MLT940 120 SM

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
La présente brochure n’est fournie qu’à titre consultatif, toute reproduction, copie, représentation, captation, cession, distribution, ou
autre, partiellement ou en totalité, sous quelque format que ce soit est interdite. Les schémas, les dessins, les vues, les commentaires
les indications, l’organisation même du document qui sont rapportés dans la présente documentation, sont la propriété intellectuelle
de MANITOU BF. Toute infraction à ce qui précède est susceptible d’entraîner des condamnations civiles et pénales. Les logos ainsi que
l’identité visuelle de l’entreprise sont la propriété de MANITOU BF et ne peuvent être utilisés sans autorisation exprès et formelle. Tous
droits réservés.
This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part
or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization
that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil
and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU BF and may not be used
without express and formal authorization. All rights are reserved.
Die vorliegende Broschüre dient allein zur Beratung. Nachdruck, Fotokopieren, Vervielfältigung, Darstellung, Erfassung,
Überlassung, Verbreitung oder Sonstiges (ganz oder teilweise) in jeglicher Form sind verboten. Die Entwürfe, Zeichnungen,
Bilder, Darstellungen, Ansichten, Kommentare, Hinweise und der Aufbau der Druckschrift selbst, die in der vorliegenden
Dokumentation enthalten sind, sind geistiges Eigentum von MANITOU BF. Alle Verstöße gegen das Vorstehende können zu straf-
oder zivilrechtlicher Verfolgung führen. Die Logos und Markenzeichen sowie Unternehmens- und Produktbezeichnungen sind
Eigentum von MANITOU BF und dürfen ohne ausdrückliche Genehmigung nicht verwendet werden. Alle Rechte vorbehalten.
Este folleto se ofrece a título meramente informativo y queda prohibida su reproducción, copia, representación, captación, cesión,
distribución y demás, parcial o total, en el formato que sea. Los esquemas, dibujos, vistas, comentarios, indicaciones, la organización
misma del documento aportado en esta documentación son propiedad intelectual de MANITOU BF. Cualquier infracción a lo
antedicho puede acarrear condenas civiles y penales. Los logotipos y la identidad visual de la empresa son propiedad de MANITOU
BF y no pueden utilizarse sin su autorización expresa y formaL. Reservados todos los derechos.
Il presente manuale è fornito esclusivamente a titolo di consultazione; è vietata qualsiasi riproduzione, copia, rappresentazione,
acquisizione, cessione, distribuzione o altro, parziale o totale, e in qualsivoglia formato. Gli schemi, i disegni, le viste, i commenti,
le indicazioni e l’organizzazione stessa del documento, riportati nella presente documentazione, sono proprietà intellettuale
di MANITOU BF. Qualsiasi violazione a quanto riportato sopra è passibile di condanna civile e penale. I loghi e l’identità visiva
dell’azienda sono di proprietà di MANITOU BF e non possono essere utilizzati senza previa autorizzazione espressa e formale. Tutti i
diritti sono riservati.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
Group 00 (General characteristics and safety) 1-1
ENGINE
Group 10 (Engine) 2-1
OPTIONS - ACCESSORIES
Group 110 (Options - Attachments) 3-1
TRANSMISSION
Group 20 (Transmission) 4-1
AXLE ASSEMBLY - AXLE

Group 30 (Axle) 5-1
BRAKE
Group 40 (Brake) 6-1
TELESCOPIC BOOM
Groupe 50 (Boom) 7-1
HYDRAULIC
Group 70 (Hydraulic) 8-1
ELECTRICITY
Group 80 (Electricity) 9-1
DRIVER CAB
Group 85 (Driver s cab) 10-1
GENERAL
00
- GENERAL INSTRUCTIONS AND SAFETY
NOTICE
- GENERAL CHARACTERISTICS
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
(11/10/2012) 00-00-M208EN
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-M208EN (11/10/2012)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 3
00
MAINTENANCE POSITION
2 4
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.
(11/10/2012) 00-00-M208EN
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-M208EN (11/10/2012)
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.
(11/10/2012) 00-00-M208EN
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-M208EN (11/10/2012)
00
GENERAL CONTROL AND ADJUSTMENT
pages
STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(11/10/2012) 00-04-M208EN
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-M208EN (11/10/2012)
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-M208EN
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-M208EN (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-M208EN
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 45
2
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
-
09
1
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
X716
26
1
B17 26
2
5
3
1 30
S38
25
MR2-PLD
INHIBED 2
A716
1
S39
INHIBED 2 35
X465 1 5 8 9 11 13 14 15 X466
10
CAN H
GND CAN H
CAN L
6
ADM2
4
A464
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 X464
10-01-M208EN (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-M208EN
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-M208EN (26/09/2012)
10
ENGINE COMPONENTS LOCATION
pages
MERCEDES ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
FUEL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
(26/09/2012) 10-03-M208EN
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-M208EN (26/09/2012)
ENGINE COMPONENTS LOCATION 3
FUEL CIRCUIT
10
MLT 741-120 HLSU E3 S1
MLT 940-120 HLSU E3 S1
Fuel tank
Filter
Engine
Key :
Tank aspiration
Fuel injection system
Back to tank
(26/09/2012) 10-03-M208EN
4 ENGINE COMPONENTS LOCATION
10
10-03-M208EN (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-M208EN
2 ENGINE CONTROL AND ADJUSTMENT
ENGINE TIGHTENING TORQUES
ENGINE ASSEMBLY
10
2,4 daN.m ± 10%
FUEL CIRCUIT - 120CV
10-04-M208EN (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-M208EN
FUEL GAUGE ADJUSTMENT PROCEDURE
Fig.B
10
Fig.A
– Position the gauge 1 (Fig. A) in the tank so that the spring 2

(Fig. C) enters the housing 3 (Fig. A) provided for this purpose
at the bottom of the tank.
Nota : To guide you, you can empty the tank and insert a light
through the drain hole. 4 (Fig. A).
3
– A 12 to 14 mm gap A (Fig. B) between the top of the gauge
and the tank indicates that the gauge is correctly positioned.
4
If not, reposition the gauge.
Fig.C
– Position the top of the gauge to align the fixing holes with
the tappings on the tank. (The gauge can only be fitted one
2 way round as the holes are not equidistantly spaced) (Fig. D).
– If necessary remove the remnants of gasket sealant from
the fixing screws.
– Place a copper washer (Ref. 48 499) under the head of each
of the five screws 1 (Fig. D), then fix the assembly to the tank.
Fig.D – Connect the harness.
– If removed earlier, re-fit the drain plug, and then re-fill the
tank.
1
1
1
1
1
10-04-M208EN (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-M208EN
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-M208EN (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-M208EN
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-M208EN (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

2 4
4
b Refer to MR647370EN for ensuring correct engine oil level.
(26/09/2012) 10-04-M208EN
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-M208EN (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-M208EN
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-M208EN (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-M208EN
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 P
BRVI: Fan reversal control unit
14 cm3/tr
Y43
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
Hydraulic oil temperature switch
10-04-M208EN (26/09/2012)
CONDITIONS OF FAN REGULATION COMPONENTS
When the engine coolant temperature increases, the current to the control valve falls.
When the engine air temperature increases the current to the control valve falls.
10
When the transmission oil temperature sensor exceeds it maximum threshold the switch is activated
thus engaging the fan at maximum speed. When it falls below its minimum threshold the switch is
deactivated.
When the hydraulic oil temperature sensor exceeds it maximum threshold the switch is activated thus
engaging the fan at maximum speed. When it falls below its minimum threshold the switch is deactivated.
Fan speed values

Fan speed as a function of engine coolant temperature
Engine coolant temperature (T°) Engine input pressure (Bar) Fan speed (rpm)
70 28 739
75 69 1468
80 108 1979
85 127 2213
90 146 2438
95 163 2643
100 173 2747
Fan speed as a function of engine turbocharged air temperature

Engine turbocharged air
Engine input pressure (Bar) Fan speed (rpm)
temperature (T°)
38 31 939
41 65 1550
43 98 1984
48 150 2592
52 169 2790
Transmission oil temperature sensor activation threshold

Minimum Typical Max
Temperature range - 20 °C 90 °C 110 °C
Activation threshold 90 °C
Deactivation threshold 84,6 °C
Hydraulic oil temperature switch activation threshold

Minimum Typical Max
Temperature range - 20 °C 75 °C 110 °C
Activation threshold 89 °C
Deactivation threshold 69,5 °C
For temperature-dependent electrical thresholds, e electrical data for engine coolant temperature
sensor, engine air temperature sensor, hydraulic oil temperature sensor and transmission oil temperature
sensor.
(26/09/2012) 10-04-M208EN
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-M208EN (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-M208EN
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-M208EN (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-M208EN
4 ENGINE REMOVAL
10
“HYDRAULIC MOTOR” REMOVAL
e 70 “Hydraulic components removal”
10-06-M208EN (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-M208EN
6 ENGINE REMOVAL
Remove the 6 fixing screws (Item 10) from the alternator belt
11 cover (Item 11). Remove the cover, disengaging the front part
10
first, then the rear part.
10
10 10
10
14 Disconnect the transmission hose (Item 12) from the rear of

15
the cooler (Item 13), thus draining the transmission oil from its
reservoir. Undo the hose clip (Item 14) on the bottom radiator
hose (Item 15), thus draining the coolant.
13
12
17 16 Remove the hose clips (Item 16) from the top radiator hose (Item
17) and remove the hose. Unscrew the hose clip fixing screw
18 (Item 18). Remover the hose clips (Item 19) from the expansion
16
19
tank (Item 20) hose and remove the hose.
19
20
Remove the rear bonnet bracket (Item 21), unscrewing the four
fixing bolts (Item 22) with a 13 mm spanner.
21
23
22
10-06-M208EN (26/09/2012)
ENGINE REMOVAL 7
Remove the fixing bolts (Item 26) from the bonnet strut bracket
(Item 27), using a 13 mm spanner. Carry out this operation on
26 both the front and rear bonnet brackets.
10
27
Working from underneath (Item 29), remove the two flexible

mountings (Item 28) from the radiator.
29
28
28
Undo the hose clips (Item 30) from the hoses (Item 31) using a 13
mm spanner, then remove the bolts (Item 32) from the radiator
air inlet line (Item 33) using a 17 mm spanner.
Disengage it and slide it towards the rear of the engine bay.
32
31 31
32
33
30 30
Undo the hose clip (Item 34) on the radiator/engine air outlet line
34
35
(Item 35) and on the hose (Item 36) fixed to the radiator (Item 37).
36
37
(26/09/2012) 10-06-M208EN
8 ENGINE REMOVAL
Unscrew the two fixing bolts (Item 38) from the radiator/engine
air outlet line (Item 39) using a 17 mm spanner.
Unscrew the hose clip (Item 40) using a 13 mm spanner.
39
10
38
40
Screw in a lifting eye (Item 45) and tip the radiator forward,
freeing it from its rubbers.
45
Using a hoist, lift the radiator from the engine bay.
Lower the cooler.
10-06-M208EN (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-M208EN
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-M208EN (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-M208EN
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-M208EN (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-M208EN
14 ENGINE REMOVAL
10
10-06-M208EN (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-M208EN
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
10-07-M208EN (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-M208EN
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-M208EN (26/09/2012)
ENGINE REFIT 5
9 Re-fit the connector (Item 8) to the starter motor (Item 9) using

using a 15 mm spanner.
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-M208EN
6 ENGINE REFIT
Fit the compensator (Item 16). Fix the four fixing bolts (Item 17)
behind the turbo (Item 18), without forgetting the protective
18
17
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-M208EN (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-M208EN
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-M208EN (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
(Item 14) using a 13 mm spanner.
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-M208EN
10 ENGINE REFIT
Fit the bonnet brackets (Item 20) and strut bracket; use a 13
mm spanner to secure their bolts (Item 21).
22
10
29
21
Locate the radiator (Item 22) and the bonnet (Item 23) in position
and then tighten their bolts (Item 24) using a 13 mm spanner.
24
24 Repeat the procedure for the rear bonnet bracket.
23
24
24
22
Engage the end of the support strut (Item 25) in the housing on
the bonnet (Item 26) and secure it using the strut cover (Item 27).
27
26
10
25
Locate the upper expansion tank hose in position (Item 28) and
28 29
tighten its hose clips (Item 29) using a 7 mm spanner.
33
Locate the lower expansion tank hose (Item 30) in position and
tighten its hose clips (Item 31) using a 7 mm spanner.
31
29
32 Fix the clamp (Item 32) to the expansion tank (Item 33).
31 30
10-07-M208EN (26/09/2012)
ENGINE REFIT 11
Connect the transmission hose (Item 34) to the rear of the radiator
36
(Item 35) using a 36 mm spanner. Push the bottom coolant hose
37
onto its spigot (Item 36) and tighten the hose clip (Item 37) using
a 7 mm spanner.
10
35
34
Locate and secure the engine cover (Item 38) in position using
the six bolts (Item 39) and a 13 mm spanner.
39
39
39
38
39 39
Locate and secure the radiator side cover (Item 40) using the
two bolts (Item 41), not forgetting the clamps (Item 42), using
41
42 a 13 mm spanner.
Plug in connector X247 (Item 43).
40
43
42
41
Re-fit the oil reservoir (Item 44) and transmission (Item 45) return
hoses using a 36 mm spanner.
44 Re-connect connector X246 (Item 46) while holding the opening
of the bypass hose (Item 47) as high in the air as possible.
45
46
47 Re-fill with transmission oil and coolant.
(26/09/2012) 10-07-M208EN
12 ENGINE REFIT
10
HYDRAULIC MOTOR REFIT
10-07-M208EN (26/09/2012)
OPTIONS - ATTACHMENTS
- TELEHANDLER OPTION CONFIGURATION
- OPTION FORCED GEAR
- CRC BOOM SUSPENSION OPTION
- E.C.S. OPTION (EASY CONNECTING SYSTEM)
110
TELEHANDLER OPTION CONFIGURATION
SOFTWARE INSTALLATION FOR ADDING TELEHANDLER OPTIONS
Fitting the options below requires extra installations via the diagnostic PAD tool.
b You must have a VPN connection via the RJ45 network port and a BLUE smart card.
( i Technical Information: 1920)

– OPTION FORCED GEAR
– CRC BOOM SUSPENSION OPTION
– ACCESSORY LINE DEPRESSURIZATION ECS (EASY CONNECTING SYSTEM) OPTION

110
(15/12/2012) 110-M208A-EN
A2 TELEHANDLER OPTION CONFIGURATION
110
110-M208A-EN (15/12/2012)
OPTION FORCED GEAR
pages
FORCED OPERATION MODE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B2

– CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT . . . . . . . . . . . . . . . . . . . B2
FORCED OPERATION SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3
– ELECTRIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
110
(15/12/2012) 110-M208B-EN
B2 OPTION FORCED GEAR
FORCED OPERATION MODE OPERATION
b This OPTION must only be used with an attachment requiring continuous hydraulic movement
such as: brush, supply bucket, mixer, spray etc. It is strictly forbidden in handling operations
and for all other cases (winch, crane jib, crane jib with winch, hook, etc.).
X611
X612
1 - Safety hydraulic movement

2 - Potentiometer
CONTINUOUS HYDRAULIC MOVEMENT OF THE ATTACHMENT
– Make sure the potentiometer C is set to 0%.
A
– Switch button A to the front or the back (depending on the
type of attachment), press button B and release button A. The
red indicator 1, flashes to indicate that it is in operation.
– Set the required flow rate using potentiometer C.
– To stop continuous hydraulic movement of the attachment,

move switch A forwards or backwards or press button B.
Indicator 1 goes out.
– Set potentiometer C to 0%.
b Never leave the driver’s cab without resetting the

potentiometer C to 0%. Before starting the lift truck, make
sure the potentiometer is set to 0%.
B C
1
NOTE: If the operator leaves the driver’s cab, the continuous
hydraulic movement will automatically stop and must be
restarted.
110
110-M208B-EN (15/12/2012)
OPTION FORCED GEAR B3
FORCED OPERATION SCHEMATIC
ELECTRIC
A606
S612
X612
§ 80
K10
R611 § 80
F24
A1
KEY
Electrical connectors
Name
Wiring harness type Item Designation
component
Main/Electric plate X7 A1 PLATE
Rear/Main X42 REAR/MAIN INTERFACE
Main X606 A606 SPU MODULE
Main X611 R611 CONTINUE FLOW POTENTIOMETER (OPTION)
Main X612 S612 SWITCH + INDICATOR LAMP (OPTION)
Electrical components
Item. Designation
A1 PLATE
A606 SPU MODULE
R611 POTENTIOMETER CONTINUE FLOW (OPTION)
S612 SWITCH + INDICATOR LAMP (OPTION)
110
Fuses and relays

Item Current Designation
F24 7,5A HYDRAULIC MOVEMENT CONTROL UNIT
K10 ARM SENSOR RELAY
(15/12/2012) 110-M208B-EN
B4 OPTION FORCED GEAR
110
110-M208B-EN (15/12/2012)
CRC BOOM SUSPENSION OPTION
pages
PRINCIPE DE FONCTIONNEMENT DU KIT « CRC » . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C2

– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C2
BOOM SUSPENSION VALVE (VASF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C3
OPERATING LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C6
CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C7
– HYDRAULIC CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C7
LOCATION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C8
SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .C9
– POSITION SENSOR SETTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C9
110
(16/12/2012) 110-M208C-EN
C2 CRC BOOM SUSPENSION OPTION
PRINCIPE DE FONCTIONNEMENT DU KIT « CRC »
The jib is suspended to reduce shaking of the lift truck on rough

ground (e.g. moving straw in a field).
A1
Applications are at:
A
• 70%: road and field transit.
• 30%: others, floating function for clearing out animal houses,
A2 snow-plowing.
Optimum effectiveness: 1500 kg (i.e. 3 bigballers)

• Operator comfort
• Less strain on components
• Better safety
OPERATION
– Set the forks or attachment on the ground and relieve the front wheels a few centimeters only.
– Press switch A in position A1, the visual indicator comes on indicating that jib suspension is activated.
– Press switch A in position A2, the visual indicator goes out indicating that jib suspension is deactivated.
b Jib suspension is enabled up to a fork clamp axle height of 3m from the ground with the jib
retracted. When operating above this height or performing another hydraulic movement
(tilting, telescoping, attachment), jib suspension is momentarily deactivated and the switch
A indicator goes out.
When the IC engine is off, jib suspension is automatically deactivated.

110
110-M208C-EN (16/12/2012)
CRC BOOM SUSPENSION OPTION C3
BOOM SUSPENSION VALVE (VASF)
110
(16/12/2012) 110-M208C-EN
Pilot pressure: 110 bar Operating pressure: 30 bar 0/+6 bar

Safety valve set to 320 bar 0/+15 bar Safety valve set at 32,5 bar
OPTION CRC
VL
The parachute valve’s function is to avoid
the load dropping should a break occur in
the connection between the valve and the
PRES
accumulator.
The S1 and S2 solenoid valves must be
1 2
3
C1
PX
C2
EV(S1)
activated when the vehicle exceeds 3 kph
30b
1.5 L to allow the boom suspension to work via
AC the accumulator.
EV(S2)
PORTS
300b
V1-V2 = M22x1,5
VASF (O) T = M16x1,5
T V1 V2
ACC. = M18x1,5
110
PX = G1/4
C1-C2 = Ø 11,5
110-M208C-EN (16/12/2012)
BOOM SUSPENSION PRESSOSTAT VALVE B25
PIN Function
X225 1 2
1 Switch
2
2 Supply relay P
1
Corresponding connector
Diagram
PIN Mini Typique Maxi

Supply voltage 12 V 42 V
Consumption 6 mA
Note:
- The Pressostat contact opens at 7,5 ± 0,7 bar.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
PRESSOSTAT B12-B13-B14
PIN Function
1 Power supply X229 X230 X233 X234

X231 X232
2 Switch
P P P
Diagram
PIN Mini Typique Maxi

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.
110
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(16/12/2012) 110-M208C-EN
OPERATING LOGIC
Boom suspension schematic IC engine

running
no hydraulic
movements K10=1
Press switch S1
suspension activation
Boom Boom raised S2=1

lowered to
ground S2=0 Boom suspension
not activated
Boom lowered to ground S2=0
Boom suspension
activated
K11=1
Supply to Electrovalve S1 and

Electrovalve S2 and indicator lamp
Hydraulic movement: Lowering,

crowd forward, crowd backward Clamp axle height
TS > 3m/ground S10=0
K10=0 (K11=1)
Electrovalve S1 and Electrovalve

S2 and indicator lamp cut-off
Hydraulic movement Clamp axle height TS < 3m/

stop ground S10=1
K10=1 (K11=1)
(normal operation)
Press switch S1: engine stop

stop suspension
110
Power cut-off K10=0

K11=0
Boom suspension
in stop position
110-M208C-EN (16/12/2012)
CIRCUITS
HYDRAULIC CIRCUIT
EV(
S2) VASF
Px
VT
EV(
S1)
Key :
AC: Accumulator
P: Pump
T: Tank
VASF: Boom Suspension Valve
VT: Telescope cylinder
AC
P
L1
0
29
T
110
(16/12/2012) 110-M208C-EN
LOCATION OF COMPONENTS
T
4 P 1
3 2
1
K1
2
K1
0
K1
110
110-M208C-EN (16/12/2012)
SETTINGS
POSITION SENSOR SETTING
– Position the boom as shown (Fig. A). The clamp

axle must be at least 3m above ground level.
– Set the position switch 1 (Fig. B) so that it

triggers in this configuration.
– To check setting, press switch 4 (Fig. C). The

3m
switch should light up. The switch light should

go out when the boom is lowered below the
height noted above (Fig. A).
Fig. A – Adjust setting if necessary.
– Re-fit the cover behind the boom.

1
Fig. B
Fig. C
110
(16/12/2012) 110-M208C-EN
110
110-M208C-EN (16/12/2012)
E.C.S OPTION (EASY CONNECTING SYSTEM)
pages
DÉCOMPRESSION DE LA LIGNE ACCESSOIRE (OPTION E.C.S.) . . . . . . . . . . . . . . . . . . . . . . . .D2

– PRINCIPE DE FONCTIONNEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D2
SCHÉMAS DE PRINCIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D3
– ÉLECTRIQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
– LÉGENDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D3
110
(16/12/2012) 110-M208D-EN
E.C.S. OPTION
D2 (EASY CONNECTING SYSTEM)
DEPRESSURIZING ACCESSORY LINE (E.C.S. OPTION)
OPERATING PRINCIPLE
S209
X209
For easily connecting and disconnecting the attachment.
– Press push-button A for two seconds to depressurize the attachment circuit.

– Connect or disconnect the rapid connectors of the hydraulic attachment
110
110-M208D-EN (16/12/2012)
E.C.S. OPTION
(EASY CONNECTING SYSTEM) D3
SCHEMATIC DIAGRAMS
ELECTRIC
§ 80
S209
X209
§ 80
A606
F17
F14
A1
KEY
Name
Wiring harness type Item Designation
component
Main X209 S209 EASY CONNECT SYSTEM SWITCH (OPTION)
Item Designation
A1 PLATE
A606 SPU MODULE
110
S209 EASY CONNECT SYSTEM SWITCH (OPTION)
Fusibles et relais
Item Intensité Designation
F24 7,5A HYDRAULIC MOVEMENT CONTROL UNIT
(16/12/2012) 110-M208D-EN
E.C.S. OPTION
D4 (EASY CONNECTING SYSTEM)
110
110-M208D-EN (16/12/2012)
TRANSMISSION
- TRANSMISSION SCHEMATIC DIAGRAMS
20
- TRANSMISSION CONTROL AND
ADJUSTEMENT
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT
- SPECIFIC TRANSMISSION TOOLING
- TRANSMISSION CHARACTERISTICS AND l 647379EN

SPECIFICATIONS
(TRANSFER BOX
- TRANSMISSION CONTROL AND TYPE 357)
ADJUSTEMENT
- TRANSMISSION REMOVAL
- TRANSMISSION REFIT
- SPECIFIC TRANSMISSION TOOLING
- TRANSMISSION CHARACTERISTICS AND l 647030DE/EN

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

AND DIAGRAMS
TRANSMISSION SCHEMATIC DIAGRAMS
20
pages
CHAÎNE CINÉMATIQUE / RAPPORT TRANSMISSION HYDROSTATIQUE . . . . . . . . . . . . . . .2
(05/11/2012) 20-02-M208EN
2 TRANSMISSION SCHEMATIC DIAGRAMS
POWER FLOW DIAGRAM/GEAR RATIOS
Clockwise
Front Drive Axle Rear drive axle

I.C. engine
20
Transfer box
Forward gear
Front and rear axles final drive: Z1/Z2 11/31

Front Drive Axle
Z1 11 teeth Rapport hub reduction: Z4/(Z3+Z4) 1/6
Rear Drive Axle
Z2 31 teeth Axle overall: 1/16.909
Z3 70 teeth
Z4 14 teeth Number of ratios:: 2
Z5 27 teeth Z8/Z9 19/86
Ratios :
Transfer box Z6/Z7 13/17
Maximum input torque:: 740 N.m
Transfer box Maximum input revolutions: 5000 rpm
Z6 39 teeth
Z7 51 teeth
Z8 19 teeth
Z9 55 teeth
20-02-M208EN (05/11/2012)
TRANSMISSION CONTROL AND ADJUSTMENT
20
pages
TIGHTENING TORQUES, HYDROSTATIC TRANSMISSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

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
(12/10/2012) 20-04-M208EN
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-M208EN (12/10/2012)
ADJUSTMENT 3
TIGHTENING TORQUES, HYDROSTATIC TRANSMISSION

41 daN.m ± 10%
20
3,8 daN.m ± 10%
3,8 daN.m ± 10%
(12/10/2012) 20-04-M208EN
4 ADJUSTMENT
20
20-04-M208EN (12/10/2012)
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
(12/10/2012) 20-04-M208EN
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-M208EN (12/10/2012)
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)
(12/10/2012) 20-04-M208EN
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-M208EN (12/10/2012)
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
(12/10/2012) 20-04-M208EN
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-M208EN (12/10/2012)
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.
(12/10/2012) 20-04-M208EN
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-M208EN (12/10/2012)
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
(12/10/2012)
C 20-04-M208EN
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-M208EN (12/10/2012)
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).
(12/10/2012) 20-04-M208EN
20
16
A4VG-DA/A6VM-DA HYDROSTATIC TRANSMISSIONS SETTING FILE
CONTROL DATE : MACHINE TYPE : HYDRAULIC PUMP TYPE. :
20-04-M208EN
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
(12/10/2012)
TH7 SETTING FORCE AT TOW HOOK: ..............................Kg
TRANSMISSION REMOVAL
20
pages
HYDROSTATIC TRANSMISSION REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– HYDROSTATIC MOTOR REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
(22/10/2012) 20-06-M208EN
2 TRANSMISSION REMOVAL
HYDROSTATIC TRANSMISSION REMOVAL

20
Key :
A - Hydrostatic pump
B - Hydrostatic motor
• Stabilise the machine on level ground over a pit.

• Raise the boom approx. 40°, so as to position the sling above the hydrostatic pump.
• Deactivate battery power supply by means of the battery cut-off.
Specific tools:
- Lifting crane (1 000 kg min.).

- Hoist
20-06-M208EN (22/10/2012)
TRANSMISSION REMOVAL 3
HYDROSTATIC PUMP REMOVAL

2
Attach a sling (1) to the boom attachment points (2).

Raise it so as to position the sling above the hydrostatic pump.
Place the security device (3) and activate the battery cut-off.
20
1
Remove the clover plate (4) in the boom well, four screws (5)
using a 13 mm wrench.
5 5
5 5
Remove the plate (6) under the machine, four screws, using a
13 mm wrench.
Remove the plate (7) under the machine, four screws, using a
7 13 mm wrench.
7
Remove the transmission universal joint (7), two flanges (8) and
four screws on either side (9) using an 8 mm wrench.
9 9
(22/10/2012) 20-06-M208EN
Disconnect the two connectors X9 (10) and X12 (11), mark them
10 for ease of refitting.
11
20
Remove the hose (12) using a 17 mm wrench.
Remove the tube (13) using a 41 mm wrench.

12 13
Remove the hoses (14 and 15), using a 17 mm wrench, mark

them for ease of refitting.
15
14
Remove the hose (16).
16
17
20-06-M208EN (22/10/2012)
Remove the two half flanges (18), two screws each using a
19 mm wrench.
20 19
18
18
Remove the hose (20) using a 36 mm wrench
20
Remove the two fastening screws (21) between the hydrostatic
pump and the hydraulic pump using a 19 mm wrench.
Disconnect connector X44 from the hydraulic pump.
21
22 Disconnect and clear the access to the hydrostatic pump (22)

and the hydraulic pump (23).
23
Place a sling (24) on the pump and install a hoist (25).

25
24
Remove the two fastening screws (26), using a 19 mm hexagon
wrench.
26
(22/10/2012) 20-06-M208EN
Disconnect the pump (27) from the engine (28).

20
28 27
Lower the hydrostatic pump with the hoist.
20-06-M208EN (22/10/2012)
HYDROSTATIC MOTOR REMOVAL
Place the security device (1) and activate the battery cut-off.
20
Remove the clover plate (2) in the boom well, four screws (3)
3 3
3 3
Remove the plate (4) under the machine, four screws using a
13 mm wrench.
Disconnect the two connectors X33 (5) and X193 (6), mark them
for ease of refitting.
(22/10/2012) 20-06-M208EN
Remove the hose (7) using a 17 mm wrench.
Remove the hoses (8) using a 42 mm wrench, mark it for ease

of refitting.
7
20
Remove the hoses (9) using a 42 mm wrench, mark them for

ease of refitting.
10
Remove the four half flanges (Rep.10), two screws each using
an 8 mm hexagon wrench.
Remove the two half flanges (11), mark them for ease of refitting.
11 10
10 11
Remove the four motor fastening screws (12) using a 24 mm

wrench.
Remove the hydrostatic motor.
12
12
20-06-M208EN (22/10/2012)
TRANSMISSION REFIT
20
pages
HYDROSTATIC TRANSMISSION REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– HYDROSTATIC PUMP REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– HYDROSTATIC MOTOR REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(24/10/2012) 20-07-M208EN
2 TRANSMISSION REFIT
HYDROSTATIC TRANSMISSION REFIT

20
Key :
A - Hydrostatic pump
B - Hydrostatic motor
• Stabilise the machine on level ground over a pit.

• Raise the boom approx. 40°, so as to position the sling above the hydrostatic pump.
Specific tools:
- Lifting crane (1 000 kg min.).

- Hoist
20-07-M208EN (24/10/2012)
TRANSMISSION REFIT 3
HYDROSTATIC PUMP REFIT

2
Place the hydrostatic pump under the truck.
Place a sling (1) on the pump and install a hoist (2).
Lift the hydrostatic pump with the hoist.
20
1
Connect the pump to the engine, then tighten the two fastening
4 screws (3), using a 19 mm hexagon wrench.
5
Remove the hoist (4) and the sling (5).
Approach/connect the hydraulic pump to the hydrostatic pump,

tighten the two fastening screws (6) using a 19 mm wrench.
Connect the connector X44 to the hydraulic pump.
Attach the hose (7), using a 36 mm wrench.

7 8
Install the hose (8).
Attach the two half-flanges (9), two screws each using a 19 mm
9
9 wrench.
(24/10/2012) 20-07-M208EN
Attach the hose (10).
Attach the hose (11).
11
10
20
Attach the hoses (12 and 13) according to their markings, using
a 17 mm wrench.
12
13
Attach the hose (14) using a 17 mm wrench.
Attach the tube (15), using a 41 mm wrench.

14 15
Attach the two connectors X9 (16) and X12 (17).

16
17
20-07-M208EN (24/10/2012)
18 Position and attach the transmission universal joint (18), two

flanges (19) and four screws on either side (20) using an 8 mm
b
wrench.
Apply Loctite normal 243 thread lock to each screw.
20 20
20
19
Position and attach the plate (21) under the machine, four
screws using a 13 mm wrench.
Position and attach the plate (22) under the machine, four
21 screws using a 13 mm wrench.
22
Position and attach the cover plate (23) in the boom well, four
screws using a 13 mm wrench.
23
Remove the sling (24).
Remove the safety system (25).
Turn the power back on with the battery cut-off.
Top-up the hydraulic oil level.
24
25
(24/10/2012) 20-07-M208EN
HYDROSTATIC MOTOR REFIT
Refit the transfer gear box.
Connect the transfer gear box motor then tighten the four
fastening screws (1), using a 24 mm wrench.
1
20
3
Install the two hoses (2) according to their markings.
Attach the four half flanges (3), two screws each, using an 8 mm
hexagon wrench.
2 3
3 2
Attach the hoses (4), using a 42 mm wrench, en according to

their markings.
Attach the hoses (5), using a 42 mm wrench, according to their

markings.
Attach the hose (6), using a 17 mm wrench.
20-07-M208EN (24/10/2012)
Connect the two connectors X33 (7) and X193 (8).
20
Position and attach the plate under the machine (9), four screws
Position and attach the cover plate (10) in the boom well, four
screws, using a 13 mm wrench.
10
Remove the safety system (11).
Turn the power back on with the battery cut-off.
11 Top-up the hydraulic oil level.
(24/10/2012) 20-07-M208EN
20
20-07-M208EN (24/10/2012)
SPECIFIC TRANSMISSION TOOLING
20
pages
BASIC BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
(12/10/2012) 20-09-M208EN
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-M208EN (12/10/2012)
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
(12/10/2012) 20-09-M208EN
4 SPECIFIC TRANSMISSION TOOLING
20
20-09-M208EN (12/10/2012)
AXLE
- AXLE CONTROL AND ADJUSTEMENT
- AXLE CHARACTERISTICS AND l 547983EN
30
SPECIFICATIONS
(AXLE 212)
- SPECIFIC AXLE TOOLS
AXLE CONTROL AND ADJUSTMENT
30
pages
COUPLE DE SERRAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– PONT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(26/09/2012) 30-04-M208EN
2 AXLE CONTROL AND ADJUSTMENT
TIGHTENING TORQUE
AXLE
34 daN.m ± 10%
34 daN.m ± 10%
30
63 daN.m ± 15%
63 daN.m ± 15%
30-04-M208EN (26/09/2012)
BRAKE
- BRAKE CHARACTERISTICS AND

SPECIFICATIONS
- BRAKE COMPONENTS LOCATION
- BRAKE CONTROL AND ADJUSTEMENT
- SPECIFIC BRAKE TOOLS
40
BRAKE CHARACTERISTICS AND SPECIFICATIONS
pages
MLT BRAKE CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
40
(08/10/2012) 40-01-M208EN
BRAKE CHARACTERISTICS AND
2 SPECIFICATIONS
40
40-01-M208EN (08/10/2012)
SPECIFICATIONS 3
MLT BRAKE CHARACTERISTICS
Brake fluid L.H.M S8 214 B SHELL V=0,75L
MAX
190
66
Master cylinder: ø27 mm

Second section: ø20 mm
Cubic capacity: 11-20 cm3
27
0
45
40
Braking ratio:
270 / 45 = 6
Braking ratio: Braking ratio:

270/45 = 6 190x80 / 64x8 = 29,69
Planetary reducer Oil back brake disc:

R = 1/6 Nombre de disques par roue 8
80
Braking surface per disc side 109,9 cm2
Total braking surface area for one axle 32174 N
8
Towards Total forklift braking surface 32174 N
hydrostatic pump
Pressure of use advised 70 à 80 bar
Friction material WELLMAN N°266
Dynamic friction coeffi cient 0,115
Static friction coeffi cient 0,095
Make DANA
Disc diameter 178 mm
Disc thickness 4,75 - 4,85 mm
Track width 77.8 mm
PARKING BRAKE
SERVICE BRAKE
(08/10/2012) 40-01-M208EN
4 SPECIFICATIONS
40
40-01-M208EN (08/10/2012)
BRAKE COMPONENTS LOCATION
pages
HYDRAULIC BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
40
(18/10/2011) 40-03-M208EN
2 BRAKE COMPONENTS LOCATION
KEY: HYDRAULIC BRAKE CIRCUIT DIAGRAM

Rep. Désignation
MC Master Cylinder
P Pressure
R Brake fluid return
RLF Brake fluid tank
40
40-03-M208EN (18/10/2011)
BRAKE COMPONENTS LOCATION 3
HYDRAULIC BRAKE CIRCUIT
RLF R
MC
40
A
V
(18/10/2011) 40-03-M208EN
4 BRAKE COMPONENTS LOCATION
40
40-03-M208EN (18/10/2011)
BRAKE CONTROL AND ADJUSTMENT
pages
40
BRAKE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– BRAKE CIRCUIT BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
TRAILER BRAKING CIRCUIT BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PARKING BRAKE PAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
CHECKING AND ADJUSTING THE PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
SERVICE BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
– SETTING BRAKE PEDAL HEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
PARKING BRAKE (CABLE OPERATED BRAKE). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
– HAND BRAKE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(06/11/2012) 40-04-M208EN
2 BRAKE CONTROL AND ADJUSTMENT
BRAKE CIRCUIT
BRAKE CIRCUIT BLEEDING
REQUIRED EQUIPMENT: 1 pressurized brake bleeder

(pressure 1 to 1,2 bar) Ref. 554 019.
– Raise the jib.

– Remove the forward cover plat (Item 1).
40
– Remove the lower left dashboard cover (Item 2).
– Behind the brake pedal, position the bridle at the hole (Item
L) furthest away from the swivel point, in the “Long”: brake
bleeding position.
40-04-M208EN (06/11/2012)
BRAKE CONTROL AND ADJUSTMENT 3
– Take the top off the brake fluid reservoir and fit the brake
bleeder adapter (Item 3).
3
– Operate the bleed valve.
– Place a transparent brake bleeding hose on the left hand

bleed nipple (Item 5) on the rear axle.
4
– Loosen the vent screw, then when the brake fluid flows without
5
air bubbles, retighten the vent screw.
40
– Repeat the operation on the right hand bleed nipple (Item
6) on the rear axle.
As a general rule, when bleeding the brake circuit start with the
most distant bleed point and work towards the nearest.
– Carry out the same procedure on the right hand, then left
hand bleed nipples (Item 7) on the front axle and then bleed
the master cylinder if necessary.
6
– Top up the brake fluid tank level.
Fluid to be used :
i “CHARACTERISTICS” in chapter “O - GENERAL POINTS”.
When bleeding is complete re-fi t the bridle in its service position

(Item C), position “short”.
(06/11/2012) 40-04-M208EN
TRAILER BRAKING CIRCUIT BLEEDING
REQUIRED EQUIPMENT: 1 pressurized brake bleeder (pressure 1

to 1,2 bar) Ref. 554 019.
– Raise the jib.

– Remove the transmission cover plate (Item 1).
40
– Remove the lower left hand instrument panel cover (Item 2).
– Take the top off the brake fluid reservoir and fit the brake
bleeder adapter (Item 3).
40-04-M208EN (06/11/2012)
– Place a transparent brake bleeding tube on the trailer braking

valve bleed nipple (Item 4).
4
– Operate the bleed valve.
– Loosen the vent screw, then when the brake fluid flows without
air bubbles, retighten the vent screw.
– Top up the brake fluid tank level.

Fluid to be used :
i “CHARACTERISTICS” in chapter “O - GENERAL POINTS”
40
(06/11/2012) 40-04-M208EN
PARKING BRAKE PAD REMOVAL
– Place the telehandler on horizontal ground, with the handbrake off and in neutral.
– Chock the lift truck.
– Remove the parking brake cable (Item 1).

– Remove the caliper upper mounting bolt (Item 2).
– Swivel the caliper around the lower bolt (Item 3).
1
3
40
– Compress the spring (Item 4) using two screwdrivers.

– Remove the pads (Item 5).
5
RE-FITTING PARKING BRAKE PADS
– Re-fitting is the reverse of the operations described in the chapter “PARKING BRAKE PAD REMOVAL”.
– Check and adjust the parking brake.
40-04-M208EN (06/11/2012)
CHECKING AND ADJUSTING THE PARKING BRAKE
A
B
For public highway certifi ed telehandlers
– Place the lift truck on level ground with the rated load in the transport position.
40
– Check braking by locking the parking brake (Item 1) in position A.
– Pull on the lift truck rear towing pin with a minimum force of 3500 daN. The wheels of the lift truck
must not rotate.
– Carry out adjustments if necessary:
– Progressively tighten the end of the lever (Item 1) and recheck braking.
– Repeat the operation until the correct braking adjustment is obtained.
For non HRT approved lift truck
– Place the lift truck on a slope less than 15% with the rated load in the transport position.
– Check braking by locking the parking brake (Item 1) in position A.
– The adjustment is correct when the lift truck is held stationary on a slope.
– Carry out adjustments if necessary:
- Press the service brake pedal, then release the parking brake moving the lever (Item 1) to
position B.
- Progressively tighten the end of the lever (Item 1) and recheck braking.
- Repeat the operation until the correct braking adjustment is obtained.
(06/11/2012) 40-04-M208EN
SERVICE BRAKE
SETTING BRAKE PEDAL HEIGHT
1) BRAKE PEDAL
– Adjust the height of the brake pedal (Item A) to 160 mm above the cab fl oor (without mats) using
the stop (Item B).).
– Tighten the locknut (Item C).
– Adjust the brake pedal free play (Item A) (3 to 4 mm) by turning the pushrod (Item D).
– Tighten the locknut (Item E).
2) TH7 VALVE ADJUSTMENT
– Pedal in its rest position, resting on the stop (Item B).

– Place a 0,5 mm to 1 mm shim; between the screw head (Item F) and the TH7 pushrod.
– Adjust the stop position (Item F).
– Tighten the locknut (Item G).
40
NOTE: The pedal switch must change state (passnt) as soon as the TH7 pushrod is free to move, that is
at the very start of braking.
Pedal in rest position
Pedal free play

3 to 4 mm
40-04-M208EN (06/11/2012)
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
(06/11/2012) 40-04-M208EN
40
40-04-M208EN (06/11/2012)
SPECIFIC BRAKE TOOLING
pages
HYDRAULIC BRAKE BLEED KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
40
(12/10/2012) 40-09-M208EN
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-M208EN (12/10/2012)
BOOM
- BOOM CHARACTERISTICS AND

SPECIFICATIONS
- BOOM COMPONENTS LOCATION
- BOOM CONTROL AND ADJUSTEMENT
- BOOM REMOVAL
- BOOM REFIT
50
BOOM CHARACTERISTICS AND SPECIFICATIONS
pages
DUPLEX (7 METRE MLT): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

TRIPLEX (9 METRE MLT): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
MOBILE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
– DUPLEX (7 METRE MLT): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
50
– TRIPLEX (9 METRE MLT): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(06/11/2012) 50-01-M208EN
2 BOOM CHARACTERISTICS AND SPECIFICATIONS
MLT 741-120 H Series 3-E3
DUPLEX (7 METRE MLT):
Consists of 2 components:
– 1 fixed
– 1 mobile (T1)
Machines equipped with a Duplex boom:
– MLT 741-120 H
Boom weight:
– Approx. 1390 kg
50
T1
50-01-M208EN (06/11/2012)
BOOM CHARACTERISTICS AND SPECIFICATIONS 3
TRIPLEX (9 METRE MLT):
Consists of 3 components:
– 1 fixed
– 2 mobile (T1 & T2)
Deployment:
Deployment of the Triplex boom is controlled simultaneously.

 T1 and T2 extend at the same time.
Machines equipped with a Duplex boom:
– MLT 940-120 H
Boom weight:
– Approx. 1875 kg
50
T2
T1
(06/11/2012) 50-01-M208EN
4 BOOM CHARACTERISTICS AND SPECIFICATIONS
MOBILE COMPONENTS
DUPLEX (7 METRE MLT):
Mobile component (T1):
– Weight: Approx. 470 kg

– Centre of gravity: G
TRIPLEX (9 METRE MLT):

50
Mobile components (T1+T2):

Mobile component (T2):

50-01-M208EN (06/11/2012)
BOOM COMPONENTS LOCATION
pages
COMPONENT CODE INDEX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– DUPLEX BOOM (7 METRES): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– TRIPLEX BOOM (9 METRES): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS (7 M) . . . . . . . . . . . . . . . . . . . . . . .3
50
LOCATION OF THE TRIPLEX BOOM MAIN COMPONENTS (9 M) . . . . . . . . . . . . . . . . . . . . . . .4
(06/11/2012) 50-03-M208EN
2 BOOM COMPONENTS LOCATION
COMPONENT CODE INDEX
DUPLEX BOOM (7 METRES):
Item Designation
CSP Counterbalance valve
T1 Telescope 1 (Boom head)
VI Tilting cylinder
VT Telescope cylinder
TRIPLEX BOOM (9 METRES):
Item Designation
CSP Counterbalance valve
CSPD Double counterbalance valve
T1 Telescope 1
T2 Telescope 2 (Boom head)
VI Tilting cylinder
VT1 Telescope cylinder 1
VT2 Telescope cylinder 2
50
50-03-M208EN (06/11/2012)
BOOM COMPONENTS LOCATION 3
LOCATION OF THE DUPLEX BOOM MAIN COMPONENTS (7 M)
VT
T1
CSP
Boom foot
V1
V2
50
C
D C
B
VI
A
CSP
A
C
D
A
B
(06/11/2012) 50-03-M208EN
4 BOOM COMPONENTS LOCATION
LOCATION OF THE TRIPLEX BOOM MAIN COMPONENTS (9 M)
Key to hoses
1 - Tilting V1
2 - Telescope V2
3 - Tilting V2
4 - Attachment 1
1
6
V1
CSP
5 -
4
Telescope V1 3
5
6 -
2
Attachment 2 V2
V2
CSP V1
CSP
V1
2
50
V2
2 5
6
5 4
1
6 3 6
1
1
4 2 4
5 5
3 6
4
1
2
3 3
VI
CSP
VT1
T2
CSPD T1
VT2
CSP
Boom foot
50-03-M208EN (06/11/2012)
BOOM CONTROL AND ADJUSTMENT
pages
DISMANTLING TRIPLEX BOOM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– REMOVING TELESCOPES T1+T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– REMOVING TELESCOPE T2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
50
REFIT TRIPLEX BOOM COMPONENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– RECOMMENDATIONS FOR BLOCK ASSEMBLY AND GREASING AREAS . . . . . . . . . . . . 7
(19/10/2012) 50-04-M208EN
2 BOOM CONTROL AND ADJUSTMENT
DISMANTLING TRIPLEX BOOM COMPONENTS

50
Key:
A - Telescope T1
B - Telescope T2
• Stabilise the machine on horizontal ground.

• Fully retract the telescope.
• Remove any attachment mounted on the carriage.
• Decompress all hydraulic components.
• Place the boom in the horizontal position with the carriage tilted fully upwards.
Specific tools:
– Floor crane or hoist + slings (1 000 kg min.).

– Mallet.
– Trestles.
50-04-M208EN (19/10/2012)
BOOM CONTROL AND ADJUSTMENT 3
MLT940-120 H Series 3-E3
REMOVING TELESCOPES T1+T2
Remove the telescope cylinder circlip (1)

1
Place a block between the telescope cylinder and the boom.
50
Remove the telescope cylinder pivot pin (2).
Place a strap around the boom and pull out halfway (3).
3
(19/10/2012) 50-04-M208EN
Hold/Secure the boom (4) at its centre of gravity by means of a

5
strap (5) and a lifting device (hoist) i ‘‘BOOM CHARACTERISTICS
AND SPECIFICATIONS’’.
Remove the U-clamp (6) using a 13 mm wrench.

6
Dismantle then remove the six slide pads (7).
7 7
7
50
Fully remove the boom (8).

8
50-04-M208EN (19/10/2012)
10
11
11
9
9
Identify and unscrew the six hoses
10 - (x2) telescoping circuit (9)
- (x2) tilting circuit (10)
- (x2) attachments circuit (11)
10
10
11
9
9 11
50
Set down the boom (12) on trestles with the hoist + strap (13).
13
12
(19/10/2012) 50-04-M208EN
REMOVING TELESCOPE T2
1
Perform i ‘‘REMOVING TELESCOPES T1+T2’’
Remove the telescope cylinder circlip (1)

2
Remove the telescope cylinder pivot pin (2).

50
3
Place a strap around the boom and pull the boom head out
halfway (3).
Hold/Secure the boom (3) at its centre of gravity with a strap

and a lifting system (hoist) i ‘‘BOOM CHARACTERISTICS AND
SPECIFICATIONS’’.
Dismantle then remove the six slide pads (4).

4
4 4
4
4
Fully remove the boom head.

4 4
4
Set the boom head don on trestles.
50-04-M208EN (19/10/2012)
REFIT TRIPLEX BOOM COMPONENTS
b
Carry out the reverse of the procedure described above.
Follow the block assembly and greasing recommendations given below.
b Apply ‘‘Loctite normal 243 thread lock’’ to all screw/nut connections located only inside the boom.
RECOMMENDATIONS FOR BLOCK 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 pad before installation.
3 - Install the slide pads in the following order: side pads, upper pads, lower pads.
4 - Finish adjusting the calibration system, at the upper part of the tubes by inserting pads while
complying with the operating clearances shown.
50
(19/10/2012) 50-04-M208EN
50
50-04-M208EN (19/10/2012)
BOOM REMOVAL
pages
TRIPLEX BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– BOOM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
(17/10/2012) 50-06-M208EN
2 BOOM REMOVAL
TRIPLEX BOOM
50

• Fully retract the telescope.
• Remove any attachment mounted on the carriage.
• Place the boom at mid-height so as to gain access the lift and compensating cylinder head
pivot pins.
• Decompress all hydraulic components.
Weight of complete boom ≈ 1 875 kg
Specific tools:

– Mallet.
– Trestles.
50-06-M208EN (17/10/2012)
BOOM REMOVAL 3
BOOM REMOVAL
1
Unscrew and remove the rear cover (1) attached to the frame.
Remove the link rod swivel joint (2).

2
Identify and disconnect the connectors X114 and X115.
50
Hold/Secure the boom in place (3) with a strap (4) and a lifting
system (hoist).
4
3 Weight of complete boom ≈ 1 875 kg
Place a container under truck at the level of the rear hoses.
5 5 Identify and unscrew the six hoses

- (x2) telescoping circuit (5)
- (x2) tilting circuit (6)
6 - (x2) attachments circuit (7)
7
Place plugs on the hoses, connectors and hydraulic tubes.
7
(17/10/2012) 50-06-M208EN
4 BOOM REMOVAL
Remove the screw (8) from the lift cylinder head pivot pin (9)
8
Block the lift cylinder(10) to hold it in position.
Remove the lift cylinder head pivot pin (9).
Carefully remove the lift cylinder.
10
50
Remove the screw (11) from the compensation cylinder head

pivot pin (12).
Remove the compensation cylinder head pivot pin (12).

12
Place a block between the frame and the compensation cylinder
to hold it in position when the boom is removed.
11
Remove the screw (13) from the boom foot pivot pin (14) using
14
a 27 mm wrench.
Remove the boom foot pivot pin.
13
b Before removing the boom foot pivot pin, place the boom
in a horizontal position. The boom’s centre of gravity is
located towards the front, there is a risk of overturning
when the pivot pin is removed.
50-06-M208EN (17/10/2012)
BOOM REMOVAL 5
Lift the boom (14) using the hoist + strap (15), then set it down
on a flat surface.
15
14
50
(17/10/2012) 50-06-M208EN
6 BOOM REMOVAL
50
50-06-M208EN (17/10/2012)
BOOM REFIT
pages
TRIPLEX BOOM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– BOOM REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
50
(19/10/2012) 50-07-M208EN
2 BOOM REFIT
TRIPLEX BOOM
50

Weight of complete boom ≈ 1 875 kg
Specific tools:

– Mallet.
– Trestles.
50-07-M208EN (19/10/2012)
BOOM REFIT 3
BOOM REFIT
3
Using a lifting system (hoist) (1), position the boom (2)on the
1
truck, aligning the boom foot pivot pin (3).
2
Greasing recommendations before pivot pin assembly:

- Fill the cells or pivot pin ring holes.
- Apply a fine film of grease on the pin surface.
88
Insert the pin (4) and the washer on the boom foot.
6 Attach the pin on the boom foot by tightening the screw (5)
50
Using a lifting system (hoist), position the boom (6) at mid-height
Raise the lift cylinder (7) to align the fixing pins.
7 Block the lift cylinder to hold it in position.
(19/10/2012) 50-07-M208EN
4 BOOM REFIT

9 - Apply a fine film of grease on the pin surface.
8
Insert the pin (8) into the lift cylinder head, then attach it by
tightening the screw (9) using a 27 mm wrench.
Remove the block.

- Apply a fine film of grease on the pin surface.
Insert the pin (10) into the compensation cylinder head, then
10 attach it by tightening the screw (11) using a 27 mm wrench.
Remove the block.

11
50
Connect the six hoses

- (x2) telescoping circuit (12)
12 12 - (x2) tilting circuit (13)
- (x2) attachments circuit (14)
13
14
14
13
Refit the link rod swivel joint (15).

15
Plug connectors X114 and X115.
50-07-M208EN (19/10/2012)
BOOM REFIT 5
Refit the rear cover (16).
16 Remove the slings from the boom.
Test the machine: retract/extend all the cylinders to end of

travel in order to fill them with hydraulic fluid.
50
(19/10/2012) 50-07-M208EN
6 BOOM REFIT
50
50-07-M208EN (19/10/2012)
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 FORMS
– STEERING PUMP / DIRECTIONAL BLOCK OSPC 200 LS

– COUNTER BALANCE VALVE
– DOUBLE EXTENSION BALANCING VALVE
– FLOW REGULATING VALVE
– SX 14 S DISTRIBUTOR (INLET)
– SX 14 S DISTRIBUTOR (TILT)
70
– SX 14 S DISTRIBUTOR (TELESCOPING - ACCESSORY)
– SX 14 S DISTRIBUTOR (ELEVATION)
– SX 14 S DISTRIBUTOR (CLOSING)
– TILT CUT-OFF VALVE (VCI)
– STEERING SELECTOR
– HYDRAULIC PUMP A10VO EK1
(07/11/2012) 70-01-M208EN
70
70-01-M208EN (07/11/2012)
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)
DOUBLE EXTENSION BALANCING VALVE bf2,3

Role :
C1
- Insulates the cylinder in case of hose breakage.
C2
- Cylinder movement requires the starting of the I.C.
engine.
V1
- Limits max. pressure due to impacts.
V2
70
C1 C2
300b 1 1 300b 1 - Balancing valve.
2 - By-pass ring.
3 - Temporization screws.
2 2
3
V1 3 V2
Maximum pressure (bar) 350
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(01/02/2011) F70-3-0015EN
70
F70-3-0015EN (01/02/2011)
SPECIFICATIONS 1
FLOW REGULATING VALVE

SPi
Role:
This valve sends hydraulic flow to reservoir in proportion

to the solenoid valve supply value.
EPi
C 70
SPi
B
EPi
A
Maximum pressure (bar) 345 345

Nominal flow rate (L/min) 105 l/mn
Resistance 10 Ω
Maximum current 1,2 A
(08/10/2012) F70-3-0036EN
2 SPECIFICATIONS
C
If «SPi» is supplied at a maximum, the passage
from «A» to «C» is open to the maximum. That
corresponds to maximum pump output.
B SPi
EPi
A = Pump
B = Valve unit
C = Return
C =X%
If «SPi» is supplied at X %, the passage of «A» to «C»
is open at X % that corresponds to X % ofthe flow.
Pressure is thus greater upstream of «SPi».
70
«EPi» is opened and flow goes from the reservoir in

B SPi proportion to the solenoid valve supply.
EPi
F70-3-0036EN (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) F70-3-0043EN
2 CHARACTERISTICS
70
F70-3-0043EN (29/01/2012)
HYDRAULIC PUMP A10VO EK1

Values indicative only
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 741-120 H SERIES 3-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MLT 940-120 H SERIES 3-E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
– KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– HYDRAULIC DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
70
(22/10/2012) 70-02-M208EN
2 HYDRAULIC SCHEMATIC DIAGRAMS

KEY
HYDRAULIC DIAGRAM KEY

Position on
Item Designation Characteristics (Options)
diagram
A ACCUMULATOR O41
BT TRANSFER GEAR BOX C4
CA SUCTION STRAINER S22
CAR NON-RETURN VALVE I19 - O40
CSP COUNTERBALANCE VALVE C34 - C41
CSP DOUBLE COUNTERBALANCE VALVE C31
D 6 ELEMENT DISTRIBUTOR K39
D3 3 POSITION STEERING VALVE G12
Position 1: short steering
Position 2: front wheel steering
Position 3: crab steering
EVPV GEAR CHANGE ELECTROVALVE A2
FDAV FRONT DISC BRAKE C3 - E3
FR RETURN FILTER S20
M ENGINE 1104D-E44 TA K9
Min. rpm 930 rpm (+20/0)
Nominal speed laden 2200 rpm
Max. rpm unladen 2400 rpm
MA MANIPULATOR O38
MC MASTER CYLINDER C11
70
ME FAN MOTOR Q12

MER REVERSIBLE FAN MOTOR M14
MH HYDROSTATIC MOTOR K18
P HYDRAULIC PUMP O30
PAAV FRONT ATTACHMENT PLUG C21
PD STEERING PUMP C7
PF BRAKE PEDAL C10
PH HYDROSTATIC PUMP M11
PR COOLING PUMP Q17
R HYDRAULIC TANK S18
RAD RADIATOR O16 - O19
RLF BRAKE FLUID TANK C12
VC COMPENSATING CYLINDER A32 - A35 110x55 c310
VDAR REAR STEERING CYLINDER E3
VDAV FRONT STEERING CYLINDER E14
VL LIFTING CYLINDER A40
VPV GEAR CHANGE CYLINDER A5
VT1 TELESCOPE CYLINDER A29
VVT(O) CARRIAGE LOCKING CYLINDER (OPTION) A23
NOTE: 1- The calibration pressures of the main relief valves, on the inlet elements, are given for maximum engine rpm.
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
70-02-M208EN (22/10/2012)
HYDRAULIC SCHEMATIC DIAGRAMS 3
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
EVPV
2 1
A B
VPV VVT(O)
A P T VT VI VL A
BT
RLF PAAV
L R
PD 200 bar
PF C1 C2 C1 C2
C2 C1 315 bar 315 bar
FDAV MC
C C
110 bar 110 bar
L.S.
315 bar
CSP CSP CSP
V2 V1 VC V1 V2 V1 V2
170 bar
P T C1 C2
VDAR
VDAV 3
E 2 E
FDAV 1 200 bar
CSP
V1 V2
D3
3 2 1
AV AR
LP
3 2 1
G G
PP
l/mn l/mn l/mn l/mn l/mn l/mn l/mn l/mn
M LS D b B1 A1 B2 A2 B3 A3 b B4 A4
I DLS I
CAR b V_B b V_B

3 bar T2 U
T1 G
b a
P2
R T1 T2 PS MB P
B
70
K Tdd K
480 bar
M
Vg max
Vg min
480 bar 32 bar

a V_A a V_A a 12V
23 bar
14V LS
450 bar A b
a
X1 X2 G S MA
MH
PH LS
270 bar
A B X1 X3 T B A T T B T B
T
MER ²190 bar 280 bar 200 bar 280 bar
EE EI ET EA EL EF
M a a Pr Tpr
M
D 0.8 mm
190 bar
14,5 cm /tr
MA P T
O A O
0,7 lt
190 bar 23 bar
X
14,5 cm /tr 1 3 2 4
RAD RAD
ME
B
P
Q PR Q
CAR
M 63 cm³ M
L L1 S VCI
FR CA
S 10 Microns 125 Microns S
(22/10/2012) 70-02-M208EN
KEY
HYDRAULIC DIAGRAM KEY HYDRAULIC DIAGRAM KEY

Position on Position on
Item Designation Characteristics (Options) Item Designation Characteristics (Options)
diagram diagram
A ACCUMULATOR O35 VC COMPENSATING CYLINDER C33 - C35
BT TRANSFER GEAR BOX A3 VCI TILTING CONTROL CUT-OFF VALVE Q33
CA SUCTION STRAINER S18 VDAR REAR STEERING CYLINDER E14
CAR NON-RETURN VALVE I5 - G35 VDAV FRONT STEERING CYLINDER E2
CSP COUNTERBALANCE VALVE C31 - C34 - C38
VI TILTING CYLINDER A35
CSPD DOUBLE COUNTERBALANCE VALVE C24
VL LIFTING CYLINDER/ A40
D 6 ELEMENT DISTRIBUTOR M24
VPV GEAR CHANGE CYLINDER A5
EE INLET ELEMENT M24
VT1 TELESCOPE CYLINDER 1 A27
EI TILTING ELEMENT M27
VT2 TELESCOPE CYLINDER 2 A31
ET TELESCOPE ELEMENT M30
EA ATTACHMENT ELEMENT M33 VVT(O) CARRIAGE LOCKING CYLINDER (OPTION) A23
EL LIFTING ELEMENT M36

NOTE: 1- The calibration pressures of the main relief valves, on the inlet elements, are given for maximum engine rpm.
EF CLOSING ELEMENT M41
2- The calibration pressures of the secondary relief valves are at an engine speed of 1000 rpm.
D3 3 POSITION STEERING VALVE E11 3- The pressure relief valves should be adjusted at an oil temperature of 50°C.
Position 1: short steering
Position 2: front wheel steering
Position 3: crab steering
EVPV GEAR CHANGE ELECTROVALVE A2
FDAV FRONT DISC BRAKE C3 - E3
70
FR RETURN FILTER S15

LP RELIEF VALVE G7
M ENGINE 1104D-E44 TA K5
Min. rpm 930 rpm (+20/0)
Nominal speed laden 2200 rpm
Max. rpm unladen 2400 rpm
MA MANIPULATOR I32
MC MASTER CYLINDER C10
ME FAN MOTOR G7
MER REVERSIBLE FAN MOTOR M9
MH HYDROSTATIC MOTOR K14
P HYDRAULIC PUMP Q28
PAAV FRONT ATTACHMENT PLUG A21
PD STEERING PUMP C6
PF BRAKE PEDAL C9
PH HYDROSTATIC PUMP M6
PP PRESSURE PORT I24
PR COOLING PUMP Q12
R HYDRAULIC TANK S14
RAD RADIATOR O11 - O14
RLF BRAKE FLUID TANK A11
70-02-M208EN (22/10/2012)
HYDRAULIC SCHEMATIC DIAGRAMS 5
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
EVPV
2 1
A B
VPV VVT(O)
A P T VT1 VT2 VI VL A
BT
RLF PAAV
L R
PD 200 bar
PF C1 C2 C1 C2
C2 C1
C2 C1 315 bar 315 bar
350 bar
FDAV MC
C C
110 bar 110 bar
L.S. CSPD
315 bar
CSP CSP CSP
V2 V1 V2 V1 VC V1 V2 V1 V2
170 bar
P T C1 C2
VDAR
VDAV 3
E 2 E
FDAV 1 200 bar
CSP
V1 V2
D3
3 2 1
AV AR
LP
3 2 1
G G
PP
l/mn l/mn l/mn l/mn l/mn l/mn l/mn l/mn
M LS D b B1 A1 B2 A2 B3 A3 b B4 A4
I DLS I
CAR b V_B b V_B

3 bar T2 U
T1 G
b a
P2
R T1 T2 PS MB P
B
70
K Tdd K
480 bar
M
Vg max
Vg min
480 bar 32 bar

a V_A a V_A a 12V
23 bar
14V LS
450 bar A b
a
X1 X2 G S MA
MH
PH LS
270 bar
A B X1 X3 T B A T T B T B
T
MER ²190 bar 280 bar 200 bar 280 bar
EE EI ET EA EL EF
M a a Pr Tpr
M
D 0.8 mm
190 bar
14,5 cm /tr
MA P T
O A O
0,7 lt
190 bar 23 bar
X
14,5 cm /tr 1 3 2 4
RAD RAD
ME
B
P
Q PR Q
CAR
M 63 cm³ M
L L1 S VCI
FR CA
S 10 Microns 125 Microns S
(22/10/2012) 70-02-M208EN
70
70-02-M208EN (22/10/2012)
HYDRAULIC COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDRAULIC CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
– 1 – MAIN HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– 2 – HYDROSTATIC TRANSMISSION CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– 3 – VENTILATION CONTROL HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– 4 – LIFTING - TELESCOPING HYDRAULIC SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– 5 – BOOM HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– 6 – COMPENSATION - BOOM FEED HYDRAULIC CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . 9
70
– 7 – STEERING HYDRAULIC CIRCUIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
(08/11/2012) 70-03-M208EN
2 HYDRAULIC COMPONENTS LOCATION
KEY
1 - Main 5 - Boom
2 - Operation 6 - Compensation
3 - Ventilation 7 - Steering
4 - Lifting - telescoping
Representation on circuit Electric code

Item Designation
1 2 3 4 5 6 7 equivalence
A ACCUMULATOR √ √
BT TRANSFER GEAR BOX √
CA SUCTION STRAINER √
CAR NON-RETURN VALVE √ √
CSP COUNTERBALANCE VALVE √ √
CSPD DOUBLE COUNTERBALANCE VALVE √
D 6 ELEMENT DISTRIBUTOR √ √ √ √
D3 3 POSITION STEERING VALVE √
EVPV GEAR CHANGE ELECTROVALVE √
FDAV FRONT DISC BRAKE √
FR RETURN FILTER √
LP RELIEF VALVE √
MA MANIPULATOR √
MC MASTER CYLINDER √
ME FAN MOTOR √
MER REVERSIBLE FAN MOTOR √
70
MH HYDROSTATIC MOTOR √
P HYDRAULIC PUMP √
PAAV FRONT ATTACHMENT PLUG √
PD STEERING PUMP √
PF BRAKE PEDAL √
PH HYDROSTATIC PUMP √ √ √
PP PRESSURE PORT √
PR COOLING PUMP √
R HYDRAULIC TANK √ √
RAD RADIATOR √ √
RLF BRAKE FLUID TANK √
VC COMPENSATING CYLINDER √
VCI TILTING CONTROL CUT-OFF VALVE √
VDAR REAR STEERING CYLINDER √
VDAV FRONT STEERING CYLINDER √
VI TILTING CYLINDER √
VL LIFTING CYLINDER/ √
VPV GEAR CHANGE CYLINDER √
VT TELESCOPE CYLINDER (MLT 741) √
VT1 TELESCOPE CYLINDER 1 (MLT 940) √
VT2 TELESCOPE CYLINDER 2 (MLT 940) √
70-03-M208EN (08/11/2012)
HYDRAULIC COMPONENTS LOCATION 3
HYDRAULIC CIRCUITS
1 – MAIN HYDRAULIC CIRCUIT
MLT 741 - 120 H Series 3 - E3

MLT 940 - 120 H Series 3 - E3
PP
R D
T
CAR Ls
P
FR
70
R
CAR
CA
PH S
T1
(08/11/2012) 70-03-M208EN
MA
T
4
1 P
3
Tpr Tdd 2
T P 2 1 4 3
Pr
VCI
CAR
2 – HYDROSTATIC TRANSMISSION CIRCUIT

70
MLT 741 - 120 H Series 3 - E3

MLT 940 - 120 H Series 3 - E3
PH
MH
70-03-M208EN (08/11/2012)
A
EVPV P
CAR
VPV
BT PH
70
RAD
PH
T2
MH
T2
T1
(08/11/2012) 70-03-M208EN
3 – VENTILATION CONTROL HYDRAULIC CIRCUIT
MLT 741 - 120 H Series 3 - E3

MLT 940 - 120 H Series 3 - E3
PR
ME
RAD MER
R
70
70-03-M208EN (08/11/2012)
4 – LIFTING - TELESCOPING HYDRAULIC SYSTEM
MLT 741 - 120 H Series 3 - E3

D
VT
CSP
V1
C1
V2
C2
VL
CSP
V1
V1
V2
V2
CSP
70
MLT 940 - 120 H Series 3 - E3
D
V2
C2
V1
C1
CSP
VL
V1
CSP
V2
(08/11/2012) 70-03-M208EN
5 – BOOM HYDRAULIC CIRCUIT
MLT 741 - 120 H Series 3 - E3
PAAV
VI
CSP
70
MLT 940 - 120 H Series 3 - E3
CSPD PAAV
VT1
A
B
C
D
E
F
A B
C D
E
F
VT2
CSP
VI
CSP
70-03-M208EN (08/11/2012)
6 – COMPENSATION - BOOM FEED HYDRAULIC CIRCUIT
MLT 741 - 120 H Series 3 - E3
VC
70
MLT 940 - 120 H Series 3 - E3
VC
(08/11/2012) 70-03-M208EN
7 – STEERING HYDRAULIC CIRCUIT
MLT 741 - 120 H Series 3 - E3

MLT 940 - 120 H Series 3 - E3
LP
S
DL
ES. AV
D
VDAV
LS D
PD R
T
P
VDAR
D3
ES. AR
70
RLF
MC
FDAV
PH
PF ES. AV
FDAV
70-03-M208EN (08/11/2012)
CONTRÔLE ET RÉGLAGE HYDRAULIQUES
pages
DISTRIBUTOR CONTROL LOGIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

OPERATING PRINCIPLES OF AGGRAVATING MOVEMENTS CUT-OFF . . . . . . . . . . . . . . . . .4
REMOVAL OF SX 14 S DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
– 1 - SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
– 2 - TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– 3 - ESSENTIAL RULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– 4 - REMOVAL AND RE-FITTING OF THE SX 14 S UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– 5 - SX 14 S UNIT REPAIR PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
70
– 6 - SPECIFIC TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
(07/11/2012) 70-04-M208EN
2 HYDRAULIC CONTROL AND ADJUSTEMENT
DISTRIBUTOR CONTROL LOGIC
The JSM sends directional and proportional value data from thumbwheels 1 and 2 to the SPU computer.
The computer converts these data into PWM control signals for the 4 coils controlling attachment and
boom movements.
X167.1 S167
1
2
3
4
12
5
6 11
10
9
8
7
X606
A606
1
8
14
20 7
13
19
26
X607
1
10
18
26 9
17
25
34
X203
1
2
3
4
12
5
6 11
10
9
8
7
Y504 Y503 Y502 Y501

70
Item Designation
A606 SPU MODULE

S167 JSM (JOYSTICK SWITCH AND MOVE)
Y501 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE
Y502 TELESCOPE RETRACT PROPORTIONAL ELECTROVALVE
Y503 ATTACHMENT PROPORTIONAL ELECTROVALVE 1
Y504 ATTACHMENT PROPORTIONAL ELECTROVALVE 2
Name
Harness Item Designation
component
Main X167.1 S167 JSM (JOYSTICK SWITCH AND MOVE)
Main X208 S208 HYDRAULIC MOVEMENT NEUTRALISATION SWITCH
Main X209 S209 EASY CONNECT SYSTEM SWITCH (OPTION)
Distributor X501 Y501 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE
Distributor X502 Y502 TELESCOPE RETRACT PROPORTIONAL ELECTROVALVE
Distributor X503 Y503 ATTACHMENT PROPORTIONAL ELECTROVALVE 1
Distributor X504 Y504 ATTACHMENT PROPORTIONAL ELECTROVALVE 2
70-04-M208EN (07/11/2012)
HYDRAULIC CONTROL AND ADJUSTEMENT 3
JSM
SPU
70
Rexroth distributor
(07/11/2012) 70-04-M208EN
OPERATING PRINCIPLES OF AGGRAVATING MOVEMENTS CUT-OFF
Movement cut-off is activated by the VRP/SPU or VCI at 105% gauge signal.

If the gauge signal indicates 112% the VS is also cut off.
(These values change according to the boom angle)
The VS cut-off occurs 7% after proportional cut-off to account for the possibility of the SPU taking longer
to cut off the proportionals. The VS, therefore cuts off all movements at 112%.
MA
1
1 2 3 4
VCI
DLS
b b
2 P
Tdd VS
VRP
a a
70
b
LS
T B A T B T T B
T T
EI
a a a Pr Tpr
3
1 - Tilt cut-off valve (VCI).

2 - Movement cut-off valve (VS).
3 - Control Regulation Valve (VRP).
70-04-M208EN (07/11/2012)
REMOVAL OF SX 14 S DISTRIBUTOR
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 followed without fail in order to ensure your safety and avoid the risk of
material damage in the course of maintenance or repair operations.
(07/11/2012) 70-04-M208EN
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.
Abnormal operation of the actuators connected to the control block.
Malfunction observed Probable cause Additional checks Solutions

Lack of power at all - LS pressure relief valve Measure the pressure - Replace the LS
actuators defective (see unit specifications) pressure relief valve (cf.
§ 5.1)
- LS pressure relief valve - Adjust the LS pressure
out of adjustment relief valve
Lack of power on one - Secondary suppression - Reset to design
actuator only limiter out of pressure (see unit
adjustment specifications)
- Secondary pressure
relief valve jammed - Replace the secondary
«open» (return to tank) pressure relief valve (cf.
§ 5.5)
Lack of speed in one or all For SX 14 S fitted with Change the body +
movements “open center” inlet: “open piston assembly
center” piston stuck in
position P towards T
Lack of speed in one - Incorrect slide Manual control: - If movement is
movement movement incorrect, change the
70
measure slide movement.

- Adjustable hydraulic Direct electrical control: body + slide assembly.
control stop out of check the coil resistance If the resistance is
adjustment (R: 2,5 Ohm at 25°C) incorrect change the
- Individual compensator coil.
pressure blocked - Adjust the LS pressure
relief valve
- Replace housing and
pressure compensator
assembly
Failure to maintain - Load hold check valve - Change the body +
pressure faulty valve assembly
- Excessive play between - Change the body +
the body and the slide slide assembly
Steering abnormally hard Flow divider adjustment - Adjusting piston sliding - Replace control
problem freely sub-system (cf. § 5.3)
- Adjusting piston - Replace housing and
jammed control sub-system
(cf. § 5.7 and 5.3)
Excessive delay in Flow Divider regulation Change the filter
response to steering piston filter clogged
70-04-M208EN (07/11/2012)

Clamps faulty (SX14S - Output coil defective - Check coil resistance (R: If resistance is incorrect,
fitted on loading shovel) - Output component 6 Ohm at 20°C) change the coil.
ball valve faulty Change the ball
- 2 way valve defective valveball
Change the 2 way valve
Simultaneous movement - Individual compensator - Remove and clean
fault orifice blocked individual compensator
(cf. § 5.7)
- Individual compensator - Replace housing and
pressure blocked pressure compensator
assembly
- LS line leakage - Replace LS flow regulator
(cf. § 5.2)
Abnormal machine operation

Engine remains under load - Flow regulator blocked - Change the flow regulator
after spools have returned - Regulator filter blocked (cf. § 5.2)
to neutral - Change the filter
Abnormal control block operation

Locking fault - Mechanical defect - Check coil resistance - Change the latch
70
- Defective coil (R: 16,5 Ohm at 20°C) mechanical
- If resistance is incorrect,
change the coil
Increased force on controls Control block assembly tie Check tightening torque Loosen and adjust to
or spool return defective rods too tight tightening torque 42 ±
10% N.m.
b Before commencing
free the distribution
unit from its fixing
points
Replace the spool seals (cf.
§ 5.6)
Spool seals worn out
(07/11/2012) 70-04-M208EN
Visual defects.

Spool leaking oil Spool seals defective Change spool seals(cf.
§ 5.6)
Oil leaks at pressure relief Defective seals Remove the pressure relief
valves and plugs valve or plug and replace
the seals
Oil leakage between Defective seals between Remove distribution
elements elements modules and change seals
(cf. § 5.7)
Hydraulic controller oil - Faulty seal between Change the seal
leaks housing and body
- Defective adjustable stop
nut seal
Damaged joystick control Replace boot
bellows
3 - ESSENTIAL RULES
GENERAL NOTES CONCERNING CONNECTING UP THE DISTRIBUTION UNIT
– When the block is removed all openings must be plugged immediately to avoid any contamination
of the hydraulic circuit.
– When re-fitting the block remove the plastic plugs from openings just before re-making connections.
70
– Do not tighten connectors to a torque greater than that specified in the assembly instructions.
– Check the quality of the hydraulic oil and the filtration capacity during all maintenance or repair
operations.
– The use of PTFE tape, hemp and jointing compound is forbidden.
– Hydraulic lines and connections must be under not strain of any kind.
70-04-M208EN (07/11/2012)
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 stored pressures by moving all the distribution spools.
4.2 REMOVAL OF THE SX 14 S UNIT
– 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
– Ensure mating faces are perfectly clean.

– Check the mating surface of the unit with the machine for flatness (tolerance 0.5 mm).
70
– 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.
(07/11/2012) 70-04-M208EN
5 - SX 14 S UNIT REPAIR PROCEDURES
5.1 CHANGING THE LS LIMITER
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.
NOTE : Collect any oil leaks in an appropriate recipient.
On the inlet, unbolt the LS limiter (17 mm spanner).
Reassembly: tightening torque: cf. § 6.
5.2 ÉCHANGE DU RÉGULATEUR DE DÉBIT
NOTE: There is no need to remove the control block from the

telehandler for this operation.

- Place all actuators connected to the control block in
70
their rest position.

slides.
NOTE : Collect any oil leaks in an appropriate recipient.
On the inlet, unbolt the LS limiter (22 mm spanner).
Dépose et échange du filtre
Using flat-nosed pliers, remove the filter from the regulator.
Filtre
b Take care not to damage the O-ring at the end of the
regulator.
70-04-M208EN (07/11/2012)
5.3 DIS-ASSEMBLY OF FLOW DIVIDER REGULATION SUB-ASSEMBLY
NOTE: There is no need to remove the control block from the telehandler for this operation.

- Place all actuators connected to the control block in their rest position.
- Release all stored pressure by moving the distribution slides.
NOTE:
- Fit a vacuum pump to the fluid reservoir in order to limit
any possible oil leaks during this operation.
- Catch any ol leaks in an appropriate recipient.
- Unscrew 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
5.4 FLUSHING VALVE REMOVAL
NOTE: There is no need to remove the control block from the telehandler for this operation.

- Place all actuators connected to the control block
in their rest position.
slides.
(07/11/2012) 70-04-M208EN
- On the outlet element, unscrew the flushing valve plug (12

Plug 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.

- Place all actuators connected to the control block
in their rest position.
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).
- Remove the cup and spring.

- Remove the O-ring from the cover.
- Extract the spool from the distribution element.
Re-fitting: Grease new seals when fitting.
b Spool fitting direction.

70-04-M208EN (07/11/2012)
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).
- 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.
(07/11/2012) 70-04-M208EN
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
70-04-M208EN (07/11/2012)
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

2 - Flow controller 9 - Return housing
70
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
(07/11/2012) 70-04-M208EN
70
70-04-M208EN (07/11/2012)
HYDRAULIC COMPONENTS REMOVAL
pages
HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
HYDRAULIC COOLING PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
70
(26/09/2012) 70-06-M208EN
2 HYDRAULIC COMPONENTS REMOVAL
HYDRAULIC MOTOR
A
70
Key :
A - Hydraulic motor
– Stabilize the machine on a horizontal floor.

– Pull boom up and make sure it is positioned correctly.
– Deactivate battery power supply using a battery cut-off.
Specifi c tools:
– Allen wrench
70-06-M208EN (26/09/2012)
HYDRAULIC COMPONENTS REMOVAL 3
HYDRAULIC MOTOR REMOVAL
Remove the strut cover (Item 1) with a screwdriver, then disengage

2
the strut (Item 2) from the bonnet (Item 3).
1
Use a 13 mm spanner to remove the nut (Item 4) and remove

the mounting (Item 5).
6
6
Undo the radiator (Item 7) fixing bolts (Item 6) and the front
and rear bonnet (Item 8) mounting bolts (Item 6), using a 13
mm spanner.
6
6 8
Remove the bonnet.
4 7
5
Remove the four fixing bolts (Item 9) from the front bonnet
bracket lug using a 13 mm spanner.
Remove the six fixing bolts (Item 9) from the cover plate (Item
10) located to the front of the engine bay (Item 11), using 10 mm
70
11
9 and 13 mm spanners.
9 10
Remove the drain covers (Item 12) under the engine bay (Item
14
12 13), using a 10 mm spanner to remove the fixing bolts (Item 14).
14
14
14
12
14 13
(26/09/2012) 70-06-M208EN
16
Use a 30 mm spanner to disconnect the hydraulic motor supply
hose (Item 15) and then the outlet hose (Item 16) towards the
15 radiator.
Disconnect connectors X252 (Item 17) and X253 (Item 18) from
the upper and lower solenoid operated valves.
18
17
Disconnect the bypass hose (Item 19) located underneath the

hydraulic motor (Item 20), using a 17 mm spanner. Hold the hose
opening up in the air to avoid oil draining from the reservoir.
19
20
Disconnect the outlet hose (Item 21) from the hydraulic motor
using a 36 mm spanner, and then the union (Item 22) located
70
23
on the radiator (Item 23) using a 32 mm spanner.
22
21
Remove the fuel filter (Item 24) located to the front of the
engine bay (Item 25), removing the two bolts (Item 26) using
a 15 mm spanner.
26 26
25
24
70-06-M208EN (26/09/2012)
Affix twine (Item 28) to the radiator (Item 27) and use it to hold
the radiator leaning as far towards the rear of the machine as
possible.
28
27
33 Using a 13 mm spanner undo the six fixing bolts (Item 29), three
on each side of the radiator.
29
32
Move the entire fan cowl (Item 30), fan (Item 31), fan grille (Item
32) and hydraulic motor (Item 33) assembly upwards, then remove
30 the assembly from the engine bay.
31
29
Undo the five fan (Item 35) fixing bolts (Item 34) using two 10
mm spanners.
70
34 34
35
34 34
34
Withdraw the fan hub (Item 36) using a gear puller (Item 37).
36 37
(26/09/2012) 70-06-M208EN
Remove the four bolts (Item 38) fixing the hydraulic motor (Item
39) to the grille (Item 40) using two 13 mm spanners.
Hydraulic motor removal.
40 38
39
38
70
70-06-M208EN (26/09/2012)
70
(26/09/2012) 70-06-M208EN
HYDRAULIC COOLING PUMP
A
70
Key :
A - Hydraulic pump

– ull boom up and make sure it is positioned correctly.
– Decompress all hydraulic components before dismantling.
Specifi c tools:
70-06-M208EN (26/09/2012)
REMOVE COOLER
e 10 «Remove engine»
HYDRAULIC COOLING PUMP REMOVAL
Remove the hydraulic motor supply hose (Item 1) located on top

of the hydraulic pump (Item 2) using a 32 mm spanner.
Using a 41 mm spanner, remove the pump supply hose (Item 3).

3
Hold the open hose (Item 4) up in the air to avoid the oil tank
draining.
70
4
5 7
Remove the four bolts (Item 5) which secure the hydraulic pump
(Item 6) to the vehicle engine (Item 7), using a 13 mm spanner.
5
5
6
(26/09/2012) 70-06-M208EN
70
70-06-M208EN (26/09/2012)
HYDRAULIC COMPONENTS REFIT
pages
HYDRAULIC COOLING PUMP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

HYDRAULIC MOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
70
(27/09/2012) 70-07-M208EN
2 HYDRAULIC COMPONENTS REFIT
HYDRAULIC COOLING PUMP
A
70
Key :
A - Hydraulic pump

– Decompress all hydraulic components before dismantling.
Specific tools:
70-07-M208EN (27/09/2012)
HYDRAULIC COMPONENTS REFIT 3
HYDRAULIC COOLING PUMP REFIT

3
2
Refi t the hydraulic pump (Item 1) to the vehicle engine (Item
3
2), using a 13 mm spanner to tighten the fixing bolts (Item 3).
Connect the oil inlet hose (Item 4) to the opening at the bottom
of the pump (Item 5), using a 30 mm spanner.
Using a 30 mm spanner, attach the hose (Item 6) connecting the

pump to the hydraulic motor
70
70
6
Connect the oil inlet hose (Item 7) from pump to hydraulic motor
(Item 8), using a 30 mm spanner.
(27/09/2012) 70-07-M208EN
HYDRAULIC MOTOR
A
70
Key :
A - Hydraulic motor

Specific tools:
70-07-M208EN (27/09/2012)
RE-FITTING COOLING SYSTEM CHAPTER
2
e 10 «Replace engine»
3
1
HYDRAULIC MOTOR REFIT
3
3 Re-fit the hydraulic motor (Item 1), locating it on the fan grille
(Item 2) and assembling using the four bolts (Item 3) and a 13
mm spanner.
Place the hub (Item 4) on the hydraulic motor axle (Item 5) and
4 assemble with a nut and a 19 mm spanner.
Secure the five fan fixing bolts (Item 6) using two 10 mm spanners.
70
6 6
Insert the entire fan, fan cowl, fan grille and hydraulic motor
8
7 assembly (Item 7) then secure it to the radiator with the six fixing
bolts (Item 8) using a 13 mm spanner.
Remove the twine holding the radiator in a leaning-back position.
(27/09/2012) 70-07-M208EN
Using a 15 mm spanner locate and secure the fuel filter (Item

9) with its two fixing bolts (Item 10).
10
10
Connect the union (Item 11) using a 32 mm spanner. Connect the

hydraulic motor outlet hose (Item 12) using a 36 mm spanner.
11
12
Connect the bypass hose (Item 13) using a 17 mm spanner.

70
13
Connect connectors X252 and X253.

15
Connect and tighten the outlet hose (Item 14) using a 30 mm

spanner.
Connect and tighten the hose (Item 15) using a 30 mm spanner.
14
70-07-M208EN (27/09/2012)
Position the bonnet bracket (Item 16) and secure it using the
four fixing bolts (Item 17) and a 13 mm spanner.
17
Position the silentbloc mounting (Item 18) then secure it using
21 a nut (Item 19) and a 13 mm spanner.
17
20 16
17 Locate and secure the cooler lug (Item 20) and the bonnet (Item
19
18 17 21) using their fixing bolts (Item 17) and a 13 mm spanner.
17
17
Secure the bonnet strut in place (Item 22) then clip it in using
the strut cover (Item 23).
23
22
Locate and secure the cover plate (Item 24) using the six fixing
bolts (Item 25) and a 13 mm spanner.
70
25
25
25
24
25
27
Locate and secure the drain covers (Item 26) under the engine
bay using their fixing bolts (Item 27) and a 13 mm spanner.
27
26
27
26
27
(27/09/2012) 70-07-M208EN
70
70-07-M208EN (27/09/2012)
HYDRAULIC SPECIFIC TOOLING
pages
BASIC MANOMETER KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
70
(07/11/2012) 70-09-M208EN
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-M208EN (07/11/2012)
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
(07/11/2012) 70-09-M208EN
4 HYDRAULIC SPECIFIC TOOLING
70
70-09-M208EN (07/11/2012)
ELECTRICITY
- ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL COMPONENTS LOCATION
- ELECTRICAL CONTROL AND ADJUSTEMENT
- ELECTRICAL COMPONENTS REMOVAL
- 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
(03/12/2012) 80-01-M208EN
2 SPECIFICATIONS
80
80-01-M208EN (03/12/2012)
SPECIFICATIONS A1
ELECTRICAL AND ELECTRONIC SYSTEM OVERVIEW

pages
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A2
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A3
80
80
(14/11/2012) 80-01-M208EN
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-M208EN (14/11/2012)
SPECIFICATIONS A3
SYSTEM OVERVIEW
Seat sensor
FNR
Thumbwheels
Parachute
switch
FAN DRIVE
Tin
sensor
VCI
Gauge signal
-100%
-120%
130%
Jib
Angle
Cut-off
redundancy
VRP
VS 80
80
SX14S
ADM2
Strain gauge
LLMI Module
MR2-PLD
Transmission Can-Bus
Hydraulic operation Stability monitoring Operator presence
(14/11/2012) 80-01-M208EN
A4 SPECIFICATIONS
80
80
80-01-M208EN (14/11/2012)
SPECIFICATIONS B1
INPUTS/OUTPUTS
pages
HYDRAULIC ECU INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B3

– REXROTH RC2-2/20 ECU (WITH CAN). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
SPU INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B4
– SPU 25-15 (LSU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
ADM INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B6
– ADM 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B6
PLD INPUTS/OUTPUTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B8
– PLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B8
80
(09/11/2012) 80-01-M208EN
B2 ELECTRICAL CHARACTERISTICS AND SPECIFICATIONS
80
80-01-M208EN (09/11/2012)
SPECIFICATIONS B3
HYDRAULIC ECU INPUTS/OUTPUTS

Rexroth RC2-2/20 ECU (WITH CAN)
Key :
ECU: Electronic Control Unit A79

NC: Not connected
41 52
27 28
X79 1 2 3 14
Designation 18 ECU TYPE CONNECTOR PIN No. WIRE Function on truck Comments
Power supply X79 01 Proportional and ON/OFF output power supplies
GND X79 02 RC2-2/20 Ground
X79 24 CAN AND RX/TX RS232 Ground Cable Drain CAN
X79 27 Proportional and ON/OFF output power supplies
X79 28 RC2-2/20 Ground
X79 32 Ground
X79 39 CAN L
X79 40 CAN H
X79 41 RC2-2/21 Microcontroller power supplies
X79 42 RC2-2/21 Microcontroller power supplies
X79 50 RXD RS 232
X79 51 TXD RS 232
X79 52 Reserved for REXROTH software flashing
80
(09/11/2012) 80-01-M208EN
B4 SPECIFICATIONS
SPU INPUTS/OUTPUTS
SPU 25-15 (LSU)
Key:
SPU: Signal Processing Unit A606

NC: Not connected
X607
X606 X606 X607
SPU 25-15 LSU

12 V T APC POWER SUPPLY 12VB X606 01 12V + POST IGNITION (APC) + APC
PWM OUTPUT 8 HSD-08 X606 02 ATTACHMENT PLUS DIRECTION SELECTOR
LOW SIDE OUTPUT 2 LSD-02 X606 03 NOT USED
LOW SIDE OUTPUT 2 LSD-02 X606 04 NOT USED
LOW SIDE OUTPUT 1 LSD-01 X606 05 SAFETY ELECTROVALVE (VS) GROUND
LOW SIDE OUTPUT 1 LSD-01 X606 06 PROPORTIONAL ELECTROVALVE GROUND (Lower)
12 V BATTERY POWER SUPPLY 12VP X606 07 12V MICRO-SWITCH SUPPLY BATTERY
ANALOGUE INPUT 2 UN-09 X606 08 SENSOR 2 BOOM ANGLE INPUT SIGNAL I FROM 0,5V TO 4,5 V
LOGICAL INPUT 19 FQ-04 X606 09 NOT USED
LOGICAL INPUT 13 FQ-02 X606 10 EASY CONNECT SYSTEM GROUND DATA
LOGICAL INPUT 04 UN-06 X606 11 12V CUT-OF OVERRIDE INPUT SWITCH HELD 60° MAX
LOGICAL INPUT 14 UN-03 X606 12 12 V THUMBWHEEL 1 DIRECTION DATA INPUT THUMBWHEEL 1 OUTSIDE NEUTRAL ZONE
ECU WAKE-UP INPUT WUI X606 13 ECU WAKE-UP INPUT +12V apc THIS INPUT CAN BE CUT-OFF BY EMERGENCY STOP
PWM OUTPUT 7 HSD-07 X606 14 ATTACHMENT PROPORTIONAL CONTROL
LOGICAL INPUT 10 FQ-03 X606 15 ECU WAKE-UP INPUT +12V apc THIS INPUT CAN BE CUT-OFF BY EMERGENCY STOP
LOGICAL INPUT 12 FQ-01 X606 16 HYDRAULIC MOVEMENT NEUTRALISATION GROUND INPUT
LOGICAL INPUT 01 UN-05 X606 17 NO SENSOR 12 V SEAT INPUT DRIVER PRESENCE

80
ANALOGUE INPUT 03 UN-02 X606 18 JSM THUMBWHEEL 1 ANALOGUE INPUT FROM 0,5V TO 4,5V TELESCOPE
5V REF. STABILIZED OUTPUT U 5V INPUT X606 19 NOT USED
GROUND GROUND X606 20 ECU GROUND
STABILISED 200mA 10V REF OUTPUT SENSOR X606 21 ATTACHMENT CONTROL / STRAIN GAUGE SELECTOR CONTROL 4 POSITIONS: 25% - 50% - 75% - 100%
LOGICAL INPUT 03 UN-08 X606 22 CONTINUE FLOW CONTROL
LOGICAL INPUT UN-07 X606 23 HAND BRAKE DATA
LOGICAL INPUT 17 UN-04 X606 24 FAN REVERSE SIGNAL
ANALOGUE INPUT 01 UN-01 X606 25 BOOM ANGLE SENSOR 1 ANALOGUE INPUT SIGNAL FROM 0,5V TO 4,5 V
80-01-M208EN (09/11/2012)
SPECIFICATIONS B5
SPU 25-15 LSU

GROUND GROUND X606 26 ECU GROUND
CAN HIGH CAN H X607 01 CAN H
CAN LOW CAN L X607 02 CAN L
SPU +APC POWER SUPPLY 12VD X607 03 ECU WAKE-UP INPUT +12V apc THIS INPUT CAN BE CUT-OFF BY EMERGENCY STOP
12 V + APC POWER SUPPLY 12VD X607 04 ECU WAKE-UP INPUT +12V apc THIS INPUT CAN BE CUT-OFF BY EMERGENCY STOP
PWM OUTPUT-06 HSD-06 X607 05 TELESCOPE PROPORTIONAL ELECTROVALVE CONTROL INPUT
PWM OUTPUT-04 HSD-04 X607 06 LOWERING PROPORTIONAL ELECTROVALVE POWER SUPPLY
PWM OUTPUT-01 HSD-01 X607 07 SAFETY ELECTROVALVE (VS) POWER SUPPLY
12V POWER SUPPLY 12VC X607 08 POWER SUPPLY + ECU APC + 12VC
12V POWER SUPPLY 12VC X607 09 POWER SUPPLY + ECU APC + 12VC
CAN 2 HIGH CAN 2 HI X607 10 NOT USED
120 Ω RESISTOR CAN 1 120 X607 11 CAN TERMINAL RESISTANCE R 120
LOGICAL INPUT 16 UN-19 X607 12 NOT USED
ANALOGUE INPUT 5 UN-17 X607 13 CONTINUE FLOW ATTACHMENT FLOW SELECTOR INPUT
LOGICAL INPUT 9 UN-15 X607 14 REVERSE GEAR INFO INPUT
LOGICAL INPUT 5 UN-12 X607 15 BOOM RETRACTED NO SENSOR 12 V INPUT
ANALOGUE INPUT 4 UN-10 X607 16 JSM THUMBWHEEL 2 ANALOGUE INPUT (Attachment)
PWM OUTPUT 2 HSD-02 X607 17 TRANSMISSION CUT-OFF OUTPUT
CAN 2 LOW CAN 2 60 X607 18 NOT USED
LOGICAL INPUT 11 UN-20 X607 19 ATTACHMENT 1 & 2 LOCKING CONTROL INPUT
LOGICAL INPUT 18 UN-18 X607 20 OIL TEMPERATURE INPUT SENSOR
LOGICAL INPUT 07 UN-16 X607 21 NOT USED
LOGICAL INPUT 08 UN-14 X607 22 FORWARD GEAR INFO INPUT
LOGICAL INPUT 06 UN-13 X607 23 BOOM RETRACTED SENSOR 12 V INPUT
LOGICAL INPUT 15 UN-11 X607 24 THUMBWHEEL 2 DIRECTION SWITCH 12V INPUT (Attachment) Thumbwheel 2 Neutral zone output
PWM OUTPUT 9 HSD-09 X607 25 FAN CONTROL INPUT
LIN INTERFACE LIN X607 26 NOT USED
CAN 2 120 Ω CAN 2 120 27 NOT USED
CAN 1 MASSE CAN GROUND X607 28 CAN 1 SHIELDING GROUND
PWM OUTPUT 5 HSD-05 X607 29 TELESCOPING PROPORTIONAL ELECTROVALVE CONTROL OUTPUT
80
PWM OUTPUT 3 HSD-03 X607 30 FAN REVERSAL INPUT
ANALOGUE SENSOR GROUND GROUND A X607 31 ANALOGUE SENSOR GROUND
PWM OUTPUT 11 HSD-11 X607 32 TILTING CUT-OFF CYLINDER ELECTROVALVE
PWM OUTPUT 10 HSD-10 X607 33 CONTINUE FLOW INDICATOR OUTPUT
ECU GROUND GROUND X607 34 ECU GROUND
(09/11/2012) 80-01-M208EN
B6 SPECIFICATIONS
ADM INPUTS/OUTPUTS
ADM 2
Key:

NC: Not connected
X465 X466 X464
X464
X466
X465
ADM 2
P DOWN LOGICAL INPUT X465 01 STARTER SWITCH + APC
X465 02 NOT USED
ANALOGUE OUTPUT X465 03 NOT USED
ANALOGUE OUTPUT X465 04 OIL TEMPERATURE INDICATOR OUTPUT
LOW SIDE OUTPUT X465 05 NOT USED
LOW SIDE OUTPUT X465 06 ENGINE SPEED GAUGE OUTPUT
P UP LOGICAL INPUT X465 07 NOT USED
P UP LOGICAL INPUT X465 08 NOT USED I FROM 0,5V TO 4,5 V
P DOWN LOGICAL INPUT X465 10 PRE-HEATING OPTION INPUT
P DOWN LOGICAL INPUT X465 11 NOT USED SWITCH HELD 60° MAX
P DOWN LOGICAL INPUT X465 12 NOT USED ON WALVOIL DISTRIBUTOR
P UP LOGICAL INPUT X466 01 NEUTRAL TRANSMISSION INPUT THIS INPUT CAN BE CUT-OFF BY EMERGENCY STOP
SUPPLY X466 04 NOT USED
HIGH SIDE OUTPUT X466 05 ACCELERATOR POTENTIOMETER POWER SUPPLY

80
HIGH SIDE OUTPUT X466 06 NOT USED FROM 0,5V TO 4,5V TELESCOPE
ANALOGUE INPUT X466 08 NOT USED
LOW SIDE OUTPUT X466 09 PRE-HEATING OPTION RELAY
HIGH SIDE OUTPUT X466 10 NOT USED
LOW SIDE OUTPUT 4 LS CONFIG. X466 11 NOT USED
LOW SIDE OUTPUT 1 LS CONFIG. X466 12 NOT USED ON WALVOIL DISTRIBUTOR
CAN H X466 13 LOW SPEED CAN (HIGH)
CAN GND X466 14 CAN GND
CAN L X466 15 LOW SPEED CAN (LOW)
80-01-M208EN (09/11/2012)
SPECIFICATIONS B7
ADM 2
SUPPLY X464 01 BATTERY POWER SUPPLY
P DOWN LOGICAL INPUT X464 02 + 12V INPUT
SUPPLY X464 03 GROUND
LOW SIDE OUTPUT X464 05 RED MACHINE SHUTDOWN INDICATOR LAMP OUTPUT
LOW SIDE OUTPUT X464 06 YELLOW CHECK MACHINE INDICATOR LAMP OUTPUT
LOW SIDE OUTPUT X464 07 STARTER INDICATOR LAMP OUTPUT
SUPPLY X464 09 NOT USED
P DOWN LOGICAL INPUT X464 10 NOT USED
P DOWN ANALOGUE INPUT X464 11 NOT USED
P DOWN LOGICAL INPUT TRACK 1 ANA X464 12 ACCELERATOR POTENTIOMETER INPUT 2
P DOWN LOGICAL INPUT TRACK 2 ANA X464 13 ACCELERATOR POTENTIOMETER INPUT 1
SUPPLY GND X464 14 ACCELERATOR POTENTIOMETER GROUND
P UP LOGICAL INPUT X464 16 PARKING BRAKE SWITCH INPUT
CAN H X464 19 CAN H HIGH SPEED
CAN GND X464 20 CAN H GROUND
CAN L X464 21 CAN H LOW SPEED FROM 0.5V TO 4.5 V
80
(09/11/2012) 80-01-M208EN
B8 SPECIFICATIONS
PLD INPUTS/OUTPUTS
PLD
Key:

NC: Not connected MR2-54
X716
MR2-54
37
1
19
16 8
9 1
54
18
36
X716
PLD
INPUT OAB_S MR2-54 00 OIL SEPARATOR
INPUT NW_B MR2-54 01 CAMSHAFT SENSOR
INPUT KW_B MR2-54 02 CRANKSHAFT ANGLE POSITION SENSOR
INPUT TMOT_B MR2-54 03 COOLANT LIQUID TEMPERATURE SENSOR
INPUT TFUEL_B MR2-54 04 FUEL TEMPERATURE SENSOR
INPUT POEL_M MR2-54 05 FAN SPEED SENSOR
FINISH POELAKT_P MR2-54 06 ENGINE PRESSURE SENSOR
FINISH P2_P MR2-54 07 AIR SUPPLY PRESSURE SENSOR
INPUT NTL2_S MR2-54 08 SPEED SENSOR
FINISH MVB 2 MR2-54 09 INJECTOR VALVES 2
INPUT POELAKT_M MR2-54 10 ACTIVE OIL PRESSURE SENSOR
FINISH PV_M MR2-54 11 PROPORTIONAL VALVE GROUND
FINISH PVB_P MR2-54 12 PROPORTIONAL VALVE
PDK_P MR2-54 13 OPTIONAL FUEL PRESSURE
FINISH P23_P MR2-54 14 REFUSE REMOVAL SLOPE SENSOR/FAN SPEED SENSOR
INPUT TOEL_P MR2-54 15 OIL TEMPERATURE SENSOR
FINISH MVB 1 MR2-54 16 INJECTOR VALVES 1
80
INPUT NLUE_S MR2-54 17 SPEED SENSOR

FINISH ANLA MR2-54 18 STARTER
INPUT KW_A MR2-54 19 CRANKSHAFT ANGLE POSITION SENSOR
INPUT NW_A MR2-54 20 CAMSHAFT SENSOR
INPUT T2_B MR2-54 21 TURBO AIR TEMPERATURE SENSOR
PDK_M MR2-54 22 OPTIONAL FUEL PRESSURE
INPUT P2_M MR2-54 23 AIR SUPPLY PRESSURE SENSOR
INPUT NTL_S MR2-54 24 SPEED SENSOR
INPUT MSST_S MR2-54 25 ENGINE START SWITCH
INPUT POEL_S MR2-54 26 PASSIVE ENGINE OIL PRESSURE SENSOR
FINISH PV5 MR2-54 27 PROPORTIONAL VALVE 5
PDK_S MR2-54 28 OPTIONAL FUEL PRESSURE
INPUT P2_S MR2-54 29 PRESSURE INCREASE SENSOR
FINISH MSS_P MR2-54 30 ENGINE ON / OFF SWITCH
INPUT P23_S MR2-54 31 OPTIONAL WASTE REMOVAL SLOPE
INPUT POELAKT_S MR2-54 32 ENGINE OIL PRESSURE SENSOR
INPUT HDEL_S MR2-54 33 OIL LEVEL SENSOR
INPUT TMOT_A MR2-54 34 COOLANT LIQUID TEMPERATURE SENSOR
INPUT MSSP_S MR2-54 35 ENGINE BUTTON STOP SIGNAL
80-01-M208EN (09/11/2012)
SPECIFICATIONS B9
PLD
INPUT TFUEL_A MR2-54 36 FUEL TEMPERATURE SENSOR
FINISH MVH MR2-54 37 INJECTION PUMP ELECTROVALVE (INJECTOR H)
FINISH MVF MR2-54 38 INJECTION PUMP ELECTROVALVE (INJECTOR F)
TOEL_A MR2-54 39 OIL TEMPERATURE SENSOR
FINISH PV6_P MR2-54 42 PROPORTIONAL VALVE 6
FINISH MVD MR2-54 44 INJECTION PUMP ELECTROVALVE (INJECTOR D)
FINISH MVB MR2-54 45 INJECTION PUMP ELECTROVALVE (INJECTOR B)
FINISH MVG MR2-54 46 INJECTION PUMP ELECTROVALVE (INJECTOR G)
FINISH MVE MR2-54 47 INJECTION PUMP ELECTROVALVE (INJECTOR E)
INPUT T2_A MR2-54 48 CHARGING AIR TEMPERATURE
INPUT HOEL_M MR2-54 49 OIL LEVEL SENSOR
PV2_P MR2-54 52 PROPORTIONAL VALVE 1
FINISH MVC MR2-54 53 INJECTION PUMP ELECTROVALVE (INJECTOR C)
FINISH MVA MR2-54 54 INJECTION PUMP ELECTROVALVE (INJECTOR A)
INPUT / OUTPUT CAN H X716 01 INTERFACE CAN
INPUT / OUTPUT CAN L X716 02 INTERFACE CAN
GROUND HF-GND X716 03 HF CAN
GROUND HF-GND X716 04 HF CAN
12V POWER SUPPLY KL30 X716 05 BATTERY POWER SUPPLY (+)
12V POWER SUPPLY KL30 X716 06 BATTERY POWER SUPPLY (+)
NOT USED (OT_TRIGGER) X716 07 NOT USED
INPUT KL50 X716 08 KEY START
GROUND KL31 X716 09 BATTERY GROUND (-)

NOT USED
80
FINISH PVB_P X716 10
GROUND KL31 X716 11 BATTERY GROUND (-)
FINISH ANLA X716 12 STARTER
INPUT / OUTPUT KDIAG X716 13 STEERING DIAGNOSTICS
FINISH PV3 X716 14 NOT USED
INPUT KL15 X716 15 + 12V INPUT
FINISH PV4 X716 16 NOT USED
(09/11/2012) 80-01-M208EN
B10 SPECIFICATIONS
80
80-01-M208EN (09/11/2012)
SPECIFICATIONS C1
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
Rep.
Désignation Pages
Électriques
A605/B605 STRAIN GAUGE C2
B36 HORN C2
B38+B46 WHEEL ALIGNMENT SENSOR C3
B67 BRAKE FLUID LEVEL CONTACT C3
R201 ACCELERATOR POTENTIOMETER C4
S61 LIGHTING STALK SWITCH C4
S192 WIPER STALK SWITCH C5
S167 JSM JOYSTICK C6
80
80
(02/10/2012) 80-01-M208EN
C2 SPECIFICATIONS
A605/B605 STRAIN GAUGE
PIN Function
4
3
5 1 Shielding
2
1
2 Power supply
3 Weight
4 CAN_H
5 CAN_L A605 B605

Diagram
PIN Minimum Typical Maxi

Supply voltage 9V 10 V 16 V
Consommation 150 mA
Note:
- CAN integrated terminal resistance 120 Ω.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B36 HORN
PIN Function
80
1 Horn power supply
80
2 Weight
Diagram

Supply voltage 9V 12 V 15 V
Resistance (10%) / 2,17 Ω /
Nominal frequency 500 ± 20 Hz
Consommation 6A
Note:
- Sound level 107 dB(A) / 13V.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M208EN (02/10/2012)
SPECIFICATIONS C3
B38+B46 WHEEL ALIGNMENT SENSOR
PIN Function
A Signal
3 B Power supply
2
1 C Weight
B38
Diagram

Supply voltage / 12 V /
Direct current / 10 mA /
Outlet logic Switch closed = wheels aligned
Type of outlet PNP at Vbat
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
B67 BRAKE FLUID LEVEL CONTACT
PIN Function
B67 X67.1 80
1 Level info
80
2 Weight
X67.2
Diagram

Courant d’alimentation 4 mA 6 mA /
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(02/10/2012) 80-01-M208EN
C4 SPECIFICATIONS
R201 ACCELERATOR POTENTIOMETER
PIN Function
1 8V to 36V supply
R201
2 0V earth
3 Signal 1 : 80% - 20%

1
3 4 4 Signal 2 : 20% - 80%
6
5 8V to 36V supply
6 0V earth
Corresponding connector Diagram

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

S2: 36V to 8V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
S61 LIGHTING STALK SWITCH
PIN Function
1 Light supply
80 S61
0
2 Side lights
80
3 Low beam
3
2 4 Main beam
1
4
5 Horn power supply
7
6 Horn
5
8 7 Turn indicators supply
9 6
Right-hand indicator Diagram
8
light
Left-hand indicator
9
light

Voltage 12 V 24 V
Consommation 3A 5A 7A
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M208EN (02/10/2012)
SPECIFICATIONS C5
S192 WIPER STALK SWITCH
PIN Function
0 1 Power supply
X192
0
1
2
1 2 Rear screen wiper control

2
3 3 Rear screen wiper parking
7
4 8
5 6 9
4 Rear screen washer
5 Front screen washer supply
6 Front screen washer control
7 Front screen wiper speed 1
8 Front screen wiper speed 2

X193
9 Intermittent
1
1Y Rear screen wiper parking
2
2Y Front windscreen-wiper parking
Corresponding connectors
S192
Diagram
80
80
Voltage 12 V 24 V
Consumption As per outputs
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(02/10/2012) 80-01-M208EN
C6 SPECIFICATIONS
S167 JSM JOYSTICK
PIN Function
1 JSM Earth
1 2 Roller 1 direction A (+)

2
3 Roller 1 direction B (-)
3
4 4 Roller 2 direction A (+)
12
5
6 11
10 5 Roller 2 direction B (-)
9
6 Signal Roller 1
8
7 7 Signal Roller 2
8 12V JSM Power supply
9 Optional BP jib head solenoid valve
10 N/A
11 Forward gear
12 Reverse gear
S167
Diagram
80
80
X167 PIN Minimum Typical Maxi

6-7 1V 6V 11 V
Outlet voltage
2-3-4-5 0 12 V
Supply voltage 8 12 V
Potentiometer current below 5 V ± 10% / 1 mA 2 mA
Note:
- Direction A B + -: 0 = roller neutral
12 V = direction validation
Xm1(Powershift connector) PIN Minimum Typical Maxi

1 (+) 12 V
Outlet voltage
2 (-) 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M208EN (02/10/2012)
ELECTRICAL SCHEMATIC DIAGRAMS
pages
CODES ON THE ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

CABLE DESIGNATION ON AN ELECTRICAL WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . .3
POSITION OF CONNECTORS ON DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
– 1 – STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– 2 – BUS AND DIAGNOSTIC CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– 3 – TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– 4 – HYDRAULIC MOVEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– 5 – SENSORS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
– 6 – LIGHTING/SIGNALLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
– 7 – VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
– 8 – AIR CONDITIONING OPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
80
(02/10/2012) 80-02-M208EN
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
16
9 A464
8
A
7
12
10
13
C
15
14
13 14 3
E H219 H218 2
X219 X218
G 11
12
10 17
7
K10 11
F2
I
8
1
9 A716
F24
1
A1
K
80
2
B38 B46
4 3
Example of marking on cables and components on an electrical diagram
Key:
1 - Power supply 10 - Computer connector designation
2 - Electrical component 11 - Wire 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 - Diagram reference
9 - Computer designation
80-02-M208EN (02/10/2012)
ELECTRICAL SCHEMATIC DIAGRAMS 3
CABLE DESIGNATION ON AN ELECTRICAL WIRING HARNESS
The electrical harnesses installed on the truck are composed of connectors.
In order to identify the connectors, their numbers include these.
X64
X32
The identification of the wires are marked on the diagrams ( u Ref.11: MARKING OF CABLES ON A
HARNESS).
G-M 1
Colours Cross section (mm²)
80
Colour code:
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
(02/10/2012) 80-02-M208EN
POSITION OF CONNECTORS ON DIAGRAMS
Connectors Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Diag. 8
+15 √
+15 BAT √
+30 √
+30 KEY √
FUSE 1 √
FUSE 2 √
FUSE 3 √
FUSE 4 √
Xm √
Xrs √
X1 √ √ √ √ √ √
X2 √ √ √
X3 √
X4 √ √ √ √ √
X5 √ √ √ √
X6 √ √ √
X7 √ √ √ √ √
X8 √ √ √
X9 √
X9 √
X10 √
X11 √ √ √ √
X12 √
X19.1 √
X19.2 √
X19.3 √
X25 √
X29 √ √ √ √
X31 √ √ √
X33 √
X34 √
80
X35 √
X36.1 √
X36.2 √
X37.1 √
X37.2 √
X38 √
X39 √
X40 √
X41 √
X42 √ √ √ √ √
X43 √
X44 √
X46 √
X47 √ √
X48 √
X49 √
X50 √
X51 √
X52.S √
X53 √
80-02-M208EN (02/10/2012)
X54 √
X55 √
X58 √ √ √ √ √ √
X59 √
X61 √
X63 √ √
X64 √
X65 √
X66 √
X67 √
X68 √ √
X70 √
X71 √
X72 √
X73 √
X74 √ √
X79 √ √
X83.1 √
X83.2 √
X90 √
X100 √
X101 √
X102 √
X103 √
X104.1 √
X104.2 √
X104.3 √
X105
X105 √
X106 √
X107 √
X108 √
X109 √
X110 √
X111 √
80
X112 √
X114 √
X115 √
X116 √
X124 √
X125 √
X129 √
X131 √ √
X164 √
X165 √
X167.1 √ √
X168 √ √
X173.1 √
X173.2 √
X178.1 √
X178.2 √
X185 √ √ √ √ √ √
X186 √ √ √ √
X191 √
(02/10/2012) 80-02-M208EN
X191 √
X192 √
X193 √
X193 √
X200 √
X201 √
X203 √
X206 √ √ √ √ √
X208 √
X209 √
X213 √
X214 √
X215 √
X216 √
X217 √
X218 √
X219 √
X221 √
X225 √
X226 √ √
X228 √ √ √ √
X230.1 √
X230.2 √
X231 √
X232.1 √ √ √ √
X232.2 √
X233 √
X234 √
X235 √
X280 √ √
X281 √
X300 √
X301 √
X310 √
X400 √
80
X401 √
X464 √ √ √ √
X465 √ √
X466 √ √ √
X476 √
X501 √
X502 √
X503 √
X504 √
X505 √
X506 √
X512 √
X526 √ √ √ √
X569 √
X604 √
X605 √ √
X606 √ √ √ √ √
X607 √ √ √ √ √
X609 √
80-02-M208EN (02/10/2012)
X610 √
X611 √
X613 √ √
X709 √
X711 √ √
X714 √
X715 √
X716 √
X724.1 √
X724.2 √
X750 √
X751 √
X900 √
X901 √
X903 √
X905 √
80
(02/10/2012) 80-02-M208EN
ELECTRICAL DIAGRAMS
1 – STARTING
Wiring harness Name Position on Hydraulic code
Item Designation Hydraulic code
type component diagram equivalence Item Designation Position on diagram
equivalence
Engine +30 BAT G1 BATTERY M8
A1 PLATE I18
MainPlate +30. A1 PLATE I19
A228 CONTROL INDICATOR LAMP C8
Main/Electric plate +15 A1 PLATE I17
A464 ADM2 MODULE A26 to A30
Main +15 KEY S83 IGNITION SWITCH G16
A716 MODULE MR2-PLD (ENGINE) O24 to O26
Main/Electric plate X1 A1 PLATE G18
B63 STOP SWITCH PRESSURE SWITCH I30
Main/Electric plate X4 A1 PLATE G19 - G25
G1 BATTERY O8
Main/Electric plate X5 A1 PLATE I24
G26 ALTERNATOR O11
Electric plate X6 A1 PLATE (SHUNT) G24
H232 DASHBOARD MODULE INDICATOR LAMP C11
Main/Electric plate X7 A1 PLATE G23
M22 STARTER O9
Main/Electric plate X8 A1 PLATE G22 - I20 - I22
R105 HEATING M12
S68 EMERGENCY STOP BUTTON C17
Engine X19.1 K19 SERVICE RELAY M15
S83 IGNITION SWITCH I11
Engine X19.2 K19 SERVICE RELAY O16
Engine X19.3 K19 SERVICE RELAY M16
Main/Engine X29 MAIN/ENGINE INTERFACE G4 - G6 - M15 - M29
Fuses and relays
C26 - G10 - M17
Main/Engine X58 MAIN/ENGINE INTERFACE
M19 - M26 Item Current Designation Position on diagram
Dashboard X68 S68 EMERGENCY STOP BUTTON C17
F1G 20A OPTION O19
Main X83.1 S83 IGNITION SWITCH I12
F2G 30A PLATE O20
Main X83.2 S83 IGNITION SWITCH I12 F3G 50A SERVICE RELAY O18
Engine X105 R105 AIR HEATER M12 F4G 30A STARTER O18
Main X131 MAIN/AIR CONDITIONING INTERFACE I8 F16 15A OPTION I18
Dashboard/Main X185 DASHBOARD/MAIN INTERFACE C19 - E10 F26 10A EMERGENCY STOP BUTTON I19
Dashboard X228 A228 CONTROL INDICATOR LAMP C8 F709 15A MODULE MR2-PLD (ENGINE) M23
F903 10A ADM2 MODULE K7
Dashboard X232.1 H232 DASHBOARD MODULE INDICATOR LAMP C10
F905 15A AIR HEATER M14
Main X464 A464 ADM2 MODULE C26
K1 NEUTRAL RELAY I23
80
K12 START-UP AUTHORISATION RELAY G20

K19 SERVICE RELAY M15
Main X526 PLATFORM (OPTION) C21
K751 STARTER RELAY M21
Engine X709 F709 MODULE MR2-PLD FUSE M23
K901 NEUTRAL RELAY M4
F1G - F2G
Engine X711 POWER SUPPLY FUSE M18
F3G - F4G
Engine X714 G26 ALTERNATOR M11
Engine X715 M22 STARTER M9
Engine X751 K751 STARTER RELAY M22
Engine X901 K901 NEUTRAL RELAY M4
Engine X903 F903 MODULE ADM2 FUSE K7
Engine X905 F905 AIR HEATER FUSE
80-02-M208EN (02/10/2012)
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 A464 A
A228 H232 S68
X68
C C
E E
G G
K12
F16 F26 K1
I I
S83
X83.1 / X83.2 A1 B63
X63
K K
F903
K901 F905
80
M M
K751
K19
R105 F3G F4G F1G F2G F709
G1 G26
M22
O O
A716
Q Q
S S
(02/10/2012) 80-02-M208EN
2 – BUS AND DIAGNOSTIC CAN
Electrical connectors Electrical components

Wiring harness Name Position on Hydraulic code Hydraulic code
Item Designation Item Designation Position on diagram
type component diagram equivalence equivalence
Main/Electric plate X1 A1 PLATE E11 A1 PLATE G10
Main/Engine X29 MAIN/ENGINE INTERFACE M16 A79 MICRO CONTROLLER RC2 G32
Rear/main harness X42 REAR/MAIN INTERFACE M18 A125 DIAGNOSTIC PLUG RC2 G30
Main/Engine X58 MAIN/ENGINE INTERFACE M17 A280 DIAGNOSTIC PLUG G26
Main X63 B63 STOP SWITCH PRESSURE SWITCH O27 A464 ADM2 MODULE E15
Main X79 A79 MICRO CONTROLLER RC2 E32 A476 ENGINE DIAGNOSTIC PLUG G5
Main X125 A125 DIAGNOSTIC PLUG RC2 E27 A605 STRAIN GAUGE Q30
Dashboard/Main X185 DASHBOARD/MAIN INTERFACE G37 A606 SPU MODULE O28
Main X280 A280 DIAGNOSTIC PLUG E20 A716 MODULE MR2-PLD (ENGINE) Q15
Main X464 A464 ADM2 MODULE G17 P613 LONGITUDINAL SECURITY MODULE (LLMI) Q24
Main X466 A464 ADM2 MODULE G15
Main X476 A476 ENGINE DIAGNOSTIC PLUG E6
Rear harness X605 A605 STRAIN GAUGE O19 Fuses and relays
Main X606 A606 SPU MODULE Q29
Item Current Designation Position on diagram
Main X607 A606 SPU MODULE O28
F7 5A DIAGNOSTIC PLUG RC2 E13
Main X613 P613 LONGITUDINAL SECURITY MODULE (LLMI) O24
F30 7,5A MICRO CONTROLLER RC2 G13
Engine X716 A716 MODULE MR2-PLD (ENGINE) O15
CAN Network
PAD
80
SPU LLMI
VCI
CAN A
CAN B
ECU RC2-2/20 ECM ADM2 ECM MR2
80-02-M208EN (02/10/2012)
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
C C
E E
A464
F7
F30
A476 A1 A280 A125 A79
G G
I I
K K
80
M M
O O
A606
P613
A716 A605
Q Q
S S
(02/10/2012) 80-02-M208EN
3 – TRANSMISSION

Main Xm S167 JSM (JOYSTICK SWITCH AND MOVE) G33 A1 PLATE K6
Main Xrs KRS RESET RELAY E32 A17 HYDROSTATIC MODULE I35
Main/Electric plate X1 A1 PLATE I20 A228 CONTROL INDICATOR LAMP Q20
Main/Electric plate X2 A1 PLATE M23 A464 ADM2 MODULE Q27
Main/Electric plate X4 A1 PLATE I6 - M5 - I16 - I22 A606 SPU MODULE A10
I25 - I27 B39 ANGLE GEAR BOX SENSOR O16
M25 - M27
B43 HAND BRAKE SENSOR Q17
Electric plate X6 A1 PLATE (SHUNT) M17 - M24
B63 STOP SWITCH PRESSURE SWITCH M27
M12 - M15 - I12
I17 - I24 H213 MAX POWER WARNING INDICATOR LAMP E30
I29 - I32 H214 LOW SPEED INDICATOR LAMP A36
M33 - M36
H215 HIGH SPEED INDICATOR LAMP A35
Engine X9 Y9 FORWARD GEAR ELECTROVALVE O12
H225 BRAKE INDICATOR LAMP (OPTION) E10
Main/Electric plate X11 A1 PLATE M8 - M28
H232 DASHBOARD MODULE INDICATOR LAMP Q23
Engine X12 Y12 REVERSE GEAR ELECTROVALVE O14
R201 ACCELERATOR POTENTIOMETER M29
Main/Engine X29 MAIN/ENGINE INTERFACE M12 - M14
E36 - M4 - O16 S167 JSM (JOYSTICK SWITCH AND MOVE) E15
Front/Main X31 FRONT/MAIN INTERFACE
O33 - O36 S168 EMERGENCY STOP BUTTON E27
Front X33 Y33 TIME-DELAY SUPPLY ELECTROVALVE 2 G36 S216 HIGH/LOW SPEED SELECTOR A31
Front X34 Y34 SLOW SPED ELECTROVALVE O33 S217 TRANSMISSION RESET A18
Front X35 Y35 HIGH SPEED ELECTROVALVE O36 Y9 FORWARD GEAR ELECTROVALVE O11
Front X39 B39 ANGLE GEAR BOX SENSOR O16 Y12 REVERSE GEAR ELECTROVALVE O14
Rear/Main X42 REAR/MAIN INTERFACE Q7 - O9 - O18 Y33 SUPPLY ELECTROVALVE 2 G35
Rear X43 B43 HAND BRAKE SENSOR Q18 Y34 SLOW SPED ELECTROVALVE O33
Rear X53 TRAILER BRAKE KIT (OPTION) O9 Y35 HIGH SPEED ELECTROVALVE O35
Main X63 B63 STOP SWITCH PRESSURE SWITCH M27 Y193 TRANSMISSION ELECTROVALVE O4
Main X167.1 S167 JSM (JOYSTICK SWITCH AND MOVE) G15
Dashboard X168 S168 EMERGENCY STOP BUTTON E26
E36 - E17
Dashboard/Main X185 DASHBOARD/MAIN INTERFACE Fuses and relays
G10 - O22
G24 - G27 - E29 Item Current Designation Position on diagram
Dashboard/Main X186 DASHBOARD/MAIN INTERFACE
E38 - E18
80
Front X193 Y193 TIME-DELAYED TRANSMISSION ELECTROVALVE O4 F14 5A INDICATOR LAMPS+INSTRUMENTS+CAN K20
F23 7,5A LOW/HIGH SPEED K33
Main X201 R201 ACCELERATOR POTENTIOMETER O31
F25 15A TRANSMISSION CONTROL UNIT I21
Dashboard/Main X206 DASHBOARD/MAIN INTERFACE C38 - E20
F27 10A TRANSMISSION ELECTROVALVE K6
Dashboard X213 H213 MAX POWER WARNING INDICATOR LAMP E30
K1 NEUTRAL RELAY K25
Dashboard X214 H214 LOW SPEED INDICATOR LAMP A36
K2 TRANSMISSION ELECTROVALVE I5
Dashboard X215 H215 HIGH SPEED INDICATOR LAMP A35
K4 TRANSMISSION CUT-OFF RELAY I22
Dashboard X216 S216 HIGH/LOW SPEED SELECTOR A31
K6 REVERSE GEAR RELAY I15
Dashboard X217 S217 TRANSMISSION RESET A18
K7 FORWARD GEAR RELAY I12
Dashboard X225 H225 BRAKE INDICATOR LAMP (OPTION) E10
K15 GEAR CHANGE RELAY I30
Dashboard X228 A228 CONTROL INDICATOR LAMP Q20
K16 TRANSMISSION CUT-OFF RELAY K8
Dashboard X232.1 H232 DASHBOARD MODULE INDICATOR LAMP Q23
KRS RESET RELAY E32
Main X300 Diode SPEED CONTROL DIODE G12
Main X301 Diode SPEED CONTROL DIODE G13
Main X464 A464 ADM2 MODULE Q27
Main X466 A464 ADM2 MODULE Q28
Main X526 PLATFORM (OPTION) Q6
Main X606 A606 SPU MODULE C8
80-02-M208EN (02/10/2012)
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
A606
A A
H215 H214
X215 X214
S216
S217 X216
X217
C C
H213 Xrs
X213
S168 KRS
E S167 E
X168
H225
X225
Y33
G G
I I
K2
K7 K6 K4 A17
F25
K1 K15
F23
F27
K K
F14
K16
A1
80
M M
R201
B63
X63
Y193 Y9 Y12
O O
B39 Y34 Y35
X39
Q B43 Q
A228 H232 A464
S S
(02/10/2012) 80-02-M208EN
4 – HYDRAULIC MOVEMENT

Main/Electric plate X1 A1 PLATE I36 A1 PLATE O6 - K35
Main/Electric plate X4 A1 PLATE M9 A79 MICRO CONTROLLER RC2 M32
Main/Electric plate X5 A1 PLATE M7 A606 SPU MODULE I14
Main/Electric plate X7 A1 PLATE M11 - I35 B47 HYDRAULIC FILTER CLOGGING PRESSURE SWITCH Q38
Main/Electric plate X11 A1 PLATE I34 H226 HYDRAULIC OIL I38
Rear/main harness X42 REAR/MAIN INTERFACE M30 - O34 - M38 M44 HYDRAULIC PUMP Q33
Rear harness X44 M44 HYDRAULIC PUMP Q34 R611 POTENTIOMETER CONTINUE FLOW (OPTION) O13
Rear harness X47 B47 HYDRAULIC FILTER CLOGGING PRESSURE SWITCH Q38 S70 OPTION EXCLUSION SWITCH I8
Main/Engine X58 MAIN/ENGINE INTERFACE O4 S71 2nd/3rd HYDRAULIC OUTPUT SWITCH (OPTION) E35
Main X70 S70 OPTION EXCLUSION SWITCH I8 S129 CRC SWITCH: BOOM SUSPENSION (OPTION) E32
Main X71 S71 2nd/3rd HYDRAULIC OUTPUT SWITCH (OPTION) G35 S167 JSM (JOYSTICK SWITCH AND MOVE) E17
Main X79 A79 MICRO CONTROLLER RC2 O32 S208 HYDRAULIC MOVEMENT NEUTRALISATION SWITCH I11
Distributor X116 Y116 HYDRAULIC CUT-OFF ELECTROVALVE/VS Q17 S209 EASY CONNECT SYSTEM SWITCH (OPTION) E28
Main X129 S129 CRC SWITCH: BOOM SUSPENSION (OPTION) G32 S612 SWITCH + INDICATOR LAMP (OPTION) I31
Main X167.1 S167 JSM (JOYSTICK SWITCH AND MOVE) G17 Y116 HYDRAULIC CUT-OFF ELECTROVALVE/VS Q17
Dashboard/Main X185 DASHBOARD/MAIN INTERFACE K5 Y501 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE Q24
X191 BOOM HARNESS CONNECTOR E23 Y502 TELESCOPE RETRACT PROPORTIONAL ELECTROVALVE Q23
Main/Distributor X203 MAIN/DISTRIBUTOR INTERFACE M15 Y503 ATTACHMENT PROPORTIONAL ELECTROVALVE 1 Q21
Dashboard/Main X206 DASHBOARD/MAIN INTERFACE I38 Y504 ATTACHMENT PROPORTIONAL ELECTROVALVE 2 Q15
Main X208 S208 HYDRAULIC MOVEMENT NEUTRALISATION SWITCH E32 Y505 BOOM LOWERING PROPORTIONAL ELECTROVALVE Q19
Main X209 S209 EASY CONNECT SYSTEM SWITCH (OPTION) G28 Y506 TILTING CUT-OFF ELECTROVALVE/VCI Q26
Dashboard X226 H226 HYDRAULIC OIL I38
Distributor X501 Y501 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE Q24
Distributor X502 Y502 TELESCOPE RETRACT PROPORTIONAL ELECTROVALVE Q23 Fuses and relays
Distributor X503 Y503 ATTACHMENT PROPORTIONAL ELECTROVALVE 1 Q21 Item Current Designation Position on diagram
Distributor X504 Y504 ATTACHMENT PROPORTIONAL ELECTROVALVE 2 Q15
F14 5A INDICATOR LAMPS+INSTRUMENTS+CAN K36
Distributor X505 Y505 BOOM LOWERING PROPORTIONAL ELECTROVALVE Q19
F17 10A BUCKET SWITCH/OPTION DOUBLE-TRIPLE OUTPUT SUPPLY I34
Distributor X506 Y506 TILTING CUT-OFF ELECTROVALVE/VCI Q27 F24 7,5A HYDRAULIC MOVEMENT CONTROL UNIT O10
Main X606 A606 SPU MODULE I15 F26 10A EMERGENCY STOP BUTTON O8
80
Main X607 A606 SPU MODULE I17 F609 10A SPU MODULE I5
X609 F609 SPU MODULE FUSE I6 K3 HYDRAULIC MOVEMENT NEUTRALISATION RELAY O6
Main X610 F609 SPU MODULE FUSE I6 K10 ARM SENSOR RELAY O9
Main X611 R611 CONTINUE FLOW POTENTIOMETER (OPTION) M12 K900 JOYSTICK RELAY Q5
Main X612 S612 SWITCH + INDICATOR LAMP (OPTION) I32
Engine X900 S900 JSM (JOYSTICK SWITCH AND MOVE) S4
80-02-M208EN (02/10/2012)
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
C C
S167
E E
S209 S129 S71

X209 X129 X71
G G
A606 S612
I S70 S208 I
X70 X208
F17 H226
X612 X226
F609 F14
A1
K K
80
M M
A79
K3 K10
O
R611 O
F26
F24
A1 B47
Y116 Y506
Y504 Y505 Y503 Y502 Y501
Q Q
M44
K900
X900
S S
(02/10/2012) 80-02-M208EN
5 – SENSORS

Main/Electric plate X1 A1 PLATE M10 A1 PLATE O15
Main/Electric plate X2 A1 PLATE M9 A228 CONTROL INDICATOR LAMP C35
Main/Electric plate X4 A1 PLATE M14
A464 ADM2 MODULE C18
Main/Electric plate X5 A1 PLATE M12
A606 SPU MODULE G19
Electric plate X6 A1 PLATE (SHUNT) Q12
Main/Electric plate X7 A1 PLATE M9 B25 FUEL LEVEL SENSOR O31
Electric plate X9 A1 PLATE (SHUNT) Q9 B38 FRONT WHEEL ALIGNMENT SENSOR Q5

Engine X25 B25 FUEL LEVEL SENSOR O31 B46 REAR WHEEL ALIGNMENT SENSOR Q7
Main/Engine X29 MAIN/ENGINE INTERFACE M35 B47 HYDRAULIC FILTER CLOGGING PRESSURE SWITCH O29
Front/Main X31 FRONT/MAIN INTERFACE M5 B67 SENSOR BRAKE FLUID LEVEL O36
Front X38 B38 FRONT WHEEL ALIGNMENT SENSOR O5
B114 TELESCOPE RETRACTED POSITION SENSOR Q20
M7 - M21 - M23
Rear/Main X42 REAR/MAIN INTERFACE B115 TELESCOPE RETRACTED POSITION SENSOR Q22
M25 - M27 - M30
B173 SEAT SWITCH (OPTION) Q19
Rear X46 B46 REAR WHEEL ALIGNMENT SENSOR O7
Rear X47 B47 HYDRAULIC FILTER CLOGGING PRESSURE SWITCH O30 B281 PRESSURE SENSITIVE SWITCH (OPTION) Q37
Main/Engine X58 MAIN/ENGINE INTERFACE M31 B604 BOOM ANGLE SENSOR O24
Main X67 B67 SENSOR BRAKE FLUID LEVEL Q36 B605 STRAIN GAUGE O27
Dashboard X68 S68 EMERGENCY STOP BUTTON K13 B724 AIR FILTER CLOGGING PRESSURE SWITCH O34
Dashboard X73 S73 OVERRIDE SWITCH I27
H218 REAR WHEEL ALIGNMENT LIGHT K6
Main X90 H310 OVERLOAD BUZZER K33
H219 FRONT WHEEL ALIGNMENT LIGHT K5
Rear X114 B114 TELESCOPE RETRACTED POSITION SENSOR O21
Rear X115 B115 TELESCOPE RETRACTED POSITION SENSOR O22 H226 HYDRAULIC OIL I29
Dashboard X168 S168 EMERGENCY STOP BUTTON K12 H232 DASHBOARD MODULE INDICATOR LAMP G37
Main X173.1 B173 SEAT SWITCH (OPTION) Q19 H310 OVERLOAD BUZZER M33
Main X173.2 B173 SEAT SWITCH (OPTION) O19 H569 OVERRIDE G28
G15 - K4 - K14
Dashboard/Main X185 DASHBOARD/MAIN INTERFACE P230 CLOCK E13
E30 - G34 - K35
G10 - G12 - K12 P231 FUEL LEVEL INDICATOR LAMP I32
Dashboard/Main X186 DASHBOARD/MAIN INTERFACE K15 - G33 P233 HOUR METER / REV COUNTER E10
I28 - K36
P234 WATER TEMPERATURE INDICATOR E15
Dashboard/Main X206 DASHBOARD/MAIN INTERFACE G11 - G14 - K29
P613 LONGITUDINAL SECURITY MODULE (LLMI) O27
Dashboard X218 H218 REAR WHEEL ALIGNMENT LIGHT K6
Dashboard X219 H219 FRONT WHEEL ALIGNMENT LIGHT K5 S68 EMERGENCY STOP BUTTON I13
Dashboard X226 H226 HYDRAULIC OIL I29 S73 OVERRIDE SWITCH G27
80
Dashboard X228 A228 CONTROL INDICATOR LAMP E34 S168 EMERGENCY STOP BUTTON I12
Dashboard X230.1 P230 CLOCK E13
Dashboard X230.1 P230 CLOCK E13
Dashboard X231 P231 FUEL LEVEL INDICATOR LAMP I31
Fuses and relays
Dashboard X232.1 H232 DASHBOARD MODULE INDICATOR LAMP I35
Dashboard X232.2 H232 DASHBOARD MODULE INDICATOR LAMP G34 Item Current Designation Position on diagram
Dashboard X233 P233 HOUR METER / REV COUNTER E10
F2 10A WHEEL ALIGNMENT M9
Dashboard X234 P234 WATER TEMPERATURE INDICATOR E14
F9 10A +30 HAZARD WARNING LIGHTS M10
Main X281 B281 PRESSURE SENSITIVE SWITCH (OPTION) Q37
F14 5A INDICATOR LAMPS+INSTRUMENTS+CAN M18
X310 H310 OVERLOAD BUZZER M33
F24 7,5A HYDRAULIC MOVEMENT CONTROL UNIT O17
Main X464 A464 ADM2 MODULE E19
F25 15A TRANSMISSION CONTROL UNIT O15
Main X465 A464 ADM2 MODULE E17
F26 10A EMERGENCY STOP BUTTON O13
Main X526 PLATFORM (OPTION) E7
F28 10A OVERRIDE + SPU M11
Dashboard X569 H569 OVERRIDE G28
K10 ARM SENSOR RELAY M16
Rear X604 B604 BOOM ANGLE SENSOR O24
Rear X605 B605 STRAIN GAUGE O27
Main X606 A606 SPU MODULE I19
Main X607 A606 SPU MODULE I21
Main X613 P613 LONGITUDINAL SECURITY MODULE (LLMI) Q27
Engine X724.1 B724 AIR FILTER CLOGGING PRESSURE SWITCH O35
Engine X724.2 B724 AIR FILTER CLOGGING PRESSURE SWITCH Q35
80-02-M208EN (02/10/2012)
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 A
C A228 C
A464
P233 P234
P230
E E
G G
A606
H569
S73 X569
H232
P231
X73
I H226 I
X226
S168 S68
H219 H218
X219 X218 X168 X68
K K
80
M K10 M
F2
F14 H310
F9 F28
F26 F25
F24
O O
A1 B604
B605
B47 B25 B724 B67 B281
B173 B114 B115
X67 X281
B38 B46
Q Q
P613
S S
(02/10/2012) 80-02-M208EN
6 – LIGHTING/SIGNALLING

Main/Electric plate X1 A1 PLATE G36 - K8 A1 PLATE G29
Main/Electric plate X2 A1 PLATE G27 A17 HYDROSTATIC MODULE G38
Main/Electric plate X3 A1 PLATE G33 - K6 A124 CAR RADIO A8
Main/Electric plate X4 A1 PLATE G27 A228 CONTROL INDICATOR LAMP A12
Main/Electric plate X7 A1 PLATE G27 - K17 B36 HORN Q35
Main/Electric plate X8 A1 PLATE G28 B37 BRAKE MICRO O39
Front/Main X31 FRONT/MAIN INTERFACE M32 - M39 E40 FRONT RIGHT HEADLIGHT Q33
Front X36.1 B36 HORN Q35 E41 FRONT RIGHT WORKING LIGHT Q31
Front X36.2 B36 HORN Q35 E48 FRONT LEFT HEADLIGHT Q19
E49 FRONT LEFT WORKING LIGHT Q20
Front X37.1 B37 BRAKE MICRO O39
E50 REAR NUMBER PLATE LIGHT Q22
Front X37.2 B37 BRAKE MICRO O39
E54 REAR LEFT HEADLIGHT Q25
Front X40 E40 FRONT RIGHT HEADLIGHT Q32
E55 FRONT RIGHT WORKING LIGHT Q26
Front X41 E41 FRONT RIGHT WORKING LIGHT Q31
E64 REAR RIGHT HEADLIGHT Q28
M21 - M24
Rear/Main X42 REAR/Main INTERFACE
M31 - M40 E65 REAR LEFT WORKING LIGHT Q30
Rear X48 E48 REAR RIGHT HEADLIGHT O17 E191 REAR FOG LIGHTS Q31
Rear X49 E49 REAR LEFT WORKING LIGHT Q20 H51 REVERSE SOUND ALARM Q21
Rear X50 E50 REAR NUMBER PLATE LIGHT Q21 H232 DASHBOARD MODULE INDICATOR LAMP A16
Rear X51 H51 REVERSE SOUND ALARM Q21 M59 FRONT WINDSCREEN WIPER MOTOR C21
Rear X52.S TRAILER SOCKET (OPTION) Q36 M66 FRONT WINDSCREEN WASHER PUMP C18
Rear X54 E54 REAR LEFT HEADLIGHT Q23 M72 PNEUMATIC SEAT COMPRESSOR O10
Rear X55 E55 FRONT RIGHT WORKING LIGHT Q26 S61 LIGHT COMMUTATOR SWITCH C27
Main X59 M59 FRONT WINDSCREEN WIPER MOTOR A20 S192 WIPER COMMUTATOR SWITCH G17
Main X61 S61 LIGHT COMMUTATOR SWITCH A28 S221 REAR FOG LIGHT SWITCH A23
Main X64 E64 FRONT LEFT HEADLIGHT Q27 S235 WARNING SWITCH C37
X178 CIGARETTE LIGHTER C5
Main X65 E65 FRONT LEFT WORKING LIGHT Q30
Main X66 M66 FRONT WINDSCREEN WASHER PUMP C19
Fuses and relays
Main X72 M72 PNEUMATIC SEAT COMPRESSOR O10
Main X124 A124 CAR RADIO A8 Item Current Designation Position on diagram
80
Main X164 CAB INTERFACE G6 F1 15A MAIN BEAM HEADLIGHTS I26

Main X165 LOUDSPEAKER CONNECTORS E10 F3 15A WORKING LIGHTS M8
Main X178.1 X178 CIGARETTE LIGHTER C5 F4 7,5A CAR RADIO+ROTATING BEACON LIGHT M7
Main X178.2 X178 CIGARETTE LIGHTER C6 F5 5A RIGHT-HAND POSITION LIGHTS I35
Dashboard/Main X185 DASHBOARD/MAIN INTERFACE C25 - C39 -M37 F6 5A LEFT-HAND POSITION LIGHTS I35
F8 10A REAR HEADLIGHT+FOG LIGHT SWITCH I36
Dashboard/Main X186 DASHBOARD/MAIN INTERFACE C23 - C36
F9 10A +30 HAZARD WARNING LIGHTS G39
Rear X191 E191 REAR FOG LIGHTS Q31
F10 10A ROOF LIGHT+CIGARETTE LIGHTER M9
Main X192 S192 WIPER COMMUTATOR SWITCH G16
F11 7,5A FRONT WINDSCREEN WIPER M17
Main X193. S192 WIPER COMMUTATOR SWITCH G22 F12 7,5A WINDSCREEN WIPERREAR M16
Main X200 A124 CAR RADIO A10 F13 7,5A SEAT COMPRESSOR+REAR DEFROST M9
Dashboard/Main X206 DASHBOARD/MAIN INTERFACE F15 7,5A STOP LIGHTS I39
Dashboard X221 S221 REAR FOG LIGHT SWITCH C23 F18 10A +15 HAZARD WARNING LIGHTS G40
Dashboard X228 A228 CONTROL INDICATOR LAMP C12 F19 15A WORKING LIGHTS M6
F21 15A LOW BEAM I29
Dashboard X232.1 H232 DASHBOARD MODULE INDICATOR LAMP C17
F22 15A HORN I34
Dashboard X235 S235 WARNING SWITCH C37
F25 15A TRANSMISSION CONTROL UNIT G26
Main X280 A280 DIAGNOSTIC PLUG C7
K5 MAIN BEAM RELAY I27
Main X526 PLATFORM (OPTION) C35 K9 HORN RELAY I30
K11 LOW BEAM RELAY I33
K14 STOP LIGHT RELAY I37
80-02-M208EN (02/10/2012)
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
A124 A228 H232

A A
S221
X221
S61
M59 S235
X178 X235
C
M66 C
E E
S192
G
A1 A17 G
F25
F9 F18
K5 K11 K9 F22 F6 F5 F8
I
F1 F21 K14 I
F15
K K
F11
F19
80
F4 F3 F13 F10 F12
M M
A1
B37
O O
M72
E49 E55
H51 E50 E65 E191 E41 B36
Q Q
E48 E54
E64
E40
S S
(02/10/2012) 80-02-M208EN
7 – VENTILATION
Item Designation
type component diagram equivalence
Main X11 A1 PLATE I5
Main/Engine X58 MAIN/ENGINE INTERFACE M6
Main X74 S74 AIR CONDITIONING/MAIN INTERFACE O3
Dashboard/Main X186 DASHBOARD/MAIN INTERFACE E3
Dashboard/Main X206 DASHBOARD/MAIN INTERFACE K8
Dashboard X400 S400 FAN REVERSAL SWITCH C7
Dashboard X401 H401 FAN REVERSAL INDICATOR LAMP G8
Engine/Fan X750 X750 ENGINE/FAN INTERFACE Q6
Hydraulic code
Item Designation Position on diagram
equivalence
A1 PLATE G2
A606 SPU MODULE A17
H401 FAN REVERSAL INDICATOR LAMP I9
S74 CHEATING CIRCUIT Q3
S400 FAN REVERSAL SWITCH A5
X750 FAN REVERSAL CONNECTOR S6
Fuses and relays
F17 10A BUCKET SWITCH/OPTION DOUBLE-TRIPLE OUTPUT SUPPLY G4

80
F20 25A CHEATING CIRCUIT G3
80-02-M208EN (02/10/2012)
DIAGRAM 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
S400 A606
A1
G F20 F17
H401
80
M
S74
X750
S
(02/10/2012) 80-02-M208EN
8 – AIR CONDITIONING OPTION
Item Designation
type component diagram equivalence
Air-conditioning FUSE 1 FUSE 1 FAN FUSE C15
Air-conditioning FUSE 2 FUSE 2 AIR CONDITIONING PANEL FUSE C16
Air-conditioning FUSE 3 FUSE 3 FAN 1 FUSE C17
Air-conditioning FUSE 4 FUSE 4 FAN 2 FUSE C18
Air-conditioning RL1 RL1 AIR CONDITIONING COMPRESSOR RELAY C21
Main/Engine X58 MAIN/ENGINE INTERFACE M5
Main X74 MAIN/AIR CONDITIONING INTERFACE O9
Air-conditioning X100 P100 AIR CONDITIONING PANEL O29
Air-conditioning X101 AIR CONDITIONING/ MAIN INTERFACE O9
Air-conditioning X102 A102 AIR CONDITIONING MODULE C25
Air-conditioning X103 K103 THIRD GEAR RELAY G15
Air-conditioning X104.1 M104.1 AIR CONDITIONING MOTOR 1 O15
Air-conditioning X104.2 M104.2 AIR CONDITIONING MOTOR 2 O13
Air-conditioning X104.3 B104.3 AIR CONDITIONING HIGH PRESSURE SENSOR O15
Air-conditioning X105 A105 RECYCLING O18
Air-conditioning X106 M106 AIR-CONDITIONING COMPRESSOR O18
Air-conditioning X107 AIR CONDITIONING/ MAIN INTERFACE Q7
Air-conditioning X108 B108 OUTSIDE TEMPERATURE SENSOR O37
Air-conditioning X109 B109 THREE SPEED FAN MOTOR O24
Air-conditioning X110 B110 EVAPORATOR PRESSURE SWITCH O22
Air-conditioning X111 M111 HEATING CIRCUIT MOTOR O25
Air-conditioning X112 B112 HEATING TEMPERATURE SENSOR O26
Main X131 MAIN/AIR CONDITIONING INTERFACE O7
Engine X711 F1 POWER SUPPLY FUSE O5
Hydraulic code
Item Designation Position on diagram
equivalence
A102 AIR CONDITIONING MODULE A29
A105 RECYCLING O19
B104.3 AIR CONDITIONING HIGH PRESSURE SENSOR O14
B108 OUTSIDE TEMPERATURE SENSOR O36
B110 EVAPORATOR PRESSURE SWITCH O22
80
B112 HEATING TEMPERATURE SENSOR O26

G1 BATTERY Q4
M104.1 AIR CONDITIONING MOTOR 1 O15
M104.2 AIR CONDITIONING MOTOR 2 O12
M106 AIR-CONDITIONING COMPRESSOR O17
M109 THREE SPEED FAN MOTOR Q23
M111 HEATING CIRCUIT MOTOR O25
P100 AIR CONDITIONING PANEL O29
Fuses and relays
F1 30A POWER SUPPLY +30 O6

F20 25A AIR CONDITIONING PANEL +30 O10
FUSE 1 5A FAN C15
FUSE 2 5A AIR CONDITIONING PANEL +15 C16
FUSE 3 15A FAN 1 C17
FUSE 4 15A FAN 2 C18
K103 THREE-SPEED FAN RELAY G14
RL1 AIR CONDITIONING COMPRESSOR RELAY C21
80-02-M208EN (02/10/2012)
DIAGRAM 8
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
GND4.4
A A102 A
R2.5
R-N2.5
L-N1.5
L1.5
86 87 87a 86 87 87a 86 87 87a 86 87 87a
1 1 1 1
R2.5
FUS.1 FUS.2 FUS.3 FUS.4
RL1 85 30 85 30 85 30 85 30
FUS.1 FUS.2 FUS.3 FUS.4 86 87 87a
85 30
C A6 C5 A1 B6 A7 B5 C8 A8 A4 A5 C3 C4 C1 B4 B3 C2 A2 C
2 2 2 2 X102
FUS.1 FUS.2 FUS.3 FUS.4 X102
V0.5
L1.5
L-N1.5
R-N2.5
L-N1.5
M 0.5
M 1.5
V-B 0.5
R-N 0.5
R-N 1.5
R-N 0.5
R-N 1.5
L1.5
G 1.5
V 1.5
H 0.5
R 1.5
R 0.5
R 1.5
R 0.5
E E
R-N 0.5
C 2.5
86 87
K103 86 87 87a
85 30
G 85 30 G
X103
R-N 2.5
Z 0.5
I I
K V 0.5 V 0.5 K
R4
80
X58/8
M M
L-N1.5
V-B 0.5
L1.5
V 1.5
R4
M-B 0.5
A-B 0.5
R-N 0.5
V 0.5
S-N 1
M-B 0.5
A-B 0.5
M 1.5
B-G 0.5
Z-N 0.5
R-N 0.5
B1
G 1.5
V 0.5
N 0.5
N 0.5
C 2.5
S 0.5
M 0.5
B-G 0.5
Z-N 0.5
R-N 2.5
R-N 0.5
N 0.5
H 0.5
Z 0.5
R 0.5
S 0.5
X711 +15 X105 1 2 3 1 2 1 2 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16
1 1 2 3 B X112
B1
X105 X111 X100 X100
1 1 X104.1 X106 4 X110 X110 X109
X104.2 X104.3 X110
M106
N4
R4
O F1 F20 M104.2 M104.1 M A105 O

M B104.3 M B110 M B112 P100
p p M t 2
X108
X711 X10/1 B108
2 X131 1
2 1 2 1 M111 t
X110 M109
R4
X107 A C 2 X104.3 2
X74 X74 X104.2 X104.1
A 1
X109 X108
N4
R25
R4
A 0.5
A 0.5
N4
R-N4
Q Q
S-N 1
G1 12Vcc
N70
N 1.5
N 1.5
N 0.5
N 2.5
N 0.5
S S
GND4.4
(02/10/2012) 80-02-M208EN
80
80-02-M208EN (02/10/2012)
ELECTRICAL COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– CONNECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– GROUNDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
– FUSES AND RELAYS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
– HARNESS ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
– MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
– FUSE AND RELAY PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
– FRONT HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
– REAR HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
– DASHBOARD HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
– ENGINE HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
80
– DISTRIBUTOR HARNESS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
– FAN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
– AIR CONDITIONING OPTION HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
(12/11/2012) 80-03-M208EN
2 ELECTRICAL COMPONENTS LOCATION
KEY
CONNECTORS
Position on harness diagram

Item DESIGNATION Harness Fuse Dash- Distri- Air-
Main Front Rear Engine Fan condi-
assembly plate board butor tioning
+30 BAT BATTERY I28 K30
+30 PLATE A21 Q5 E13
+15 PLATE A21 S5 E10
+15 KEY IGNITION SWITCH G22 S5
FUSE 1 FAN FUSE I14 E7
FUSE 2 AIR CONDITIONING PANEL FUSE I14 G7
FUSE 3 FAN 1 FUSE I14 G7
FUSE 4 FAN 2 FUSE I14 G7
RL1 AIR CONDITIONING RELAY I14 E7
T1 SENSOR Q22 K9
VI FAN MOTOR O25 M13
VP FAN MOTOR O25 I13
Xm JSM (JOYSTICK SWITCH AND MOVE) I21 C27
Xrs RELAYS I17 E31
X1 PLATE A21 S18 I6
X2 PLATE A21 S20 K6
X3 PLATE A21 S22 K5
X4 PLATE A21 S24 Q5
X5 PLATE C21 S25 Q5
X6 PLATE (SHUNT) - O7
X7 PLATE C21 O34 O11
X8 PLATE C21 Q34 O15
X9 PLATE (SHUNT) - E14
X9 FORWARD GEAR ELECTROVALVE K19 M14
X10 PLATE A25 O17 E11
X11 PLATE C21 S34 I16
X12 REVERSE GEAR ELECTROVALVE K19 M17
X19.1 SERVICE RELAY G29 Q23
X19.2 SERVICE RELAY G29 Q23
X19.3 SERVICE RELAY I29 Q23
80
X25 FUEL LEVEL SENSOR O12 M5

X29 MAIN/ENGINE INTERFACE K25 A4 E34
X31 FRONT/MAIN INTERFACE K25 G4 E15
X33 SUPPLY ELECTROVALVE 2 K22 C13
X34 SLOW SPED ELECTROVALVE K22 C6
X35 HIGH SPEED ELECTROVALVE K22 C3
X36.1 HORN I35 Q13
X36.2 HORN I35 Q13
X37.1 BRAKE MICRO K35 O13
X37.2 BRAKE MICRO K35 M13
X38 FRONT WHEEL ALIGNMENT SENSOR K35 S12
X39.1 ANGLE GEAR BOX SENSOR K32 K13
X39.2 ANGLE GEAR BOX SENSOR K32 K13
X40 FRONT RIGHT HEADLIGHT Q29 G4
X41 FRONT RIGHT WORKING LIGHT M29 K4
X42 REAR/MAIN INTERFACE K25 E4 I36
X43 HAND BRAKE SENSOR I16 K32
X44 HYDRAULIC PUMP K16 K28
X46 REAR WHEEL ALIGNMENT SENSOR K9 G24
X47 HYDRAULIC FILTER CLOGGING PRESSURE SWITCH K11 G21
80-03-M208EN (12/11/2012)
ELECTRICAL COMPONENTS LOCATION 3

X48 REAR RIGHT HEADLIGHT G5 E10
X49 REAR LEFT WORKING LIGHT I5 G8
X50 REAR NUMBER PLATE LIGHT G4 M19
X51 REVERSE SOUND ALARM I3 G16
X52.S TRAILER SOCKET (OPTION) I3 I9
X53 TRAILER BRAKE KIT (OPTION) I16 K34
X54 REAR RIGHT HEADLIGHT O5 O10
X55 REAR RIGHT WORKING LIGHT M5 M8
X58 MAIN/ENGINE INTERFACE K25 C4 G34
X59 FRONT WINDSCREEN WIPER MOTOR G27 K3
X61 LIGHT COMMUTATOR SWITCH K25 O17
X63.1 STOP SWITCH PRESSURE SWITCH E25 K32
X63.2 STOP SWITCH PRESSURE SWITCH E25 K32
X64 FRONT LEFT HEADLIGHT E28 K27
X65 FRONT LEFT WORKING LIGHT E27 K29
X66 FRONT WINDSCREEN WASHER PUMP E26 O29
X67.1 SENSOR BRAKE FLUID LEVEL E25 M32
X67.2 SENSOR BRAKE FLUID LEVEL E25 M32
X68.1 EMERGENCY STOP BUTTON E24 O4
X70 OPTION EXCLUSION SWITCH I19 I39
X71 2ND/3RD HYDRAULIC OUTPUT SWITCH (OPTION) G19 M39
X72 PNEUMATIC SEAT COMPRESSOR E16 G36
X73.1 OVERRIDE SWITCH I21 C16
X73.2 OVERRIDE SWITCH I21 C16
X74 MAIN/AIR CONDITIONING INTERFACE I118 C37
X79 MICRO CONTROLLER RC2 I16 C39
X83.1 IGNITION SWITCH G22 I16
X83.2 IGNITION SWITCH I22 I18
X90 OVERLOAD BUZZER K21 C20
X100 AIR CONDITIONING PANEL G18 E15
X101 AIR CONDITIONING/MAIN INTERFACE I17 A13
X102 AIR CONDITIONING MODULE I18 A12
X103 THIRD GEAR RELAY I17 C10
80
X104.1 AIR CONDITIONING MOTOR 1 G9 K8
X104.2 AIR CONDITIONING MOTOR 2 G9 K11
X104.3 AIR CONDITIONING HIGH PRESSURE SENSOR G8 K13
X105 AIR HEATER Q23 C16
X105 RECYCLING K27 O8
X106 AIR-CONDITIONING COMPRESSOR Q20 Q8
X107 MAIN/AIR CONDITIONING INTERFACE I21 S8
X108 OUTSIDE TEMPERATURE SENSOR I28 Q13
X109 THREE SPEED FAN MOTOR K27 O16
X110 EVAPORATOR PRESSURE SWITCH K27 Q16
X111 HEATING CIRCUIT MOTOR K27 M18
X112 HEATING TEMPERATURE SENSOR K27 K16
X114 TELESCOPE RETRACTED POSITION SENSOR M5 M16
X115 TELESCOPE RETRACTED POSITION SENSOR M5 M13
X116 HYDRAULIC CUT-OFF ELECTROVALVE/VS K12 M14
X124 CAR RADIO I25 K4
X125 DIAGNOSTIC PLUG RC2 C26 O30
X129 CRC SWITCH: BOOM SUSPENSION (OPTION) I19 I39
X131 MAIN/AIR CONDITIONING INTERFACE I21 C13
X164 CAB INTERFACE I20 A33
X165 LOUDSPEAKER CONNECTORS I19 A34
(12/11/2012) 80-03-M208EN

X167.1 JSM (JOYSTICK SWITCH AND MOVE) I20 C25
X168.2 EMERGENCY STOP BUTTON G24 O8
X173.1 SEAT SWITCH E16 G37
X173.2 SEAT SWITCH E16 G37
X178.1 CIGARETTE LIGHTER I118 G32
X178.2 CIGARETTE LIGHTER I118 G34
X185 DASHBOARD/MAIN INTERFACE I27 S14 K4
X186 DASHBOARD/MAIN INTERFACE I26 S11 G5
X191 REAR FOG LIGHTS K25 C7
X192 WIPER COMMUTATOR SWITCH G23 M20
X193 TRANSMISSION ELECTROVALVE K22 C10
X193. WIPER COMMUTATOR SWITCH G23 K20
X200 CAR RADIO I25 M4
X201 ACCELERATOR POTENTIOMETER M22 C10
X203 MAIN/DISTRIBUTOR INTERFACE I20 C23 G15
X206 DASHBOARD/MAIN INTERFACE I26 S9 I4
X208 MOVEMENT NEUTRALISATION SWITCH I19 K39
X209 EASY CONNECT SYSTEM SWITCH (OPTION) I19 M39
X213 MAX POWER WARNING INDICATOR LAMP I23 A19
X214 LOW SPEED INDICATOR LAMP I23 C19
X215 HIGH SPEED INDICATOR LAMP I23 E19
X216 HIGH/LOW SPEED SELECTOR I23 E19
X217 TRANSMISSION RESET I23 O19
X218 REAR WHEEL ALIGNMENT LIGHT I23 O23
X219 FRONT WHEEL ALIGNMENT LIGHT G23 O21
X221 REAR FOG LIGHT SWITCH G23 O11
X225 BRAKE INDICATOR LAMP (OPTION) G24 O14
X226 HYDRAULIC OIL G23 O16
X228 CONTROL INDICATOR LAMP E25 E11
X230.1 CLOCK G25 I37
X230.2 CLOCK G25 I37
X231 FUEL LEVEL INDICATOR LAMP G25 G36
X232.1 DASHBOARD MODULE INDICATOR LAMP G25 C37
80
X232.2 DASHBOARD MODULE INDICATOR LAMP G25 C37

X233 SPEED INDICATOR (TACHYMETER) I25 K30
X234 WATER TEMPERATURE INDICATOR I25 K25
X235 WARNING SWITCH I25 G25
X280 DIAGNOSTIC PLUG C25 O28
X281.1 PRESSURE SENSITIVE SWITCH (OPTION) E26 M32
X281.2 PRESSURE SENSITIVE SWITCH (OPTION) E26 M32
X300 SPEED CONTROL DIODE A19 S31
X301 SPEED CONTROL DIODE C19 S32
X400 FAN REVERSAL SWITCH I24 C7
X401 FAN REVERSAL INDICATOR LAMP G24 C4
X464 ADM2 MODULE G24 O3
X476 ENGINE DIAGNOSTIC PLUG C25 I27
X501 TELESCOPE EXTEND PROPORTIONAL ELECTROVALVE K13 I9
X502 TELESCOPE RETRACT PROPORTIONAL ELECTROVALVE K13 G7
X503 ATTACHMENT PROPORTIONAL ELECTROVALVE 1 K12 K12
X504 ATTACHMENT PROPORTIONAL ELECTROVALVE 2 K14 M16
X505 BOOM LOWERING PROPORTIONAL ELECTROVALVE K14 K10
X506 TILT CUT-OFF ELECTROVALVE/VCI K14 E5
80-03-M208EN (12/11/2012)

X526 PLATFORM (OPTION) I22 E13
X569 OVERRIDE G24 M14
X604 BOOM ANGLE SENSOR M5 G12
X605 STRAIN GAUGE O9 G28
X606 SPU MODULE I16 C22
X607 SPU MODULE G16 C24
X609 SPU MODULE FUSE C22 Q39
X610 SPU MODULE FUSE C21 S34
X611 POTENTIOMETER (OPTION) I24 I11
X612 NOT USED I24 I10
X613 LONGITUDINAL SECURITY MODULE (LLMI) I23 I13
X709 MODULE MR2-PLD (ENGINE) G28 Q32
X711 POWER SUPPLY FUSE G28 M36
X714 ALTERNATOR Q16 G8
X715 STARTER O16 K9
X716 MODULE MR2-PLD (ENGINE) O20 K19
X721 AIR PRE-HEATING (OPTION) Q17 K8
X724.1 AIR FILTER CLOGGING PRESSURE SWITCH Q14 G4
X724.2 AIR FILTER CLOGGING PRESSURE SWITCH Q14 G4
X750 FAN REVERSAL CONNECTOR O22 E21 K5
X751 STARTER RELAY G28 M37
X900 JSM (JOYSTICK SWITCH AND MOVE) RELAY G28 O37
X901 NEUTRAL RELAY G28 Q37
X903 ADM2 MODULE G29 Q27
X905 AIR HEATER G29 Q30
GROUNDS
Gnd1 ENGINE HARNESS GROUND M19 E13
Gnd2 ENGINE HARNESS GROUND M19 E14
Gnd2.1 FRAME GROUND K22 G14
Gnd2.2 FRAME GROUND K22 G12
80
Gnd3.1 FRAME GROUND M16 G32
Gnd4.1 FRONT CAB GROUND E27 G2
Gnd4.2 FRONT CAB GROUND E27 G2
Gnd4.3 FRONT CAB GROUND E27 I2
Gnd4.4 FRONT CAB GROUND E27 I2
Gnd4.5 FRONT CAB GROUND G27 I2
Gnd5 CAB REAR GROUND I16 E39
FUSES AND RELAYS

Item Current DESIGNATION Harness Fuse Dash- Distri- Air-
F1G 20A OPTION K40
F2G 30A PLATE K40
F3G 50A SERVICE RELAY K40
F4G 30A STARTER K40
F1 15A MAIN BEAM HEADLIGHTS K7
F2 10A WHEEL ALIGNMENT I7
F3 15A WORKING LIGHTS I7
(12/11/2012) 80-03-M208EN

Item Current DESIGNATION Harness Fuse Dash- Distri- Air-
F4 7,5A CAR RADIO+ROTATING BEACON LIGHT I7
F5 5A RIGHT-HAND POSITION LIGHTS I7
F6 5A LEFT-HAND POSITION LIGHTS G7
F7 5A DIAGNOSTIC PLUG RC2 G7
78 10A REAR HEADLIGHT+FOG LIGHT SWITCH G7
F9 10A +30 HAZARD WARNING LIGHTS G7
F10 10A ROOF LIGHT+CIGARETTE LIGHTER E7
F11 7,5A FRONT WINDSCREEN WIPER K9
F12 7,5A REAR WINDSCREEN WIPER I9
F13 7,5A SEAT COMPRESSOR+REAR DEFROST I9
F14 5A INDICATOR LAMPS+INSTRUMENTS+CAN I9
F15 7,5A STOP LIGHTS I9
F16 15A OPTION POWER SUPPLY G9
F17 10A BUCKET SWITCH/OPTION DOUBLE-TRIPLE OUTPUT SUPPLY G9
F18 7,5A +15 HAZARD WARNING LIGHTS G9
F19 15A WORKING LIGHTS G9
F20 25A CHEATING CIRCUIT E10
F21 15A LOW BEAM K12
F22 15A HORN I12
F23 7,5A LOW/HIGH SPEED I12
F24 7,5A HYDRAULIC MOVEMENT CONTROL UNIT I12
F25 15A TRANSMISSION CONTROL UNIT I12
F26 10A EMERGENCY STOP BUTTON G12
F27 10A WORKING MODE POWER SUPPLY G12
F28 10A OVERRIDE+SPU G12
F29 5A OPTION G12
F30 7,5A MICRO CONTROLLER RC2 E12
F609 10A SPU MODULE S42
F709 15A MODULE MR2-PLD (ENGINE) S32
F903 10A ADM2 MODULE S26
F905 10A AIR HEATER S29
K1 NEUTRAL RELAY O6
K2 WORKING MODE ELECTROVALVE RELAY M6
K3 HYDRAULIC MOVEMENT AUTHORISATION RELAY O8
80
K4 TRANSMISSION CUT-OFF RELAY O9

K5 MAIN BEAM RELAY M9
K6 REVERSE GEAR RELAY O10
K7 FORWARD GEAR RELAY M10
K8 na O12
K9 HORN RELAY M12
K10 ARM SENSOR RELAY O13
K11 LOW BEAM RELAY M13
K12 START-UP AUTHORISATION RELAY O14
K13 na M14
K14 STOP LIGHT RELAY O15
K15 GEAR CHANGE RELAY M15
K16 TRANSMISSION CUT-OFF RELAY M16
K17 SLOW-FAST SPEED RELAY G16
K18 HAZARD WARNING LIGHT RELAY E16
K19 SERVICE RELAY S22
K751 STARTER RELAY M41
K900 JOYSTICK RELAY O41
K901 NEUTRAL RELAY Q41
KRS RESET RELAY G30
80-03-M208EN (12/11/2012)
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
+30
View of fuse and relay plate
+15
X10 Key:
X1
A Main harness A
X2
X3
Front harness
X300 X4
X301 X5 Rear harness
X7 Dashboard harness
X8
C X11 Engine Harness C
Air conditioning option X610 X609
X476
Distributor harness
X280 X125
X65 Fan harness
X63.1 X281.1
X64
X63.2 X281.2 Air conditioning harness (Option)
X67.1 X66
E X67.2
Connection between harnesses E
X68.1 Gnd4.1
X72 X228 Gnd4.2
X68.2
X173.1 Gnd4.3
X168.1
X104.1 X173.2 X168.2 Gnd4.4
X61 Gnd4.5
X464
X48 X104.3
X193 X230.1
X465 X59 X709
X192 X230.2
X466 X901 X905
G X231 G
X226 X225 X900 X903
X104.2 X232.1
X221 X569 X751 X19.1
+15KEY X232.2
X219 X401 X711 X19.2
X50 X100
X607 X71 X83.1
X218 X400 +30BAT X19.3
X606 X178.1 X129 X83.2 X233
X217
RL1 X103 Xm X234
Gnd5 X178.2 X208 X613
FUS.1 X234
X101 X74 X209 X167.1 X216
X79
FUS.2 X107
I X52 X49 Xrs X70 X215 I
X102 X203 X131 X185
FUS.3 X108
X214 X611 X200 X36.1
FUS.4 X73.1 X186
X213 X612 X124 X36.2
X165 X26 X73.2 X206
X51 X43
X90 X526 X37.1
X53
X504 X506 X111 X39.1
X502 X37.2
Gnd3.1 Gnd2.1 X42
X116 X112 X39.2
Gnd3.2 Gnd2.2 X31
X109 X38.2
K X503 Gnd3.3 X33 X29
X110
K
X46 X501
X505 X193 X58
X115 X44 X105
X09 X191
X47 X34
X114 X12
X35
X604
X201
X41
X55
80
M M
X750
Gnd1
Gnd2
X715
X605 X25
X721
O O
X716
VI
VP
X54
X724.1
X714 T1
Q X724.2 Q
X105 X40
X106
S S
Forward gear
(12/11/2012) 80-03-M208EN
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
X29.p
A A
X164.s X165.s
X73.1 X73.2 X90.s

X74
X58.p
X201 X131.s
C X191.p C
X79
X203.s X167.1s Xm
X42.p
Gnd5
E E
X526.p Xrs X178.1 X178.2
X31.p X72
X606 X607
X173.1 X173.2
G Gnd4.1 G
Gnd4.2 Krs
Gnd4.3 X129
Gnd4.4
I I
Gnd4.5 X612.s X611.s
X83.1 X83.2 X70
X613
X476
X59
X193
0
X208
0
1
2
K K
X63.1
X124
X63.2
X64 X65
X67.1
X209
80
X192
X67.2
X200
M M
X281.1
X281.2 X71
X464 X280 X66
X125
X465 X10.s
O O
X466
0
X7.s
X61
+30
Q X8.s Q
X610.p X609.s
X300 X301
X206.s X186.s X185.s X610.s
+15
F609
X1.s X2.s X3.s X4.s X5.s X11.s
S S
+15 Key
80-03-M208EN (12/11/2012)
FUSE AND RELAY PLATE
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
+15 +30 X9
FLASHER
E
X10
F10 10 F20 25 F30 7.5 K18
F9 10 F19 15 F29 5
F8 10 F18 7.5 F28 10
G
F7 5 F17 10 F27 10
F6 5 F16 15 F26 15
K17
X1
F5 5 F15 7.5 F25 15
F4 7.5 F14 5 F24 7.5
I
F3 15 F13 7.5 F23 7.5 X11
F2 10 F12 7.5 F22 15

F1 15 F11 7.5 F21 15
X3 X2
K
X4 K16
80
M
K2 K5 K7 K9 K11 K13 K15
K1 K3 K4 K6 K8 K10 K12 K14
X6 D4 D1 X7 X8
D3
X5
(12/11/2012) 80-03-M208EN
FRONT HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
X35 X34 X193 X33
E X31.s
G
Gnd 1
2.2 d2.
Gn
X40
9.1
X3
K
X39
.2
X41
80
M
7.2
X3
X37
.1
6.2
X3
X3
6.1
X38
80-03-M208EN (12/11/2012)
REAR 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 A
C C
TER
OME
ENS
EXT 177 0
EL
0-Z0
MOD -070
AY 0177
VISH
P/N
E E
X48
X49
G X604 X51 G
Gnd3.1
Gnd3.2
Gnd3.3
X47 X46 X605
I I
X52.s X42.s
K K
X44 X43 X53.s
80
X115 X114 X50
M M
X55
X54
O O
Q Q
S S
(12/11/2012) 80-03-M208EN
DASHBOARD 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 A
X213
X232.2
X214
C STOP
X401 X400 X232.1
X228 X215
E E
X216
X231
G G
p X235
86.
X1 12
9
X230.1
3
6
X206.p
I I
X230.2
X1
85.
p
K K
X234 X233
80
M M
X569 9
10 RP
15
Mx
100
20
0 25
2651
30
29
O O
X68.1 X68.2 X168.1 X168.2 X221 X225 X226 X217 X219 X218
Q Q
RESET
S S
80-03-M208EN (12/11/2012)
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 A
X716
C C
X105
X750.s
E Gn X29.s E
d1 d2
Gn
X724.1
G G
X714
X58.s
X724.2
I I
12V
105Ah
850A
F1G
F2G
K K
F3G
X721 X715 +30 F4G
X25 X9 X12
80
X711
M M
X751 51
K7
O O
X900
00
K9
X19.3
X19.2 X19.1
X903 X905 X709
Q Q
X901
01
K9
BOSCH
12V 75A
K19
F903 F905 F909
S S
(12/11/2012) 80-03-M208EN
DISTRIBUTOR HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
06
E
X5
EV
X203.p
G
02
X5
01
I
X5
05
X5
03
X5
K
16
EV
X1
80
04
X5
ACCESS. 1
STOP
EV / VS
O
ACCESS. 2
80-03-M208EN (12/11/2012)
FAN HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
VP
T1
X750.p
K
VI.s
80
M
(12/11/2012) 80-03-M208EN
AIR CONDITIONING OPTION HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
X102 X101
A
X103
C
X100
E
RL1
FUS.1
FUS.2
G FUS.3
FUS.4
X104.1 X104.2 X104.3 X112

11
X1
80
X109
X105
Q X110
X106 X108
X107
S
80-03-M208EN (12/11/2012)
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
(15/11/2012) 80-04-M208EN
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-M208EN (15/11/2012)
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.
– Place the lift truck on fl at, level ground with the wheels straight.
b Use the test button

or a long press (5 seconds).
only when instructed, following the guidance for a short press (less than 1 second)
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 - Lower the jib until the movement is will be sounded.
2 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.
(15/11/2012) 80-04-M208EN
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-M208EN (15/11/2012)
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
(15/11/2012) 80-04-M208EN
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
Keep the load as close to the ground as possible throughout this operation. and all the
- First green led continuously
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-M208EN (15/11/2012)
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.
(15/11/2012) 80-04-M208EN
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-M208EN (15/11/2012)
ELECTRICAL COMPONENTS REFIT 1
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
(15/11/2012) 80-07-M208EN
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-M208EN (15/11/2012)
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.
(15/11/2012) 80-07-M208EN
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 - Make the machine safe by placing 2 stands (Item 2)
2 (Part No Manitou 554772) on each side of the chassis.
3 - Remove the jack to completely unload the rear axle.
2
80
80-07-M208EN (15/11/2012)
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:
– Torque bolt No. 1 to 34 N.m
80
– 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%
(15/11/2012) 80-07-M208EN
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-M208EN (15/11/2012)
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
(27/09/2012) 80-08-M208EN
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-M208EN (27/09/2012)
ELECTRICAL TROUBLESHOOTING 3
FAULT PATH
PLD MERCEDES (A19)

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
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A19)

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-M208EN (27/09/2012)
FAULT TYPE
PLD MERCEDES (A19)

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
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A19)

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-M208EN (27/09/2012)
FAULTS CODES - ENGINE (MR2-PLD)
A716
PLD MERCEDES (A716)

- 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
80
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
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

- 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-M208EN (27/09/2012)
PLD MERCEDES (A716)

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.
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

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-M208EN (27/09/2012)
PLD MERCEDES (A716)

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
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

- 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-M208EN (27/09/2012)
PLD MERCEDES (A716)

- 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.
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

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-M208EN (27/09/2012)
PLD MERCEDES (A716)

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.
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

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-M208EN (27/09/2012)
PLD MERCEDES (A716)

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...
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

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-M208EN (27/09/2012)
PLD MERCEDES (A716)

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)
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

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-M208EN (27/09/2012)
PLD MERCEDES (A716)

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.
(27/09/2012) 80-08-M208EN
PLD MERCEDES (A716)

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-M208EN (27/09/2012)
80
(27/09/2012) 80-08-M208EN
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-M208EN (27/09/2012)
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
(27/09/2012) 80-08-M208EN
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-M208EN (27/09/2012)
ELECTRICAL SPECIFIC TOOLING
pages
DIAGNOSTIC TOOLKIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
RECEPTION STATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
WORKSHOP AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
BREAKOUT BOX KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
SOLENOID ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
80
(27/09/2012) 80-09-M208EN
2 ELECTRICAL SPECIFIC TOOLING
DIAGNOSTIC TOOLKIT
80
80-09-M208EN (27/09/2012)
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
(27/09/2012) 80-09-M208EN
RECEPTION STATION
Reception station (battery charging) .................................................................... 745236
WORKSHOP AREA
80
Workshop area (area + station) .............................................................................. 745235
80-09-M208EN (27/09/2012)
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
(27/09/2012) 80-09-M208EN
DIAGNOSTIC TOOL MERCEDES
Minidiag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774616
80
80-09-M208EN (27/09/2012)
DRIVER’S CAB
- DRIVER’S CAB CHARACTERISTICS AND

SPECIFICATIONS
- DRIVER’S CAB COMPONENTS LOCATION
- DRIVER’S CAB CONTROL AND ADJUSTEMENT
- DRIVER’S CAB TROUBLESHOOTING
85
DRIVER’S CAB CHARACTERISTICS AND
SPECIFICATIONS
pages
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– OPERATING PRINCIPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– DESCRIPTION OF OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– DESCRIPTION OF COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
85
(27/09/2012) 85-01-M208EN
2 SPECIFICATIONS
AIR CONDITIONING
OPERATING PRINCIPLE
EXTERIOR OF VEHICLE
(high pressure circuit)
Exterior air
Liquid
liquifies
CAPACITOR
Hot exterior air High

temperature
FILTER
Purifi es
and amortizes the
fl uid COMPRESSOR
COM
REDUCING
Suction
VALVE and compression
Recirculation or exterior air

85
ÉVAPORATEUR
Reducing
fl uid and drop in
temperature The
fl uid evaporates
Cooled and dried air
INTERIOR OF VEHICLE
(low pressure circuit)
85-01-M208EN (27/09/2012)
SPECIFICATIONS 3
DESCRIPTION OF OPERATION
Indicative diagram
not representative of
telehandler
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 fluid in gas state at low pressure and at low temperature is sucked in and compressed by the
compressor (Item 1) which sends it at high pressure and high temperature to the condenser (Item 2).
Phase 2: condensation
85
The fluid passes in the condenser (Item 2) to transmit its heat to the exterior of the vehicle, using the fan.
By crossing through the condenser the fluid liquidifies while keeping a high temperature and pressure.
It is then filtered in a drier (or dessicator) (Item 3).
Phase 3: reducing
The fluid enters the reducer (or expansion valve) (Item 4) so as to reduce its pressure and temperature
considerably while remaining in liquid state.
(27/09/2012) 85-01-M208EN
4 SPECIFICATIONS
Phase 4: evaporation
The fluid goes through the evaporator (Item 5) to absorb the cab interior heat and vaporizes while
keeping a 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.
High and low pressure checks of the circuit are carried out by a HP and LB pressure switch attached
directly on the dehydrator filter (Item 3).
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.
DESCRIPTION OF COMPONENTS
The compressor
The compressor is the component that allows to:
• pass the fluid in the circuit by sucking it in gas state from the evaporator in low pressure
and low temperature,
• to compress it to send it in high pressure and high temperature to the condenser.
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 element protecting the installation. Its functions are as follows:
• Filtering any solid particles passing in the fluid that may damage the compressor or
obstruct the reduce valve, for example.
• To dehumidify fluid and oil to preserve circuit elements against:
 corrosive agents
 the freezing of the humidity at outlet of the reducing valve so as to prevent the equipment
from blocking.
• Storing the fluid in liquid state and as such constituting a reserve tank to make up for
pressure variations. It therefore contributes to the absorption of pressure differences
85
generated by the compressor.
The « binary » pressure switch

Attached on the drier filter, the pressure switch is the equipment security component that is
sensitive to pressure variations.
It secures the equipment from both too low or too high pressure values by acting directly on
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.
85-01-M208EN (27/09/2012)
SPECIFICATIONS 5
The reducing valve

The reducing valve is attached to the evaporator inlet.
• By reducing, it makes the fluid pressure drop and therefore the temperature drop so as
to cool the air that passes through the evaporator.
• It adjusts the flow rate so as to calibrate the quantity of fluid so that it is completely
vaporized at the outlet of the evaporator.
The evaporator
The evaporator block is a thermal exchanger equipped with a reducing valve and a fan.
The fan sucks in the air through the evaporator (cold). The humidity in the air is therefore
condensed on the evaporator blades and the air that exits is cooled down.
This thermal exchange allows the refrigerant fluid to evaporate at low pressure.
The anti-frost thermostat

The electrical thermostat is linked to a sensor placed between the two blades of the evaporator.
The variation in temperature of the evaporator causes a variation in the resistance of the preset
thermostat potentiometer, and controls the compressor clutch relay.
85
(27/09/2012) 85-01-M208EN
6 SPECIFICATIONS
85
85-01-M208EN (27/09/2012)
DRIVER’S CAB COMPONENTS LOCATION
pages
AIR CONDITIONING LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
85
(27/09/2012) 85-03-M208EN
2 DRIVER’S CAB COMPONENTS LOCATION
AIR CONDITIONING LOCATION
Key :
Fluid in gas state at high pressure and at high temperature.
Fluid in liquid state at high pressure and at medium temperature.
Fluid in gas state at low pressure and at low temperature.
85
Engine harness
connection
85-03-M208EN (27/09/2012)
DRIVER’S CAB CONTROL AND ADJUSTMENT
pages
AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
– ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . 2
– CHARACTERISTICS REFRIGERANT FLUID R134A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– SECURITY MEASURES FOR THE MANIPULATION OF R134A . . . . . . . . . . . . . . . . . . . . . . . 3
– REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT. . . . . . . . . . . . . . . . 4
– LOADING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
– CHECKING THE WORKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
85
(05/12/2012) 85-04-M208EN
DRIVER’S CAB CONTROL AND
2 ADJUSTMENT
AIR CONDITIONING
ASSEMBLY INSTRUCTIONS FOR AIR CONDITIONING CIRCUIT
Carry out the assembly operations in a dry and dust free area. Use COMPRESSOR oil PAG ISO 100
SP 20 for the lubrication of all seals and seal surfaces before assembly.
Description Type Couple de serrage

Hose condenser outlet – filter inlet M6 16 N.m
Hose filter outlet – reducing valve inlet M6 16 N.m
Hose compressor outlet – cab inlet M8 25 N.m
Hose cab outlet – condenser inlet M8 25 N.m
Hose reducing valve outlet – cab inlet M10 33 N.m
Hose cab outlet – compressor inlet M10 33 N.m
Connection to the compressor:
Key :
1 - Compressor
2 - Compressor outlet/condenseur inlet horse
3 - Dryer outlet/evaporator inlet horse
4 - Compressor inlet/evaporator outlet horse
2
85
4
3
85-04-M208EN (05/12/2012)
ADJUSTMENT 3
CHARACTERISTICS REFRIGERANT FLUID R134a
Designation Hydro fluorocarbon

Use Refrigerant
Chemical characteristics Tetrafl uoroethane 134a
Chemical formula CH2F-CF3
Physical state Gaz liquéfié
Color Incolore
Smell Légèrement éther
Ebullition point (in atmospheric pressure - 26,5 °C
Fusion point - 101 °C
Density at 25 °C 1,21 kg/l
Critical pressure 40,7 bar
Critical temperature + 101 °C
Weight in vapor state 5 times heavier than air
1 kg in liquid state at 1 bar 200 l in gas state
Solubility of water in the product 0,097% in weight
Thermal decomposition From 110 °C
Dangerous decomposition products Hydrogen halides and traces of carbonyl halides
Dangerous reactions With the alkaline metals and metals belonging to the alkaline earths
(Al-Zn-Be etc.)
Lightening point No lightening point (very stable)
Spontaneous combustion temperature Greater than 75 °C
Explosibility limit ower and higher none
Potential to destroy ozone layer None, ODP=0
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. 85
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.
(05/12/2012) 85-04-M208EN
4 ADJUSTMENT
REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT
Refrigerant fluid: R134a

Load equipment: Load station
Quantity of fl uid: 1000 g ± 50 g
PAG ISO 100 SP20 Oil: No additional oil should be added. Check that there is 135 ml in
compressor.
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 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,
• Simultaneously put on air conditioning at maximum “III” speed,
• 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).
85
• 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).
85-04-M208EN (05/12/2012)
ADJUSTMENT 5
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,
– Simultaneously, put the air conditioning on at maximum speed “III”.
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.
CHECKING THE WORKING
The following checks must be performed with the vehicle engine switched on.
AIR CONDITIONER CONTROLS
b The air conditioner works only when the telescopic lift is started up. With the air conditioner
running, always work with the doors and windows closed.
In winter: To ensure the correct working and complete efficacy of the air conditioning system,
start up the compressor once a week, even if it is only for short periods, to allow lubrication of
the internal gaskets. At low temperatures: Heat the engine before starting up the
compressor to allow the coolant in the liquid state, collected at the bottom of the compressor
circuit, to get transformed into gas under the action of the heat given out by the engine; in the
liquid state the coolant can damage the compressor.
b If the air conditioner is not working properly, have it checked by your dealer (see: 3 - MAINTENANCE:
F - EVERY 2000 HOURS OF OPERATION). Never attempt to repair faults yourself. 85
(05/12/2012) 85-04-M208EN
6 ADJUSTMENT
A - Control unit
A Legend of functions:
1 - Decrease internal temperature

2 - Increase internal temperature
3 - Temperature indicator setting
4 - Indicator 1a fan speed
3
7 - Fan speed increase command
8 - Fan speed decrease command
2 7 9 - Internal air temperature sensor
10 - °C / °F conversion and vice versa
1 8 11 - External temperature reading command
4 5 6
12 - Recirculation command
9
13 - Compressor exclusion
14 - Automatic function reset
14 13 12 11 10
To switch off the unit, press the «Fan speed reduction command» button (Ref. 8) to deactivate the fan
completely; to switch it back on again, press the «Fan speed increase command» button (Ref. 7).
ERROR CODES
In case of a fault that affects the automatic regulation, the control unit displays an error code consisting
of the letter E followed by a number which identifies the type of fault according to the following Table::
E 1 external air temperature sensor (E.T.) interrupted.

E 2 external air temperature sensor (E.T.) short circuit..
E 3 cab air temperature sensor (I.T.) interrupted..
E 4 cab air temperature sensor (I.T.) short circuit.
E 5 mixed air temperature sensor (M.T.) interrupted.
E 6 mixed air temperature sensor (M.T.) short circuit.
85
Since automatic regulation is not possible, the keys for increasing and decreasing the internal temperature
are used to change the position of the mixer, while the fan speed is fixed at the 2a speed.
If the error is solved, the control unit resumes normal operation only after resetting the + key.
85-04-M208EN (05/12/2012)
ADJUSTMENT 7
AIRCONDITIONING PLANT – CHECKING THE WORKING
Electronic control of the temperature (E.AC.C.)

To check to ensure the correct working of the heating and cooling system, make sure the engine is
started up with the hoods closed, at ambient temperature between +15°C and 30°C and the engine
cooling fluid sufficiently hot.
If the ambient temperature is higher or lower than these values, the system automatically adjusts itself
in the maximum cooling or maximum heating conditions.
1 - Checking the water regulator valve

Press the cab internal temperature increase/decrease button, the water regulator valve shifts to the
maximum heating HI or maximum cooling LO condition.
Make sure the mixed air temperature changes accordingly.
2 - Checking the mixed air temperature sensor

If the sensor is defective, the following error codes appear on the display:
E5 = Mixed air temperature sensor (MT) open.
E6 = Mixed air temperature sensor (MT) short circuit.
3 - Checking the cab internal air temperature sensor

E3 = Internal air temperature sensor (IT) open.
E4 = Internal air temperature sensor (IT) short circuit.
4 - Operating the compressor

On pressing the ECON button, the relative LED lights up and switches off alternately and the compressor
is activated and deactivated, respectively, by means of the electromagnetic clutch.
5 - External air inlet and recirculation command

On pressing the Recirculation button, the relative LED lights up indicating the condition of ventilation
with recirculating air. On pressing the recirculation button again, the LED switches off indicating the
condition of ventilation with external air inlet.
6 - Fan speed command

The cab ventilation can be adjusted at three fan speeds: minimum, medium and maximum.
7 - °C and °F selection
When the relative LED is Off, the temperature is indicated in °C , when the LED is On the temperature
85
is read in °F (Fahrenheit).
The maximum cab temperature value setting is 37°C or 99°F.
8 - External temperature sensor connector

On pressing the external temperature button (Ref. 11), the external temperature value appears on the
display.
E1 = External air temperature sensor (ET) open.
E2 = External air temperature sensor (ET) short circuit.
(05/12/2012) 85-04-M208EN
8 ADJUSTMENT
ADJUSTING THE AIR CONDITIONING PRESSURES
Remove the caps (Ref. 1 and 2) on the compressor connections.
Connect the high pressure (Ref. 1) and low pressure (Ref. 2) pipes.
• Start up the vehicle engine.

• Switch on the air conditioner as follows:
– Select air diffusion speed “I” by means of the fan knob.
– Press the air conditioning switch so that the LED lights up.
– Adjust the temperature regulation knob to maximum cold
– Open all the diffuser spouts.
– Set minimum speed (approx. 800 rpm)
– Wait for at least 5 minutes to allow the circuit to stabilize.
– Check the low pressure LP and high pressure HP values of the circuit to make sure they are between:
• 0.5 bar and 2 bar in low pressure LP,

• 6 bar and 20 bar in high pressure HP,
85
85-04-M208EN (05/12/2012)
DRIVER’S CAB TROUBLESHOOTING
pages
AIR CONDITIONER BREAKDOWN DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

– FAULTY AIR CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
– FAULTY VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
– FAULTY HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
85
(07/11/2012) 85-08-M208EN
2 DRIVER’S CAB TROUBLESHOOTING
AIR CONDITIONER BREAKDOWN DIAGNOSTICS
FAULTY AIR CONDITIONING
Faulty air conditioning

Position I, II or III fan YES
function?
YES See “FAULTY
VENTILATION”
NO Air conditioning warning
light on?
NO Correct pressure switch YES
functioning?
YES
Replace pressure
switch
NO Correct electric YES
harness?
Connect up loading
Repair harness
station
NO
At HP stop = LP ≥ 3bar
YES Make a 360g
charge and do a leak
detection
NO YES
Functioning with HP > LP?
YES Correct thermostat HP pressure reaching NO

functioning? 28 bars?
YES YES LP pressure below zero NO
Check and/or replace
thermostat bar?
NO YES Check T° at all HP
Condenser fan connections to detect
functioning? blockage
NO Correct fan YES
functioning?
YES NO
Replace fan Clean condenser fins Correct charge?
NO Correct electric YES De-gas the

harness? system
YES
Repair harness Replace regulator
NO Correct clutch YES

Emptying possible?
functioning?
Compressor clutch YES NO
85
Do a new 725g ±25g

change charge
NO Correct compressor Carry out leak
belt tension ? detection to determine
YES faulty element
Tighten or replace
compressor belt
Recover charge and
remove cylinder head
NO Compressor valves and YES

pistons OK?
Change If there are filings in the oil:
- compressor 1 - Remove compressor, dehydrator, regulator

- compressor exit to regulator entry hosing
- condenser 2 - Rinse out - using “flush” action - hosing, condenser and evaporator
- regulator
- dehydrator 3 - Replace compressor, regulator and dehydrator
85-08-M208EN (07/11/2012)
DRIVER’S CAB TROUBLESHOOTING 3
FAULTY VENTILATION
Faulty ventilation
YES 3 turbine speeds NO
functioning correctly?
Is at least one of the
NO Are ventilation ports 3 speeds correctly NO
open? functioning?
Open ventilation YES YES NO
Correct 12 volt supply?
ports
NO YES Repair electrical
Suction air filter OK
harness
Replace or clean air YES Circuit-breaker NO
filter functioning correctly?
Electric harness YES
Check air distribution Replace circuit-breaker
between HVAC and
instrument panel YES Inter-turbine electric NO
harness correct?
Repair electrical
Replace HVAC turbine
harness
FAULTY HEATING
Faulty heating
NO YES
Is heating mode active?
Is cooling liquid NO
Refer to user manual circulating through the
circuit?
YES NO
Is there a leak?
NO Is the liquid at YES Add cooling liquid and

temperature (80°C)? purge circuit
YES
Turn over truck IC engine Replace faulty element
Is heating valve NO
correctly functioning?
YES
Replace valve
85
See “FAULTY
VENTILATION”
(07/11/2012) 85-08-M208EN
4 DRIVER’S CAB TROUBLESHOOTING
85
85-08-M208EN (07/11/2012)

MLT940 120 SM

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

MLT940 120 SM

Hochgeladen von

Copyright:

Verfügbare Formate

REPAIR MANUAL

This document has been printed from my e doc

AXLE ASSEMBLY - AXLE

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

– Position the gauge 1 (Fig. A) in the tank so that the spring 2

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).

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

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.

Water pump removal.

Remove the thermostat, e MR647370EN.