanner, mark it to

make refitting it easier.
19 20 21
Disconnect the three connectors X28 (Item 19), X34 (Item 20)
and X92 (Item 21), mark them to make refitting them easier.
18
Disconnect the connector X23 (Item 22) and the ground X105
(Item 23).
23
22
Remove the retaining screw (Item 24) from the distributor

support bracket using a 19 mm spanner.
70
24
Remove the retaining screw (Item 25) from the distributor

25
(29/10/2012) 70-06-M209EN
Remove the distributor (Item 26).
26
70
70-06-M209EN (29/10/2012)
HYDRAULIC COMPONENTS REFIT
pages
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– DISTRIBUTOR REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
70
(29/10/2012) 70-07-M209EN
2 HYDRAULIC COMPONENTS REFIT
DISTRIBUTOR
100 50
60 30 140 15
125
A
1
70 80 90
70
Key:
A - Distributor

• Lift the boom.
70-07-M209EN (29/10/2012)
HYDRAULIC COMPONENTS REFIT 3
DISTRIBUTOR REFIT
Raise the distributor (Item 1), tighten the retaining screw (Item
2) using a 19 mm spanner.
1
2
In the cab, tighten the retaining screw (Item 3) on the distributor

Connect the ground X105 (Item 4) and the connector X23 (Item
5) in the plug (Item 6).
70
4
Connect the three connectors X28 (Item 7), X34 (Item 8) and
X92 (Item 9) by following the markings.
7 8 9
Fasten the hose (Item 10) using a 19 mm spanner by following
the markings.
10
(29/10/2012) 70-07-M209EN
Fasten the three hoses (Item 11) using a 19 mm spanner by

following the markings.
11
11
11
Fasten the hose (Item 12) using a 30 mm spanner.

13
Fasten the three hoses (Item 13) using a 19 mm spanner by

12
13
13
Disconnect the two connectors X29 (Item 14) and X35 (Item 15)
by following the markings.
70
15
14
Fasten the two hoses (Item 16) using a 19 mm spanner by

17 18 17
Fasten the four hoses (Item 17) using a 36 mm spanner by
18
19 Fasten the four hoses (Item 18) using a 30 mm spanner by

18
17
17 18
16
88 Fasten the hose (Item 19) using a 19 mm spanner.
16
70-07-M209EN (29/10/2012)
HYDRAULIC COMPONENTS REFIT 5
Fasten the hose (Item 20) using a 46 mm spanner.
Fasten the T+hose (Item 21) using a 46 mm spanner.
Fasten the hose (Item 22) to the T (Item 21) using a 41 mm

21
spanner.
22
20
In the cab, connect the emergency stop connector (Item 23).
Position and fasten the two cover plates (Item 24 and 25)
(six screws) using a 4 mm hexagonal spanner.
23
25
24
Position and fasten the cover plate (Item 26) to the cab.
26
70
Remove the two safety systems (Item 27).
Turn the current back on by means of the battery cut-out.
Top up with hydraulic oil.
27
(29/10/2012) 70-07-M209EN
70
70-07-M209EN (29/10/2012)
HYDRAULIC SPECIFIC TOOLING
pages
COFFRET MANOMÈTRES DE BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

COFFRET MANOMÈTRE DIGITAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
70
(26/09/2012) 70-09-M209EN
2 HYDRAULIC SPECIFIC TOOLING
BASIC MANOMETER KIT
This box contains all the components required for measuring

pressure on all Manitou products.
1 2 3 3 4 5 5 6
70
8 7
Basic manometer kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7. 2 Hoses for Maniscopic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8. 7 Manometer connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
70-09-M209EN (26/09/2012)
HYDRAULIC SPECIFIC TOOLING 3
DIGITAL MANOMETER BOX
FUNCTIONS :
• Manometer functions: the screen can display all the

following items:
- Temperature upstream to +/- 2°C

- Upstream pressure P1 showing minimum and maximum
(700 bar class 0.1)
- Downstream pressure P2 showing minimum and maximum
(700 bar class 0.1)
- Differential pressure dP=P1-P
• Hold Function: the operator is able to freeze the display to

take notes at will
• Unit Function: the operator can change the measurement

unit at will (bar, psi, kPa, mCe).
• Tare Function: enables taring
• Leakage Test Function: enables pressure variations to be

measured over a set time period
• Recording Function: a max. of 16000 values may be recorded.

The sampling period can be configured.
70
• Zero Function: zero is carried out on 2 sensors
Digital Manometer box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662187
Consisting of:
1. 1 dP HP 700 bar Mano digital manometer

2. 1 measurement hose DN2 1215/1620, L = 1,5 m, 630 bar
3. 2 measurement hoses DN2 1620/1620, L = 1,5 m, 630 bar
4. 2 1620 Manometer adaptors
(26/09/2012) 70-09-M209EN
4 HYDRAULIC SPECIFIC TOOLING
70
70-09-M209EN (26/09/2012)
ELECTRICITY
- ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL COMPONENTS LOCATION
- ELECTRICAL CONTROL AND ADJUSTEMENT
- ELECTRICAL COMPONENTS REFIT
- ELECTRICAL SPECIFIC TOOLING
80
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
pages
ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A

INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C
80
(30/01/2012) 80-01-M209EN
2 SPECIFICATIONS
80
80-01-M209EN (30/01/2012)
SPECIFICATIONS A1
ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW

pages
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
80
80
(14/11/2012) 80-01-M209EN
A2 SPECIFICATIONS
OPERATION
Telescope retraction control: VRP installed as part of the distributor raising/lowering system. Flow
limiting nozzle fitted to pressure distributor inlet descent control.
Boom extension control: SPU computer (signal is monitored).
Accessory line +/- cut-off: SPU calculator (signal is controlled).
Tilt +/- cut-off: VCI (Tilt cut-off valve) fitted externally.
Dangerous movements cut-out: Activated by VRP/SPU or VCI at 105% gauge signal, and if gauge signal
exceeds 120%, additional VS cut-out. (Percentages can change, depending on telescopic boom angle).
Control and change of rotational direction of the FAN DRIVE fan: SPU computer (the signal is checked).
Operation is identical to the MLT T = 2 cut-out thresholds, depending on strain gauge signal.
80
80
80-01-M209EN (14/11/2012)
SPECIFICATIONS A3
SYSTEM OVERVIEW
Seat sensor
FNR
Thumbwheels
Parachute
switch
FAN DRIVE
Tin
sensor
VCI
-100%
-120%
130%
Gauge signal Jib

Angle
Cut-off
redundancy
VRP
80
VS
80
SX14S
ADM2
Strain gauge
LLMI Module
MR2-PLD
Transmission Can-Bus
Hydraulic operation Stability monitoring Operator presence
(14/11/2012) 80-01-M209EN
A4 SPECIFICATIONS
80
80
80-01-M209EN (14/11/2012)
ELECTRICAL CHARACTERISTICS
AND SPECIFICATIONS B1
INPUTS/OUTPUTS
pages
HYDRAULIC ECU INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3

– ECU RC2-2/20 REXROTH (WITH CAN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
– CASAPPA (CED100X) ECU. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
SPU INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4
– SPU 25-15 (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
ADM INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6
– ADM 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6
PLD INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B8
– PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
80
(13/11/2012) 80-01-M209EN
B2 AND SPECIFICATIONS
80
80-01-M209EN (13/11/2012)
HYDRAULIC ECU INPUTS/OUTPUTS

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

NC: Not Cabled
41 52
27 28
X109 1 2 3 14
Designation 18 ECU TYPE CONNECTOR PIN N° WIRE Function on carriage Comments

Power supply X109 01 Red Proportional outlet and all or nothing power supplies
GND X109 02 Black Ground RC2-2/20
X109 24 Black CAN ground and RX/TX RS232 CAN drain cable
X109 27 Red Proportional outlet and all or nothing power supplies
X109 28 Black Ground RC2-2/20
X109 31 Brown Control pump proportional output
X109 32 Black Ground RC2-2/20
X109 39 Blue CAN L
X109 40 Brown CAN H
X109 41 Red RC2-2/21 microcontroller power supply
X109 42 Red RC2-2/21 microcontroller power supply
X109 50 Orange RxD RS 232
X109 51 Grey/Purple TxD RS 232
X109 52 Purple Reserved for REXROTH software flashing
CASAPPA (CED100X) ECU
80
CASAPPA
X109/A
X109/A X109/B
X109/B

Battery V VBB X109/A 01 Red/Black CASAPPA ECU power supply
CAN-Low CAN-L X109/A 06 Brown CAN-L J1939
CAN-High CAN-H X109/A 07 Brown CAN-H J1939
Power Gnd + CAN Gnd GND X109/A 12 Black CASAPPA ECU ground
PWM output - PWM - X109/B 09 PWM -
PWM output + PWM + X109/B 11 PWM Control pump
(13/11/2012) 80-01-M209EN
SPU INPUTS/OUTPUTS
SPU 25-15 (LSU)
Key:
SPU: Signal Processing Unit SPU

NC: Not Cabled
X57
X56 X56 X57
SPU 25-15 LSU

12 V T APC POWER SUPPLY 12VB X56 01 Red 12V + POST CONTACT (APC) + APC
PWM 8 OUTPUT HSD-08 X56 02 Red + DIRECTION SELECTOR ATTACHMENT
LOW SIDE 2 OUTPUT LSD-02 X56 03 Red BOOM HEAD ELECTROVALVE GROUND
LOW SIDE 2 OUTPUT LSD-02 X56 04 NOT USED
LOW SIDE 1 OUTPUT LSD-01 X56 05 Green SAFETY ELECTROVALVE (VS) GROUND
LOW SIDE 1 OUTPUT LSD-01 X56 06 Green PROPORTIONAL ELECTROVALVE GROUND (Lowering)
12 V BATTERY POWER SUPPLY 12VP X56 07 Yellow 12V BATTERY MICROSWITCH POWER SUPPLY
ANALOGUE INLET 2 UN-09 X56 08 Orange/Blue SENSOR 2 BOOM ANGLE ANALOGUE SIGNAL INPUT I FROM 0,5V TO 4,5V
LOGIC INPUT 19 FQ-04 X56 09 NOT USED
LOGIC INPUT 13 FQ-02 X56 10 White/Green EASY CONNECT SYSTEM GROUND INFO
LOGIC INPUT 04 UN-06 X56 11 Light blue/White 12V INPUT CUT-OFF (OVERRIDE) SWITCH HELD AT 60° MAX
LOGIC INPUT 14 UN-03 X56 12 Red 12 V INPUT DIRECTION INFO ROLLER 1 JSM ROLLER 1 IS OUTSIDE OF THE NEUTRAL ZONE
ECU WAKE-UP INFO WUI X56 13 Orange/Yellow ECU WAKE-UP INFO +12V apc THIS SUPPLY CAN BE CUT-OFF BY THE EMERGENCY STOP
PWM 7 OUTPUT HSD-07 X56 14 Orange DIRECTION 2 PROPORTIONAL ATTACHMENT CONTROL
Brown/Green TRANSMISSION CUT-OFF INPUT (ON ACCELERATOR) Brown/Green for MLT 845-120 H
LOGIC INPUT 10 FQ-03 X56 15
Yellow/Red TRANSMISSION CUT-OFF INPUT (ON GEAR LEVER) Yellow/Red for MLT 845-120
LOGIC INPUT 12 FQ-01 X56 16 Brown/Yellow HYDRAULIC MOVEMENT NEUTRALISATION GROUND INPUT
LOGIC INPUT 01 UN-05 X56 17 White/Blue 12V SEAT INPUT SENSOR NO. DRIVER PRESENCE
80
ANALOGUE INLET 03 UN-02 X56 18 Yellow ROLLER 1 JSM ANALOGUE INPUT FROM 0,5V TO 4,5V TELESCOPIC BOOM
STABILISED 5V REF. OUTPUT U 5V INPUT X56 19 NOT USED
GROUND GROUND X56 20 Black ECU GROUND
STABILISED 200mA 10V REF OUTPUT SENSOR X56 21 Grey ATTACHMENT CONTROL SELECTOR CONTROL / STRAIN GAUGE +12Vdc 4 POSITIONS : 25% - 50% - 75% - 100%
LOGIC INPUT 03 UN-08 X56 22 Red/Green FORCED OPERATION CONTROL
LOGIC INPUT UN-07 X56 23 Red HAND BRAKE INFO
LOGIC INPUT 17 UN-04 X56 24 Yellow FAN SIGNAL INVERSION
ANALOGUE INLET 01 UN-01 X56 25 Light blue/Yellow SENSOR 1 BOOM ANGLE ANALOGUE SIGNAL INPUT FROM 0,5V TO 4,5V
GROUND GROUND X56 26 Black ECU GROUND
80-01-M209EN (13/11/2012)
SPU 25-15 LSU

CAN HIGH CAN H X57 01 Brown CAN H
CAN LOW CAN L X57 02 Blue CAN L
SPU POWER SUPPLY + APC 12VD X57 03 Red ECU POWER SUPPLY + 12VD Unpowered if emergency stop in operation
12V POWER SUPPLY + APC 12VD X57 04 Red ECU POWER SUPPLY + 12VD Unpowered if emergency stop in operation
PWM-06 OUTPUT HSD-06 X57 05 Pink DIRECTION ELECTROVALVE POWER SUPPLY + TELESCOPE
PWM-04 OUTPUT HSD-04 X57 06 Purple LOWERING PROPORTIONAL ELECTROVALVE POWER SUPPLY
PWM-01 OUTPUT HSD-01 X57 07 Yellow SAFETY ELECTROVALVE (VS) POWER SUPPLY
12V POWER SUPPLY 12VC X57 08 Red POWER SUPPLY + APC ECU + 12VC
12V POWER SUPPLY 12VC X57 09 Red POWER SUPPLY + APC ECU + 12VC
CAN 2 HIGH CAN 2 HI X57 10 NOT USED
RESISTANCE 120 Ω CAN 1 120 X57 11 NOT USED
LOGIC INPUT 16 UN-19 X57 12 Red 12V INPUT CONTACT BP1 EV TDF
ANALOGUE INLET 5 UN-17 X57 13 Orange/Green FLOW SELECTOR ANALOGUE INPUT FORCED OPERATION ATTACHMENT
LOGIC INPUT 9 UN-15 X57 14 Light blue/Black REVERSE GEAR INPUT INFO
LOGIC INPUT 5 UN-12 X57 15 Pink 12V INPUT BOOM RETRACTED SENSOR NO
ANALOGUE INLET 4 UN-10 X57 16 Purple ROLLER 2 JSM ANALOGUE INPUT (Attachment)
PWM 2 OUTPUT HSD-02 X57 17 Brown TRANSMISSION CUT-OFF OUTPUT
CAN 2 LOW CAN 2 60 X57 18 NOT USED
LOGIC INPUT 11 UN-20 X57 19 Green/Yellow ATTACHMENT 1 & 2 LOCKING CONTROL INPUT
LOGIC INPUT 18 UN-18 X57 20 White PROPORTIONAL ELECTROVALVE FAN
LOGIC INPUT 07 UN-16 X57 21 NOT USED
LOGIC INPUT 08 UN-14 X57 22 Pink FORWARD GEAR INFO INPUT
LOGIC INPUT 06 UN-13 X57 23 Orange 12V INPUT RETRACTED BOOM SENSOR
LOGIC INPUT 15 UN-11 X57 24 Orange ROLLER 2 (Attachment) 12V SWITCH DIRECTION Roller 2 neutral zone output
PWM 9 OUTPUT HSD-09 X57 25 White FAN CONTROL INPUT
LIN INTERFACE LIN X57 26 NOT USED
CAN 2 120 Ω CAN 2 120 X57 27 NOT USED
CAN 1 MASSE CAN GROUND X57 28 Black CAN 1 SHIELDING GROUND
PWM 5 OUTPUT HSD-05 X57 29 Brown TELESCOPE PROPORTIONAL ELECTROVALVE CONTROL OUTPUT
PWM 3 OUTPUT HSD-03 X57 30 White FAN INVERSION INPUT
ANALOGUE SENSOR GROUND GROUND A X57 31 Green ANALOGUE SENSOR GROUND
80
PWM 11 OUTPUT HSD-11 X57 32 Pink/Grey VCI (TILTING CUT-OFF CYLINDER) ELECTROVALVE
PWM 10 OUTPUT HSD-10 X57 33 Yellow/Black FORCED OPERATION INDICATOR LAMP OUTPUT
ECU GROUND GROUND X57 34 Black ECU GROUND
(13/11/2012) 80-01-M209EN
ADM INPUTS/OUTPUTS
ADM 2
Key:
SPU: Signal Processing Unit ADM2

NC: Not Cabled
ADM2-12 ADM2-15 ADM2-21
ADM2-21
ADM2-12
ADM2-15
ADM 2
P DOWN LOGIC INPUT ADM2-12 01 Green STARTER SWITCH + APC
ADM2-12 02 Brown/Blue DIAGNOSTICS
ANALOGUE OUTPUT ADM2-12 03 Blue/Pink ENGINE OIL PRESSURE INDICATOR OUTPUT
ANALOGUE OUTPUT ADM2-12 04 Pink OIL TEMPERATURE INDICATOR OUTPUT
LOW SIDE OUTPUT ADM2-12 05 NOT USED
P UP LOGIC INPUT ADM2-12 07 NOT USED
P UP LOGIC INPUT ADM2-12 08 NOT USED I FROM 0,5V TO 4,5V
P DOWN LOGIC INPUT ADM2-12 10 Yellow/Red PREHEATING OPTION INPUT
P DOWN LOGIC INPUT ADM2-12 11 NOT USED SWITCH HELD AT 60° MAX
P DOWN LOGIC INPUT ADM2-12 12 NOT USED ON WALVOIL DISTRIBUTOR
P UP LOGIC INPUT ADM2-15 01 Pink/Black NEUTRAL TRANSMISSION INPUT THIS SUPPLY CAN BE CUT-OFF BY THE EMERGENCY STOP
SUPPLY ADM2-15 04 NOT USED
HIGH SIDE OUTPUT ADM2-15 05 Light blue ACCELERATOR POTENTIOMETER POWER SUPPLY
80
HIGH SIDE OUTPUT ADM2-15 06 NOT USED FROM 0,5V TO 4,5V TELESCOPIC BOOM
ANALOGUE INLET ADM2-15 08 NOT USED
LOW SIDE OUTPUT ADM2-15 09 Blue/Black PREHEATING OPTION RELAY
HIGH SIDE OUTPUT ADM2-15 10 NOT USED
LOW SIDE OUTPUT CONFIG 4 LS ADM2-15 11 Pink/Green MAX OIL TEMPERATURE OUTLET
LOW SIDE OUTPUT CONFIG 1 LS ADM2-15 12 NOT USED ON WALVOIL DISTRIBUTOR
CAN H ADM2-15 13 Yellow LOW SPEED CAN (HIGH)
CAN GND ADM2-15 14 Brown/Red GROUND CAN
CAN L ADM2-15 15 Light blue LOW SPEED CAN (LOW)
80-01-M209EN (13/11/2012)
ADM 2
SUPPLY ADM2-21 01 Red/Yellow +12V BATTERY POWER SUPPLY
P DOWN LOGIC INPUT ADM2-21 02 Brown +12V INPUT
SUPPLY ADM2-21 03 Black GROUND
LOW SIDE OUTPUT ADM2-21 05 Red/Yellow RED ENGINE STOP INDICATOR OUTPUT
LOW SIDE OUTPUT ADM2-21 06 Blue/Yellow YELLOW CHECK MACHINE INDICATOR OUTPUT
LOW SIDE OUTPUT ADM2-21 07 Green/Grey STARTER INDICATOR OUTPUT
SUPPLY ADM2-21 09 NOT USED
P DOWN LOGIC INPUT ADM2-21 10 NOT USED
P DOWN ANALOGUE INPUT ADM2-21 11 NOT USED
P DOWN LOGIC INPUT ANA PISTE 1 ADM2-21 12 Light blue/Green INPUT 2 ACCELERATOR POTENTIOMETER
P DOWN LOGIC INPUT ANA PISTE 2 ADM2-21 13 Light blue/Yellow INPUT 1 ACCELERATOR POTENTIOMETER
SUPPLY GND ADM2-21 14 Light blue/Grey ACCELERATOR POTENTIOMETER GROUND
P UP LOGIC INPUT ADM2-21 16 PARKING BRAKE SWITCH INPUT
ADM2-21 17 NOT USED
ADM2-21 18 NOT USED
CAN H ADM2-21 19 Yellow CAN H HIGH SPEED
CAN GND ADM2-21 20 Brown/Red CAN H GROUND
CAN L ADM2-21 21 Light blue CAN H LOW SPEED FROM 0,5V TO 4,5V
80
(13/11/2012) 80-01-M209EN
PLD INPUTS/OUTPUTS
PLD
Key:
SPU: Signal Processing Unit MR2

NC: Not Cabled MR2-54
MR2
MR2-54
37
1
19
16 8
9 1
54
18
36
MR2
PLD
START OAB_S MR2-54 00 OIL SEPARATOR
START NW_B MR2-54 01 CAMSHAFT SENSOR
START KW_B MR2-54 02 CRANKSHAFT ANGLE POSITION SENSOR
START TMOT_B MR2-54 03 COOLANT LIQUID TEMPERATURE SENSOR
START TFUEL_B MR2-54 04 FUEL TEMPERATURE SENSOR
START POEL_M MR2-54 05 FAN SPEED SENSOR
OUTPUT POELAKT_P MR2-54 06 OIL PRESSURE SENSOR
OUTPUT P2_P MR2-54 07 AIR SUPPLY PRESSURE SENSOR
START NTL2_S MR2-54 08 SPEED SENSOR
OUTPUT MVB 2 MR2-54 09 INJECTOR VALVES 2
START POELAKT_M MR2-54 10 ACTIVE OIL PRESSURE SENSOR
OUTPUT PV_M MR2-54 11 PROPORTIONAL VALVE GROUND
OUTPUT PVB_P MR2-54 12 PROPORTIONAL VALVE
PDK_P MR2-54 13 OPTIONAL FUEL PRESSURE
OUTPUT P23_P MR2-54 14 SLOPE SENSOR WHEN REMOVING REFUSE / FAN SPEED SENSOR
START TOEL_P MR2-54 15 OIL TEMPERATURE SENSOR
OUTPUT MVB 1 MR2-54 16 INJECTOR VALVES 1
80
START NLUE_S MR2-54 17 SPEED SENSOR

OUTPUT ANLA MR2-54 18 STARTER
START KW_A MR2-54 19 CRANKSHAFT ANGLE POSITION SENSOR
START NW_A MR2-54 20 CAMSHAFT SENSOR
START T2_B MR2-54 21 TURBO AIR TEMPERATURE SENSOR
PDK_M MR2-54 22 OPTIONAL FUEL PRESSURE
START P2_M MR2-54 23 AIR SUPPLY PRESSURE SENSOR
START NTL_S MR2-54 24 SPEED SENSOR
START MSST_S MR2-54 25 ENGINE START SWITCH
START POEL_S MR2-54 26 PASSIVE ENGINE OIL PRESSURE SENSOR
OUTPUT PV5 MR2-54 27 PROPORTIONAL VALVE 5
PDK_S MR2-54 28 OPTIONAL FUEL PRESSURE
START P2_S MR2-54 29 PRESSURE INCREASE SENSOR
80-01-M209EN (13/11/2012)
PLD
OUTPUT MSS_P MR2-54 30 ENGINE GO: STOP SWITCH
START P23_S MR2-54 31 OPTIONAL SLOPE WHEN REMOVING REFUSE
START POELAKT_S MR2-54 32 ENGINE OIL PRESSURE SENSOR
START HDEL_S MR2-54 33 OIL LEVEL SENSOR
START TMOT_A MR2-54 34 COOLANT LIQUID TEMPERATURE SENSOR
START MSSP_S MR2-54 35 ENGINE STOP SIGNAL BUTTON
START TFUEL_A MR2-54 36 FUEL TEMPERATURE SENSOR
OUTPUT MVH MR2-54 37 INJECTION PUMP ELECTROVALVE (INJECTOR H)
OUTPUT MVF MR2-54 38 INJECTION PUMP ELECTROVALVE (INJECTOR F)
TOEL_A MR2-54 39 OIL TEMPERATURE SENSOR
OUTPUT PV6_P MR2-54 42 PROPORTIONAL VALVE 6
OUTPUT MVD MR2-54 44 INJECTION PUMP ELECTROVALVE (INJECTOR D)
OUTPUT MVB MR2-54 45 INJECTION PUMP ELECTROVALVE (INJECTOR B)
OUTPUT MVG MR2-54 46 INJECTION PUMP ELECTROVALVE (INJECTOR G)
OUTPUT MVE MR2-54 47 INJECTION PUMP ELECTROVALVE (INJECTOR E)
START T2_A MR2-54 48 CHARGE-AIR TEMPERATURE
START HOEL_M MR2-54 49 OIL LEVEL SENSOR
PV2_P MR2-54 52 PROPORTIONAL VALVE 1
OUTPUT MVC MR2-54 53 INJECTION PUMP ELECTROVALVE (INJECTOR C)
OUTPUT MVA MR2-54 54 INJECTION PUMP ELECTROVALVE (INJECTOR A)
INPUT / OUTPUT CAN H MR2 01 Yellow CAN H INTERFACE
INPUT / OUTPUT CAN L MR2 02 Light blue CAN L INTERFACE
GROUND HF-GND MR2 03 Brown/Red GROUND CAN
GROUND HF-GND MR2 04 Brown/Grey GROUND CAN
12V POWER SUPPLY KL30 MR2 05 Blue BATTERY POWER SUPPLY (+12V)
12V POWER SUPPLY KL30 MR2 06 Blue BATTERY POWER SUPPLY (+12V)
80
NOT USED (OT_TRIGGER) MR2 07 NOT USED
START KL50 MR2 08 Green KEY START
GROUND KL31 MR2 09 Black BATTERIE GROUND (-)
OUTPUT PVB_P MR2 10 NOT USED
GROUND KL31 MR2 11 Black BATTERIE GROUND (-)
OUTPUT ANLA MR2 12 Orange STARTER
INPUT / OUTPUT KDIAG MR2 13 Grey/Blue STEERING DIAGNOSTICS
OUTPUT PV3 MR2 14 NOT USED
START KL15 MR2 15 Brown + 12V INPUT
OUTPUT PV4 MR2 16 NOT USED
(13/11/2012) 80-01-M209EN
80
80-01-M209EN (13/11/2012)
SPECIFICATIONS C1
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
Rep.
Désignation Pages
Électriques
KEY KEY OPERATED STARTER SWITCH C2
S4 BRAKE FLUID LEVEL CONTACT C3
S5 AIR FILTER SWITCH C3
S12 TRANSMISSION OIL THERMOSWITCH C4
S16+S37 STOP PRESSURE SWITCH C4
S17 RANSMISSION OIL THERMOSWITCH (NO H) C5
S52 EMERGENCY STOP C5
Y1+Y4 REVERSE+SLOW SPEED ELECTROVALVE (H) C6
Y10 HIGH SPEED ELECTROVALVE (H) C6
Y6+Y7+Y8+Y9 PROPORTIONAL SOLENOID VALVE BOOM/ACCESSORY C7
Y14 HYD CUT-OFF VALVE/VS C7
Y15 PROPORTIONAL SOLENOID VALVE, BOOM DESCENT VRP C8
Y16 VCI TILT CUT-OFF C8
Y18 SOLENOID VALVE C9
Y30 PEC (PRESSURE ELECTRONIC CONTROL) ON CASAPPA PUMP C10
XTP ACCELERATOR POTENTIOMETER C11
X01 DECLUTCH PUSH BUTTON (No H) C11
X14 HORN C12
X15+X21 WHEEL ALIGNMENT SENSOR C12
X36 JSM JOYSTICK C13
INDICATOR LIGHT PANEL C14
X68 FUEL LEVEL AND HOUR METER C14
X77 FRONT WINDSCREEN WIPER MOTOR C15
80
X89 WATER TEMPERATURE INDICATOR C15
X99 STRAIN GAUGE C16
X100 BOOM ANGLE ANGULAR SENSOR C16
X134 RETRACTED BOOM SWITCH C17
X165 FUEL GAUGE C17
X188 LIGHTING STALK SWITCH C18
X503 TRANSMISSION OIL TEMPERATURE SENSOR (NO H) C19
X504 HYDRAULIC OIL TEMPERATURE SENSOR C19
B18 ENGINE COOLANT TEMPERATURE SENSOR C20
B19 ENGINE AIR TEMPERATURE SENSOR C21
(16/11/2012) 80-01-M209EN
C2 SPECIFICATIONS
KEY KEY OPERATED STARTER SWITCH
X54 PIN Function

1 + Battery
2 + Battery
4 3 Not used
2 1
3 4 Preload shunt
5 + Post contact (+APC)

X55
6 + Post contact (+APC)
5
6 7 Starter
7
8 8 Preheating Shunt
9
9 Preheating relay control
10
10 Not used
Corresponding connector
KEY
X54-X55
Diagram
80
PIN Minimum Typical Maximum

Switchable current / 8A /
On line drop / 300 mV /
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C3
S4 BRAKE FLUID LEVEL CONTACT
PIN Function
Module A1 info
1
(dashboard)
2 Cab Front Ground

S4
Diagram

Supply current 4 mA 6 mA /
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S5 AIR FILTER SWITCH
PIN Function
1 Clogging info
80
2 Engine Ground
S5
Diagram

Manimux current 1 4 mA 6 mA /
Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V
Inlet type Type 1 negative logic inlet (ELN1)
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C4 SPECIFICATIONS
S12 TRANSMISSION OIL THERMOSWITCH
PIN Function
1 Signal info
2 Signal Ground
S12
Diagram

Courant 1 mA / /
ECU current U< V=0 U> V=1 Umax = V
Inlet type
Note:
Only forward motion clutch info
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S16+S37 STOP PRESSURE SWITCH
PIN Function
1 12 V supply
80
2 Stop Light Control S16
Diagram

Supply voltage 12 V 42 V
Consumption 3,5 A
Note:
- The Pressostat contact closes at a pressure of 3 ± 0,4 bar in the braking circuit.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C5
S17 RANSMISSION OIL THERMOSWITCH (NO H)
PIN Function
1 Signal info
S17
2 Signal Ground
Diagram

ECU current mA 0 mA /
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S52 EMERGENCY STOP
PIN Function
Power supply
1
1 MR2+ADM2
S52
80
2
2 + Post contact
4
3
3 Power supply SPU
4 + Post contact
Diagram
PIN Minimum Typical Maxi

Supply voltage 12 V
Consumption
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C6 SPECIFICATIONS
Y1+Y4 REVERSE+SLOW SPEED ELECTROVALVE (H)
PIN Function
1 Power supply
2 Ground
Y1
Diagram

Supply voltage 12 V
Consommation
Note:
– X313 - Y1 : Reverse solenoid valve
– X312 - Y4 : Slow speed solenoid valve
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y10 HIGH SPEED ELECTROVALVE (H)
PIN Function
1 Power supply
80
2 Ground
Y10
Diagram

Supply voltage 12 V
Consommation
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C7
Y6+Y7+Y8+Y9 PROPORTIONAL SOLENOID VALVE BOOM/ACCESSORY
PIN Function
A Power supply
1
2 B Ground
Y6
Diagram
PIN Minimum Typical Max

Supply voltage 5,45 V
Coil resistance (at 20°C) 4,2 Ω
Tolerance 10%
Consumption 0 to 1,5 A 1,5 A
Note: Solenoid valve control is by current variation. Voltage is indicative only.

– X28 - Y8 : Telescope retraction proportional solenoid valve
– X29 - Y9 : Telescope extension proportional solenoid valve
– X34 - Y7 : Accessory proportional solenoid valve (S1)
– X35 - Y6 : Accessory proportional solenoid valve (S2)
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
Y14 HYD CUT-OFF VALVE/VS
PIN Function
A Power supply
1
80
2 B Ground
Corresponding connector Y14
Diagram

Supply voltage 0 12 V 14 V
Resistance (at 20°C) 9,6 Ω
Tolerance 10%
Consumption 1,4 A
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C8 SPECIFICATIONS
Y15 PROPORTIONAL SOLENOID VALVE, BOOM DESCENT VRP
PIN Function
A Power supply
1
2 B Ground
Corresponding connector Y15
Diagram

Supply voltage 12 V
Tolerance 10%
Consumption 0 to 1,5 A 1,5 A
Note:
Solenoid valve control is by current variation. Voltage is indicative only.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Y16 VCI TILT CUT-OFF
PIN Function
1 Power supply
1
80
2 2 Ground
Y16
Diagram

Supply voltage 6V
Tolerance 10%
Consumption 0 1,5 A
Comments:
Solenoid valve control is by current variation. Voltage is indicative only.
When cut-out is in effect, the VCI is not powered.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C9
Y18 SOLENOID VALVE
PIN Function
1 + Post contact
2 Parking brake switch
Y18
Diagram

Supply voltage 12 V
Consumption
Resistance 1.2 Ω
Note:
- Measurements taken at 20°C
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80
(16/11/2012) 80-01-M209EN
C10 SPECIFICATIONS
Y30 PEC (PRESSURE ELECTRONIC CONTROL) ON CASAPPA PUMP
PIN Function
1 PWM-OUT+
1
2
2 PWM-OUT-
Y30
Diagram

Voltage 12 V (±10%)
Resistance 6,2 Ω (±7%)
Courant 1,25 A
Power 15 W
Pressure (bar)
80
Current (A)
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C11
XTP ACCELERATOR POTENTIOMETER
PIN Function
1 8V to 36V supply XTP XTP

2 0V Ground
3 Signal 22% - 71%

1
3 4 4 Signal 78% - 29%
6
5 8V to 36V supply
6 0V Ground
Corresponding connector Diagram

Power supply 1 8V / 36 V
Weight 2 / 0V /
Signal 4 20% / 80%
Power supply 5 8V / 36 V
Ground 6 / 0V /
Signal 3 80% / 20%
Comments: Electrical range: S1: 8V to 36V

S2: 36V to 8V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X01 DECLUTCH PUSH BUTTON (No H)
PIN Function
1 Declutch Info
1
X01
80
2 2 M1 chassis ground
Diagram

Manimux current 1 4 mA 6 mA /
Voltage threshold U < 2V = 0 U > 6,5V = 1 Umax = 16V
Inlet type Type 1 negative logic inlet (ELN1)
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C12 SPECIFICATIONS
X14 HORN
PIN Function
1 Horn power supply
Corresponding connector X14
CHASSIS GND (M3)
Diagram

Supply voltage 9V 12 V 15 V
Resistance (10%) / 2,17 Ω /
Nominal frequency 500 ± 20 Hz
Average current 6A
Note:
- Sound level 107 dB(A) / 13V.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X15+X21 WHEEL ALIGNMENT SENSOR
PIN Function
A Signal
3 B Power supply X15
80
2
1 C Ground
X15
Diagram

Supply voltage / 12 V /
Direct current / 10 mA /
Outlet logic Switch closed = wheels aligned
Type of outlet PNP at Vbat
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C13
X36 JSM JOYSTICK
PIN Function
1 JSM Earth
2 Roller 1 direction A (+)
3 Roller 1 direction B (-)
4 Roller 2 direction A (+)
1 12 5 Roller 2 direction B (-)

2 11
3 6 Signal Roller 1
10
4 9 7 Signal Roller 2
5 8
6 7 8 12V JSM Power supply
Optional BP jib head
9
solenoid valve
10 N/A
11 Forward gear
12 Reverse gear
X36
X36
Diagram
80
6-7 1V 6V 11 V
Outlet voltage
2-3-4-5 0 12 V
Supply voltage 8 12 V
Potentiometer current below 5V ± 10% / 1 mA 2 mA
Note:
- Direction A B + -: 0 = roller neutral
12 V = direction validation
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C14 SPECIFICATIONS
INDICATOR LIGHT PANEL
Connecteurs PIN Function

1 Oil pressure indicator lamp
2 Coolant temperature lamp
3 Not used
4 Air filter clogging lamp
5 Oil filter clogging lamp
P
1 Battery load lamp
2 Parking Brake Lamp
3 + Post contact
4 Indicator lamp Diagram
5 Ground
6 High beam lamp
+ Post contact
7
Braking oil level lamp
8 Ground

Voltage 12 V
Consommation
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X68 FUEL LEVEL AND HOUR METER
PIN Function
1 + Post contact X68
2 Fuel level sensor
80
1
3 Ground
4 Frequency input
2
00
0 5 Rear lighting X68
00
Diagram

Voltage 10V 12V 16V
Consommation
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C15
X77 FRONT WINDSCREEN WIPER MOTOR
PIN Function
1 + Post contact
X77
2 Engine power supply
3 Control switch
4 Ground
X77
Diagram

Voltage 12 V
Consommation 3.5 A
Note:
- 32 tr/min
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X89 WATER TEMPERATURE INDICATOR
PIN Function
1 + After ignition on X89
2 Ground
80
3 Not used
8 4 Not used
4
5 5 Resistive signal
1 6 Rear lighting
7 Not used
Diagram
8 Not used

Voltage 10 V 12V 16 V
100 mA without rear lighting
Consommation
150 mA with rear lighting
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C16 SPECIFICATIONS
X99 STRAIN GAUGE
PIN Function
4
3 X99
5 1 Shielding
2
1
2 Power supply
3 Ground
4 CAN_H
5 CAN_L
Corresponding connector X99
Diagram

Supply voltage 9V 10 V 16 V
Consumption 150 mA
Note:
- CAN integrated terminal resistance 120 Ω.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X100 BOOM ANGLE ANGULAR SENSOR
PIN Function X100

1 Common Ground X100
2 Common 5 V power supply
80
6
5 3 Track 1 angle signal
4
1 4 Common Ground
2
3
5 Common 5 V power supply
6 Track 2 angle signal

Diagram

Supply voltage / 5V /
Direct current / 8 mA /
Outlet voltage 0,5 V 2,5 V 4,5 V
Load resistance 20 000 Ω / /
Angular range 0° / 90°
Comment: Plan for min/max angle calibration on each machine at 0 km.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C17
X134 RETRACTED BOOM SWITCH
PIN Function
1 NO Switch
1 X134
4 2 NF Switch
2
3
3 Chassis Ground NF
X134
4 Chassis Ground
NO
Diagram

Voltage 9V V Bat 16 V
Consumption 6 mA
Note:
When the boom is retracted, the NO switch is closed and the NF switch is open.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X165 FUEL GAUGE
PIN Function
1 Fuel level info
80
X165
CHASSIS GND
Diagram

Supply voltage 1 / 12 V /
Empty tank resistance 1 / 345 Ω /
Full tank resistance 1 / 2Ω /
Inlet type Analogue inlet
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C18 SPECIFICATIONS
X188 LIGHTING STALK SWITCH
PIN Function
X188
Headlight power supply
1
+ Battery
2 Position lights
3 3 Low beam
2
1
4 4 Main beam
7
Horn power supply
5
+ Post contact X188
5
8 6 Horn
9 6 Diagram
7 Right indicator
Indicator power supply
8
+ Post contact
9 Left indicator

Voltage 12 V
Consommation 5A - 7A
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80
80-01-M209EN (16/11/2012)
SPECIFICATIONS C19
X503 TRANSMISSION OIL TEMPERATURE SENSOR (NO H)
PIN Function
1 Supply
2
1 2 Oil temperature info

X503
Diagram

Temperature range - 20°C 75°C + 110°C
Activation threshold 89°C
Deactivation threshold 69,5°C
Comments:
The thermo switch powers the switch when its trigger threshold is reached, in order to activate the fan at maximum speed. When the deactivation
threshold is reached the thermo switch ceases to power the switch.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X504 HYDRAULIC OIL TEMPERATURE SENSOR
PIN Function
1 Supply
80
2
1 2 Oil temperature info X504
Diagram

Temperature range - 20°C 90°C + 110°C
Activation threshold 116,4°C
Deactivation threshold 84,6°C
Comments:
The thermo switch powers the switch when its trigger threshold is reached, in order to activate the fan at maximum speed. When the deactivation
threshold is reached the thermo switch ceases to power the switch.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/11/2012) 80-01-M209EN
C20 SPECIFICATIONS
B18 ENGINE COOLANT TEMPERATURE SENSOR
PIN Function
1 Temperature info
2 Engine Ground

Temperature range 0 °C / 120 °C
Resistance at 70 °C / /
Comments:
The sensor’s current is variable, whereas the voltage is constant. There is a law relating current and temperature. This law defines the curve A = f (T °C).
The responsiveness and precision of the sensor (usually ± 3,5 °C) have to be known.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
80
___________________________________________________________________________________________
80-01-M209EN (16/11/2012)
SPECIFICATIONS C21
B19 ENGINE AIR TEMPERATURE SENSOR
PIN Function
1 Temperature info
2 Engine Ground

Temperature range 0 °C / 120 °C
Resistance at 41 °C
Resistance at 43 °C
Comments:
The sensor’s current is variable, whereas the voltage is constant. There is a law relating current and temperature. This law defines the curve A = f (T °C).
The responsiveness and precision of the sensor (usually ± 3,5 °C) have to be known.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80
(16/11/2012) 80-01-M209EN
C22 SPECIFICATIONS
80
80-01-M209EN (16/11/2012)
ELECTRICAL SCHEMATIC DIAGRAMS
pages
CODES ON THE ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CABLE MARKING ON AN ELECTRICAL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
– MLT 845-120 H SERIES 4-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
– MLT 845-120 SERIES 5-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B
80
(08/10/2012) 80-02-M209EN
2 ELECTRICAL SCHEMATIC DIAGRAMS
CODES ON THE ELECTRICAL DIAGRAMS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
10 10 16
15 17
MR2 MR2 9 ADM-12 ADM2 9
toward (TAB.01)
A 8 toward (TAB.01)
toward (TAB.01)
3 7 12 8
F44 2 toward (TAB.01)

toward (TAB.01)
toward (TAB.01)
ADM-15
13
C toward (TAB.01)
17
7
14
1
ADM-21
11
2
KN
G 3
5 12
4
I S5
11
5
12 17
K X121
80
4
BATTEY “30”
M
GND
CHASSIS GND
Example of marking on cables and components on an electrical diagram
Key:
1 - Power supply 10 - Computer connector designation
2 - Electrical component 11 - Wire N° designation
3 - Electrical component designation 12 - Electrical connector PIN N° designation
4 - Electrical connector 13 - Grounds
5 - Electrical connector designation 14 - CAN
6 - Splice 15 - CAN Shielding
7 - Computer connector 16 - Marking grid
8 - Computer 17 - Refer to diagram XX: toward (TAB.XX)
9 - Computer designation
80-02-M209EN (08/10/2012)
ELECTRICAL SCHEMATIC DIAGRAMS 3
CONNECTORS
– Harness connector:
X8-2
Connector Pin N°
– ADM2 module connector:

ADM2/12-4
Connector Pin N°
– MR2 module connector:

MR2-13
Pin N°
– SPU module connector:

SPU X56-13
Connector Pin N°
80
(08/10/2012) 80-02-M209EN
4 ELECTRICAL SCHEMATIC DIAGRAMS
CABLE MARKING ON AN ELECTRICAL WIRING HARNESS
The electrical wiring harnesses installed on the truck are composed of connectors.
There are numbers on the connectors so that they can be identified.
X64
X32
There are inscriptions on the diagrams so that the wires can be identified (u Item 11: CABLE MARKING
ON AN ELECTRICAL WIRING HARNESS).
N 1,5
Colour Section in mm²
Colour codes:
80
A Light blue
B White
C Orange
G Yellow
H Grey
L Blue
M Brown
N Black
R Red
S Pink
V Green
Z Purple
80-02-M209EN (08/10/2012)
ELECTRICAL SCHEMATIC DIAGRAMS A1
MLT 845-120 H SERIES 4-E3

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

ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A7
– 1 – START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A7
– 2 – TRANSMISSION AND SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A10
– 3 – CAN BUS AND DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
– 4 – LIGHTING/SIGNALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A16
– 5 – HYDRAULIC MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A18
– 6 – OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A20
80
(08/10/2012) 80-02-M209EN
A2 ELECTRICAL SCHEMATIC DIAGRAMS
POSITION OF CONNECTORS ON DIAGRAMS
Connectors Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7
ADM2-12 √ √ √
ADM2-15 √ √
ADM2-21 √ √
F40 √
F41 √
F42 √
F43 √
F44 √
F45 √
G1 √
KA √
KN √
M1 √
M3 √
MR2 √ √
P01 √
P06 √
P09 √
P10 √
P13 √
P12A √ √
P12B √ √
RC √ √
XTP √
X5 √
X6 √
X7 √
X8 √ √
X02 √
X04 √ √ √ √
X05 √
80
X09 √
X10 √
X11 √
X12 √
X13 √
X14 √
X15 √
X15 √ √
X16 √
X17 √
X19 √
X20 √ √
X21 √
X22 √
X23 √
X24 √ √
X26 √ √
X26. √
80-02-M209EN (08/10/2012)
X28 √
X29 √
X30 √ √
X33 √
X34 √
X35 √
X36 √
X39 √
X41 √ √ √ √ √ √
X45 √ √ √ √ √ √
X46 √
X47 √
X48 √
X50 √
X51 √
X52 √
X54 √
X55 √
X56 √ √ √ √ √
X57 √ √ √ √ √
X58 √
X68 √
X70 √
X71 √
X72 √
X73 √
X74 √
X77 √
X79 √
X87 √
X89 √
80
X92 √
X93 √
X97 √
X99 √
X100 √
X104 √
X105 √
X109 √
X112 √
X113 √
X114 √
X115 √
X116 √
X117 0
X117/A √
(08/10/2012) 80-02-M209EN
X117/B √
X118 √ √
X119 √
X121 √ √
X134 √
X149 √
X150 √
X151 √
X154 √
X155 √
X165 √
X188 √
X193 √
X205 √
X206 √
X208 √
X209 √
X215 √
X221 √
X223 √
X224 √
X224. √
X225 √
X226 √
X227 √
X228 √
X229 √
X232 √
X238 √
X239 √
X240 √
80
X241 √
X242 √
X243 √
X245 √
X246 √
X247 √
X248 √
X249 √
X355A √
X355B √
X356A √
X356B √
X300 √
X301 √
X302 √
X303 √
X304 √
X305 √
X306 √
X307 √
80-02-M209EN (08/10/2012)
X308 √ √ √ √ √
X309 √
X310 √
X311 √ √
X312 √
X313 √
X314 √
X315 √
X316 √
X317 √
X318 √ √ √
X319 √
X320 √ √ √
X321 √
X322 √
X323 √
X325 √
X326 √
X327 √
X328 √
X329 √
X330 √
X331 √
X332 √
X333 √
X334 √
X335 √
X338 √
X501 √
X502 √
X503 √
80
X504 √
X505 √
X506 √
(08/10/2012) 80-02-M209EN
80
80-02-M209EN (08/10/2012)
ELECTRICAL DIAGRAMS
1 – START-UP
Electrical connectors
Name of Position on Hydraulic code
Harness type Item Designation
component diagram equivalence
Engine ADM2-12 ADM2 ADM2 MODULE (CAB) A32
Engine ADM2-15 ADM2 ADM2 MODULE (CAB) E32
Engine ADM2-21 ADM2 ADM2 MODULE (CAB) G32
Engine F40 F40 FUSE KEY SWITCH E13
Engine F42 F42 DIAGNOSTIC PLUG MR2-PLD E11
Engine F43 F43 ADM2 MODULE (CAB) E10
Engine F45 F45 STARTER E8
Engine G1 G1 ALTERNATOR A5
Engine KA KA MERCEDES STARTING RELAY C7
Engine KN KN NEUTRAL SAFETY RELAY E39
Engine MR2 MR2 MR2-PLD MODULE (ENGINE) A26
Engine M1 M1 STARTER C8
Engine RC NOT USED O38
Engine XTP XTP ACCELERATOR POTENTIOMETER M36
Engine X5 DIAGNOSTIC PLUG MR2-PLD E26
Engine X6 X6A DIESEL DECONGEALANT HEATING ELEMENT E15
Engine X7 KC + FC1 AIR HEATING (OPTION) E18
Engine X8 S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH G38
Main/Engine X15 ENGINE/MAIN INTERFACE M38
Main/Engine X24 MAIN/ENGINE INTERFACE O7
Main/Electric plate X41 ELECTRIC PLATE O28
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) M18
Main X47 F25 ANTI-START FUSE O26
Main X54 KEY KEY SWITCH M8
80
Main X56 SPU SPU MODULE O22
Main X57 SPU SPU MODULE O22 - O34 - Q37
Main X114 S52 EMERGENCY STOP O19
Main X118 DIGICODE CONNECTOR Q32
Main/Engine X121 MAIN/ENGINE INTERFACE K37
Main X193 OPTIONAL CONNECTOR Q28
Main/Electric plate X308 ELECTRIC PLATE O25 - Q24 - O29
Main/Electric plate X311 REVERSE GEAR SHUTTLE CONNECTOR Q24
Main X317 F30 INDICATOR LAMP FAULT + SPU O16
Electric plate X318 ELECTRIC PLATE GROUND CONNECTOR O24
Main X328 F36 SPU FUSE O18
Main X332 H16 INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP O13
Main X333 H10 AIR HEATING INDICATOR LAMP O14
Main X334 H15 ENGINE FAULT INDICATOR LAMP O15
Main X501 X501 FAN SWITCH O36
Main/Fan X502 MAIN/FAN INTERFACE Q36
Fan X503 X503 FAN THERMOSTAT Q36
Fan X505 X505 PROPORTIONAL ELECTROVALVE FAN S38
Fan X506 X506 FAN INVERSION ELECTROVALVE S39
(08/10/2012) 80-02-M209EN
Electrical components
Hydraulic code
Item Designation Position on diagram
equivalence
ADM2 ADM2 MODULE (CAB) A34
B1 12V BATTERY A15
B2 12V BATTERY (OPTION) A16
EH AIR HEATING E20
G1 ALTERNATOR A6
H10 AIR HEATING INDICATOR LAMP Q14
H15 ENGINE FAULT INDICATOR LAMP Q15
H16 INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP Q13
KEY KEY SWITCH M8
M1 STARTER A8
MR2 MR2-PLD MODULE (ENGINE) A27
RC1 RESISTANCE CAN (120Ω) O39
S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH G36
S46 BATTERY CUT-OFF A13
S52 EMERGENCY STOP O19
X6A DIESEL DECONGEALANT HEATING ELEMENT E16
X501 FAN SWITCH O36
X503 TEMPERATURE SENSOR (NOT USED) Q36
X504 HYDRAULIC OIL TEMPERATURE SENSOR Q34
X505 PROPORTIONAL ELECTROVALVE FAN S38
X506 FAN INVERSION ELECTROVALVE S40
XTP ACCELERATOR POTENTIOMETER K37
Fuses and relays
Item Current Designation Position on diagram
F4 15A FAN + DIAGNOSTICS + DIESEL FUEL THINNING FILTER O29

F14 15A DIGICODE + SENSORS O28
F21 15A DIGICODE + ROOF LIGHT + WARNING O27
80
F25 25A ANTI-START O26

F30 10A FAULT INDICATOR LAMP + SPU O16
F36 10A SPU O18
F40 70A KEY SWITCH E13
F42 7,5A DIAGNOSTIC PLUG MR2-PLD E11
F43 10A ADM2 MODULE (CAB) E10
F45 30A STARTER E8
FC 225A AIR HEATING (OPTION) A20
FC1 7,5A AIR HEATING - ADM2 INFORMATION (OPTION) C19
FG 125A MASTER POWER SWITCH C13
K4 ANTI-START RELAY O25
KA MERCEDES STARTING RELAY C7
KC AIR HEATING RELAY (OPTION) C20
KN NEUTRAL SAFETY RELAY E39
80-02-M209EN (08/10/2012)
DIAGRAM 1
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
G1 FC MR2 MR2 ADM-12 ADM2
B1 B2
M1
G1 S46
KC
M1
FG
C C
ADM-15
KA
FC1
ENGINE GND
EH
X5
CHASSIS GND X7
E F45 F44 F43 F42 F41 F40 ENGINE GND E

KN
X6
X6A
ADM-21
G G
S5
I I
X121
K K
XTP XTP
80
KEY
M X54-X55 X15 M
X45
RC
F25
F30 F21 F14 F4
RC1
O S52 X501 O
F36
K4
STOP H16 H10 H15 X193

X118
Q Q
X504 X503
X505 X506
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
X24
GND
CHASSIS GND CHASSIS GND
(08/10/2012) 80-02-M209EN
2 – TRANSMISSION AND SENSORS
Engine ADM2-12 ADM2 ADM2 MODULE (CAB) K7
Engine ADM2-15 ADM2 ADM2 MODULE (CAB) K7
Main X8 S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH O9
Main X02 X02 SEAT SWITCH (NO) O28
Main/Electric plate X04 ELECTRIC PLATE C6
Main X09 Y2 FORWARD GEAR ELECTROVALVE Q33
Main X10 Y3 REVERSE GEAR ELECTROVALVE Q35
Main X12 S37 HAND BRAKE PRESSURE SWITCH Q17
Main X15 X15. FRONT WHEEL ALIGNMENT SENSOR O4
Main X20 X20 REVERSING SOUND ALARM (OPTION) K39
Main X21 X21 REAR WHEEL ALIGNMENT SENSOR O3
Main X22 S17 HYDRAULIC OIL FILTER Q13
Main X36 X36 JSM (JOYSTICK SWITCH AND MOVE) G29
Main/Electric plate X41 ELECTRIC PLATE E23 - I8
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A4
Main X46 K8 NEUTRAL SAFETY RELAY M38
Main X50 H11 FRONT WHEEL ALIGNMENT LIGHT M5
Main X51 H14 REAR WHEEL ALIGNMENT LIGHT M3
Main X52 X52 WHEEL ALIGNMENT SWITCH Q6
Main X56 SPU SPU MODULE I24 - M25
Main X57 SPU SPU MODULE I24 - M25
Main X68 X68 HOUR METRE / FUEL LEVEL I21
Main X71 X71 BRAKE PEDAL SWITCH G31
Main X72 S4 BRAKE LIQUID LEVEL CONTACT O11
Main X89 COOLANT LIQUID TEMPERATURE INDICATOR I17
Main X118 DIGICODE CONNECTOR G23
Main X165 X165 FUEL LEVEL SENSOR I21
X238 S48 BRAKE CIRCUIT PRESSURE SWITCH E4
80
Main X300 K18 HAND BRAKE RELAY Q19

Main X301 K12 SNAIL SPEED K29
Main X302 K13 SLOW SPEED M29
Main X303 K14 REVERSE GEAR RELAY I38
Main X304 X304 SLOW SPEED SWITCH Q29
Main X305 X305 FAST / SLOW SPEED SWITCH G34
Main X306 H15. SLOW SPEED M3
Main X307 H10. FAST SPEED M33
Main/Electric plate X308 ELECTRIC PLATE G8
Main X309 X309 ACCELERATOR PEDAL SWITCH G23
Main X310 REVERSE GEAR INFORMATION G37
Main/Electric plate X311 REVERSE GEAR SHUTTLE CONNECTOR G36
Main X312 Y4. SNAIL SPEED ELECTROVALVE Q26
Main X313 Y1 REVERSE GEAR ELECTROVALVE Q27
Main X314 Y10 FAST SPEED ELECTROVALVE Q31
80-02-M209EN (08/10/2012)
Electric plate X318 ELECTRIC PLATE GROUND CONNECTOR A37
Main/Electric plate X319 BRAKE CIRCUIT CONNECTOR I6
Main X320 OPTIONAL CONNECTOR E7
Main X321 NOT USED I16
Main X322 NEUTRAL SWITCH INFORMATION (OPTION) G33
Main X323 X323 HAND BRAKE SWITCH M19
Main X325 D4 - D5 DIODE CONNECTOR K37
Main X327 Y18 HAND BRAKE ELECTROVALVE Q23
X355A PARKING BRAKE SWITCH/X41 M17
X355B X41/PARKING BRAKE SWITCH M17
X356A PARKING BRAKE SWITCH/SPU M16
X356B SPU/PARKING BRAKE SWITCH M16
80
(08/10/2012) 80-02-M209EN
Hydraulic code
equivalence
H10. FAST SPEED M34
H11 FRONT WHEEL ALIGNMENT LIGHT M5
H14 REAR WHEEL ALIGNMENT LIGHT M4
H15. SLOW SPEED M33
S4 BRAKE LIQUID LEVEL CONTACT Q11
S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH Q9
S17 HYDRAULIC OIL FILTER Q13
S37 HAND BRAKE PRESSURE SWITCH Q17
S48 BRAKE CIRCUIT PRESSURE SWITCH G3
D4 DIODE - SAFETY RELAY/REVERSE GEAR K37
D5 DIODE - SAFETY RELAY/FORWARD GEAR K36
X02 SEAT SWITCH (NO) O28
X15. FRONT WHEEL ALIGNMENT SENSOR O5
X20 REVERSING SOUND ALARM (OPTION) K38
X21 REAR WHEEL ALIGNMENT SENSOR O4
X36 JSM (JOYSTICK SWITCH AND MOVE) G25
X52 WHEEL ALIGNMENT SWITCH Q6
X68 HOUR METRE / FUEL LEVEL G18
X71 BRAKE PEDAL SWITCH G31
X165 FUEL LEVEL SENSOR I21
X304 SLOW SPEED SWITCH Q29
X305 FAST / SLOW SPEED SWITCH G34
X309 ACCELERATOR PEDAL SWITCH G23
X323 HAND BRAKE SWITCH M19
Y1 REVERSE GEAR ELECTROVALVE K39
Y2 FORWARD GEAR ELECTROVALVE Q34
Y3 REVERSE GEAR ELECTROVALVE Q36
Y4. SNAIL SPEED ELECTROVALVE Q26
Y10 FAST SPEED ELECTROVALVE Q32
Y18 HAND BRAKE ELECTROVALVE Q23
Fuses and relays

80
F2 5A ECU + WHEEL ALIGNMENT + DIAGNOSTICS C8

F11 10A SUSPENSION ELECTROVALVE + BRAKE PRESSURE C7
F12 7,5A PARKING BRAKE C8
F13 15A FNR TRANSMISSION C22
F15 5A INSTRUMENTS + INDICATORS C9
K0 NC TRANSMISSION CUT-OFF RELAY C30
K1 RELAY (NOT USED) C26
K2 FORWARD GEAR RELAY C33
K3 REVERSE GEAR RELAY C37
K5 TRANSMISSION PRESSURE RELAY C6
K8 NEUTRAL SAFETY RELAY M40
K12 SNAIL SPEED K31
K13 SLOW SPEED M31
K14 REVERSE GEAR RELAY G40
K18 HAND BRAKE RELAY Q21
K21 BRAKE CIRCUIT RELAY E7
80-02-M209EN (08/10/2012)
DIAGRAM 2
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
X45
F13
F11 F2 F12 F15 K1 K0 K2 K3
C K5 C
X41
E E
K21
S48 X118 X36 X71

X311
X309
G X68 G
X309
CHASSIS GND
X36 X305
X308 K14
X89
X68
X303
I X165 I
X41
X121 X326
Y1
K12 D5 D4
K K
X301 X20
X24
K13
80
H15 H10
M K8 M
X302
H14 H11 X323
X46
X02
O X21 X15 O
K18
X21 X15
S5 S4 S17 X304
X52 S37 X300
Y18 Y4 Y10 Y2 Y3
Q Q
CHASSIS GND
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
(08/10/2012) 80-02-M209EN
3 – CAN BUS AND DIAGNOSTICS
Electrical connectors Electrical components

Name of Position on Hydraulic code Hydraulic code
Harness type Item Designation Item Designation Position on diagram
component diagram equivalence equivalence
Engine ADM2-12 ADM2 ADM2 MODULE (CAB) Q5 RC1 RESITANCE CAN (120Ω) M39
Engine ADM2-21 ADM2 ADM2 MODULE (CAB) M38 A12 LONGITUDINAL SECURITY MODULE A29
Engine MR2 MR2 MR2-PLD MODULE (ENGINE) S5 X99 STRAIN GAUGE C24
Engine RC RC1 RESITANCE CAN (120Ω) M37 RC2-2 MODULE RC2-2 K4
Main/Engine X15 ENGINE/MAIN INTERFACE K33
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A5
Fuses and relays
Main X48 F31 REXROTH ECU RC2-2 I9
Main X56 SPU SPU MODULE M20 Item Current Designation Position on diagram
Main X57 SPU SPU MODULE M20 F2 5A ECU + WHEEL ALIGNMENT + DIAGNOSTICS A8
Main X58 A12 LONGITUDINAL SECURITY MODULE E30 F14 15A DIGICODE + SENSORS A10
Main X99 X99 STRAIN GAUGE C25 F31 5A REXROTH ECU RC2-2 I9
Main X109 RC2-2 MODULE RC2-2 K6 F34 5A DIAGNOSTICS I10
Main X115 OBD CONNECTOR DIAGNOSTICS C18 F35 5A DIAGNOSTICS C4
Main X315 F34 FUSE DIAGNOSTICS I10
Main X316 F35 FUSE DIAGNOSTICS C4
CAN Network
PAD
LLMI
80
SPU
VCI
CAN A
CAN B
ECU RC2-2/20 ECM ADM2 ECM MR2
80-02-M209EN (08/10/2012)
DIAGRAM 3
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
X45
A12
A A
F2 F14 X99
X115
C X308 C
X41
X99
F35
X58
E E
G G
I I
F31 F34
K K
RC2-2 X109
80
M M
RC RC1
O O
Q Q
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
CHASSIS GND
GND
(08/10/2012) 80-02-M209EN
4 – LIGHTING/SIGNALING

Main M3 X14 HORN GROUND G40 V5 DIODE POSITION LIGHT / WORKING LIGHTS G31
Cab P09 P09 ROOF WINDSCREEN WIPER MOTOR Q8 V6 DIODE E34
Cab P10 P10 REAR WINDSCREEN WIPER MOTOR Q10 X13 FRONT RIGHT HEADLIGHT Q40
Cab P12A P12A HEATING O16 X14 HORN G40
Cab P12B P12B HEATING O17 X16 REAR RIGHT HEADLIGHT Q33
Main/Electric plate X04 ELECTRIC PLATE E7 X17 REAR RIGHT HEADLIGHT Q28
Main X13 X13 FRONT RIGHT HEADLIGHT Q40 X18 REAR LICENSE PLATE LIGHT O33
Main X14 X14 HORN G40 X20 REVERSING SOUND ALARM (OPTION) O29
Main X16 X16 REAR RIGHT HEADLIGHT Q33 X30 HEATING FAN SWITCH I24
Main X17 X17 REAR RIGHT HEADLIGHT Q27 X74 FRONT LEFT HEADLIGHT Q35
Main X19 REAR TRAILER CONNECTOR (OPTION) K29 X77 FRONT WINDSCREEN WIPER MOTOR Q20
Main X20 X20 REVERSING SOUND ALARM (OPTION) O29 X79 FRONT WINDSCREEN WIPER SWITCH M24
Main/Cab X26 MAIN/CAB INTERFACE M9 X149 REAR AND ROOF WINDSCREEN WIPER SWITCH K24
Main X30 X30 HEATING FAN SWITCH I24 X150 REVOLVING LIGHT SWITCH G4
Main/Electric plate X39 ELECTRIC PLATE G33 X151 FRONT AND REAR WORKING LIGHT SWITCH K4
Main/Electric plate X41 ELECTRIC PLATE E40 X152 WORKING LIGHT SWITCH ON BOOM (OPTION) E24
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A4 X187 WARNING SWITCH E31
Main X70 M3 WINDSCREEN WASHER PUMP Q23 X188 LIGHT COMMUTATOR SWITCH A34
Main X73 S16 BRAKE CIRCUIT PRESSURE SWITCH O26 X210 LEFT SIDE WORKING LIGHT C23
Main X74 X74 FRONT LEFT HEADLIGHT Q35 X211 RIGHT SIDE WORKING LIGHT C21
Main X77 X77 FRONT WINDSCREEN WIPER MOTOR Q20
Main X79 X79 FRONT WINDSCREEN WIPER SWITCH M24
Main X149 X149 REAR AND ROOF WINDSCREEN WIPER SWITCH K24
Fuses and relays
Main X150 X150 REVOLVING LIGHT SWITCH G4
Main X151 X151 FRONT AND REAR WORKING LIGHT SWITCH K4 Item Current Designation Position on diagram
Main X154 V5 DIODE POSITION LIGHT / WORKING LIGHTS G30 F3 10A HORN + STOP LIGHT C19
X155 V5 DIODE POSITION LIGHT / WORKING LIGHTS G32 F5 7,5A LEFT INDICATOR LIGHTS E37
Electric plate X188 X188 LIGHT COMMUTATOR SWITCH C36 F6 7,5A RIGHT SIDELIGHT E34
Main/Electric plate X308 ELECTRIC PLATE E18 F7 7,5A LEFT SIDELIGHT E33
Main X329 F33 WORKING LIGHTS FUSE C4 F8 7,5A ROTATING LIGHT C9
80
Main X330 WORKING LIGHT ON BOOM (OPTION) E4 F9 15A REAR WORKING LIGHTS C9
F10 15A FRONT WORKING LIGHTS C10
F16 10A WARNING INDICATOR LIGHTS C17
F17 10A FRONT WINDSCREEN WIPER C18
F18 15A MAIN BEAM HEADLIGHTS E36
F19 7,5A RIGHT INDICATOR LIGHTS E37
Hydraulic code F20 15A DIPPED BEAM HEADLIGHTS E35
equivalence
F21 15A DIGICODE + ROOF LIGHT + WARNING C7
K6 FLASHING/WARNING UNIT C31
F22 25A LIGHT COMMUTATOR SWITCH C7
M3 WINDSCREEN WASHER PUMP Q24
F23 15A REAR WINDSCREEN WIPER + ROOF WINDSCREEN WIPER C11
P06 ROTATING LIGHT O7
F24 15A HEATING + AIR CONDITIONING C12
P07 FRONT LEFT WORKING LIGHTS Q15
F33 15A WORKING LIGHTS C4
P08 REAR LEFT WORKING LIGHTS Q16
P09 ROOF WINDSCREEN WIPER MOTOR Q8
P10 REAR WINDSCREEN WIPER MOTOR Q10
P12A HEATING O16
P12B HEATING O17
P14 REAR RIGHT WORKING LIGHTS Q19
P15 FRONT RIGHT WORKING LIGHTS Q18
P16 CEILING LIGHT Q13
S16 BRAKE CIRCUIT PRESSURE SWITCH O27
80-02-M209EN (08/10/2012)
DIAGRAM 4
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
X188
X45
X211 X210
F21 F22 F8 F9 F10 F23 F24 F16 F17 F3

K6
C C
X188
F33
X04 V6
X308
E X152 X187 E
F7 F6 F20 F18 F19 F5
X14
V5 X39
G G
CHASSIS GND (M3)
X150
X30
I I
X151
X19
K X149 K
80
M M
X26
X79
S16 X20
X20
O O
P06 P12A P12B X18
X74 X13
X17 X16
P09 P10 X77 M3
Q P07 P15 Q
X74 X13
P16 P08 P14
P09 P10 X77
X17 X16
CABIN CHASSIS GND CHASSIS GND

ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
(08/10/2012) 80-02-M209EN
5 – HYDRAULIC MOVEMENT

Main/Electric plate X04 ELECTRIC PLATE E7 S29 COMPENSATION PRESSURE SWITCH I7
Distributor X23 Y14 HYDRAULIC CUT-OFF ELECTROVALVE/VS Q17 S30 COMPENSATION PRESSURE SWITCH M7
Distributor X28 Y8 TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE Q27 X33 MOVEMENT NEUTRALISATION SWITCH C22
Distributor X29 Y9 TELESCOPE EXTENSION PROPORTIONAL ELECTROVALVE Q30 X100 BOOM ANGLE SENSOR G19
Main X33 X33 MOVEMENT NEUTRALISATION SWITCH C22 X117 ATTACHMENT LOCKING SWITCH C26
Distributor X34 Y7 PROPORTIONAL ELECTROVALVE ATTACHMENT (S1) Q23 X119 OVERRIDE SWITCH C17
Distributor X35 Y6 PROPORTIONAL ELECTROVALVE ATTACHMENT (S2) Q25 X134 RETRACTED BOOM SENSOR K19
Main/Electric plate X41 ELECTRIC PLATE C12 Y4 COMPENSATION ELECTROVALVE (BASE) Q8
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A5 Y5 COMPENSATION ELECTROVALVE (HEAD) Q6
Main X56 SPU SPU MODULE A38 Y6 PROPORTIONAL ELECTROVALVE ATTACHMENT (S2) Q26
Main X57 SPU SPU MODULE E38 Y7 PROPORTIONAL ELECTROVALVE ATTACHMENT (S1) Q23
Main/Distributor X87 MAIN/DISTRIBUTOR INTERFACE K31 Y8 TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE Q28
Distributor X92 Y15 BOOM LOWERING PROPORTIONAL ELECTROVALVE Q20 Y9 TELESCOPE EXTENSION PROPORTIONAL ELECTROVALVE Q30
Distributor X93 Y16 TILTING CUT-OFF ELECTROVALVE/VCI Q14 Y14 HYDRAULIC CUT-OFF ELECTROVALVE/VS Q17
Main X100 X100 BOOM ANGLE SENSOR G17 Y15 BOOM LOWERING PROPORTIONAL ELECTROVALVE Q20
Main X104 Y30 LSU PUMP ELECTROVALVE Q38 Y16 TILTING CUT-OFF ELECTROVALVE/VCI Q15
Distributor X105 DISTRIBUTOR HARNESS GROUND S30 Y30 LSU PUMP ELECTROVALVE Q38
Main X117 X117 ATTACHMENT LOCKING SWITCH C26 SPU SPU MODULE A40
Main X119 X119 OVERRIDE SWITCH C17
Main X134 X134 RETRACTED BOOM SENSOR K17
X240 S29 COMPENSATION PRESSURE SWITCH I7
Fuses and relays
X241 S30 COMPENSATION PRESSURE SWITCH M7
X242 Y4 COMPENSATION ELECTROVALVE (BASE) O7 Item Current Designation Position on diagram
X243 Y5 COMPENSATION ELECTROVALVE (HEAD) O5 F11 10A SUSPENSION ELECTROVALVE + BRAKE PRESSURE C7
Main X320 OPTIONAL CONNECTOR G7 F14 15A DIGICODE + SENSORS A12
X117/A X117 ATTACHMENT LOCKING SWITCH C29
X117/B X117 ATTACHMENT LOCKING SWITCH E29
80
80-02-M209EN (08/10/2012)
DIAGRAM 5
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 X45 X56 SPU A

1
toward (TAB.01) +12V (APC)
2
ATTACHEMENT (S1)
3
toward (TAB.06) BOOM HEAD VALVE GND
4
5
F14 6
SAFETY VALVE GROUD
BOOM LOWERING VALVE GROUD
7
toward (TAB.03) MICRO RELAIS SUPLY
8
F11 9
10
toward (TAB.06) EASY CONNECT SYSTEM
11
MOVENTS FORCING
C toward (TAB.02) 12
ROLLER 1 C
13
toward (TAB.01) IN TIMER ECU +12V APC
14
X41 15
ATTACHEMENT (S2)
toward (TAB.02) TRANSMISION CUT
X119 X33 X117 16
17
toward (TAB.02) SEAT MICROSWITCH (NO)
18
toward (TAB.02) JSM ROLLER 1
X04 19
20
toward (TAB.01&03) GROUD
21
toward (TAB.03) +12Vdc
22
toward (TAB.06) OIL FLOW CONTINUOUS
23
toward (TAB.02) PARKING BRAKE INFO
E toward (TAB.01)
24 E
25
26
X57
1
toward (TAB.03) CAN H
2
toward (TAB.03) CAN L
3
toward (TAB.01) SPU +APC
4
5
EV. SENS+ TELECOPE
6
7
X100 SAFETY VALVE
G 8 G
X100 toward (TAB.01)
toward (TAB.01)
9
+12V APC
+12V APC
10
11
12
toward (TAB.02) BP1 ev TDF
13
toward (TAB.06) ANALOG INPUT OIL FLOW CONTINUOUS
14
toward (TAB.02) GEAR INFO
15
ANALOG SENSOR (N.O.) BOOM RETRACTION
16
17
toward (TAB.02) TRANSMISSION CUT
18
19
ATTACHM. LOCK
I S29 toward (TAB.01)
20
FAN PROP. VALVE
I
21
22
23
24
toward (TAB.02) ROLLER 2
25
FAN PROP. VALVE
26
X134 X87
27
28
toward (TAB.03) CAN GND
29
30
toward (TAB.01) FAN INVERSION
31
ANALOG SENSORS GND
K 32 K
VCI VALVE
33
toward (TAB.06) OIL FLOW CONTINUOUS SIGN. LAMP
34
S30
80
M M
O O
Y5 Y4
Y16 Y14 Y15 Y7 Y6 Y8 Y9
Q Q
Y30
HYDRAULIC
DISTRIBUTOR GND (X105)
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
CHASSIS GND
(08/10/2012) 80-02-M209EN
6 – OPTIONS

P01 LOUDSPEAKER HARNESS ON CAR RADIO E15 B1, LEFT LOUDSPEAKER G15
P06 B1 LEFT LOUDSPEAKER G15 B2, RIGHT LOUDSPEAKER G17
Cab P12A P12A HEATING Q23 G1 ALTERNATOR Q14
Cab P12B P12B HEATING Q25 M11 AIR CONDITIONING PUMP Q26
P13 B2, RIGHT LOUDSPEAKER G17 M12 PNEUMATIC SEAT COMPRESSOR I8
Main/Electric plate X04 ELECTRIC PLATE E23 - C25 P11 AIR CONDITIONING THERMOSTAT Q21
X05 K23 BOOM HEAD ELECTROVALVE RELAY I3 P12A HEATING Q23
X11 M12 PNEUMATIC SEAT COMPRESSOR G8 P12B HEATING Q25
Main/Cab X26 MAIN/CAB INTERFACE O20 S28 PRESSURE SWITCH G32
X26 M11 AIR-CONDITIONING COMPRESSOR Q27 S29, PRESSURE SWITCH I32
Main X30 X30 HEATING FAN SWITCH I24 S31 PRESSURE SWITCH E32
Main/Electric plate X41 ELECTRIC PLATE E12 S44 BOOM PRESSURE SWITCH E35
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A4 S47 OIL THERMOSTAT Q11
Main X56 SPU SPU MODULE E6 - K15 S51 TELESCOPE HEAD ELECTROVALVE REEL K4
Main X57 SPU SPU MODULE I11 - I15 - M15 V1 DIODE M38
Main X97 K23 BOOM HEAD ELECTROVALVE RELAY G5 X30 HEATING FAN SWITCH I26
Main X112 X112 PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP K14 X112 PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP K16
Main X113 X113 CONTINUE FLOW POTENTIOMETER I14 X113 CONTINUE FLOW POTENTIOMETER I15
Main X116 X116 EASY CONNECT SYSTEM (ECS) (NF) O9 X116 EASY CONNECT SYSTEM (ECS) (NF) Q8
X205 AIR CONDITIONING MODULE M29 X157 OIL FAN Q17
X206 AIR CONDITIONING MODULE O27 X208 AIR-CONDITIONING FAN Q28
X208 X208 AIR-CONDITIONING FAN O28 X209 AIR-CONDITIONING FAN Q30
X209 X209 AIR-CONDITIONING FAN O29 X221 BOOM SUSPENSION TIME DELAY RELAY M40
X215 K22 OIL FAN RELAY Q15 X222 TELESCOPE SUSPENSION SWITCH C31
X221 X221 BOOM SUSPENSION TIME DELAY RELAY M39 X224 AIR CONDITIONING PUMP PRESSURE SWITCH M25
X223 Y20 LEFT 2 BOOM SUSPENSION ELECTROVALVE O34 X248 ANGULAR SWITCH C33
X224 Y22 RIGHT 2 BOOM SUSPENSION ELECTROVALVE O32 Y13 BOOM HEAD ELECTROVALVE M4
X224 X224 AIR CONDITIONING PUMP PRESSURE SWITCH M24 Y19 LEFT LIFTING ELECTROVALVE S1 Q38
X225 S28 PRESSURE SWITCH G31 Y20 LEFT LIFTING ELECTROVALVE S2 Q34
X226 S29 COMPENSATION PRESSURE SWITCH I31 Y21 RIGHT LIFTING ELECTROVALVE S1 Q36
80
X227 K19 BOOM SUSPENSION CUT-OFF RELAY K38 Y22 RIGHT LIFTING ELECTROVALVE S1 Q33
X228 K20 BOOM SUSPENSION RELAY G38
X229 V1 DIODE M38 Fuses and relays
X232 V2 DIODE G34
X239 S47 OIL THERMOSTAT O12
X245 Y19 LEFT 1 BOOM SUSPENSION ELECTROVALVE O38 F1 10A PNEUMATIC SEAT C9
X246 Y21 RIGHT 1 BOOM SUSPENSION ELECTROVALVE O36 F11 10A SUSPENSION ELECTROVALVE + BRAKE PRESSURE C25
X247 S31 PRESSURE SWITCH E31 F14 10A DIGICODE + SENSORS C12
X248 X248 ANGULAR SWITCH C33 F24 15A HEATING + AIR CONDITIONING C23
X249 S44 BOOM PRESSURE SWITCH E34 F27 10A BOOM HEAD ELECTROVALVE E4
Main/Electric plate X308 ELECTRIC PLATE E9 F45, 30A THERMAL FUSE O16
Electric plate X318 ELECTRIC PLATE GROUND CONNECTOR G18 F46 THERMAL FUSE M28
Main X320 OPTIONAL CONNECTOR E25 K19 BOOM SUSPENSION CUT-OFF RELAY K39
Main/Electric plate X331 SEAT COMPRESSOR CONNECTOR G9 K20 BOOM SUSPENSION RELAY G39
Main X338 F27 HEAD TELESCOPE ELECTROVALVE FUSE E5 K22 OIL FAN RELAY Q17
K23 BOOM HEAD ELECTROVALVE RELAY I5
80-02-M209EN (08/10/2012)
DIAGRAM 6
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
X45
X222
C F11 X248
C
X248
F1 F14 F24 X04
F27
E X308 E
S31
X41
P01 P01
S44
X97
P06 P13
G
K20 G
X11 S28
B1 B2
K23
M12
I I
X113
S29
X113 X30
S51 X112 K19

X112
K K
F46
80
Y13 V1
X224
M M
X205
X221
CONDITIONING
MODULE
F45
O
X206 O
K22 P11 Y22 Y20 Y21 Y19

X116 S47 X208 X209
P12A P12B
Q M11 Q
G1 X157
CABIN CHASSIS GND
CABIN CHASSIS GND
CHASSIS GND ENGINE GND

ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
(08/10/2012) 80-02-M209EN
80
80-02-M209EN (08/10/2012)
ELECTRICAL SCHEMATIC DIAGRAMS B1
MLT 845-120 SERIES 5-E3

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

ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B7
– 1 – START-UP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B7
– 2 – TRANSMISSION AND SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B10
– 3 – CAN BUS AND DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B12
– 4 – LIGHTING/SIGNALING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B14
– 5 – HYDRAULIC MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B16
– 6 – OPTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B18
80
(08/10/2012) 80-02-M209EN
B2 ELECTRICAL SCHEMATIC DIAGRAMS
POSITION OF CONNECTORS ON DIAGRAMS
Connectors Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6

ADM2-12 √ √ √
ADM2-15 √ √
ADM2-21 √ √
F40 √
F41 √
F42 √
F43 √
F44 √
F45 √
G1 √
KA √
KN √
M1 √
M3 √
MR2 √ √
P01 √
P06 √
P09 √
P10 √
P12A √ √
P12B √ √
P13 √
RC √ √
XTP √
X5 √
X6 √
X7 √
X8 √ √
X01 √
X02 √
X04 √ √ √ √
X05 √
80
X08 √
X09 √
X10 √
X11 √
X12 √
X13 √
X14 √
X15 √
X15 √ √
X16 √
X17 √
X19 √
X20 √
X21 √
X23 √
X24 √ √ √
X26 √ √
X26 √
80-02-M209EN (08/10/2012)

X28 √
X29 √
X30 √ √
X33 √
X34 √
X35 √
X36 √
X39 √
X41 √ √ √ √ √ √
X45 √ √ √ √ √ √
X46 √
X47 √
X48 √
X50 √
X51 √
X52 √
X54 √
X55 √
X56 √ √ √ √ √
X57 √ √ √ √ √
X58 √
X61 √
X68 √
X70 √
X71 √
X72 √
X73 √
X74 √
X77 √
X79 √
X87 √
X89 √
80
X92 √
X93 √
X97 √
X98 √
X99 √
X100 √
X104 √
X104/A √
X105 √
X109 √
X109/A √
X109/B √ √
X112 √
X113 √
X114 √
X115 √
X116 √
X117/A √
(08/10/2012) 80-02-M209EN

X117/B √
X118 √ √ √
X118.S √ √
X118P √
X118S √
X119 √
X121 √ √ √
X134 √
X149 √
X150 √
X151 √
X154 √
X155 √
X165 √
X188 √
X193 √
X205 √
X206 √
X208 √
X209 √
X215 √
X221 √
X223 √
X224 √
X224 √
X225 √
X226 √
X227 √
X228 √
X229 √
X232 √
X238 √
80
X239 √
X240 √
X241 √
X242 √
X243 √
X245 √
X246 √
X247 √
X248 √
X249 √
X300 √
X308 √ √ √ √ √
X310 √
X311 √ √
X315 √
X316 √
X317 √
X318 √ √ √
X319 √
X320 √ √ √
80-02-M209EN (08/10/2012)

X322 √
X323 √
X325 √
X326 √
X327 √
X328 √
X329 √
X330 √
X331 √
X332 √
X333 √
X334 √
X335 √
X335P √
X335S √
X336 √
X337 √
X338 √
X355A √
X355B √
X356A √
X356B √
X501 √
X502 √
X503 √
X504 √
X505 √
X506 √
80
(08/10/2012) 80-02-M209EN
80
80-02-M209EN (08/10/2012)
ELECTRICAL DIAGRAMS
1 – START-UP
Name of Position on Hydraulic
component diagram equivalence code
Engine ADM2-12 ADM2 ADM2 MODULE (CAB) A32
Engine ADM2-15 ADM2 ADM2 MODULE (CAB) E32
Engine ADM2-21 ADM2 ADM2 MODULE (CAB) G32
Engine F42 F42 DIAGNOSTIC PLUG MR2-PLD E11
Engine F45 F45 STARTER E8
Engine G1 G1 ALTERNATOR A5
Engine KA KA MERCEDES STARTING RELAY C7
Engine KN KN NEUTRAL SAFETY RELAY E39
Engine MR2 MR2 MR2-PLD MODULE (ENGINE) A26
Engine M1 M1 STARTER C8
Engine RC NOT USED O38
Engine XTP XTP ACCELERATOR POTENTIOMETER M36
Engine X5 DIAGNOSTIC PLUG MR2-PLD E26
Engine X6 X6A DIESEL DECONGEALANT HEATING ELEMENT E15
Engine X7 KC + FC1 AIR HEATING (OPTION) E18
Engine X8 S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH G38
Engine/Casappa X15 ENGINE/CASAPPA INTERFACE M38
Main/Electric plate X41 ELECTRIC PLATE O28
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) K18
Main X47 F25 ANTI-START FUSE O25
Main X56 SPU SPU MODULE O21
80
Main X57 SPU SPU MODULE O21 - O37
Main X114 S52 EMERGENCY STOP O19
Main X118 DIGICODE CONNECTOR O30
Main X118.S DIGICODE CONNECTOR Q32
Main X193 OPTIONAL CONNECTOR Q27
Main/Electric plate X308 ELECTRIC PLATE O25 - O28
Main/Electric plate X311 REVERSE GEAR SHUTTLE CONNECTOR Q23
Main X317 F30 INDICATOR LAMP FAULT + SPU O16
Electric plate X318 ELECTRIC PLATE GROUND CONNECTOR O23
Main X328 F36 SPU FUSE O18
Main X332 H16 INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP O13
Main X333 H10 AIR HEATING INDICATOR LAMP O14
Main X334 H15 ENGINE FAULT INDICATOR LAMP O15
Main X501 X501 FAN SWITCH O36
Main/ Fan X502 MAIN/FAN INTERFACE Q36
Fan X505 X505 PROPORTIONAL ELECTROVALVE FAN S38
Fan X506 X506 FAN REVERSAL ELECTROVALVE (OPTION) S39
(08/10/2012) 80-02-M209EN
Hydraulic code
equivalence
ADM2 ADM2 MODULE (CAB) A34
B1 12V BATTERY A15
B2 12V BATTERY (OPTION) A16
EH AIR HEATING (OPTION) E20
G1 ALTERNATOR A6
H10 AIR HEATING INDICATOR LAMP Q14
H15 ENGINE FAULT INDICATOR LAMP Q15
H16 INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP Q13
KEY KEY SWITCH M8
M1 STARTER A8
MR2 MR2-PLD MODULE (ENGINE) A27
S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH G36
S46 BATTERY CUT-OFF A13
S52 EMERGENCY STOP O18
XTP ACCELERATOR POTENTIOMETER K37
X6A DIESEL DECONGEALANT HEATING ELEMENT E16
X501 FAN SWITCH O36
X503 TRANSMISSION OIL TEMPERATURE SENSOR Q35
X504 HYDRAULIC OIL TEMPERATURE SENSOR Q34
X505 PROPORTIONAL ELECTROVALVE FAN S38
X506 FAN REVERSAL ELECTROVALVE (OPTION) S40
Fuses and relays
F4 15A FAN + DIAGNOSTICS + DIESEL FUEL THINNING FILTER O28

F14 15A DIGICODE + SENSORS O27
F21 15A DIGICODE + ROOF LIGHT + WARNING O26
F25 25A ANTI-START O25
80
F30 10A FAULT INDICATOR LAMP + SPU O16

F36 10A SPU O18
F42 7,5A DIAGNOSTIC PLUG MR2-PLD E11
F45 30A STARTER E8
FC 225A AIR HEATING (OPTION) A20
FC1 7,5A AIR HEATING - ADM2 INFORMATION (OPTION) C19
FG 125A MASTER POWER SWITCH C13
K4 ANTI-START RELAY O24
KA MERCEDES STARTING RELAY C7
KC AIR HEATING RELAY (OPTION) C20
KN NEUTRAL SAFETY RELAY E39
80-02-M209EN (08/10/2012)
DIAGRAM 1
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
G1 FC MR2 MR2 ADM-12 ADM2
B1 B2
M1
G1 S46
KC
M1
FG
C C
ADM-15
KA
FC1
ENGINE GND
EH
X5
CHASSIS GND X7
E F45 F44 F43 F42 F41 F40 ENGINE GND E

KN
X6
X6A
ADM-21
G G
S5
I I
X121
K K
XTP XTP
80
KEY
M X54-X55 X15 M
X45
RC
F25
F30 F21 F14 F4
O S52 X501 O
F36
K4
STOP H16 H10 H15 X193 X118 X118.S
Q Q
X504 X503
X505 X506
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
X24
GND
CHASSIS GND CHASSIS GND
(08/10/2012) 80-02-M209EN
2 – TRANSMISSION AND SENSORS

Engine ADM2-12 ADM2 ADM2 MODULE (CAB) K7 H11 FRONT WHEEL ALIGNMENT LIGHT M5
Engine ADM2-15 ADM2 ADM2 MODULE (CAB) K7 H14 REAR WHEEL ALIGNMENT LIGHT M3
Main X8 S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH O9 S4 BRAKE LIQUID LEVEL CONTACT O11
Main X01 X01 GEAR LEVER M34 S5 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH O9
Main X02 X02 SEAT SWITCH (NO) O28 S12 TRANSMISSION OIL PRESSURE SWITCH O12
Main/Electric plate X04 ELECTRIC PLATE C6 S17 TRANSMISSION OIL TEMPERATURE SENSOR Q14
Main X08 S17 TRANSMISSION OIL THERMOSWITCH O13 S37 HAND BRAKE PRESSURE SWITCH Q17
Main X09 Y2 FORWARD GEAR ELECTROVALVE Q33 S48 BRAKE CIRCUIT PRESSURE SWITCH G3
Main X10 Y3 REVERSE GEAR ELECTROVALVE Q35 D4 DIODE - SAFETY RELAY/REVERSE GEAR K37
Main X12 S37 HAND BRAKE PRESSURE SWITCH Q17 D5 DIODE - SAFETY RELAY/FORWARD GEAR K36
Main X15 X15. FRONT WHEEL ALIGNMENT SENSOR O4 X01 GEAR LEVER M34
Main X21 X21 REAR WHEEL ALIGNMENT SENSOR O3 X02 SEAT SWITCH (NO) O28
Main/Engine X24 MAIN/ENGINE INTERFACE K10 X15. FRONT WHEEL ALIGNMENT SENSOR O5
Main X36 X36 JSM (JOYSTICK SWITCH AND MOVE) G29 X21 REAR WHEEL ALIGNMENT SENSOR O4
Main/Electric plate X41 ELECTRIC PLATE E23 - I9 X36 JSM (JOYSTICK SWITCH AND MOVE) G29
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A4 X52 WHEEL ALIGNMENT SWITCH Q6
Main X46 K8 NEUTRAL SAFETY RELAY M38 X61 TRANSMISSION CUT-OFF SWITCH M31
Main X50 H11 FRONT WHEEL ALIGNMENT LIGHT M5 X68 HOUR METRE / FUEL LEVEL G21
Main X51 H14 REAR WHEEL ALIGNMENT LIGHT M3 X71 BRAKE PEDAL SWITCH K29
Main X52 X52 WHEEL ALIGNMENT SWITCH Q6 X165 FUEL LEVEL SENSOR I21
Main X56 SPU SPU MODULE I24 - M26 X323 HAND BRAKE SWITCH M19
Main X57 SPU SPU MODULE I24 - M26 Y2 FORWARD GEAR ELECTROVALVE Q33
Main X61 X61 TRANSMISSION CUT-OFF SWITCH M31 Y3 REVERSE GEAR ELECTROVALVE Q35
Main X68 X68 HOUR METRE / FUEL LEVEL I21 Y18 HAND BRAKE ELECTROVALVE Q23
Main X71 X71 BRAKE PEDAL SWITCH K29
Main X72 S48 BRAKE LIQUID LEVEL CONTACT O11
Main X89 COOLANT LIQUID TEMPERATURE INDICATOR I18
Fuses and relays
Main X98 S12 TRANSMISSION OIL PRESSURE SWITCH O12
Main X118 DIGICODE CONNECTOR G23 Item Current Designation Position on diagram
Main/Engine X121 MAIN/ENGINE INTERFACE K10 F2 5A ECU + WHEEL ALIGNMENT + DIAGNOSTICS C8
80
Main X165 X165 FUEL LEVEL SENSOR I21 F11 10A SUSPENSION ELECTROVALVE + BRAKE PRESSURE C7
X238 S48 BRAKE CIRCUIT PRESSURE SWITCH E4 F12 7,5A PARKING BRAKE C8
Main X300 K18 HAND BRAKE RELAY Q19 F13 15A FNR TRANSMISSION C22
Main/Electric plate X308 ELECTRIC PLATE G8 F15 5A INSTRUMENTS + INDICATORS C9
X310 NOT USED G37 K0 NC TRANSMISSION CUT-OFF RELAY C30
Main/Electric plate X311 REVERSE GEAR SHUTTLE CONNECTOR G36 K1 RELAY (NOT USED) C26
Electric plate X318 ELECTRIC PLATE GROUND CONNECTOR A37 K2 FORWARD GEAR RELAY C33
Main/Electric plate X319 BRAKE CIRCUIT CONNECTOR I6 K3 REVERSE GEAR RELAY C37
Main X320 OPTIONAL CONNECTOR E7 K5 TRANSMISSION PRESSURE RELAY C21
X322 NOT USED G37 K8 NEUTRAL SAFETY RELAY M40
Main X323 X323 HAND BRAKE SWITCH M19 K18 HAND BRAKE RELAY O21
Main X325 D4 - D5 DIODE CONNECTOR K37 K21 BRAKE CIRCUIT RELAY E7
Main X327 Y18 HAND BRAKE ELECTROVALVE Q23
Main X118.S DIGICODE CONNECTOR G23
X355A PARKING BRAKE CONNECTOR SWITCH/X41 M17
X355B CONNECTOR X41/PARKING BRAKE SWITCH M17
X356A CONNECTOR PARKING BRAKE SWITCH/SPU M16
X356B SPU CONNECTOR/PARKING BRAKE SWITCH M16
80-02-M209EN (08/10/2012)
DIAGRAM 2
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
X45
K5
F11 F2 F12 F15 F13 K1 K0 K2 K3
C C
X41
E E
K21
S48 X36 X311
G X68 G
X308
CHASSIS GND
X36
X89
X68
I X165 I
X41
X121
X326
X71 D5 D4
K K
X24 X61
X01
80
M K8 M
H14 H11 X323

X46
X02
O X21 X15 O
S12
K18
X21 X15
S5 S4
X52 S17 S37 X300
Y18 Y2 Y3
Q Q
CHASSIS GND
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
(08/10/2012) 80-02-M209EN
3 – CAN BUS AND DIAGNOSTICS

Engine ADM2-12 ADM2 ADM2 MODULE (CAB) O5 A12 LONGITUDINAL SECURITY MODULE A25
Engine ADM2-21 ADM2 ADM2 MODULE (CAB) I39 X99 STRAIN GAUGE A22
Engine MR2 MR2 MR2-PLD MODULE (ENGINE) O5
Engine RC NOT USED I39
Engine/Casappa X15 ENGINE/CASAPPA INTERFACE I35
Fuses and relays
Main/Electric plate X41 ELECTRIC PLATE C11 Item Current Designation Position on diagram
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A5 F2 5A ECU + WHEEL ALIGNMENT + DIAGNOSTICS A8
Main X48 F31 REXROTH ECU FUSE G9 F14 15A DIGICODE + SENSORS A11
Main X56 SPU SPU MODULE K19 F31 5A REXROTH ECU G9
Main X57 SPU SPU MODULE K19 F34 5A DIAGNOSTICS + CASAPPA G10
Main X58 A12 LONGITUDINAL SECURITY MODULE E27 F35 5A DIAGNOSTICS C4
Main X99 X99 STRAIN GAUGE C23
Main X104 OPTION M6
Main X109 OPTION I5
Casappa A X109/A CASAPPA CASAPPA ELECTRONICS CONTROL UNIT O27
Casappa B X109/B CASAPPA CASAPPA ELECTRONICS CONTROL UNIT M27
Main X115 OBD CONNECTOR DIAGNOSTICS C18
Main X118 DIGICODE CONNECTOR M28
Main/Casappa A X118P DIGICODE INTERFACE M28 CAN Network
Main/Casappa A X118S DIGICODE INTERFACE M30
Main/Engine X121 MAIN/ENGINE INTERFACE Q30
Main X315 F34 DIAGNOSTICS FUSE + CASAPPA G10
Main X316 F35 FUSE DIAGNOSTICS C4
PAD
Main/Casappa A X335 MAIN/CASAPPA INTERFACE I32
Main/Casappa A X335P MAIN/CASAPPA CONNECTOR I35
Engine/Casappa A X335S ENGINE CONNECTOR/CASAPPA I32
SPU LLMI
80
VCI
CAN A
CAN B
ECU PP LSU ECM ADM2 ECM MR2
80-02-M209EN (08/10/2012)
DIAGRAM 3
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
X45
A12
A A
F2 F14 X99
X115
C X308 C
F35
X41
X99
X58
E E
G G
F31 F34
X335 X335S X335P X15

X109
I I
RC
K K
80
M M
X109/A
O X109/B O
Q Q
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
CHASSIS GND
GND
(08/10/2012) 80-02-M209EN
4 – LIGHTING/SIGNALING

Main M3 X14 HORN GROUND G40 P16 CEILING LIGHT Q13
Cab P09 P09 ROOF WINDSCREEN WIPER MOTOR Q8 S16 BRAKE CIRCUIT PRESSURE SWITCH O27
Cab P10 P10 REAR WINDSCREEN WIPER MOTOR Q10 V5 DIODE G31
Cab P12A P12A HEATING O16 V6 DIODE E34
Cab P12B P12B HEATING O17 V7 DIODE M29
Main/Electric plate X04 ELECTRIC PLATE E7 X13 FRONT RIGHT HEADLIGHT Q40
Main X13 X13 FRONT RIGHT HEADLIGHT Q40 X14 HORN G40
Main X14 X14 HORN G40 X16 REAR RIGHT HEADLIGHT Q33
Main X16 X16 REAR RIGHT HEADLIGHT Q33 X17 REAR RIGHT HEADLIGHT Q28
Main X17 X17 REAR RIGHT HEADLIGHT Q28 X18 REAR LICENSE PLATE LIGHT O33
Main X19 REAR TRAILER CONNECTOR K29 X20 REVERSING SOUND ALARM (OPTION) O30
Main X20 X20 REVERSING SOUND ALARM (OPTION) O30 X30 HEATING FAN SWITCH I24
Main/Cab X26 MAIN/CAB INTERFACE M9 X74 FRONT LEFT HEADLIGHT Q35
Main X30 X30 HEATING FAN SWITCH I24 X77 FRONT WINDSCREEN WIPER MOTOR Q20
Main/Electric plate X39 ELECTRIC PLATE G33 X79 FRONT WINDSCREEN WIPER SWITCH M24
Main/Electric plate X41 ELECTRIC PLATE E40 - K31 X149 REAR AND ROOF WINDSCREEN WIPER SWITCH K24
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A4 X150 REVOLVING LIGHT SWITCH G4
Main X70 M3 WINDSCREEN WASHER PUMP Q23 X151 FRONT AND REAR WORKING LIGHT SWITCH K4
Main X73 S16 BRAKE CIRCUIT PRESSURE SWITCH O26 X152 TELESCOPE WORKING LIGHT SWITCH (OPTION) E24
Main X74 X74 FRONT LEFT HEADLIGHT Q35 X187 WARNING SWITCH E30
Main X77 X77 FRONT WINDSCREEN WIPER MOTOR Q20 X188 LIGHT COMMUTATOR SWITCH C36
Main X79 X79 FRONT WINDSCREEN WIPER SWITCH M24 X210 LEFT SIDE WORKING LIGHT C23
Main X149 X149 REAR AND ROOF WINDSCREEN WIPER SWITCH K24 X211 RIGHT SIDE WORKING LIGHT C21
Main X150 X150 REVOLVING LIGHT SWITCH G4
Main X151 X151 FRONT AND REAR WORKING LIGHT SWITCH K4
Main X154 V5 DIODE G30
Fuses and relays
X155 V5 DIODE G32
Cab X188 X188 LIGHT COMMUTATOR SWITCH C36 Item Current Designation Position on diagram
Main/Electric plate X308 ELECTRIC PLATE E18 F3 10A HORN + STOP LIGHT C19
Main X329 F33 WORKING LIGHTS FUSE C4 F5 7,5A LEFT INDICATOR LIGHTS E38
80
Main X330 WORKING LIGHT ON BOOM (OPTION) E4 F6 7,5A RIGHT SIDELIGHT E34
Main X336 V7 DIODE M30 F7 7,5A LEFT SIDELIGHT E33
Main X337 V7 DIODE M28 F8 7,5A ROTATING LIGHT C9
F9 15A REAR WORKING LIGHTS C10
F10 15A FRONT WORKING LIGHTS C10
F16 10A WARNING INDICATOR LIGHTS C17
F17 10A FRONT WINDSCREEN WIPER C18
F18 15A MAIN BEAM HEADLIGHTS E36
Hydraulic code F19 7,5A RIGHT INDICATOR LIGHTS E37
equivalence
F20 15A DIPPED BEAM HEADLIGHTS E35
K6 FLASHING/WARNING UNIT C31
M3 WINDSCREEN WASHER PUMP Q24
P06 ROTATING LIGHT O7
F23 15A REAR WINDSCREEN WIPER + ROOF WINDSCREEN WIPER C11
P07 FRONT LEFT WORKING LIGHTS Q15
P08 REAR LEFT WORKING LIGHTS Q16
F33 15A WORKING LIGHTS C4
P09 ROOF WINDSCREEN WIPER MOTOR Q8
P10 REAR WINDSCREEN WIPER MOTOR Q10
P12A HEATING O16
P12B HEATING O17
P14 REAR RIGHT WORKING LIGHTS Q19
P15 FRONT RIGHT WORKING LIGHTS Q17
80-02-M209EN (08/10/2012)
DIAGRAM 4
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
X188
X45
X211 X210
F21 F22 F8 F9 F10 F23 F24 F16 F17 F3

K6
C C
X188
F33
X04 V6
X308
E X152 X187 E
F7 F6 F20 F18 F19 F5
X14
V5 X39
G G
CHASSIS GND (M3)
X150
X30
I I
X151
X19
K X149 K
80
V7
M M
X26
X79
S16 X20
X20
O O
P06 P12A P12B X18
X74 X13
X17 X16
P09 P10 X77 M3
Q P07 P15 Q
X74 X13
P16 P08 P14
P09 P10 X77
X17 X16
CABIN CHASSIS GND CHASSIS GND

ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
(08/10/2012) 80-02-M209EN
5 – HYDRAULIC MOVEMENT

Main/Electric plate X04 ELECTRIC PLATE E7 SPU SPU MODULE A40
Distributor X23 Y14 HYDRAULIC CUT-OFF ELECTROVALVE/VS Q17 S29 COMPENSATION PRESSURE SWITCH I7
Distributor X28 Y8 TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE Q28 S30 COMPENSATION PRESSURE SWITCH M7
Distributor X29 Y9 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE Q30 X33 MOVEMENT NEUTRALISATION SWITCH C22
Main X33 X33 MOVEMENT NEUTRALISATION SWITCH C22 X100 BOOM ANGLE SENSOR G17
Distributor X34 Y7 PROPORTIONAL ELECTROVALVE ATTACHMENT (S1) Q23 X117 ATTACHMENT LOCKING SWITCH C26
Distributor X35 Y6 PROPORTIONAL ELECTROVALVE ATTACHMENT (S2) Q26 X119 OVERRIDE SWITCH C17
Main/Electric plate X41 ELECTRIC PLATE C12 X134 RETRACTED BOOM SENSOR K17
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A5 Y4 COMPENSATION ELECTROVALVE (BASE) Q8
Main X56 SPU SPU MODULE A38 Y5 COMPENSATION ELECTROVALVE (HEAD) Q6
Main X57 SPU SPU MODULE E38 Y6 PROPORTIONAL ELECTROVALVE ATTACHMENT (S2) Q26
Main/Distributor X87 MAIN/DISTRIBUTOR INTERFACE K31 Y7 PROPORTIONAL ELECTROVALVE ATTACHMENT (S1) Q23
Distributor X92 Y15 BOOM LOWERING PROPORTIONAL ELECTROVALVE Q20 Y8 TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE Q28
Distributor X93 Y16 TILTING CUT-OFF ELECTROVALVE/VCI Q15 Y9 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE Q30
Main X100 X100 BOOM ANGLE SENSOR G17 Y14 HYDRAULIC CUT-OFF ELECTROVALVE/VS Q17
Distributor X105 DISTRIBUTOR HARNESS GROUND S30 Y15 BOOM LOWERING PROPORTIONAL ELECTROVALVE Q20
Main X119 X119 OVERRIDE SWITCH C17 Y16 TILTING CUT-OFF ELECTROVALVE/VCI Q15
Main X134 X134 RETRACTED BOOM SENSOR K17 Y30 LSU PUMP ELECTROVALVE Q37
X240 S29 COMPENSATION PRESSURE SWITCH I7
X241 S30 COMPENSATION PRESSURE SWITCH M7
X242 Y4 COMPENSATION ELECTROVALVE (BASE) O7
Fuses and relays
X243 Y5 COMPENSATION ELECTROVALVE (HEAD) O5
Main X320 OPTIONAL CONNECTOR G7 Item Current Designation Position on diagram
Casappa B X104/A Y30 LSU PUMP ELECTROVALVE Q37 F11 10A SUSPENSION ELECTROVALVE + BRAKE PRESSURE C7
Casappa B X109/B CASAPPA CASAPPA ELECTRONICS CONTROL UNIT O38 F14 15A DIGICODE + SENSORS A12
Main X117/A X117 ATTACHMENT LOCKING SWITCH C29
Main X117/B X117 ATTACHMENT LOCKING SWITCH E29
80
80-02-M209EN (08/10/2012)
DIAGRAM 5
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 X45 X56 SPU A

1
toward (TAB.01) +12V (APC)
2
ATTACHEMENT (S1)
3
toward (TAB.06) BOOM HEAD VALVE GND
4
5
F14 6
SAFETY VALVE GROUD
BOOM LOWERING VALVE GROUD
7
toward (TAB.03) MICRO RELAIS SUPLY
8
F11 9
10
toward (TAB.06) EASY CONNECT SYSTEM
11
MOVENTS FORCING
C toward (TAB.02) 12
ROLLER 1 C
13
toward (TAB.01) IN TIMER ECU +12V APC
14
X41 15
ATTACHEMENT (S2)
toward (TAB.02) TRANSMISION CUT
X119 X33 X117 16
17
toward (TAB.02) SEAT MICROSWITCH (NO)
18
X04 19
20
21
toward (TAB.03) +12Vdc
22
toward (TAB.06) OIL FLOW CONTINUOUS
23
toward (TAB.02) PARKING BRAKE INFO
E toward (TAB.01)
24 E
25
26
X57
1
toward (TAB.03) CAN H
2
toward (TAB.03) CAN L
3
4
5
EV. SENS+ TELECOPE
6
7
X100 SAFETY VALVE
G 8 G
toward (TAB.01)
9
+12V APC
+12V APC
10
11
12
toward (TAB.02) BP1 ev TDF
13
toward (TAB.06) ANALOG INPUT OIL FLOW CONTINUOUS
14
15
ANALOG SENSOR (N.O.) BOOM RETRACTION
16
17
toward (TAB.02) TRANSMISSION CUT
18
19
ATTACHM. LOCK
I S29 toward (TAB.01)
20
FAN PROP. VALVE
I
21
22
23
24
toward (TAB.02) ROLLER 2
25
FAN PROP. VALVE
26
X134 X87
27
28
toward (TAB.03) CAN GND
29
30
toward (TAB.01) FAN INVERSION
31
ANALOG SENSORS GND
K 32 K
VCI VALVE
33
toward (TAB.06) OIL FLOW CONTINUOUS SIGN. LAMP
34
S30
80
M M
O O
Y5 Y4
Y16 Y14 Y15 Y7 Y6 Y8 Y9
Q Q
Y30
HYDRAULIC
DISTRIBUTOR GND (X105)
ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
CHASSIS GND
(08/10/2012) 80-02-M209EN
6 – OPTIONS

P01 LOUDSPEAKER HARNESS ON CAR RADIO E15 B1 LEFT LOUDSPEAKER G15
P06 B1 LEFT LOUDSPEAKER G15 B2 RIGHT LOUDSPEAKER G17
P13 B2 RIGHT LOUDSPEAKER G17 G1 ALTERNATOR Q14
P12A P12A HEATING Q23 M11 AIR CONDITIONING PUMP Q26
P12B P12B HEATING Q25 M12 PNEUMATIC SEAT COMPRESSOR I8
Main/Electric plate X04 ELECTRIC PLATE E23 - C25 P11 AIR CONDITIONING THERMOSTAT Q21
X05 K23 BOOM HEAD ELECTROVALVE RELAY I3 P12A HEATING Q23
X11 M12 PNEUMATIC SEAT COMPRESSOR G8 P12B HEATING Q25
Main X26 ELECTRICAL CAB CONNECTOR O20 S28 PRESSURE SWITCH G32
X26 M11 AIR CONDITIONING PUMP Q27 S29 PRESSURE SWITCH I32
Main X30 X30 HEATING FAN SWITCH I24 S31 PRESSURE SWITCH E32
Main/Electric plate X41 ELECTRIC PLATE E12 S44 BOOM PRESSURE SWITCH E35
Main/Electric plate X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) A4 S47 OIL THERMOSTAT Q11
Main X56 SPU SPU MODULE E6 - K15 S51 TELESCOPE HEAD ELECTROVALVE REEL K4
Main X57 SPU SPU MODULE I11 - I15 - M15 V1 DIODE M38
Main X97 K23 BOOM HEAD ELECTROVALVE RELAY G5 X30 HEATING FAN SWITCH I26
Main X112 X112 PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP K14 X112 PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP K16
Main X113 X113 CONTINUE FLOW POTENTIOMETER I14 X113 CONTINUE FLOW POTENTIOMETER I15
Main X116 X116 EASY CONNECT SYSTEM (ECS) (NF) O9 X116 EASY CONNECT SYSTEM (ECS) (NF) Q8
X205 AIR CONDITIONING MODULE M29 X157 OIL FAN Q17
X206 AIR CONDITIONING MODULE O27 X208 AIR-CONDITIONING FAN Q28
X208 X208 AIR-CONDITIONING FAN O28 X209 AIR-CONDITIONING FAN Q30
X209 X209 AIR-CONDITIONING FAN O29 X221 BOOM SUSPENSION TIME DELAY RELAY M40
X215 K22 OIL FAN RELAY Q15 X222 TELESCOPE SUSPENSION SWITCH C31
X221 X221 BOOM SUSPENSION TIME DELAY RELAY M39 X224 AIR CONDITIONING PUMP PRESSURE SWITCH M25
X223 Y20 LEFT 2 BOOM SUSPENSION ELECTROVALVE O34 X248 ANGULAR SWITCH C33
X224 X224 AIR CONDITIONING PUMP PRESSURE SWITCH M24 Y13 BOOM HEAD ELECTROVALVE M4
X224 Y22 RIGHT 2 BOOM SUSPENSION ELECTROVALVE O32 Y19 LEFT 1 BOOM SUSPENSION ELECTROVALVE Q38
X225 S28 PRESSURE SWITCH G31 Y20 LEFT 2 BOOM SUSPENSION ELECTROVALVE Q34
X226 S29 COMPENSATION PRESSURE SWITCH I31 Y21 RIGHT 1 BOOM SUSPENSION ELECTROVALVE Q36
80
X227 K19 BOOM SUSPENSION CUT-OFF RELAY K38 Y22 RIGHT 2 BOOM SUSPENSION ELECTROVALVE Q33
X228 K20 BOOM SUSPENSION RELAY G38
X229 V1 DIODE M38 Fuses and relays
X232 V2 DIODE G34
X239 S47 OIL THERMOSTAT O12
X245 Y19 LEFT 1 BOOM SUSPENSION ELECTROVALVE O38 F1 10A PNEUMATIC SEAT C9
X246 Y21 RIGHT 1 BOOM SUSPENSION ELECTROVALVE O36 F11 10A SUSPENSION ELECTROVALVE + BRAKE PRESSURE C25
X247 S31 PRESSURE SWITCH E31 F14 10A DIGICODE + SENSORS C12
X248 X248 ANGULAR SWITCH C33 F24 15A HEATING + AIR CONDITIONING C23
X249 S44 BOOM PRESSURE SWITCH E34 F27 10A BOOM HEAD ELECTROVALVE E4
Main/Electric plate X308 ELECTRIC PLATE E9 K19 BOOM SUSPENSION CUT-OFF RELAY K38
Electric plate X318 ELECTRIC PLATE GROUND CONNECTOR G18 K20 BOOM SUSPENSION RELAY G38
Main X320 OPTIONAL CONNECTOR E25 K22 OIL FAN RELAY Q17
Main/Electric plate X331 SEAT COMPRESSOR CONNECTOR G9 K23 BOOM HEAD ELECTROVALVE RELAY I5
Main X338 F27 HEAD TELESCOPE ELECTROVALVE FUSE E5 F45 30A THERMAL FUSE O16
F46 THERMAL FUSE M28
80-02-M209EN (08/10/2012)
DIAGRAM 6
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
X45
X222
C F11 X248
C
X248
F1 F14 F24 X04
F27
E X308 E
S31
X41
P01 P01
S44
X97
P06 P13
G
K20 G
X11 S28
B1 B2
K23
M12
I I
X113
S29
X113 X30
S51 X112 K19

X112
K K
F46
80
Y13 V1
X224
M M
X205
X221
CONDITIONING
MODULE
F45
O
X206 O
K22 P11 Y22 Y20 Y21 Y19

X116 S47 X208 X209
P12A P12B
Q M11 Q
G1 X157
CABIN CHASSIS GND
CABIN CHASSIS GND
CHASSIS GND ENGINE GND

ING KEY “30”
ING KEY “15”
ING KEY “15”
BATTEY “30”
S S
GND
(08/10/2012) 80-02-M209EN
80
80-02-M209EN (08/10/2012)
ELECTRICAL COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
– HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– ELECTRIC FUSE PLATE AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– CAB HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– ENGINE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– CONTROL VALVE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
80
(15/11/2012) 80-03-M209EN
2 ELECTRICAL COMPONENTS LOCATION
KEY
CONNECTORS
Position on harness diagram

Item DESIGNATION Harness Electric Comments
Cab Main Engine Distributor Fan
assembly plate
(A) DASHBOARD INDICATOR LAMPS E36 Q14
(B) DASHBOARD INDICATOR LAMPS E37 Q14
(C) WARNING SWITCH E37 Q11
(D) CAR RADIO E40 S12
(E) ADAPTATION TUV E38 S7
(F) REAR ELECTRIC SOCKET I5
ADM2-12 ADM2 MODULE (CAB) G36 S33
ADM2-15 ADM2 MODULE (CAB) G25 Q33
ADM2-21 ADM2 MODULE (CAB) G27 M33
F40 FUSE KEY SWITCH A35 A36
F41 FUSE KEY SWITCH A35 C36
F42 DIAGNOSTIC PLUG MR2-PLD A38 I34
F43 ADM2 MODULE (CAB) A38 I34
F44 ADM2 MODULE (CAB) A37 I34
F45 STARTER A37 I34
G1 ALTERNATOR Q17 E5
KA MERCEDES STARTING RELAY A36 G36
KN NEUTRAL SAFETY RELAY A36 E36
M1 STARTER O17 E9
MR2 MR2-PLD MODULE (ENGINE) Q21 O12E
RC NOT USED A35 O24
P01 LOUDSPEAKER HARNESS ON CAR RADIO E39 A2
P02 CAB/MAIN INTERFACE K27 E2
P05 LEFT LOUDSPEAKER G16 A12
P06 ROTATING LIGHT G15 I12
P07 FRONT LEFT WORKING LIGHT G27 A15
P08 REAR LEFT WORKING LIGHT G16 I15
P09 ROOF WINDSCREEN WIPER MOTOR G21 K7
P10 REAR WINDSCREEN WIPER MOTOR I14 S7
80
P11 AIR CONDITIONING THERMOSTAT K19 S15

P12 HEATING K18 K18
P13 RIGHT LOUDSPEAKER K16 K12
P14 REAR RIGHT WORKING LIGHT K7 S12
P15 FRONT RIGHT WORKING LIGHT I24 K16
P16 CEILING LIGHT I19 S16
XTP ACCELERATOR POTENTIOMETER M25 E28
X5 DIAGNOSTIC PLUG MR2-PLD A35 O28
X6 DIESEL DECONGEALANT HEATING ELEMENT M25 Q14
X7 AIR HEATING (OPTION) O17 G5
X8 ENGINE AIR FILTER CLOGGING PRESSURE SWITCH O17 E11
X01 GEAR LEVER K26 I31 (Not H)
X02 SEAT SWITCH (NO) G17 I15
X04 ELECTRIC PLATE A39 I11 S17
X08 TRANSMISSION OIL THERMOSWITCH K24 A24 (Not H)
X09 FORWARD GEAR ELECTROVALVE K23 A22
X10 REVERSE GEAR ELECTROVALVE M23 A21
X12 HAND BRAKE PRESSURE SWITCH M32 E34
X13 FRONT RIGHT HEADLIGHT Q30 A35
X14 HORN M32 E18
80-03-M209EN (15/11/2012)
ELECTRICAL COMPONENTS LOCATION 3

assembly plate
X15 FRONT WHEEL ALIGNMENT SENSOR M32 E35
X15 ENGINE/MAIN INTERFACE M25 E24
X16 REAR RIGHT HEADLIGHT Q5 C13
X17 REAR RIGHT HEADLIGHT G5 C15
X19 REAR TRAILER CONNECTOR (OPTION) I26 Q37
X20 REVERSING SOUND ALARM (OPTION) K2 C17
X21 REAR WHEEL ALIGNMENT SENSOR K10 C19

X22 HYDRAULIC OIL FILTER I24 A40 (H)
X23 HYDRAULIC CUT-OFF ELECTROVALVE/VS K23 M14
X24 MAIN/ENGINE INTERFACE M25 A29 E20
X26 MAIN/CAB INTERFACE I27 I18
X28 TELESCOPE RETRACTION PROPORTIONAL ELECTROVALVE K23 I6
X29 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE K23 I8
X30 HEATING FAN SWITCH E37 K10
X33 MOVEMENT NEUTRALISATION SWITCH E40 I2
X34 PROPORTIONAL ELECTROVALVE ATTACHMENT (S1) K22 K12
X35 PROPORTIONAL ELECTROVALVE ATTACHMENT (S2) K22 M15
X36 JSM (JOYSTICK SWITCH AND MOVE) I21 I20

X39 ELECTRIC PLATE A38 I8 K38
X41 ELECTRIC PLATE A39 G15 S26
X45 ELECTRIC PLATE POWER SUPPLY (KEY SWITCH) C41 Q13 I36
X46 NEUTRAL SAFETY RELAY C41 S31

X47 ANTI-START FUSE A36 I33
X48 ECU FUSE I17 C3
X50 FRONT WHEEL ALIGNMENT LIGHT E33 S12
X51 REAR WHEEL ALIGNMENT LIGHT E33 S11
X52 WHEEL ALIGNMENT SWITCH E33 S10
X54 KEY SWITCH E38 S8
80
X55 KEY SWITCH E38 S9
X56 SPU MODULE I15 E7
X57 SPU MODULE I15 E8
X58 LONGITUDINAL SECURITY MODULE E41 S16
X61 TRANSMISSION CUT-OFF SWITCH E39 K2 (Not H)
X68 HOUR METRE / FUEL LEVEL C38 O41
X70 WINDSCREEN WASHER PUMP I25 A39
X71 BRAKE PEDAL SWITCH G25 S19
X72 BRAKE LIQUID LEVEL CONTACT G25 S22
X73 BRAKE CIRCUIT PRESSURE SWITCH G25 S21
X74 FRONT LEFT HEADLIGHT G30 A34
X77 FRONT WINDSCREEN-WIPER MOTOR I28 S7
X79 FRONT WINDSCREEN WIPER SWITCH E38 K10
X87 MAIN/DISTRIBUTOR INTERFACE K24 S24 G15
X89 COOLANT LIQUID TEMPERATURE INDICATOR C34 I25
X92 BOOM LOWERING PROPORTIONAL ELECTROVALVE K21 K10
X93 TILTING CUT-OFF ELECTROVALVE/VCI K23 E5
X97 HEAD TELESCOPE ELECTROVALVE RELAY (OPTION) I25 K20
X98 TRANSMISSION OIL PRESSURE SWITCH K22 A23 (Not H)

(15/11/2012) 80-03-M209EN

assembly plate
X99 STRAIN GAUGE O9 E4
X100 BOOM ANGLE SENSOR M2 C11
X104 LSU ELECTROVALVE PUMP (OPTION) K18 G15
X104/A LSU PUMP ELECTROVALVE K18 (Not H)
MODULE RC2-2 K15 G4 (H)
X109
NOT USED (OPTION) K15 G4 (Not H)
X109/A CASAPPA ELECTRONICS CONTROL UNIT K15 (Not H)
X109/B CASAPPA ELECTRONICS CONTROL UNIT K15 (Not H)
X112 PUSH BUTTON + CONTINUE FLOW INDICATOR LAMP E32 I26
X113 CONTINUE FLOW POTENTIOMETER E32 I27

X114 EMERGENCY STOP G38 K40
X115 OBD CONNECTOR DIAGNOSTICS I15 G22
X116 EASY CONNECT SYSTEM (ECS) (NF) I32 E31
X117 ATTACHMENT LOCKING SWITCH (OPTION) E38 M2
X118 DIGICODE CONNECTOR I25 I22

X119 OVERRIDE SWITCH E40 M2
X121 MAIN/ENGINE INTERFACE K17 A3 K33
X134 RETRACTED BOOM SENSOR M3 C10
X149 REAR AND ROOF WINDSCREEN WIPER SWITCH E39 M10
X150 REVOLVING LIGHT SWITCH E39 M10
X151 FRONT AND REAR WORKING LIGHT SWITCH C39 I9
X154 DIODE POSITION LIGHT / WORKING LIGHTS I27 I17

X165 FUEL LEVEL SENSOR K23 C37
X188 LIGHT COMMUTATOR SWITCH E36 S10
X193 OPTIONAL CONNECTOR I27 I16
X300 HAND BRAKE RELAY C41 S30
X301 SNAIL SPEED A40 I28 (H)
X302 SLOW SPEED A40 I29 (H)
X303 REVERSE GEAR RELAY A40 I30 (H)
X304 SLOW SPEED SWITCH E33 Q14 (H)
X305 FAST / SLOW SPEED SWITCH E32 Q14 (H)
80
X306 SLOW SPEED E32 Q14 (H)

X307 FAST SPEED E32 S14 (H)
X308 ELECTRIC PLATE A37 I4 Q40
X309 ACCELERATOR PEDAL SWITCH C39 S29 (H)
X310 REVERSE GEAR INFORMATION A41 I30 (H)
X311 REVERSE GEAR SHUTTLE CONNECTOR A35 Q8 I21
X312 SNAIL SPEED ELECTROVALVE M22 C26 (H)
X313 REVERSE GEAR ELECTROVALVE M22 C26 (H)
X314 FAST SPEED ELECTROVALVE M22 C26 (H)
X315 FUSE DIAGNOSTICS I17 C3
X316 FUSE DIAGNOSTICS I17 C3
X317 INDICATOR LAMP FAULT + SPU I17 A7
X318 ELECTRIC PLATE GROUND CONNECTOR C41 Q13 I37
X319 BRAKE CIRCUIT CONNECTOR A38 G6 Q39
X320 CONNECTOR (OPTION) A39 S17
X321 NOT USED (OPTION) C39 S27 (H)
X322 NEUTRAL SWITCH INFORMATION (OPTION) C39 S28 (H)
X323 HAND BRAKE SWITCH E39 K2
X324 NOT USED (OPTION) C39 I9
80-03-M209EN (15/11/2012)
Position on harness diagram Position on harness diagram

Item DESIGNATION Harness Electric Comments Item Current DESIGNATION Harness Electric Comments
Cab Main Engine Distributor Fan Cab Main Engine Distributor Fan
assembly plate assembly plate
X325 DIODE CONNECTOR C42 S33
F4 15A FAN + DIAGNOSTICS + DIESEL FUEL THINNING FILTER A6
X326 DIODE CONNECTOR C42 S33
X327 HAND BRAKE ELECTROVALVE M32 E32 F5 7,5A LEFT INDICATOR LIGHTS A7
X328 SPU FUSE I17 A8 F6 7,5A RIGHT SIDELIGHT A8
X329 WORKING LIGHTS FUSE A36 I34 F7 7,5A LEFT SIDELIGHT A9
X330 WORKING LIGHT ON BOOM (OPTION) C41 I38 F8 7,5A ROTATING LIGHT A10
X331 SEAT COMPRESSOR CONNECTOR A37 G3 Q38 F9 15A REAR WORKING LIGHTS A10
X332 INDICATOR LAMP IMMEDIATE ENGINE FAULT STOP C35 I14 F10 15A FRONT WORKING LIGHTS A11
X333 AIR HEATING INDICATOR LAMP E35 I13 F11 10A SUSPENSION ELECTROVALVE + BRAKE PRESSURE A12
X334 ENGINE FAULT INDICATOR LAMP C35 I12 F12 7,5A PARKING BRAKE A13
X335 MAIN/ENGINE INTERFACE M26 A28 F13 15A FNR TRANSMISSION A13
X336 DIODE CONNECTOR K26 Q36 (Not H) F14 15A DIGICODE + SENSORS A14
X337 DIODE CONNECTOR K26 Q35 (Not H) F15 5A INTRUMENTS + INDICATORS C4
X338 HEAD TELESCOPE ELECTROVALVE FUSE A36 I35 F16 10A WARNING INDICATOR LIGHTS C5
X501 FAN SWITCH (OPTION) E36 K9 F17 10A FRONT WINDSCREEN WIPER C6
X502 MAIN/FAN HARNESS INTERFACE M21 I15 F18 15A MAIN BEAM HEADLIGHTS C7
X503 TRANSMISSION OIL TEMPERATURE SENSOR Q23 G8 F19 7,5A RIGHT INDICATOR LIGHTS C8
X504 FAN THERMOSTAT S23 M8 F20 15A DIPPED BEAM HEADLIGHTS C9

X505 PROPORTIONAL ELECTROVALVE FAN O26 K8
X506 FAN REVERSAL ELECTROVALVE (OPTION) Q25 I8 F23 15A REAR WINDSCREEN WIPER + ROOF WINDSCREEN WIPER C11

F25 25A ANTI-START I33 On X47
F27 10A BOOM HEAD ELECTROVALVE I36 On X338
GROUNDS
F30 10A FAULT INDICATOR LAMP + SPU I32 On X317
F31 5A REXROTH ECU C1 On X48
F33 15A WORKING LIGHTS I35 On X329
Cab Main Engine Distributor Fan F34 5A DIAGNOSTICS C1 On X315
assembly plate
FG ENGINE HARNESS GROUND O22 E14 F35 5A DIAGNOSTICS C1 On X316
GND ENGINE HARNESS GROUND O22 E17 F36 10A SPU I34 On X328
M1 FRONT LEFT CAB GROUND G28 I11 F40 70A KEY SWITCH A35 A36
M2 FRONT RIGHT CAB GROUND K28 I11 F41 70A KEY SWITCH A35 C36
M3 CHASSIS/HORN GROUND M31 E29 F42 7,5A DIAGNOSTIC PLUG MR2-PLD A38 I34
80
M4 REAR CAB GROUND I15 A3 F43 10A ADM2 MODULE (CAB) A38 I34
M5 DISTRIBUTOR SUPPORT BRACKET GROUND K24 Q25 F44 15A ADM2 MODULE (CAB) A37 I34
P03 CAB GROUND K28 G2 F45 30A STARTER A37 I34
X105 DISTRIBUTOR SUPPORT BRACKET GROUND K24 C12 KA MERCEDES STARTING RELAY A36 G38
KN NEUTRAL SAFETY RELAY A36 E36
K0 NC TRANSMISSION CUT-OFF RELAY E16
K1 n/a C16
K2 FORWARD GEAR RELAY C13
K3 REVERSE GEAR RELAY E13
K4 ANTI-START RELAY E4
FUSES AND RELAYS K5 TRANSMISSION PRESSURE RELAY C16
K6 FLASHING UNIT E9
Position on harness diagram K7 BUZZER E7

Item Current DESIGNATION Harness Electric Comments K8 NEUTRAL SAFETY RELAY S31 On X46
assembly plate (H)
K12 SNAIL SPEED I28
F1 10A PNEUMATIC SEAT A3 On X301
(H)
F2 5A ECU + WHEEL ALIGNMENT + DIAGNOSTICS A4 K13 SLOW SPEED I29
On X302
F3 10A HORN + STOP LIGHT A5 (H)
K14 REVERSE GEAR RELAY I30
On X303
K18 HAND BRAKE RELAY S30 On X300
(15/11/2012) 80-03-M209EN
2D LOCATION HARNESS ASSEMBLY
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
Electric fuse plate and relay view
Key: RC F40 KN F44 F42
X5 F41 KA F45 F43

Main harness X320
A A
X329 X303 X310
X308 X39 X04
Electric plate fuse and relay X302
X338
X41
X47 X331 X319 X301
Cab harness X311
X321 X300 X326
Engine harness X322 X46 X325
X309
Control valve harness X330
C C
Fan harness X45
X334 X324
X318
Additional harnesses X332 X151
X89 X68
X333 (A) (B)
(E) X150 X119
Connection between harnesses X112 X113 X188
X58
X50
Connector MLT 845-120 H Series 4-E3 X305 X304 X51 X30 X117 X149 X61
E X501 (C) X79
E
X307 X52 X323 X33
Connector MLT 845-120 Series 4-E3
X306 X54 P01 (D)
X55
P08 P07 M1 X114
ADM2-15 ADM2-12 ADM2-21 X74

P06
P06 Dashboard view

G G
X02 X72
X17 X73
P09
X71
X317
M4 X22 X70 X77
P09
X328 P16
X154
I X56 X316 X118 I
X17
(F) X193
X57 X315 X97
P15
X115 X48 X36
X19 X26
X116
X109 X165 P02
P11 X336 M2
P13 M5
X337
X121 X92 X34 X28 X93 X105
X20 X109/A P03
X35 X29 X23 X87
P14 X01
X109/B P12
K K
X104
X21 X104/A X98 X09 X08
X314 X10
X15 X335
80
X313 M3 X14
X312 X15 X335 X327
M X24 M
X12
X134 X502 XTP X15
X100
X6
FG
GND
X99 M1
O O
X7
X505
MR2
X506
X16
Q X8 X13 Q
X503
G1
X504
S S
Forward gear
80-03-M209EN (15/11/2012)
ELECTRIC FUSE PLATE AND RELAYS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
A F1 F2 F3 F4 F5 F3 F7 F8 F9 F10 F11 F12 F13 F14
K5
F15 F16 F17 F18 F19 F20 F21 F22 F23 F24
C
K2 K1
E
K4 K7 K6 K3 K0
X41
G X331 X319
X308 X39 X04

I
K
4
K5
F1
3
F1
2
F1
1
K1
F1
F9
80
F8
K0
F7
4
F2
3
K2
F6
F2
2
F2
F5
1
F2
K3
M
F4
0
F2
F3
9
F1
4
F2
8
F1
F2
F1
7
F1
K6
6
F1
5
F1
K7
K4
A
B
Q C
X45
X311 X318
D
X188
X188
S
E
(15/11/2012) 80-03-M209EN
CAB HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
P07
A
P05
P01
P01
P02
P03
P06
P08
K P15
P09 P12
P13
80
Key: P11
P14
P16
P10
S
Splice
80-03-M209EN (15/11/2012)
MAIN HARNESS
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
X335 X74 X13

F30 F36 (Non H)(Non H) X24
X121 X10 X09 X98 X08 (H)
A X70 X22 A
X317 X328
M4
X16 X17 X20 X21 (H)

X165
X134 X100 X314
F31 X48
(H)
C F34 X315 X313 C
(H)
F35 X316 X312
X99
E E
X14 M3 X116 X327 X12 X15
X56 X57
(H)
G X109 X115 X502 X104 G
F25 F33 F27

K12 K13 F14
I X324 M1 M2 X334 X333 X332 X02 X193 X154 X26 X36 X311 (H) (H) (H) (H) (Non H) X318 X330 I
X45
X89 X112 X113 X301 X302 X303 X310 X01 X47 X329 X338
X151 X118
X33
X61 X501
(Non H)
K X30 X39 X114 X97 K
X323
X119 X79
X117 X149
80
M M
X150
O O
X304 (H)
Q Q
X305 (H)
X308 X68
X306 (H)
M5 X337 X336
X307 (H) X87 X321 X322 X300 X46 X325 X331 X319
X326 (Non H) (Non H)
(H) X309
1
(H) K18 K8
Key:
2
0
00
00
X77 X54 X55 X52 X51 X50 (H)

X58 X04 X320 X71 X71 X73 X72
(Non H) (H) X19
S (H) : MLT 845-120 H Série 4-E3 S
X41
(Non H) : MLT 845-120 Série 5-E3
(15/11/2012) 80-03-M209EN
ENGINE HARNESS
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 F40 A
C
F41 C
G1
E E
KN
M1 X8 GND FG X24 X15 XTP
KA
G
X7 G
F45
F44
I I
F43
F42
K K
X121
80
M M
ADM2-21
MR2
RC X5
O O
ADM2-15
Q Q
X6
ADM2-12
S S
80-03-M209EN (15/11/2012)
CONTROL VALVE HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
C
X105
E
EV
X93
X87
G
X28
X29
X92
K
X34
EV
X23
80
M
ACCESS. SENS +
STOP X35
EV / VS
O
ACCESS. SENS -
(15/11/2012) 80-03-M209EN
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
(Non H)
X503
(H)
X506
X502
K X505
80
X504
Key:
(H) : MLT 845-120 H Série 4-E3
S
(Non H) : MLT 845-120 Série 5-E3
80-03-M209EN (15/11/2012)
ELECTRICAL CONTROL AND ADJUSTMENT
pages
LONGITUDINAL STABILITY INDICATOR (LLMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE . . . . . . . . 3
– CALIBRATION OF THE STRAIN GAUGE AND THE ANGLE SENSOR
(DEALER PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– RECALIBRATION OF STRAIN GAUGE (OWNER PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . 6
– GENERIC REGULATION LAW EN15000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– LED ILLUMINATION AS A FUNCTION OF THE CHANGING GAUGE SIGNAL. . . . . . . . . 8
80
(26/09/2012) 80-04-M209EN
2 ELECTRICAL CONTROL AND ADJUSTMENT
LONGITUDINAL STABILITY INDICATOR (LLMI)
ERROR CODES
The error codes are indicated by LEDs A3 to A7 on the warning device and
longitudinal stability limiter.
A7
A6
A5
A4
A3
ERROR CODES
LEDS
DESCRIPTIONS
A7 A6 A5 A4 A3
Regulating fault (fault detected during the test).
Lowering regulating valve fault.
Safety valve cut-off fault (fault detected during the test).
Safety valve fault.

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

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

Electric handling controller 10 V output fault.
Forced operation button fault (OPTION)
80-04-M209EN (26/09/2012)
ELECTRICAL CONTROL AND ADJUSTMENT 3
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE

– These tests are essential for checking the correct operation and adjustment of the different components of the device.
b
– Place the lift truck on fl at, level ground with the wheels straight.
Use the test button only when instructed, following the guidance for a short press (less than 1 second)
or a long press (5 seconds).
In case of doubt during the test procedure, a clean exit can be made by a short press on the “BUCKET” MODE
or “SUSPENDED LOAD” buttons .
Long press on the test button
TEST OK
Short - One audible beep and progresses to
press stage 2.
the test
STAGE 1 1 button. TEST NOT OK
- Two audible beeps and lighting of
- Place the lift truck without any
attachment, with the jib fully the fault warning light .
- An audible beep. retracted and raised. - Exit test mode.
- First green LED flashing. - On stabilizers if fitted. - Go to stage 4.
- Test button lit.
TEST OK
Short - One audible beep and progresses to
press stage 3.
2 the test
STAGE 2 button. TEST NOT OK
1 -- Lower the jib with the engine - Two audible beeps and lighting of
running at full revs and the
the fault warning light .
- First green LED continuously lit. hydraulic control at the maximum
- Exit test mode.
- Second green LED flashing. setting. Lowering slows until
- Go to stage 4.
- Test button lit. movement is cut-off.
TEST OK
- Conformity of aggravating
Short movement cut-off.
press - Exit test mode. All the LEDs will light
3
the test for 2 seconds and an audible beep
STAGE 3 2 - Lower the jib until the movement is will be sounded.
button.
1 cut-off.
80
- Try in the following order a reverse TEST NOT OK
- The first and second green LED’S tilt, a forward tilt (dumping) and a
continuously lit. telescope extension. None of these 3 - Fault warning light comes on .
- The third green LED flashing. movements should be possible. - Exit test mode.
- Test button lit. - Go to stage 4.
- The fault indicator and a beep indicate a fault.
- Press the button briefly to view the error code.
- If there are several error codes, press the button briefly several times to loop through
the error codes.
NOTE: A defective fuse can generate several error codes. If this is the case, check the fuses (see: 2 -
DESCRIPTION: 11 - FUSES AND RELAYS IN THE CAB)
STAGE 4 Should there be the error code shown
opposite, adjusting the longitudinal A7
stability limiter and warning device A6
- The fault warning light remains may solve the problem (see: 3 -
permanently on until the error is MAINTENANCE: G - OCCASIONAL A4
repaired. MAINTENANCE). A3
- Consult your dealer, specifying the error codes(s).

NOTE: For the stage 3 test, specify the non-conforming aggravating hydraulic movements, if
necessary.
(26/09/2012) 80-04-M209EN
CALIBRATION OF THE STRAIN GAUGE AND THE ANGLE SENSOR (DEALER

PROCEDURE)
Stability limit Error light

light
BUCKET mode
switch
Overload
indicator
SUSPENDED
LOAD mode
indicator
Test button
Machine position: flat ground, wheels pointing forward, parking brake on, safe area.
RECORDING MINIMUM ANGLE:
- Press the “PARACHUTE” switch (activated for the next 10 seconds).
STAGE - Before the end of the 10 seconds press at the same time the “SUSPENDED LOAD” and “TEST” buttons. +
1
- Completely retract and lower the boom.
- Press the «TEST» button (short press) to record stage 1.
RECORDING THE MAXIMUM ANGLE + MAXIMUM GAUGE STRAIN:

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

80
MEASURING THE TIME OF DESCENT FROM MAXIMUM TO MINIMUM ANGLE:

STAGE
3 - Lower the boom to its stop with the engine running at maximum revolutions (boom retracted).
- Ensure that the boom is below 4° (boom retracted).

STAGE
4
80-04-M209EN (26/09/2012)
RECORDING MINIMUM GAUGE STRAIN:
b
- Activate the «PARACHUTE» switch to enable hydraulic movements.
STAGE The boom must be below 4°.

5
- Extend the boom until the rear wheels leave the ground.
Wait several seconds for the machine to stabilize.
b After this calibration, check that movement cut-offs work correctly.
80
(26/09/2012) 80-04-M209EN
RECALIBRATION OF STRAIN GAUGE (OWNER PROCEDURE)

According to the use the telehandler is put to, the strain gauge may require to be periodically reset.
This operation can be carried out by the operator. The procedure is described below. Only the gauge is calibrated.
Main conditions:
– Have a load at equal to at least half the machine’s maximum capacity.

– The rear axle temperature must be below 50°C. If this temperature is exceeded the operator must not carry out the procedure.
– The procedure must be carried out on flat ground with all wheels facing the front.
Simultaneously press and hold down
STAGE 1
START the «BUCKET» MODE and TEST . buttons
- Without attachments.
- Two audible beeps will be sounded and all the LEDs will flash twice to confirm the start of the procedure.
- Jib fully retracted and raised.
- On stabilizers if fitted.
Short press
the test
STAGE 2 1 - Without attachments. button.
- Stabilizers raised, if fitted.
- Carriage tilted fully backward.
- An audible beep. - Jib fully retracted and in the down position a few centimeters off the ground.
- First green LED flashing.
- Flashing test button.
Short press
/ the test
- With the fork carrier or the bucket and a load (keep jib retracted to allow all other button.
hydraulic movements).
- Jib fully retracted and in the down position a few centimeters off the ground.
b
2 - Two audible
STAGE 3 beeps will
80
1 / be sounded
- First green led continuously Keep the load as close to the ground as possible throughout this operation. and all the
LEDs will
lit.
- Hold down the disable the «aggravating» hydraulic movement cut-off flash twice to
- Second green led flashing.
button (indicator lamp lit), and extend the jib until the rear wheels are off the confirm the
- Flashing test button.
ground. end of the
NOTE: This stage consists of unloading the rear axle. It can be done using a jack procedure.
but without bearing on the rear axle..
STAGE 4
FINISH /
- After completing the resetting procedure, the telehandler is in an overloaded condition. Retract the
boom to restore the situation.
- All LEDs lit.
- A continuous audible beep
b When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see: TESTING THE LONGITUDINAL
STABILITY LIMITER AND WARNING DEVICE (LLMC).
80-04-M209EN (26/09/2012)
GENERIC REGULATION LAW EN15000
Governing start Cut-off
115%
Vs cut-off zone
Cut-off zone
95%
Regulation zone
75%
Gauge (%)
55%
Nominal zone
35%
15%
-10% -5% 0° 10° 20° 30° 40° 50° 60° 70° 80°
Angle (°)
Example for MLT LSU:
With a 20° boom angle, the regulation of dangerous movements will begin when the strain gauge shows
95% (blue line). The end of regulation for the first cut-out is reached with a gauge signal of 110% (red
80
line). If necessary, the VS safety valve will cut-out at a gauge signal of 120% (white line).
There are, therefore, two possible cut-outs on these machines.
Example for all other machines:
With a boom angle of 20°, the regulation of dangerous movements will begin with a 90% strain gauge
signal (blue line). The end of this regulation and the VS safety valve cut-out will take effect with a 110%
gauge signal (red line).
These machines have just one cut-out.
Machine stability loss starts at a gauge signal of 130%.
The above values are indicative only. Each machine has its own, different rules.
(26/09/2012) 80-04-M209EN
LED ILLUMINATION AS A FUNCTION OF THE CHANGING GAUGE SIGNAL
OPERATION OF THE LLMI (LONGITUDINAL STABILITY INDICATOR)
L8
L7
L6
L5
L4
L3
L2
L1
LLMI Mode 1 algorithm

LEDs (L1 to L8) Conditions if gauge is increasing Conditions gauge is falling
L1 (always lit) None None
L1+L2 Gauge >= 52% Gauge >= 50%
L1+L2+L3 Gauge >= 60% Gauge >= 58%
L1+L2+L3+L4 Gauge >= 68% Gauge >= 66%
L1+L2+L3+L4+L5 Gauge >= 76% Gauge >= 74%
L1+L2+L3+L4+L5+L6 Gauge >= 84% Gauge >= 82%
L1+L2+L3+L4+L5+L6+L7 Gauge >= 92% Gauge >= 90%
L1+L2+L3+L4+L5+L6+L7+L8 Gauge >= 100% Gauge >= 98%
80
80-04-M209EN (26/09/2012)
ELECTRICAL COMPONENTS REFIT
pages
STRAIN GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– CHARACTERISTICS OF THE AXLE SURFACE IN CONTACT WITH
THE STRAIN GAUGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– CHARACTERISTICS OF PRODUCTS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– CHARACTERISTICS OF THE ATTACHMENT SCREWS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– PRECAUTIONS FOR ASSEMBLY AND TIGHTENING TORQUE. . . . . . . . . . . . . . . . . . . . . . . 4
80
(11/10/2012) 80-07-M209EN
2 ELECTRICAL COMPONENTS REFIT
STRAIN GAUGE
LOCATION
Key :
80
A - Strain Gauge
b PREPARATION AND SAFETY INSTRUCTIONS
– The wheels should be aligned and the rear axle should be free of any strains (tipped truck).
– The contact surface should be perfectly clean.
– Do not apply Loctite to the screws.
– Replace the gauge if it is faulty.
– Gauge and axle stored at the same temperature.
– Wear a mask and gloves when applying the glue.
80-07-M209EN (11/10/2012)
ELECTRICAL COMPONENTS REFIT 3
CHARACTERISTICS OF THE AXLE SURFACE IN CONTACT WITH THE STRAIN GAUGE
The area in contact with the strain gauge (Item 1) has a

protective painted coating. Scrape this surface with a filling
knife in order to remove the paint film to the best extent
1
possible. To remove and remaining traces of adhesive use
the Soft Surface Cleaner Degreaser (aerosol).
Abrade the area to be stuck to provide a key for the glue

(Item 2).
80
CHARACTERISTICS OF PRODUCTS USED
ACROBOND PU 284/30 (two-part polyurethane structural glue): Part No 273504.
Handling time before start of polymerization and hardening phase is 30 minutes approx.
b If the product stays inside the mixer for more than 30 min., change the mixer.
(11/10/2012) 80-07-M209EN
CHARACTERISTICS OF THE ATTACHMENT SCREWS
The bolts used are delivered with the strain gauge.
– Bolt H, M10x30 pitch 1.5 Class 10.9.
PRECAUTIONS FOR ASSEMBLY AND TIGHTENING TORQUE
1 The two components (strain gauge and axle) must be

kept at the same temperature for at least 4 hours before
commencing assembly.
The strain gauge should be assembled with a completely

unloaded axle.
To ensure this:
1 - Lift the rear axle from the floor using a hydraulic jack
1
(Item 1) (Part No Manitou 505507).
2 2 - Make the machine safe by placing 2 stands (Item 2)
(Part No Manitou 554772) on each side of the chassis.
3 - Remove the jack to completely unload the rear axle.
80
2
2
80-07-M209EN (11/10/2012)
ELECTRICAL COMPONENTS REFIT 5
1st stage :
Using a gun, apply the two-part mixture to the axle by

placing 4 «balls» of glue as shown opposite (Item 1).
1
b Wear a mask and gloves when applying this product.
2nd stage :
Insert two M10x30 bolts into the strain gauge, then place
the assembly on the axle.
Take care to keep the central part of the gauge free of glue.
Zone with no
trace of glue
3rd étape :
The 2 M10 bolts should tightened progressively and in the following way:
80
– Torque bolt No. 1 to 34 N.m
– Torque bolt No. 2 to 34 N.m
– Torque bolt No. 1 to nominal torque 67 N.m ± 5%
– Torque bolt No. 2 to nominal torque 67 N.m ± 5%
(11/10/2012) 80-07-M209EN
4rd stage :
Then fit the plastic housing (Item 1) and secure it with

two pan-head screws M4x10.
b Do not use any grease on the M10x30 bolt heads

as grease is incompatible with the glue.
1
80
80-07-M209EN (11/10/2012)
ELECTRICAL TROUBLESHOOTING
pages
DESCRIPTION ENGINE FAULTS CODES (MR2-PLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– FAULT PRIORITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– FAULT PATH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– FAULT TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
FAULTS CODES - ENGINE (MR2-PLD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
FAULTS CODES - TRUCK (SPU 25-15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
FAULTS CODES - LONGITUDINAL STABILITY INDICATOR (LLMI) . . . . . . . . . . . . . . . . . . . . .26
80
(06/12/2012) 80-08-M209EN
2 ELECTRICAL TROUBLESHOOTING
DESCRIPTION ENGINE FAULTS CODES (MR2-PLD)
The fault codes can be read off with a diagnosis unit (e.g. minidiag2).
• The display differentiates between current and non-current faults.

• Current fault codes cannot be cleared.
The fault codes listed apply to the MR2-PLD.
The fault codes stored in the control unit describe the priority (valence = „w“), path („pp“) and type („aa“)
of the fault which has developed.
Example of a fault code: 10605

1 = fault priority (w)
06 = fault path (pp)
05 = fault type (aa)
FAULT PRIORITY
In the 5-digit fault code, the first digit (0,1 or 2) indicates the fault priority. Proceed as follows, depending
on the fault priority:
Fault priority 0
If necessary, these faults can be rectified during the next maintenance service.
Fault priority 1
The fault must be rectified as soon as possible.

It can be expected that the running characteristics of the engine will be affected.
80
The driving and the braking characteristics of the vehicle may have changed if driving mode is active. If
working speed governor mode is active, the operating characteristics of the equipment may have changed.
Fault priority 2
The fault must be rectified immediately.

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

or specialist workshop.
80-08-M209EN (06/12/2012)
ELECTRICAL TROUBLESHOOTING 3
FAULT PATH
PLD MERCEDES (MR2)

Fault N° Fault Repair instructions
00 Not assigned
01 CAN interface
02 not assigned
03 crankshaft sensor
04 camshaft sensor
05 engine only if no clear assignment is possible
06 not assigned
07 carburation system / lambda control air monitoring, gas monitoring CNG
08 knock sensor CNG ecu
09 lambda sensor (LSU) CNG ecu
10 engine-oil temperature sensor
11 fuel temperature sensor CNG ecu: gas temperature
12 charge-air temperature sensor
13 ambient pressure sensor
14 charge-air pressure sensor
15 coolant temperature sensor
16 engine-oil pressure sensor
17 fuel pressure sensor fuel monitoring (also in the case of CNG)
18 booster path / boost pressure control air routing, Wastegate, VTG etc.
19 fuel circulation fuel pump, fuel filter etc.
20 engine-oil circulation oil pump etc.
21 coolant circulation water pump etc.
22 terminal 15 detection (ignition)
23 terminal 30 detection (supply)
24 scavenging gradient sensor (P2S-P3)
25 engine-oil level sensor
26 speed sensor booster 1 boost pressure control
27 speed sensor booster 2 boost pressure control
28-29 not assigned
80
30 fuel pressure sensor**
31-39 not assigned
40 control unit internal fault CAUTION: measure: exchange control unit!
41 not assigned
42-47 in-gas valves cylinder 1-6 electric circuit, CNG- ECU
48 control MV bank 1 electric circuit
49 control MV bank 2 electric circuit
50 control MV cylinder 1 electric circuit
58-63 ignition output stage cylinder 1-6 electric circuit, CNG- ECU
64 heater flange**
65 oil separator
66-68 not assigned
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

69 gas shut-off valve electric circuit, CNG- ECU
70 proportional valve 1 electric circuit
72 proportional valve 3
75 ECU voltage supply terminal 30 / battery
77 proportional valve bank 1 electric circuit
78 proportional valve bank 2 electric circuit
79 not assigned
80 starter/starter control
81 throttle valve angle sensor B electric circuit, CNG- ECU
82 throttle valve angle sensor A electric circuit, CNG- ECU
83 throttle valve-motor electric circuit, CNG- ECU
84 Lambda sensor (heater circuit) electric circuit, CNG- ECU
85-89 not assigned
90 Cylinder 1 mechanical/hydraulic fault, e.g. LRR, EZA
98 not assigned
99 immobilizer
80
**diagnosis version 6 and newer
80-08-M209EN (06/12/2012)
FAULT TYPE
PLD MERCEDES (MR2)

00 communication line 1 defective communication interface (e.g. CAN)
01 communication line 2 defective communication interface (e.g. CAN)
02 data not plausible communication interface (e.g. CAN)
03 not assigned
04 no communication communication interface (e.g. CAN)
plus-lead shorted to battery voltage (e.g.
05 shortened to battery voltage (+lead)
terminal 30)
06 ground short (-lead) minus-lead shorted to ground
minus-lead shorted to battery voltage (e.g.
07 shortened to battery voltage (-lead)
terminal 30)
08 ground short (+lead) plus-lead shorted to ground
09 open circuit fault general open circuit
10 signal level too low crankshaft/camshaft
11 signal assignment not plausible crankshaft/camshaft
12 signal timeout generally speed sensor
13 signal polarity wrong crankshaft/camshaft
14 not assigned
15 measuring range exceeded analogue sensor - voltage signal
16 remains under measuring range analogue sensor - voltage signal
17 measuring value not plausible analogue sensor
18 booster path defective
19 signal inconsistent
20 pressure too high
21 pressure too low
22 temperature too high
23 temperature too low
auxiliary controller /
24 internal fault
microcontroller 2 defective
25 fluid level too high
26 fluid level too low
80
27 control disturbed injector valves
28 injector valve-solenoid valve shorted injector valves
29 fill level to high**
30 engine speed too high
31 engine speed too low
32 not assigned
33 starter relay hangs starter
34 Highside transistor high-resistance internal fault, PV-bank 1
35 Highside transistor high-resistance internal fault, PV-bank 2
36 Highside transistor high-resistance internal fault, PV5
37 cylinder number not plausible internal fault
38 starter driver high-resistance internal fault
39 starter driver low-resistance internal fault
40 level-detection starter defective internal fault, starter
41 transistor defective internal fault, proportional valves
42 nominal range exceeded e.g. battery voltage
43 remains under nominal range e.g. battery voltage
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

44 limit value achieved engine-smoothness control
45 limit value achieved individual cylinder adaptation
46 EZA- Timeou individual cylinder adaptation
fuel map (characteristic data map)
47 internal fault
defective
cylinder number <> engine type not
48 internal fault
plausible
49 calibration fault
50 hardware detection wrong internal fault
51 EEPROM- read error 1 internal fault
54 CAN data area defective internal fault
55 AD converter monitoring internal fault
56 run off control defective internal fault**
57 power supply defective internal fault (so far only at CNG)**
58 fuel map data set manipulated internal fault**
59 not assigned
60 key number limited to 8 WSP (immobilizer)
61 counter overflow WSP (immobilizer)
62 not assigned
e.g. WSP : TPC via CAN TPC (TransPonder
63 no signal from redundant source
Code)
64 no signal from signal source e.g. WSP : TPC via terminal 50
65 valid but incorrect signal code e.g. WSP: key wrong
66-72 not assigned
73 limit value achieved loader ganging governor
74 set value deviation too high integrator monitoring (e.g. booster)
75 system deviation too high monitoring system deviation (e.g. booster)
76 limit value not achieved e.g. boost pressure in booster trailing-throttle
80
77 control current not within tolerance e.g. CNG, throttle valve setting-forces too high
78 general actuator fault e.g. CNG, mechanical throttle valve failure
79 not assigned
80 knocking combustion CNG: problem gas quality
81 combustion with misfiring CNG
82-85 not assigned
86 starter does not engage starter
81-99 not assigned
**diagnosis version 6 and newer
80-08-M209EN (06/12/2012)
FAULTS CODES - ENGINE (MR2-PLD)
MR2
PLD MERCEDES (MR2)

- check oil temperature sensor B11, replace if necessary.
nominal value: 2.4 kOhm (corresponds to 21 °C)
- check wire N3/39 - B11/1 for open circuit fault and if
shortened to battery
voltage, repair if necessary.
oil temperature sensor
0 10 15 - check wire N3/15 - B11/2 for open circuit fault, repair if
measuring range exceeded
necessary.
- if fault code is still present: replace and program ECU
engine control
(e.g. MR-PLD).
- perform functional check
-check oil temperature sensor B11 and replace if necessary.
nominal value: 2.4 kOhm (corresponds to 21 °C)
- check wire N3/39 - B11/1 for ground short, repair if
oil temperature sensor
necessary.
0 10 16 remains under measuring
- if fault code still present: replace and program ECU engine
range
control
(e.g. MR-PLD).
- if fault codes 11415 or 11416 are present, remove them
first
- fault code 01315 remains present: read out actual values
ambient pressure sensor 014 and 015 and
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0 13 15
measuring range exceeded compare with each other.
- actual value inside tolerance band (+/- 10%) while engine
stops: replace and
program ECU engine control (e.g. MR-PLD).
- if fault codes 11415 or 11416 are present, remove them
first
- fault code 01316 remains present: read out actual values
ambient pressure sensor
014 and 015 and
compare with each other.
range
- actual value inside tolerance band (+/- 10%) while engine
stops: replace and
program ECU engine control (e.g. MR-PLD).
booster path:
0 18 22 boost air temperature to high
temperature to high
booster path (control) set
0 18 74
value deviation too high
engine oil circulation
0 20 20
pressure too low
engine oil circulation
0 20 26
fluid level too high / too low
coolant circulation
0 21 22
temperature too high
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

- check oil level sensor B14, replace if necessary.
- check wire N3/33 - B14/1 for open circuit fault, repair or
oil level sensor replace if necessary.
0 25 09
open circuit fault - check wire N3/49 - B14/2 for open circuit fault, repair or
replace if necessary
- check oil level, correct if necessary.
- check wire N3/33 - B14/1 if shortened to battery voltage,
repair of replace if
oil level sensor
0 25 15 necessary.
- check oil level sensor B14 resistance, replace if necessary
- nominal value: 20-25 Ohm
- perform functional check.
- check wire N3/33 - B14/1 for ground short, repair or
oil level sensor
replace if necessary.
- check oil level sensor B14 resistance, replace if necessary.
range
nominal value: 20-25 Ohm
- check oil level during engine standstill, correct if
necessary.
- check calibration of oil pan type, correct if necessary.
- calibration of oil level sensor, correct if necessary.
- check cable, plug, plug connections and electrical
oil level sensor
0 25 17 components for damage,
measured value not plausible
correct connection, loose contact and corrosion, repair if
necessary.
- check oil level sensor B14 resistance, replace if necessary.
nominal resistance: 22 Ohm when oil pan filled.
- check all affected connectors, plug connections and
electrical components for
damage, loose contact, corrosion etc. and repair if
internal fault:
0 40 24 necessary.
auxiliary controller defective
- if fault code is still present, renew and program control
unit
80

internal fault:
0 40 37 necessary.
cylinder number implausible
unit.
- if fault code 07543 is present, remove this fault code first.
internal fault:
0 40 38 high resistance starter driver
necessary.
(redundant-/auxiliary path)
unit.
internal fault:
0 40 40 necessary.
level detection starter defective
unit.
80-08-M209EN (06/12/2012)
PLD MERCEDES (MR2)

internal fault:
0 40 47 necessary.
characteristic data map defective
unit.
internal fault:
0 40 48 necessary.
cylinder number implausible
unit.
internal fault:
0 40 50 necessary.
incorrect hardware detection
unit.
internal fault: damage, loose contact, corrosion etc. and repair if
0 40 51 EEPROM: Checksum failure necessary.
1 (memory fault) - if fault code is still present, renew and program control
unit.
internal fault:
0 40 56
backup control defective
oil separator:
0 65 06 short circuit to ground
diagnostic line
oil separator:
0 65 64
oil separator defective
battery voltage: possible sources of fault:
0 75 42
nominal range exceeded - generator or governor defective.
80
possible sources of fault:
- battery discharged or defective.
battery voltage:
0 75 43 - generator or governor defective.
remains below nominal range
- fuse F30 at the basic module is defective.
- wires of voltage supply are defective.
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

important note:
- upon removing mechanical or electrical faults at the
injector valves, the enginesmoothness
control has to be set to zero.
- the engine smoothness control can be set to zero in the
menu «controls» at the
menu level «check of the engine-smoothness control».
note:
- injection quantity adjustment for the engine-smoothness
control for cylinder 1
not within the authorized tolerance (± 6 %).
engine-smoothness control: - check engine-smoothness control via the select menu
0 90 44
LRR-limitation cylinder 1 «controls».
- perform compression check via the select menu
«controls».
- check tightening torque of the pressure-pipe tube at the
injection nozzle. Check
pressure-pipe tube for cracks.
- exchange the injector valve of the affected cylinder with
the injector valve of a
cylinder which is not affected.
- exchange injection nozzle of the affected cylinder with an
injection nozzle of a
cylinder which is not affected.
important note:
injector valves, the engine
smoothness control has to be set to zero
- the engine smoothness control can be set to zero in the
menu level «check of the engine-smoothness control».
- perform compression check via the select menu
«controls».
- compression of the affected cylinder < 75 % of the
nominal value? Remove
mechanical faults (valves, piston ring etc.).
individual cylinder - compression is OK: exchange the injector valve of the
0 90 45 adaption: affected cylinder with the
EZA-limitation cylinder 1 injector valve of a cylinder which is not affected. Have the
80
engine run. Perform

individual cylinder adaptation.
- the other cylinder is now affected by the deviation:
replace the exchanged
injector valve.
- deviation does not change due to the exchange of the
injector valves: check
injection nozzle of the affected cylinder and replace if
necessary. Check high
pressure side tube to injector valve for leakage. Eliminate
leakage problem of
the affected cylinder.
engine-smoothness control:
0 91 44 refer to fault code of example 09044...
LRR-limitation cylinder 2
individual cylinder
0 91 45 adaptation: refer to example of fault code 09045...
EZA-limitation cylinder 2
individual cylinder
80-08-M209EN (06/12/2012)
PLD MERCEDES (MR2)

individual cylinder adaption:
0 93 45 refer to example of fault code 09045...
individual cylinder
0 95 45 refer to example of fault code 09045...
individual cylinder
individual cylinder
0 98 46
timeout
- check wire A6 X1 16/1 - A3 X4 18/1 for open circuit fault,
repair or replace if
necessary.
CAN connection:
1 01 00 - switch on ignition
CAN-High defective
- delete fault memory in ECU engine control (e.g. MR-PLD)
- delete fault memory in SG FRE
- check wire A6 X1 16/2 - A3 X4 18/1 for open circuit fault,
repair of replace if
necessary
80
CAN connection:
1 01 01 - switch on ignition
CAN-Low defective
- delete fault memory in ECU engine control (e.g. MR-PLD)
- delete fault memory in SG FRE
- work off actual faults of SG FRE apart from CAN data bus
CAN connection: fault codes 10201,
1 01 02
CAN data not plausible 00202 and 10203.
- check CAN connection to SG FRE
- check cables, connectors, plug connectors and electrical
components for
damage, correct connection, loose contact and corrosion,
repair if necessary.
CAN connection:
1 01 04 - remove engine CAN bus fault in the SG FRE
no connection to CAN
- communication with the ECU engine control (e.g. MR-
PLD) restored: check
calibration of ECU engine control (e.g. MR-PLD) for one wire
capability.
CAN connection: - check parameters 10 and 13 and correct if necessary.
1 01 49
parameter fault CAN - perform functional check
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

- check wire N3/2 - N3/19 and position sensor for ground
crankshaft position sensor:
short, replace if
1 03 08 crankshaft sensor ground
necessary
short
- nominal value 1.2 kOhm
- check wire N3/2 - N3/19 and position sensor for open
circuit fault, replace if
1 03 09 crankshaft sensor open circuit
necessary
fault
- pull out position sensor while engine is stopped and
perform visual check.
- remove metal pieces/shavings if necessary.
- replace position sensor in the case of mechanical damage
(clear stress marks)
1 03 10 - replace clamping sleeve of the position sensor if
crankshaft level too low
necessary.
- press-in speed (position) sensor during engine standstill
until mechanical limit
stop.
- pull out position sensor during engine standstill and
perform visual check.
- replace position sensor in the case of mechanical damage
(clear stress marks).
- check crankshaft- and camshaft position sensor for tight
fitting, replace
crankshaft position sensor: clamping sleeve if necessary.
1 03 11 crankshaft/camshaft signal - press in both speed (position) sensor during engine
assignment not plausible standstill until mechanical
limit stop.
- check wires at plug connection N3 for damage, correct
connection and
corrosion, repair if necessary.
- check crankshaft- and camshaft position sensor at plug N3
for interchanging.
- press in speed (position) sensor during engine standstill
crankshaft position sensor: stop.
1 03 12 crankshaft timeout - no - fault code 10309 actual: work off this fault code.
80
crankshaft signal - fault code 10312 actual: check crankshaft position sensor,
crankshaft position sensor: - connect the position sensor correctly with the pin N3 of
1 03 13 crankshaft sensor wrong the control unit MR
polarity - perform functional check
- check wire N3/1 - N3/20 and position sensor for ground
camshaft position sensor: short, replace if
1 04 08
camshaft sensor ground short necessary.
- nominal value: 1.2 kOhm
camshaft position sensor: - check wire N3/1 - N3/20 for open circuit, replace if
1 04 09 camshaft sensor open circuit necessary
fault - nominal value: 1.2 kOhm
80-08-M209EN (06/12/2012)
PLD MERCEDES (MR2)

- if fault codes 10408 and 10409 are current, remove them
first
- pull out position sensor B16 during engine standstill and
perform visual check
camshaft position sensor: - remove metal pieces/shavings if necessary.
1 04 12 camshaft time-out (no camshaft - replace position sensor in the case of mechanical damage
signal) (clear stress marks).
- press in speed (position) sensor during engine standstill
stop.
- position sensor B16 correctly with pin N3 of the ECU
camshaft position sensor:
engine control
1 04 13 camshaft sensor wrong
(e.g. MR-PLD)
polarity
engine: - inform about authorized engine speed
1 05 30
engine speed too high - delete fault memory
- check wire B10, repair or replace if necessary.
- nominal value: 2.4 kOhm (corresponds to 21°C)
- check wire N3/36 - B10/1 if shortened to battery voltage
fuel temperature sensor and if open circuit
1 11 15
measuring range exceeded fault, repair if necessary.
- check wire N3/4 - B10/2 for open circuit fault, repair if
necessary.
- check sensor B10, repair or replace if necessary.
fuel temperature sensor - nominal value: 2.4 kOhm (corresponds to 21°C)
1 11 16 remains under measuring - check wire N3/36 - B10/1 for short circuit to ground, repair
range if necessary.
- check temperature sensor B9, replace if necessary.
- check wire N4/48 - B9/1 if connected to battery voltage
boost temperature sensor and if open circuit fault,
1 12 15
measuring range exceeded repair if necessary.
necessary.
80
- check temperature sensor B9, replace if necessary.
boost temperature sensor - nominal value: 2.4 kOhm (corresponds to 21°C)
1 12 16 remains under measuring - check wire N3/48 - B9/1 for short circuit to ground, repair
range if necessary.
- check boost pressure, replace if necessary.
- check wire N3/29 - B13/2 for open circuit fault and if
shorted to battery voltage,
boost pressure sensor
1 14 15 repair if necessary.
necessary.
- unplug the connector from combination sensor. fault
codes 01215 and 11415
actual: replace combination sensor.
- check wire N3/7 - B13/3 for short circuit to ground, repair
if necessary.
range
- check wire N3/29 - B13/2 for short circuit to ground, repair
if necessary.
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

necessary.
- check boost pressure sensor, replace if necessary.
1 14 17 - perform functional check.
- if fault code 01315 or 01316 also actual: replace and
calibrate ECU engine
control (e.g. MR-PLD).
- check wire N3/34 - B65/1 for open circuit fault or if
coolant temperature sensor shortened to battery
1 15 15
measuring range exceeded voltage, repair if necessary.
- check wire N3/3 - B65/2 for open circuit fault, repair or
coolant temperature sensor - nominal value: 2.4 kOhm (corresponds to 21°C)
1 15 16 remains under measuring - check wire N3/34 - B65/1 for open circuit fault, repair or
range replace if necessary.
- check oil pressure sensor, replace if necessary.
- check wire N3/26 - B12/K1 for open circuit fault or if
shortened to battery
oil pressure sensor
1 16 15 voltage, repair if necessary.
- check wire N3/5 - B12/K2 for open circuit fault, repair if
necessary.
oil pressure sensor
- check wire N3/26 - B12/K1 for short circuit to ground,
repair if necessary.
range
-.perform functional check.
- check wire N3 55/6 - B110/3 for open circuit fault, repair or
oil pressure sensor replace if
1 16 17
signal not plausible necessary.
80
combination input
1 17 15 (FPS, P-DK):
combination input
(FPS, P-DK):
1 17 16
remains under measuring
range
combination input
1 17 17 (FPS, P-DK):
signal not plausible
- check tubes and connections between turbocharger,
boost air cooler and the
booster path:
1 18 18 boost air tubes for leakage.
booster path defective
- check boost air cooler.
- if fault codes 11415 or11417 are also present, process
them first.
booster path:
1 18 20 - boost pressure system (boost air tubes, boost air cooler)
boost pressure too high
visual check..
max. output of booster speed
1 18 73
balancing governor
80-08-M209EN (06/12/2012)
PLD MERCEDES (MR2)

booster path / boost pressure
control:
1 18 74
set value deviation too high
(with power reduction)
control:
1 18 75
boost pressure deviation too
high
1 18 76 control:
braking power too low
fuel circulation:
1 19 17
- check fuse F30, replace if necessary.
- check wires and plug connectors between S1/1 and A3 X2
terminal 15 detection:
1 22 19 18/3 or A6 X1 16/15
inconsistency MR<->FR
for open circuit fault, repair or replace if necessary.
- check wires and plug connectors between S1/2 and A3 X1
18/18 for open
circuit fault, repair if necessary.
terminal 50 detection:
1 23 19 - check wires and plug connectors between S1/2 and A6 X1
inconsistency MR<->FR
16/8 for open circuit
fault, repair if necessary.
scavenging gradient sensor
1 24 15 (P2S-P3):
scavenging gradient sensor
(P2S-P3):
1 24 16
remains under measuring
range
1 26 12 no speed booster 1
1 27 12 no speed booster 2
internal fault:
80
1 40 34 HS-transistor PVB1
high-resistance
internal fault:
1 40 35 HS-transistor PVB2
high-resistance
internal fault:
1 40 36 HS-transistor PV5
high-resistance
internal fault:
1 40 38 starter driver high-resistance
(main path)
- check all affected plugs, plug connectors and electrical
components for damage,
internal fault:
loose contact, corrosion etc. and repair if necessary.
1 40 39 starter driver low-resistance
- if fault code is still present, replace and program control
(main path or auxiliary path)
unit.
internal fault:
1 40 41 PV- Highside- transistor
defective
unit.
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

internal fault: loose contact, corrosion etc. and repair if necessary.
1 40 49
parametrization fault - if fault code is still present, replace and program control
unit.
internal fault:
1 40 52 EEPROM: CKS- fault 2
(groups vehicle parameters)
unit.
internal fault: loose contact, corrosion etc. and repair if necessary.
1 40 54
CAN-data area defective - if fault code is still present, replace and program control
unit.
An inadmissible change was recognized by the fuel map
internal fault: data set (tuning), which
1 40 58
fuel map data set manipulated engine operated in the CAN backup mode (backup engine
speed).
important note:
injector valves, the enginesmoothness
control has to be set to zero.
- the engine-smoothness control can be set to zero in the
menu level «check of engine-smoothness control».
- if fault code 07543 actual, process this fault code first.
- if fuel filter installed: check fuel filter and clean or replace
it if necessary.
- bleed fuel line, after work at fuel system,.
- fault code 15026 remains actual: carry out subsequent
contact recognition
checks.
1 50 26 injector-/solenoid valve:
- corresponding fault code actual at another cylinder of the
no contact cylinder 1
same bank: check
electrical supply lines of the affected injector valve(s) for
80
short circuit, repair or

- corresponding fault code actual at another cylinder of the
same bank: exchange
injector valve of the affected cylinder with the injector
valve of a cylinder which
is not affected. Have the engine run.
- fault code moves on (with the injector valve) to the other
cylinder. Replace
exchanged injector valve.
80-08-M209EN (06/12/2012)
PLD MERCEDES (MR2)

important note:
injector valves, the
engine-smoothness control has to be set to zero.
- the engine-smoothness control can be set to zero in the
menu level «check engine-smoothness control».
- if fault code 07543 actual, process this fault code first.
- check screw terminals at the affected injector valve for
tight fitting.
control failure - check the supply line of the affected injector valve for
1 50 27 injector-/solenoid valve: interruption.
control cylinder 1 disturbed - check connectors X1 and N3 of the ECU engine control
(e.g. MR-PLD) for
correct contacting.
- fault code 15027 remains present: exchange injector valve
of the affected
cylinder with the injector valve of a cylinder which is not
affected. Have the
engine run.
- fault code moves on (with the injector valve) to the other
cylinder. Replace
exchanged injector valve.
contact recognition
1 51 26 injector-/solenoid valve: refer to example of fault code 15026...
control failure
control cylinder 2 disturbed
contact recognition
control failure
contact recognition
80
control failure
contact recognition
control failure
contact recognition
control failure
contact recognition
control failure
1 56 27 injector-/solenoid valve refer to example of fault code 15027...
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

contact recognition
control failure
Condition:
The heating flange becomes after Kl. 15 uniquely briefly
heater flange: open circuit switched on. Here if no
1 64 09 fault break-down of the battery voltage is recognized, the
(heater flange defective) heating flange is classified as
defective. Error threshold and cyclic duration are deposited
in the data record.
note: ECU engine control (e.g. MR-PLD) wrong calibration.
- check parametrization.
- parameter 06 has to be set to NOT ACTIVE
proportional valve 1:
1 70 06 - if not, then the data set of ECU engine control (e.g. MR-
short circuit to ground (-lead)
PLD) is wrong
- replace and program ECU engine control (e.g. MR-PLD).
1 70 07 shortened to battery voltage
(-lead)
note: ECU engine control (e.g. MR-PLD) wrong calibration.
- check parametrization.
- parameter 06 has to be set to NOT ACTIVE
1 70 09 - if not, then the data set of ECU engine control (e.g. MR-
open circuit fault
PLD) is wrong
note: ECU engine control (e.g. MR-PLD) wrong calibration /
short circuit to
ground
- check calibration, correct if necessary. Parameter 008 has
to be set to NOT
ACTIVE.
1 71 06 - if the calibration is OK, check wire N3/41 - Y70/1 for short
80

circuit to ground,
repair or replace if necessary.
- if still no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD).
(-lead)
80-08-M209EN (06/12/2012)
PLD MERCEDES (MR2)

note: ECU engine control (e.g. MR-PLD) wrong calibration/
open circuit fault
to be set to NOT
ACTIVE.
note:
- if a Linnig-fan is installed, the following calibration applies:
proportional valve 3: parameters 8 and 9 have to be set to ACTIVE.
1 71 09
open circuit fault parameter 14 has to be set to «Type 0».
- fault code 17109 still actual: check wires N3/41 - Y70/1 and
N3/12 - Y70/2 for
open circuit fault, repair or replace if necessary.
- if no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD).
currently not fan speed detection installed.
fan speed
1 71 12 - check calibration, correct if necessary. Parameter 14 has to
no signal (timeout)
be set to «Type 0».
short circuit to
ground
to be set to NOT
ACTIVE.
1 72 06 - if the calibration is OK, check wire N3/43 - Y70/3 for short
circuit to ground,
repair or replace if necessary.
- if still no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD).
(-lead)
open circuit fault
80
to be set to NOT
ACTIVE.
note:
- if a Linnig-fan is installed, the following calibration applies:
proportional valve 4: a) parameters 8 and 9 have to be set to ACTIVE.
1 72 09
open circuit fault b) parameter 14 has to be set to «Type 0».
- fault code17209 remains actual: check wires N3/43 - Y71/3
und N3/12 - Y71/4
for open circuit fault, repair or replace if necessary.
- if no fault can be detected, replace and program ECU
engine control
(e.g. MR-PLD)
note: ECU engine control (e.g. MR-PLD) wrong calibration
to be set to NOT
1 73 06 ACTIVE.
- if not, then the data set of the control unit MR is wrong.
(-lead)
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

1 73 09
open circuit fault
(+lead)
1 74 08
short circuit to ground (+lead)
1 76 09
open circuit fault
proportional valve bank 1:
(+lead)
1 77 08
(+lead)
1 78 08
- check wire N3/18 - terminal 50 input (terminal 86) of
starter control : starter relay if shortened
1 80 05 starter relay external current to battery voltage, repair or replace if necessary.
supply - check starter relay, replace if necessary.
- restore electrical connection(s)
- check wire N3/18 - terminal 50 input (terminal 86) of the
starter control: starter relay for short
1 80 08
short circuit to ground circuit to ground, repair or replace if necessary.
- check starter relay, replace if necessary.
- disconnect battery
- check wire N3/18 - terminal 50 input (terminal 86) of the
starter control:
1 80 09 starter relay for open
open circuit fault
circuit fault, repair or replace if necessary.
- check starter relay, replace if necessary.
starter control:
1 80 33 starter relay fixed in closed - check starter relay, replace if necessary.
80
position
Main branch:
During the controller initialization the two transistors of the
main branch are
alternating switched on briefly. The level at the starter
Starter output stage with low output changes thereby on
impedance (main branch or „High“, the main branch is classified as low impedance.
1 80 39 branch of emergency) or load Backup branch:
(relay) also to high resistance If that changes for clamp 50 signal on „High“ and follows
and/or to high inductance. this level change a
change of the level at the starter output before the starter
output stage was
activated, the backup branch is classified as low
impedance.
starter control: - check starter electrically and mechanically
1 80 86
starter does not engage - perform functional check.
- a maximum of eight key- transponder codes can be stored
in the ECU engine
control (e.g. MR-PLD).
immobilizer:
1 99 60 - if this number of keys has already been lost, train the new
key number limited to 8
keys via the select
menu «train transponder key». This requires a FDOC-
authorization.
80-08-M209EN (06/12/2012)
PLD MERCEDES (MR2)

note:
- ECU engine control (e.g. MR-PLD) is unserviceable,
because manipulations for
immobilizer: the decoding of the transponder codes (immobilizer) have
1 99 61
counter overflow been made at the
vehicle.
- replace and program ECU engine control (e.g. MR-PLD)
note:
- a ECU engine control (e.g. MR-PLD) for applications
without immobilizer has
been installed in a vehicle with immobilizer. The ECU
engine control
(e.g. MR-PLD) has activated the immobilizer, i.e. it became
unserviceable for
the prior application. The SG can only be used for an
immobilizer:
1 99 62 operation with an
X5 has been with drawn
immobilizer.
- train transponder key via the select menu «train
transponder key». This requires
FDOC-authorization.
- in the case of power shortage or excessive fuel
consumption a new ECU engine
control (e.g. MR-PLD) (adjusted to the respective engine)
has to be installed.
- fault code 19964 also actual: use spare transponder key in
order to start
- engine starts with spare key: try to train the defective
transponder key via the
select menu «train transponder key».
if the trial fails, order and train a new transponder code
(FDOC authorization
required).
- engine does not start with spare key. Check voltage
supply and wiring of the
readout-electronics, repair if necessary. If no fault is
detected, replace readoutelectronics
immobilizer: of the immobilizer.
1 99 63
80
no TPC via CAN - fault code 19964 not actual: check calibration of the SG
FRE for immobilizer.
- in the SG FRE no parameters are set for the immobilizer:
calibrate the SG FRE
for immobilizer.
- SG FRE is calibrated for immobilizer: check fault memory
for actual fault code
12319.
- fault code 12319 actual: check wire of terminal 50
between driving switch and
SG FRE for open circuit fault, repair or replace if necessary.
- fault code 12319 not actual: work off stored CAN-bus
faults.
note.
- the readout-electronics read the transponder code and
sends it permanently to
the control units FRE and MR via the wire terminal 50.
immobilizer:
1 99 64 - if fault code 19963 actual, process this fault code first.
no TPC via terminal 50
- check wire of terminal 50 between driving switch and ECU
engine control
(e.g. MR-PLD) for open circuit fault, repair or replace if
necessary.
(06/12/2012) 80-08-M209EN
PLD MERCEDES (MR2)

electric components for
internal fault
damage, loose contact, corrosion etc., and repair if
2 40 53 EEPROM: Checksum- fault 3
necessary.
(block production or immobilizer)
- if fault code still present, renew and calibrate control unit.
control solenoid valve:
shortened to battery voltage
2 48 05
Highside
bank 1
2 46 06
ground short Lowside bank 1
shortened to battery voltage
2 49 05
Highside
bank 2
2 49 06
ground short Lowside bank2
short circuit injector-/ important note:
2 50 28
solenoid valve cylinder 1 - upon removing mechanical or electrical faults at the
short circuit injector-/ injector valves, the enginesmoothness
2 51 28 control has to be set to zero.
solenoid valve cylinder 2
- The engine smoothness control can be set to zero in the
short circuit injector-/ menu «controls» in the
2 52 28
solenoid valve cylinder 3 menu level «check engine smoothness control».
short circuit injector-/ - switch off ignition for at least 10s after each testing stage,
2 53 28 start engine and read
out actual fault.
short circuit injector-/
2 54 28 - general visual check (damage, loose contact, corrosion
etc.), remove fault if
short circuit injector-/ necessary.
2 55 28
solenoid valve cylinder 6 - check electrical screw connections of the affected injector
short circuit injector-/ valve for short
2 56 28 circuit.
- disconnect electrical screw connections of the affected
injector valve.
example for fault code 25028
80
- Fault code 25028 not actual: injector valve of the affected

cylinder
- fault code 25028 remains actual: check electrical supply
lines of the respective
short circuit injector-/ injector valve(s) for short circuit, repair or replace if
2 57 28 necessary.
check electrical supply line of the affected injector valve if
shorted to battery
voltage and ground short, repair or replace if necessary.
- if fault code 25028 remains present: replace and program
ECU engine control
(e.g. MR-PLD)
note:
-several attempts were made to start the vehicle with a
non-trained key.
- wait for the end of the timeout with the ignition switched
immobilizer on, train transponder
2 99 65
wrong key key after that via the select menu «train transponder key»
(FDOC authorization
required).
- the duration of the timeout depends on the number of
the previous starting trials.
80-08-M209EN (06/12/2012)
80
(06/12/2012) 80-08-M209EN
FAULTS CODES - TRUCK (SPU 25-15)
SPU
SPU 25-15
Error code
(DTC) Component Description
Hexadecimal
010203 Sensor power supply outlet Signal voltage very high: Short circuit at battery + terminal
010204 Sensor power supply outlet Signal voltage very low: Short circuit at ground
010303 Continue flow button indicator light Signal voltage very high: Short circuit at battery + terminal
010304 Continue flow button indicator light Signal voltage very low: Short circuit at ground
010603 Boom head solenoid valve output Signal voltage very high: Short circuit at battery + terminal
010604 Boom head solenoid valve output Signal voltage very low: Short circuit at ground
010605 Boom head solenoid valve output Circuit impedance very high: Open circuit
010703 Body roll authorization output Signal voltage very high: Short circuit at battery + terminal
010704 Body roll authorization output Signal voltage very low: Short circuit at ground
010705 Body roll authorization output Circuit impedance very high: Open circuit
011203 Lifting cut off solenoid valve output Signal voltage very high: Short circuit at battery + terminal
011204 Lifting cut off solenoid valve output Signal voltage very low: Short circuit at ground
011205 Lifting cut off solenoid valve output Circuit impedance very high: Open circuit
011303 Transmission authorization output Signal voltage very high: Short circuit at battery + terminal
011304 Transmission authorization output Signal voltage very low: Short circuit at ground
011305 Transmission authorization output Circuit impedance very high: Open circuit
80
012103 Safety 2 solenoid valve output Signal voltage very high: Short circuit at battery + terminal
012104 Safety 2 solenoid valve output Signal voltage very low: Short circuit at ground
012105 Safety 2 solenoid valve output Circuit impedance very high: Open circuit
012303 Cut-off solenoid valve outputs Signal voltage very high: Short circuit at battery + terminal
012304 Cut-off solenoid valve outputs Signal voltage very low: Short circuit at ground
012305 Cut-off solenoid valve outputs Circuit impedance very high: Open circuit
012503 Telescope extension solenoid valve output Signal voltage very high: Short circuit at battery + terminal
012504 Telescope extension solenoid valve output Signal voltage very low: Short circuit at ground
012505 Telescope extension solenoid valve output Circuit impedance very high: Open circuit
013103 Inclination neutralization solenoid valve output Signal voltage very high: Short circuit at battery + terminal
013104 Inclination neutralization solenoid valve output Signal voltage very low: Short circuit at ground
013105 Inclination neutralization solenoid valve output Circuit impedance very high: Open circuit
Signal value outside calibration range: Calibration not
01330D Strain gauge calibration error
performed or incorrectly performed
013403 Safety solenoid valve output Signal voltage very high: Short circuit at battery + terminal
013404 Safety solenoid valve output Signal voltage very low: Short circuit at ground
013405 Safety solenoid valve output Circuit impedance very high: Open circuit
013507 Safety solenoid valve operational error Defective actuator (mechanical problem)
80-08-M209EN (06/12/2012)
SPU 25-15
Error code
Hexadecimal
013603 Control solenoid valve output Signal voltage very high: Short circuit at battery + terminal
013604 Control solenoid valve output Signal voltage very low: Short circuit at ground
013605 Control solenoid valve output Circuit impedance very high: Open circuit
013707 Adjustment solenoid valve operational error Defective actuator (mechanical problem)
014503 Telescope retracted solenoid valve output Signal voltage very high: Short circuit at battery + terminal
014504 Telescope retracted solenoid valve output Signal voltage very low: Short circuit at ground
014505 Telescope retracted solenoid valve output Circuit impedance very high: Open circuit
014603 Attachment line A control solenoid valve output Signal voltage very high: Short circuit at battery + terminal
014604 Attachment line A control solenoid valve output Signal voltage very low: Short circuit at ground
014605 Attachment line A control solenoid valve output Circuit impedance very high: Open circuit
014703 Attachment line B control solenoid valve output Signal voltage very high: Short circuit at battery + terminal
014704 Attachment line B control solenoid valve output Signal voltage very low: Short circuit at ground
014705 Attachment line B control solenoid valve output Circuit impedance very high: Open circuit
Ventilation rotation direction solenoid valve
014803 Signal voltage very high: Short circuit at battery + terminal
output
014804 Signal voltage very low: Short circuit at ground
output
014805 Circuit impedance very high: Open circuit
output
014903 Fan speed control solenoid output Signal voltage very high: Short circuit at battery + terminal
014904 Fan speed control solenoid output Signal voltage very low: Short circuit at ground
014905 Fan speed control solenoid output Circuit impedance very high: Open circuit
020102 Continue flow button Signal value erratic
020402 Boom head solenoid valve activation button Signal value erratic
020502 Accessory line decompression button Signal value erratic
021007 Retracted telescope not detected Defective actuator (mechanical problem)
021402 JSM FNR selector Signal value erratic
021602 Longitudinal stability display Signal value erratic
02160C Longitudinal stability display Defective sensor or actuator
80
021702 Aggravating movement contact1 Signal value erratic
022202 Override button Signal value erratic
022402 Telescope retracted sensor Signal value erratic
022602 Boom lift angle sensor Signal value erratic
022609 Boom lift angle sensor Information unavailable on CAN bus
022610 Boom lift angle sensor Sensor signal value greater than normal value
022612 Boom lift angle sensor Sensor signal value lower than normal value
022700 Strain gauges Sensor signal value greater than normal value
022701 Strain gauges Sensor signal value lower than normal value
022702 Strain gauges Signal value erratic
022709 Strain gauges Information unavailable on CAN bus
02270A Strain gauges Signal value variation abnormal for correct operation
022713 Strain gauges Signal value transmitted to CAN bus is invalid
Signal value outside calibration range: Calibration not
02320D Boom angle sensor calibration error
performed or incorrectly performed
024102 Telescope roller sensor Signal value erratic
024110 Telescope roller sensor Sensor signal value greater than normal value
024113 Telescope roller sensor Sensor signal value lower than normal value
(06/12/2012) 80-08-M209EN
SPU 25-15
Error code
Hexadecimal
024202 Attachment roller sensor Signal value erratic
024210 Attachment roller sensor Sensor signal value greater than normal value
024213 Attachment roller sensor Sensor signal value lower than normal value
024302 Inclination movement spool contact Signal value erratic
024402 Accessory movement spool contact Signal value erratic
024A05 Air inlet temperature sensor Circuit impedance very high: Open circuit
031101 ECU power supply voltage Sensor signal value lower than normal value
041609 Longitudinal stability display Information unavailable on CAN bus
044009 CAN bus error Information unavailable on CAN bus
051500 ECU Sensor signal value greater than normal value
05150C ECU Defective sensor or actuator
FAULTS CODES - LONGITUDINAL STABILITY INDICATOR (LLMI)

80
i Chapter 80 : «ELECTRICAL CONTROL AND ADJUSTMENT»
80-08-M209EN (06/12/2012)
ELECTRICAL SPECIFIC TOOLING
pages
DIAGNOSTIC TOOLKIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RECEPTION STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WORKSHOP AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BREAKOUT BOX KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SOLENOID ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
80
(26/09/2012) 80-09-M209EN
2 ELECTRICAL SPECIFIC TOOLING
DIAGNOSTIC TOOLKIT
80
80-09-M209EN (26/09/2012)
ELECTRICAL SPECIFIC TOOLING 3
12
11
10
5
9
13
6 8
7
1
3 4
80
Diagnostic case ........................................................................................................ 746120
Consisting of:
1. 1 Cigarette lighter connector supply cable ....................................................745240

2. 1 Red battery clip cable .........................................................................................745241
3. 1 Black battery clip cable ......................................................................................745242
4. 1 Supply cable ...........................................................................................................745243
5. 1 VCI portable cable ................................................................................................745244
6. 1 Manitou OBD Diag. Cable..................................................................................745245
7. 1 Manitou RC2 / RC4 Diag. Cable .......................................................................745246
8. 1 CE standard section lead L: 3m .......................................................................745247
9. 1 Diag Supply Unit 3G 60W ..................................................................................745251
10. 1 Battery LI-ION 7,4V / 9,6AH ...............................................................................745367
11. 1 PAD (PC + case assembly) .................................................................................745438
12. 1 VCI (Vehicle Communication Interface / PAD)...........................................745439
13. Styli (batch of 3)........................................................................................................745368
(26/09/2012) 80-09-M209EN
RECEPTION STATION
Reception station (battery charging) .................................................................... 745236
WORKSHOP AREA
80
Workshop area (area + station) .............................................................................. 745235
80-09-M209EN (26/09/2012)
ELECTRICAL SPECIFIC TOOLING 5
BREAKOUT BOX KIT
Breakout box (DT connectors)
Breakout box (DTM connectors)
Breakout box kit ...................................................................................................... 785503
Consisting of:
1. 1 breakout box (DT connectors).........................................................................785504

2. 1 breakout box (DTM connectors) .....................................................................785505
SOLENOID ADAPTER
80
Solenoid adapter ..................................................................................................... 662196
(26/09/2012) 80-09-M209EN
DIAGNOSTIC TOOL MERCEDES
Minidiag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774616
80
80-09-M209EN (26/09/2012)

Manitou MLT 845 MLT X 845 Service Manual-21315M320014

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Manitou MLT 845 MLT X 845 Service Manual-21315M320014

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REPAIR MANUAL

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GENERAL INSTRUCTIONS AND SAFETY NOTICE

AXLE ASSEMBLY - AXLE

- GENERAL INSTRUCTIONS AND SAFETY

In order to reduce accident risks, make sure to:

– Follow the instructions in the truck operating and maintenance manual.

When you see this symbol:

Before any intervention:

1 - Place the machine on a flat surface and chock the wheels.

RULES FOR MAINTENANCE

Be careful not to burn yourself when touching hot liquids or parts

ECU b Before carrying out any welding operations, think of

A machine operating in a contaminated environment should be

Always wear protection glasses, gloves, safety shoes as well as any

When carrying out maintenance operations near a mobile object,

When changing, or draining oils or fuel, or any other operation with

When lifting or shoring a component of the machine, make sure

When using a jack, make sure it is used on a flat, uniform surface, is

Make sure no object or tool which could cause an accident is left

Never control any leaks using a hand.

MAX Never adjust a component to over the maximum capacity indicated

STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

STANDARD TIGHTENING TORQUES

NF E 25-030-1 Screw / Nut connection :

b For hexagon screws with flanges:

- ENGINE COMPONENTS LOCALIZATION

- ENGINE CONTROL AND ADJUSTEMENT

- ENGINE CHARACTERISTICS AND l647370EN

 Direct injection by injector pump

ELECTRICAL SUPPLY AND PIN-OUT

ELECTRONIC CONTROL MODULE

Belt Fuel filter

ENGINE TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

ENGINE TIGHTENING TORQUES

2,4 daN.m ± 10%

FUEL CIRCUIT - 120CV

4,7 daN.m ± 10% 4,7 daN.m ± 10%

FUEL GAUGE ADJUSTMENT PROCEDURE

Prepare the fuel gauge by following the values given below.

Part will be removed

ALTERNATOR/CRANKSHAFT DRIVE BELT ADJUSTMENT

ENGINE COMPONENTS REMOVAL AND REFIT

PREPARATION AND SAFETY INSTRUCTIONS

– Activate battery cut-out.

3 Remove the 6 screws (Item 3) and remove the engine protection

3 Remove the belt.

Examine the belt. If any of the following conditions are present,

To refit, proceed in the opposite order to the removal.

Carry out operation A.

Disconnect the electrical terminals (Item 1) on the alternator

Remove the alternator.

To refit, proceed in the opposite order to the removal.

Disconnect the combined oil pressure and temperature sensor

Disconnect the oil pressure hose (Item 3).

D - CHANGING THE FUEL FILTER AND FUEL PUMP

Move the switch to the “vidange” (empty) position (Item 1) and

Fuel filter removal.

6 To refit, proceed in the opposite order to the removal.

b Refer to the instructions

Remove the pulley.

Remove the hoses (Item 3) from the pump (Item 4).

3 Remove the retaining screws (Item 5) from the water pump.