Mr647632en 2019-01

647632EN (11/01/2019)
MT 420 H 49K ST3A S1

MT 425 H TI 49K ST3A S1
REPAIR MANUAL
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PUBLICATION DATE COMMENTS
03 / 03 / 2017 - 1st EDITION
07 / 12 / 2017 - UPDATE GR80-04 + ADDITION: MT 425 H TI 49K and GR85 + GR110
23 / 04 / 2018 - Partial UPDATE: GR80-04
11 / 01 / 2019 - UPDATE
Manitou BF S.A Limited liability company with a Board of Directors.

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
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
organisation 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 authorisation. All rights reserved.
GENERAL, CHARACTERISTICS AND SAFETY
00
ENGINE SPECIFICATION
10
TRANSMISSION
20
AXLE
30
BRAKE
40
BOOM
50
HYDRAULICS
70
ELECTRICITY
80
DRIVER'S CAB
85
FRAME - BODYWORK
90
110
OPTIONS - ATTACHMENTS
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INTERACTIVE REPAIR MANUAL

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ABBREVIATIONS
° Angle degree
Ω Ohm: unit of electrical resistance, equal to V.A-1.
A Ampere: unit of measurement for electrical current intensity. It is one of the

basic International System (SI) units.
AOC Ammonia Oxidation Catalysts: elimination of the excess ammonia (NH3)

by oxidation from combustion gases having undergone selective catalytic
reduction (SCR) of nitrogen oxides (NOx), by injection of DEF.
APC After Power Contact: positive power supply after switching on the ignition.
BMEP Bloc Manipulateur ÉlectroProportionnel - Electro-proportional joystick unit:

controls the hydraulic movements of lowering, lifting, tilting and digging by
electronic sensors.
CAN Controller Area Network: control communication network for inter-system

communication (J1939, Open, etc.).
CO Carbon Monoxide: colourless, odourless and highly toxic gas.
CRC Comfort Ride Control: Boom suspension.
CVT Continuous Variable Transmission.
DEF Diesel Exhaust Fluid: aqueous solution consisting of 32.5% urea and 67.5%
demineralised water, used to transform 85% of pollutants (NOx) into water
vapour (H2O) and harmless nitrogen (N2).
DOC Diesel Oxide Catalyst: part of the exhaust gas filter or a post-treatment device
used to reduce polluting emissions (HC and CO).
DPF Diesel Particulate Filter : o FAP.
DSB Double Switch Board: smart double switch board connected to a LIN network
via a wiring harness.
DTC Diagnostic Trouble Code: fault codes
ECM/ECU Electronic or Engine Control Module/Unit : ECU making it possible to control

the machine or the engine.
EGR Exhaust Gaz Recirculation : Exhaust gas recirculation circuit to intake to reduce
oxygen supply and reduce NOx.
FAP Filtre À Particule (= Diesel Particulate Filter): filtration system used to trap fine
particles, carcinogenic for humans, contained in combustion gases, particular
from wood fires and Diesel engines.
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FMI Failure Mode Identifier: identifies the type of fault:

0 – The data is valid but the data is above the normal operational range.
1 – The data is valid but the data is below the normal operational range.
2 – The data is erratic, intermittent, or incorrect.
3 – The voltage is above normal or the voltage is shorted high.
4 – The voltage is below normal or the voltage is shorted low.
5 – The current is below normal or the circuit is open.
6 – The current is above normal or the circuit is grounded.
7 – The mechanical system is not responding properly.
8 – There is an abnormal frequency, an abnormal pulse width, or an abnormal
time period.
9 – There has been an abnormal update.
10 – There is an abnormal rate of change.
11 – The failure mode is not identifiable.
12 – The device or the component is damaged.
13 – The device requires calibration.
14 – There is a special instruction for the device.
15 – The signal from the device is high (least severe).
16 – The signal from the device is high (moderate severity).
17 – The signal from the device is low (least severe).
18 – The signal from the device is low (moderate severity).
19 – There is an error in the data from the device.
20 – There is an error in the data from the device (high).
21 – There is an error in the data from the device (low).
31 – The device has failed and the engine has shut down.
gr. Greek: signifies a word of Greek origin.

h hours: unit of measurement for time derived from the second (1
h = 3600 s).
HC Hydrocarbon: organic compound consisting exclusively of carbon (C) and
hydrogen (H) atoms.
Hz Hertz: One hertz is equivalent to one event per second (s-1 or 1⁄ s).
HS High Side: power side power supply.
HVAC Heating, Ventilation and Air-Conditioning: in-cab heating, ventilation and

air-conditioning block.
HMI Human-Machine Interface: dashboard screens.
i.V. Interactive View: 2nd generation MANITOU machine diagnostics software.
JSM Joystick Switch & Move: joystick serving to perform all telescope movements,
as well as to control machine forward and reverse movements with one hand.
lat. Latin: signifies a word of Latin origin.
LIN Local Interconnect Network.
LLMI Limit Load Moment Indicator: strain gauge ensuring machine stability.
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LS Low Side: ground side power supply.
LSU Load Sensing Ultra: hydraulic load detection.
m Metre: unit of measurement for length. It is one of the basic International

System (SI) units.
min. minute : unit of measurement for time derived from the second (1 min = 60 s).
NC o NF.
NF = NC Normalement Fermé (= Normally Closed): normally closed contact.
NO Normally Open: normally open contact.
NOx Nitrogen Oxide: regulated air pollutants.
PAD Plug And Diag: MANITOU machine diagnostics software.
PS/PS+ Power Shift: semi-automatic gear box.

Power Shift +: automatic gear box from 3rd gear and higher.
PWM Pulse Width Modulation: modulation of the pulse

width (MLI) of a fixed-frequency digital electronic
signal synthesising intermediate analogue signals
over a certain duration.
s Second: unit of measurement for time. It is one of the basic International

System (SI) units.
SAHR Spring Applied Hydraulically Released: method of blocking the parking brake
(negative brake).
SCR Selective Catalytic Reduction: reduction of nitrogen oxides (NOx) emitted by

internal combustion engines.
SPN Suspect Parameter Number: identifies the component concerned by the fault.
SPU Safety Power Unit: machine controller.
USB Universal Serial Bus.
V Volt: unit of electromotive force and potential difference (or voltage).

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00
TABLE OF CONTENTS
00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00.1.1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00.1.2 SERVICING POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
00.1.3 EXPLANATION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
00.1.4 SERVICING RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
00.2 GENERAL CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
00.2.1 CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
00.2.2 LUBRICANTS AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
00.2.3 DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MT 420 H 49K ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
MT 425 H TI 49K ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
00.3 GENERAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
00.3.1 LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
00.4 GENERAL CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
00.4.1 STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
00.4.2 METRIC - IMPERIAL UNIT CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00.1.1 FOREWORD
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.
00.1.2 SERVICING POSITION
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.
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00
00.1.3 EXPLANATION OF SYMBOLS
The symbols shown below are used to warn of potential hazards as well as to provide useful information
concerning a procedure.
SYMBOLE OBSERVATION
Indicates an imminent hazardous situation which, if not avoided

DANGER will result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,

WARNING may result in death or serious injury.
Indicates a potentially hazardous situation which, if not avoided,

CAUTION may result in minor injury or damage to property. It is also used to
warn users of unsafe practices.
TIP Indicates a tip to facilitate the performance of a procedure.
Indicates a message to draw attention to important information

PROTECT THE ENVIRONMENT regarding environmental protection.
SPECIFIC TOOLING Indicates special tools for performing a task.
4 "SEE": Indicates a cross-reference to a manual.
5 “SEE”: Indicates a cross-reference to a page.
0 “SEE”: Indicates a cross-reference to a picture.
"WEIGHT": Indicates the weight of an item.

3 (E.g.: it helps to anticipate an action linked to a person's health or the
choice of lifting equipment)
2 "TIGHTENING TORQUE": Indicates the value of tightening torque

to be applied.
1 "OPTION": Indicates the presence of an option.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
given in the manual are not exhaustive.
At any time, as an operator, you must consider, 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.
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00.1.4 SERVICING RULES
Do not carry out any work on the machine unless you have
followed a suitable training course and have the knowledge
required for it.
4 Make sure you have taken into consideration all the indicator
plates on the machine and in the instruction manual.
PRÉCAUTION
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.
AVERTISSEMENT
1 Before carrying out any operation on an electrically powered component,
activate the battery cut-off.
2
PRÉCAUTION
Press the battery switch at least 30 seconds after disconnecting the electrical
contact with the ignition key.
AVERTISSEMENT
If the telehandler does not have a battery isolating switch, disconnect the
battery terminals then gather them.
PRÉCAUTION
ECU
Before carrying out any welding operations, think of disconnecting computers.
PRÉCAUTION
A machine operating in a contaminated environment should be specifically

equipped. Moreover, local safety notices deal with maintenance and repair
work on such machines.
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AVERTISSEMENT
Never step on a part of the machine that has not been designed for it.
AVERTISSEMENT
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.
DANGER
When carrying out maintenance
operations near a mobile object,
make sure it is securitized.
PROTÉGER L’ENVIRONNEMENT
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.
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DANGER
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.
PRÉCAUTION
Make sure no object or tool which could cause an accident is left in the machine.
AVERTISSEMENT
Never control any leaks using a hand.
max.
min.
PRÉCAUTION
MAX Never adjust a component to over the maximum capacity indicated by the
manufacturer.
MIN
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00.2 GENERAL CHARACTERISTICS AND SPECIFICATIONS
Data obtained from Instruction Manual: 647628 of 18/01/2018
00.2.1 CHARACTERISTICS
Designation MT 420 H MT 425 H TI
Lift truck weight with standard
4190 kg 4,378 kg
attachment
Weight distribution FRONT 1985 kg 1,898 kg
per axle with standard
attachments REAR 2205 kg 2,480 kg
Traction force (unladen) 2780 daN 2,790 daN
00.2.2 LUBRICANTS AND FUEL

Designation Type Quantity
Fuel tank GNR HP (High-Performance Non-Road Diesel): EN590 / ASTM D975 60 ℓ
Engine oil MANITOU PREMIUM OIL 15W40 API CI4 8ℓ
Cooling system Cooling liquid (protection - 35°) 9ℓ
Hydraulic tank MANITOU ISO VG 46 Hydraulic oil 55.5 ℓ
Brake system MANITOU Mineral brake fluid 1ℓ
Air-conditioning system R134a gas 725 ±25 g
Axle differential Special MANITOU oil for immersed brakes 3ℓ
Transfer gear box MANITOU SAE 80W90 Mechanical transmission oil 0.6 ℓ
Wheel reduction gear MANITOU SAE 80W90 Mechanical transmission oil 4 x 0.25 ℓ
Greasing axles MANITOU blue multi-purpose lubricant
Greasing boom pads and
MANITOU black multi-purpose lubricant
wheel reduction gear pivots
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00.2.3 DIMENSIONS
MT 420 H 49K ST3A S1
A mm 1200
B mm 2130
C mm 1038
C1 mm 978
D mm 3638
D1 mm 3578
D2 mm 3012
E mm 4838
F mm 1169
F1 mm 1169
G mm 268
G1 mm 240
G2 mm 265
G3 mm -
H ° -
H1 ° -
I mm 470
J mm 797
K mm 1015
L mm 40
N mm 1350
O mm 100
P2 ° 27
P3 ° 62
R mm 2900
S mm 6364
T mm 2850
U1 mm 1965
U2 mm 2065
V mm 4170
V1 mm 1320
V2 mm 3061
W mm 1490
W1 mm -
W2 mm -
W3 mm -
Y ° 12
Z ° 116
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MT 425 H TI 49K ST3A S1
A mm 1200
B mm 2130
C mm 912
C1 mm 977
D mm 3532
D1 mm 3597
D2 mm 3032
E mm 4732
F mm 1169
F1 mm 1169
G mm 268
G1 mm 240
G2 mm 265
G3 mm -
H ° -
H1 ° -
I mm 490
J mm 797
K mm 1015
L mm 40
N mm 1330
O mm 100
P2 ° 27
P3 ° 62
R mm 2855
S mm 6193
T mm 2730
U1 mm 1965
U2 mm 2065
V mm 4050
V1 mm 1320
V2 mm 3016
W mm 1490
W1 mm -
W2 mm -
W3 mm -
Y ° 20
Z ° 108
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00.3 GENERAL LOCATION
00.3.1 LOCATION OF NAME AND IDENTIFICATION PLATE
1 - Manufacturer's plate 5 - Hydrostatic motor 9 - Boom

2 - Rear axle plate 6 - Hydrostatic pump 10 - Frame serial no.
3 - Front axle plate 7 - Hydraulic pump 11 - Attachment manufacturer's
4 - Engine plate 8 - Cab plate plate
1
MANITOU BF 44158 ANCENIS CEDEX FRANCE
MODELE
MODEL
MODELLO
MODELO
SERIE
SERIES
SERIE
SERIE 4
Année de fabrication Anno di fabbricazione Année modèle Anno modello
Year of manufacture Año de fabricación Model year Año modelo
8
N° de série N° di serie
Puissance ISO 3046
Serial Nr N° de serie
Power ISO 3046
Potenza ISO 3046
Potencia ISO 3046
Masse à vide Massa a vuoto kW

Unladen mass Masa en vacio
kg Capacité nominale
Rated capacity
Capacità nominale
P.T.R.A. P.T.C.A.
Capacidad nominal
Authorized gross vehicle weight P.T.R.A.
daN kg
Effort de traction Sforzo di trazione Effort vertical maxi. (sur crochet de remorquage)
Drag strain Esfuerzo de tracción Maximum vertical force (on trailer hook)
Sforzo verticale massimo (sul gancia di traino)
daN Esfuerzo vertical máximo (sobre gancho de remolque)
Pression des pneumatiques (Bar) daN

Tyres pressure (Bar)
Pressione dei pneumatici (Bar)
Presión de los neumáticos (Bar) N° d'homologation
Homologation Nr
9
Avant Anteriore Arrière Posteriore N° di omologazione
Front Adelante Rear Trasero N° de homologación
N°295507
10
MANITOU BF
44158 ANCENIS CEDEX
FRANCE
6 MODELE
N° dans la série
Année fabrication
11
Masse à vide
kg
C d G / Tablier
A vide / En charge : mm
Cap. Nominale
Pression de service
AVERTISSEMENT : RESPECTEZ
LA CAPACITE DE L'ENSEMBLE
"CHARIOT ET EQUIPEMENT"
N°207701
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00.4 GENERAL CONTROL AND ADJUSTMENT
b
00.4.1 STANDARD TIGHTENING TORQUES
Standard tightening torques
To be used. unless otherwise indicated in the removal or refit operations.
SCREW / NUT ASSEMBLY
- with hexagon head screws without flanges ou cylinder head hexagon socket screws.
- for dry-fitted zinc-plated fasteners and for torque tools having a ± 20 % class C tightening torque
accuracy (equivalent to pneumatic screwdrivers).
1 - NF E 25-030-1 :
Ø x “coarse” pitch Grade 8.8 Grade 10.9 Ø x “fine” pitch Grade 8.8 Grade 10.9
N.m lb-in N.m lb-in N.m lb-in N.m lb-in
M6 x 1 8.2 72.57 12.1 107 - - -
M8 x 1.25 20 177 30 265 M8 x 1 22 195 32 283
M10 x 1.5 40 354 59 522 M10 x 1.25 (x 1) 43 (46) 380 (407) 63 (68) 558 (602)
M12 x 1.75 69 611 102 903 M12 x 1.5 (x 1.25) 74 (78) 655 (690) 108 (115) 956
M14 x 2 111 982 163 1443 M14 x 1.5 123 1088 181 1602
M16 x 2 175 1549 256 2266 M16 x 1.5 190 168 279 2470
M18 x 2.5 240 2124 352 3115 M18 x 1.5 279 2469 410 3629
M20 x 2.5 341 3018 501 4434 M20 x 1.5 391 3460 574 5080
M22 x 2.5 470 4160 691 6116 M22 x 1.5 531 4700 780 6903
M24 x 3 588 5204 864 7647 M24 x 2 659 5833 967 8559
M27 x 3 874 7735 1284 11364 M27 x 2 965 8541 1418 12550
M30 x 3.5 1181 10453 1735 15356 M30 x 2 1351 11957 1984 17560
M33 x 3.5 1614 14285 2371 20985 M33 x 2 1821 16117 2674 23667
b
M36 x 4 2068 18303 3037 26880 - - - - -
For hexagon screws with flanges (NF E 25-030-1) :

Apply an increased torque of +10%.
b Where washers are used. the following coefficient is to be applied (FD E 25-502) :
- Plate : +0% - Spring (or Grower) washer without jaws (W) : +10%
- Smooth tapered washer (CL): +5% - Conical. internal teeth (CDJ-JZC) : +15%.
2 - With marking :
4 5 6 7 8
4T 6T 8T
------------ ------------ ------------
5T
(N.m)
7T
(N.m)
11
(flange : 4.8T) (flange : 6.8T) (flange : 8.8T) (flange : 10.9T) (flange : 11.9T)
Ø x Pitch N.m lb-in N.m lb-in N.m lb-in N.m lb-in N.m lb-in N.m lb-in N.m lb-in
5.4 48 7.8 69 12 106
M6 x 1 6.5 57.5 11 97 (15.5) (137.2) (17.5) (155)
(5.5) (49) (7.5) (66) (12) (106)
13 115 19 168 29 257
M8 x 1.25 16 142 25 221 (38) (336) (42) (372)
(13) (115) (19) (168) (29) (257)
25 221 39 345 61 540
M10 x 1.25 32 283 52 460 (80) (708) (89) (788)
(27) (239) (39) (345) (61) (540)
47 416 72 637 108 956
M12 x 1.25 59 522 95 841 (145) (1283) (160) (1416)
(50) (443) (71) (628) (110) (974)
75 664 108 956 172 1522
M14 x 1.5 91 805 147 1301 (230) (2036) (260) (2301)
(78) (690) (110) (974) (175) (1549)
b
113 1000 172 1522 265 2345
M16 x 1.5 137 1213 226 2000 (360) (3186) (400) (3540)
(120) (1062) (170) (1504) (270) (2390)
use the upper class where spring (or Grower) washers are used.
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00.4.2 METRIC - IMPERIAL UNIT CONVERSION

CONVERSION COEFFICIENTS:
Metric Unit (S.I) Coefficient Imperial Unit US
°C (Celsius degree) x 1.8 + 32 = °F (Fahrenheit degree)
cm3 (centimeter cube) x 0.06102 = cu.in. (cubic inches)
cv (cheval vapeur) x 0.9859 = hp (horsepower)
bar (bar) x 14.51 = psi (pound-force/square inch)
g (gram) x 0.0353 = oz av (ounce avoirdupois) (oz : lat. onza)
kg (kilogram) x 2.2046 = lb (pound) (lat . libra)
km/h (kilometer per hour) x 0.6214 = mph (miles per hour)
kW (kilowatt) x 1.34048 = hp (horsepower)
ℓ (liter) x 0.2642 = gal US (US gallon)
ℓ (liter) x 1.0567 = qt US (quart US gallon)
m (meter) x 3.2808 = ft (foot)
m (meter) x 39.37 = in (inch)
mℓ (milliliter) x 0.0338 = fl oz (fluid ounce) (fl : fluid, oz : lat. onza)
mm (millimeter) x 0.03937 = in (inch)
µm (micrometer) x 0.03937 = mil (thousands of an inch)
N (Newton) x 0.2248 = lbf (pound-force) (lb : lat. libra, f : force)
N.m (Newton meter) x 0.7376 = ft-lb (pound-force-foot) (ft : foot, lb : lat. libra)
rad/s (radian/second) x 9.5493 = rpm (revolution per minute)
t (metric ton) x 2204.62 = lb (pound) (lat. libra)
tr/min (tour per minute) x 1 = rpm (revolution per minute)
OTHER UNIT CONVERSIONS:
Unit Coefficient Unit
ft (foot) x 12 = in (inch) (pouce)
lb (pound) (lat. libra) x 16 = oz av (once avoirdupois)
m (meter) x 1000 = mm (millimeter)
mm (millimeter ) x 1000 = µm (micrometer)
t (metric ton) x 1000 = kg (kilogram)
rad (radian) x 57.2958 = ° (angle degree)
10
TABLE OF CONTENTS
10.1 ENGINE CHARACTERISTICS AND SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
ENGINE V2607-DI-E3B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
10.2 ENGINE COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.2.1 ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.3 ENGINE CONTROLS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
10.3.1 VENTILATION CONTROL (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
FUNCTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
DESCRIPTION OF HYDRAULIC VENTILATION BLOCK: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
ENGINE HYDRAULIC DIAGRAM: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
THE THREE MODES OF OPERATION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
CONTROL: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
FAN CONTROL SYSTEM ARCHITECTURE DIAGRAM: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
10.3.2 ENGINE SILENT BLOCK TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.3.3 COOLING SYSTEM TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
10.4 ENGINE REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.4.1 SIDE CASING AND ENGINE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10.4.2 ALTERNATOR BELT REMOVAL/REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.4.3 ALTERNATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.4.4 STARTER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
10.4.5 AIR FILTER ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
10.4.6 COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
VENTILATION GRILLE REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
RADIATOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
VENTILATION CONTROL BLOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
COOLER SUPPORT BRACKET REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.4.7 EXHAUST PIPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
10.4.8 FUEL TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
10.4.9 ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
10.4.10 ENGINE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
10.4.11 WATER PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.5 ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.6 SPECIFIC ENGINE TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.6.1 SPECIAL ENGINE TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
10.6.2 ELECTRONIC TENSION METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

647632EN
22 ENGINE SPECIFICATION 10 (09/01/2017)
10
LINKS TO REPAIR MANUALS:
MANUAL REFERENCE
DESIGNATION
NUMBER
647520 ENGINE V2607-DI-E3B

647632EN
10 (09/01/2017) ENGINE SPECIFICATION 23
10.1 ENGINE CHARACTERISTICS AND SPECIFICATION
10
ENGINE V2607-DI-E3B
⇒⇒ 4 cylinders in line
⇒⇒ Firing order from the attachment belt: 1 - 3 - 4 - 2
⇒⇒ Anti-clockwise (viewed from flywheel)
⇒⇒ 2.615 ℓ cubic capacity
⇒⇒ Direct injection
⇒⇒ Compression ratio: 20
⇒⇒ Power rating: 36 kW
⇒⇒ Maximum torque: 170 N.m (at 1600 rpm)
⇒⇒ Dry engine weight: 225 kg
⇒⇒ Speeds: - min rpm:. . . . . . . . . . . . . 925 ±25 rpm
- nominal laden:. . . . . . . 2,700 rpm
- max. unladen:. . . . . . . . 2,920 rpm
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10.2 ENGINE COMPONENTS LOCATION
10.2.1 ENGINE COMPONENTS

Key:
10
1 - Cooling water inlet 10 - Fuel pre-filter

2 - Alternator belt 11 - Fuel supply pump
3 - Water pump 12 - Fuel filter
4 - Alternator 13 - Pompe Injection pump
5 - Thermostat 14 - Starter
6 - Cooling water outlet 15 - Oil cooler
7 - Air inlet 16 - Oil filter
8 - Air intake manifold 17 - Injection hose
9 - Exhaust 18 - Engine ECU
18
10
7
17
17 17 5
12
17
13 8
11 4
2 1
14
16
Cooling (water)
15
Air
Diesel
Electricity
Lubrication
Exhaust
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10.3 ENGINE CONTROLS AND ADJUSTMENTS
10.3.1 VENTILATION CONTROL (OPTION)
10
LOCATION
Fan direction reversal

electrovalve
Fan control hydraulic
Fan speed control
engine
electrovalve
Warm Up
electrovalve
(hydraulic oil heater)
Fan control hydraulic

pump
FUNCTION:
⇒⇒ To adjust the speed of the engine cooling fan according to the temperature (engine and
transmission).
⇒⇒ To temporarily reverse the direction of flow to unclog the bonnet intake grilles.
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DESCRIPTION OF HYDRAULIC VENTILATION BLOCK:
10 - 1 Key: (, 010 - 1)
1 - Hydraulic fan drive motor.
10
3 2 - Ventilation control block.

8 3 - Fan speed control electrovalve Y20.
9
4 4 - Fan direction reversal electrovalve Y19.
5 - Warm Up electrovalve (hydraulic oil heater) Y23.
10 2 6 - Pressure port (P).
6
1 7 - Tank return (R).
5
8 - Enter cooler.
7 9 - To cooler.
10 - Oil temperature sensor
10 - 2 ENGINE HYDRAULIC DIAGRAM:
Key:
PPfan BRV BRV : Ventilation control block.
Fan In
X386 Y20
A
V
MV : Fan motor.
Fan IN : From hydraulic pump.
Loop A
11 cm³/tr
138 bar T
B
Y23 MV
c
T: Tank return.
Cooler 3 bar
Out X199 B
Y19
X385
T
RF Cooler
In
Y20: Fan speed control electrovalve.
Y19: Fan direction reversal electrovalve (OPTION).
t° S
X18
Y23 : Warm Up electrovalve (hydraulic oil heater).

C : One way valve.
V: Fan.
RF: Cooler.
The control unit is equipped with two electrovalves and a one way valve.
The Y19 proportional relief valve adjusts the speed of rotation of the hydraulic motor.
The full propeller rotational speed must be achieved when the relief valve is not energised.
The Y19 on-off control valve defines the direction of rotation of the hydraulic motor. When the coil is
not energised, the motor's direction of rotation corresponds to the "normal cooling" mode direction
of rotation.
The one way valve C prevents hydraulic engine cavitation, in particular during engine shutdown phases.
647632EN
THE THREE MODES OF OPERATION:
"Reversal" mode (reverse propeller rotation)

The reversal of propeller rotation is temporary. In this mode, the proportional coil of the relief valve
10
(control valve) is fully energised, thus reducing the speed of rotation of the propeller. The direction
reversal electrovalve (reversal valve) is then energised, reversing the direction of rotation of the engine.
The relief valve power supply is gradually reduced to a 0% control value, thus allowing the speed of
rotation of the cooling fan to increase. The ventilation system is then in "reversal" mode, serving to
unclog the engine bonnet grilles. A similar procedure restores the propeller's direction of rotation to
cooling mode.
The reversal cycle is possible from an engine water temperature of 40°C and 3 seconds after start-up.
Time delay operation:
–– The system does not allow reversals to be performed within a period of less than 3 min.
–– If the switch is pressed, reversals will occur every 3 minutes.
–– If the switch is pressed within the 3 minute period (e.g.: the previous reversal was performed 1 minute
ago), the system will ignore it
"Optimised cooling" mode: speed of rotation of the propeller adjusted to suit the operating
conditions
The reversal valve is not powered in this mode.

The relief valve coil is energised proportionally (PWM signal), thus reducing the speed of rotation of
the propeller below the "maximum" speed. This operating mode is conditioned by the temperature
parameters (fluid temperatures, etc.).
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"Maximum cooling" mode
In this mode, none of the coils are energised. The full pump flow is sent to the engine without any
adjustment, thus ensuring that the propeller speed of rotation is proportional to the engine speed.
The operating mode ensures "maximum" truck cooling.
10
CONTROL:
The fan control management module is connected to the truck's other electronic components via a CAN
network.
It directly controls the hydraulic unit's electrovalves.
It is connected to the fan drive control switch situated in the cab.
The engine fan speed is adjusted according to the engine coolant and the hydraulic oil temperatures.
Fan speed value:
Hydraulic oil T°C % Fan speed / Engine speed Engine water T°C % Fan speed / Engine speed
Below 65 °C 0 % = fan must rotate at minimum speed Below 80 °C 0 % = fan must rotate at minimum speed
Between 65 °C and Between 80 °C and
From 0 to 16 % From 0 to 36 %
75 °C 95 °C
Between 75 °C and Between 95 °C and
From 16 to 46 % From 36 to 76 %
90 °C 100 °C
Above 90 °C From 46 to 100 % Above 100 °C From 76 to 100 %
The ECU will select the more unfavourable value between the coolant temperature and the hydraulic
oil temperature.
Electrical values for the electrovalve signal i 80 - Electrical characteristics and specifications
Fan speed measurements with electrovalves disconnected (maximum fan speed achieved according
to engine speed) :
Engine speed (rpm) Maximum fan speed (rpm)
870 1 180
1 300 1 780
1 500 2 068
1 700 2 370
2 000 2 848
2 500 3 050
2 750 3 100
e.g.: if oil is at 70 °C and the coolant at 90 °C, the ECU will select the least favourable valve (90 °C), the fan
will run at 36% of its maximum speed (3,100 rpm) thus, for a max. engine speed (2,750 rpm) approx.:
3,100 x 0.36 = 1,116 rpm.
Above 110°C = indicator comes on and the buzzer sounds.
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FAN CONTROL SYSTEM ARCHITECTURE DIAGRAM:
MMI
10
Ventilation control
block Hydraulic
system ECU
Y20
Y19
Engine temperature
Y23 sensor
Switch Hydraulic oil temperature

CC1
CAN
PPC
sensor in transmission ECU

PSC
PPU
CC2
Components:
⇒⇒ Engine-mounted coolant temperature sensor.

⇒⇒ MMI (Man-Machine Interface) displays and transmits the engine coolant temperature signal to
the hydraulic system ECU via the CAN.
⇒⇒ Oil temperature sensor in the hydrostatic pump ECU gives the ECU temperature from which
the oil temperature is deduced.
⇒⇒ Hydraulic system ECU
⇒⇒ Fan speed control electrovalve (Y19) on the BRV hydraulic block;
⇒⇒ Fan direction reversal electrovalve (Y20) on the BRV hydraulic block;
⇒⇒ Hydraulic oil heater warm up electrovalve (Y23) on the BRV hydraulic block;
⇒⇒ Fan control switch.
647632EN
10.3.2 ENGINE SILENT BLOCK TIGHTENING TORQUES
(x4) (x2) 110 ± 11 N.m

10
110 ± 11 N.m
: Add Loctite normal thread lock No. 243 (x4) 110 ± 11 N.m
10.3.3 COOLING SYSTEM TIGHTENING TORQUES

45 N.m (x4)
8 N.m (x4)
40 N.m
647632EN
10.4 ENGINE REMOVAL - REFITTING

PREPARATION AND SAFETY INSTRUCTIONS
–– Stabilise the machine on level ground.
10
–– Position the boom in the raised position and install the safety wedge.
–– Open the engine covers.
PRECAUTION
Before starting work:
- Switch off the ignition with the ignition key.
- Wait for at least 30 seconds.
- Deactivate battery power supply by means of the battery cut-off.
When refitting, observe the special ( 6 10.3 ENGINE CONTROLS AND ADJUSTMENTS, 5 25) (6 20.1.7
TRANSMISSION TIGHTENING TORQUES, 5 51) and standard tightening torques ( 6 00.4.1 STANDARD
TIGHTENING TORQUES, 5 19).
10.4.1 SIDE CASING AND ENGINE COVER REMOVAL

10 - 3
1
Open the engine cover (1, 010 - 3).
2
Open the 2 latches of the engine side casing (2, 010 - 3).
Lift the casing vertically (3, 010 - 3) and remove.
10 - 4
Unscrew the clamp (1, 010 - 4), of the air filter cap (2, 010 - 4) and
remove.
2
3
Uncouple the gas strut (3, 010 - 4).

1
10 - 5
Remove the 4 screws (1, 0 10 - 5) and remove the engine cover/

2 central casing assembly (2., 010 - 5).
1 1
1
647632EN
10.4.2 ALTERNATOR BELT REMOVAL/REFIT
Undo the nut (1, 010 - 6) and the screw (2, 010 - 6).
10 - 6
10
Swivel the alternator (3, 010 - 6) assembly so as to free the belt (4,
2
3
010 - 6) and remove it.
5
When refitting, set the belt tension on the upper belt run to
X289
deflect between 10 and 12 mm under a pressure of 98 N (610.6.2
B+ ELECTRONIC TENSION METER, 5 42).
4
10.4.3 ALTERNATOR REMOVAL
6
1
Carry out operation (610.4.2 ALTERNATOR BELT REMOVAL/REFIT, 5 32)
Disconnect the connector (X289, 010 - 6) and the terminal lug (B+, 010 - 6)
Remove the gauge (5, 010 - 6) and set it down in a clean place.
Remove the nut (1, 010 - 6), the screw (2, 010 - 6) and the screw (6, 010 - 6).
Remove the alternator (3, 010 - 6)
10 - 7 10.4.4 STARTER REMOVAL

1
X04
Disconnect the connector (X04, 010 - 7) and the 2 terminal lugs
X160
(X05 and X160, 010 - 7).
X05
Remove the 2 screws (1, 010 - 7) and remove the starter (2, 010 - 7).
1 2
10 - 8
10.4.5 AIR FILTER ASSEMBLY REMOVAL
2
Carry out operation ( 6 10.4.1 SIDE CASING AND ENGINE COVER
1 REMOVAL, 5 31).
1
Unscrew the clamps (1, 0 10 - 8) and remove the air intake hose
(2, 010 - 8).
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10 - 9
1 Remove the 4 screws (1, 010 - 9) and remove the front mudguard
(2, 010 - 9).
1
10
2
10 - 10 Remove the 2 screws (1, 0 10 - 10) and remove the air filter (2,
2 010 - 10).
10.4.6 COOLER REMOVAL

10 - 11
VENTILATION GRILLE REMOVAL.

4 1
4
Open the cooler assembly.
Place a container under the fan motor.
1
3
Disconnect and remove the pipes (1, 010 - 11).
2
Disconnect the hose (2, 010 - 11) from the fan motor (3, 010 - 11)
4
Remove the 4 screws (4, 0 10 - 11) and remove the pump and
4
cooler grille assembly.
10 - 12
2
Undo the centre nut (1, 0 10 - 12) and remove the propeller (2,
010 - 12).
1
647632EN
10 - 13
Remove the 4 screws (1, 010 - 13) and separate the pump (2, 010 - 13)
3
from the grille (3.
1 2
10
RADIATOR REMOVAL
10 - 14
2
Drain the radiator:
44 Operator's manual 647628.
1
Disconnect the 2 upper hoses (1, 010 - 14) and plug the openings.
Disconnect the upper hose (2 , 0 10 - 14) and the lower hose

1 (3, 010 - 14)
Plug the openings.

3
10 - 15
1 Remove the 4 side screws (1, 010 - 15).

1
2
Remove the 2 front screws (2, 010 - 15) and remove the radiator.
1 2
VENTILATION CONTROL BLOCK REMOVAL

10 - 16
2
2 X386
Identify and disconnect the 3 lower hoses (1, 010 - 16) and insert
X385
plugs.
X199 Disconnect connectors (X18, X199, X385, 010 - 16) and (X386 fan
X18
drive option, 010 - 16).
Disconnect the 2 upper hoses (2, 010 - 16) and insert plugs.
1
1 1
647632EN
10 - 17 2
COOLER SUPPORT BRACKET REMOVAL
Unscrew the fuse holder (1, 010 - 17).
10
Disconnect the upper hose (2, 010 - 17) and plug the engine port.
1
4
3
3
Unscrew the 5 screws (3, 0 10 - 17) securing the cooler support
bracket (4, 010 - 17).
3
3
3
10 - 18
Remove the 2 screws (1, 010 - 18).

1
Remove the assembly (4, 010 - 17).
1
10 - 19 10.4.7 EXHAUST PIPE REMOVAL
1 Remove the screw (1, 010 - 19).

3
Remove the 2 lower screws (2, 010 - 19) from the rear mudguard
(3, 010 - 19) and take it off.
2 2
10 - 20
2
1
Remove the 4 screws (1, 010 - 20) from the exhaust casing (2, 010 - 20)
1
and remove it.
1 1
647632EN
10 - 21
Remove the 4 screws (1, 010 - 21) from the exhaust support.
1
1
2 Loosen the clamp (2, 010 - 21).
1
1
10
Remove the 2 nuts (3, 010 - 21).
10 - 22
Take out the exhaust assembly (1 , 0 10 - 22) by detaching the

silencer (2 from the exhaust pipe (2, 010 - 22) and removing the
1
2 assembly (1.
Remove the exhaust pipe (2, 0 10 - 22) and insert a plug in the
engine exhaust port.
10.4.8 FUEL TANK REMOVAL

10 - 23
Place a container under drain plug (1, 010 - 23) and unscrew the
plug.
Remove the filler plug to ensure that the oil is drained properly.
10 - 24
Open the rear cover

1
Identify and disconnect the 3 hoses (1, 010 - 24).

1
1
Disconnect the fuel gauge connector (X63, 010 - 24).
X63
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10 - 25
1
10
1
1
10 - 26
1 2 Remove the screws (1 , 0 10 - 26) and take off the rear casing
1
(2, 010 - 26).
Remove the 2 screws (3, 010 - 26) from the rear bracket (4, 010 - 26)
4 (according to option).
3
3
10 - 27
2
1 Slightly raise the bracket (1, 010 - 27) (according to option).
Hold the screw of the rear left cab silent block (2 , 0 10 - 27) and
remove the nut under the cab.
Lift the screw to take out and remove the fuel tank (3, 010 - 27).
3
647632EN
10.4.9 ENGINE REMOVAL
Block oscillation of the rear axle, place a 35 mm block (1, 010 - 29)
10 - 28 on either side of the axle.
10
Lift the rear axle and place blocks under the rear wheels (2, 010 - 29)
1
Repeat the operation on the front axle
Carry out operation (610.4.1 SIDE CASING AND ENGINE COVER REMOVAL, 5 31).
Carry out operation (610.4.5 AIR FILTER ASSEMBLY REMOVAL, 5 32)
Carry out operation (610.4.6 COOLER REMOVAL, 5 33)
Carry out operation (610.4.7 EXHAUST PIPE REMOVAL, 5 35)
10 - 29
4
Disconnect
4 ⇒⇒ The alternator connections (1, 010 - 29).

1
3 ⇒⇒ The starter connections (2, 010 - 29).
⇒⇒ The connexion of the injection solenoid (X403)(3, 010 - 29).

4 1
⇒⇒ The connections of the engine oil pressure (X404), engine

2
water temperature (X405), engine speed (X401), preheat (X03)
2 sensors, etc. (4, 010 - 29).
10 - 30
⇒⇒ The fuel supply and return hoses (1, 010 - 30) and unscrew
the clamp (2, 010 - 30).
2
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10 - 31
⇒⇒ Heating hose (1, 010 - 31).
⇒⇒ The water hose (2, 010 - 31) and remove it.
10
1
10 - 32
2
3
Unscrew the screw (1, 010 - 32) and remove the screw (2, 010 - 32)
1 from the cover support bracket (3, 010 - 32).
Fold back the cover support bracket (3, 010 - 32)
10 - 33
Remove the 2 screws (1, 010 - 33) et remove the access panel (2,
010 - 33).
1 1
2
10 - 34
Support the hydrostatic pump by means of a prop (2, 0 10 - 34)

1 under the lower pipe (1, 010 - 34).
2
647632EN
10 - 35
Attach slings to the engine lifting rings (1, 010 - 35) and pull tight
(2, 010 - 35).
2 2
10
10 - 36
Unscrew the T connector (1, 010 - 36) from the hydrostatic pump.
10 - 37
Remove the screw (1, 0 10 - 37) from the front left silent block
(2, 010 - 37).
Remove the 2 screws (3, 010 - 37) from the front left silent block
2 support (2, 010 - 37) and remove it.
1
3
3
10 - 38
1 Remove the 2 screws (1, 0 10 - 38) from the rear left silent block
2
support (2, 010 - 38).
2
3 Remove the 2 screws (3, 010 - 38) from the rear right silent block
3
support(4, 010 - 38).
4
647632EN
10 - 39
Remove the screws (1, 010 - 39), attaching the hydrostatic pump
1
to the engine.
10
1
10 - 40
Disconnect the engine (1, 010 - 40) from the hydrostatic pump by
moving it towards the front.
1 Lift, take out and remove the engine.
10.4.10 ENGINE REFIT

Refit the engine by proceeding in the reverse order to removal.
Observe the special (610.3 ENGINE CONTROLS AND ADJUSTMENTS, 5 25) (620.1.7 TRANSMISSION TIGHTENING
TORQUES, 5 51) and standard tightening torques (600.4.1 STANDARD TIGHTENING TORQUES, 5 19).
Lower the engine paying attention to the hoses and harnesses.
10 - 41
PRECAUTION
Refit the screw (1, 010 - 41) before refitting the screws of the silent block supports.
1
647632EN
10.4.11 WATER PUMP REMOVAL

44MR 647520 MAINTENANCE chapter “(7) Water pump and oil cooler”.
10
10.5 ENGINE TROUBLESHOOTING

Engine error codes (6X400 - ENGINE ECU - EVG - A13, 5 121).
10.6 SPECIFIC ENGINE TOOLING
10.6.1 SPECIAL ENGINE TOOLING

44MR 647520 GENERAL chapter “(5) special tooling”.
10.6.2 ELECTRONIC TENSION METER
Electronic tension meter (P/N 895692) for checking

belt tension.
TRANSMISSION
TABLE OF CONTENTS
20.1 TRANSMISSION SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
20
20.1.1 DRIVE TRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
20.1.2 KEY TO DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
20.1.3 FORWARD GEAR DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
20.1.4 REVERSE GEAR DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
20.1.5 HYDROSTATIC TRANSMISSION PRESSURE TEST PORT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
20.1.6 TOWING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
20.1.7 TRANSMISSION TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

20.2 TRANSMISSION REMOVAL - REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
20.2.1 HYDROSTATIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
20.2.2 HYDROSTATIC MOTOR REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
20.3 SPECIFIC TRANSMISSION TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
20.3.1 BASIC MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
20.3.2 DIGITAL MANOMETER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
MANUAL REFERENCE
DESIGNATION
NUMBER
647069 HYDROSTATIC MOTOR H1 060/080/110/160/250
647039 HYDROSTATIC PUMP SERIES H1 45/53
647041 AXLE TYPE 211

647632EN
44 TRANSMISSION 20
20
647632EN
20 TRANSMISSION 45
TRANSMISSION
20.1 TRANSMISSION SCHEMATIC DIAGRAMS
20.1.1 DRIVE TRAIN
20
Engine
Transfer
gear box
Z6 Clockwise
Z2
Z1 Z1
Z2
Z7
Forward
Z3 Z5 Z4
Front and rear axles Transfer box

Gear Number of teeth Gear Number of teeth
Z1 9 Z6 30
Z2 29 Z7 64
Z3 55
Z4 17
Z5 18
647632EN
46 TRANSMISSION 20
20.1.2 KEY TO DIAGRAMS

Conditions: MAXIMUM SPEED/MINIMUM TORQUE
Suction system
Boost system
High Pressure
Low Pressure
Cooling system
Drainage system
20
670 (670.2 HYDRAULIC SCHEMATIC DIAGRAMS, 5 100)

BA Feed block + accumulator
BRe Breather plug
BRV Ventilation control block
CA Suction strainer
CAR One way valve
FR Return filter
M Engine
MH Hydrostatic motor
MV Fan Motor
P Hydraulic pump
PH Hydrostatic pump
PP: Pressure test port
R Main hydraulic tank
RF Cooler
Y3 Forward gear proportional electrovalve

Y4 Reverse gear proportional electrovalve
Y6 2P Sauer hydrostatic motor proportional electrovalve
Y7 BDP (Brake Pressure Defeat) electrovalve
Y12 Hydraulic cut-off electrovalve
Y13 Negative Brake electrovalve
Y19 Ventilation speed control electrovalve
Y20 Ventilation fan direction reversal electrovalve (option)
Y23 Warm up electrovalve
647632EN
20 TRANSMISSION 47
20.1.3 FORWARD GEAR DIAGRAM
MH L2
A
Y6
80 cm³/tr
Y7
20
FORWARD AXLE
REAR AXLE
min max
L1
B
M5 M4
PP
PPfan BRV
Fan X386 Y20
In A
Loop A
11 cm³/tr
138 bar T
B
Cooler 3 bar Y23 MV
Out X199 B
Y19
X385 T fan
T
RF Cooler 70
In S
t°
X18 70
70
70
PDS/BPC PPC SAHR
Pressure point PSAHR
PDS/LS
Y12
IN Y13
Hydrostatic
charge pump
Y3 Y4 T
AM3 L2 MA BA
M
26.7 14.5 SBO
12 cm³/tr 350 bar A cm³/tr cm³/tr
F00B F00A
53 cm³/tr
ENGINE
P
M5 25 bar 0.32 ℓ
70 15 bar
PH
M4 350 bar
FR A P1
B P2 IC
S L1 MB 4.5 bar
B1 20µm
2 bar
B2 BRe
160 l/min
CA
135µm
R
647632EN
48 TRANSMISSION 20
20.1.4 REVERSE GEAR DIAGRAM
MH L2
A
Y6
80 cm³/tr
Y7
20
FORWARD AXLE
REAR AXLE
min max
L1
B
M5 M4
PP
PPfan BRV
Fan X386 Y20
In A
Loop A
11 cm³/tr
138 bar T
B
Cooler 3 bar Y23 MV
Out X199 B
Y19
X385 T fan
T
RF Cooler 70
In S
t°
X18 70
70
70
PDS/BPC PPC SAHR
Pressure point PSAHR
PDS/LS
Y12
IN Y13
Hydrostatic
charge pump
Y3 Y4 T
AM3 L2 MA BA
M
26.7 14.5 SBO
12 cm³/tr 350 bar A cm³/tr cm³/tr
F00B F00A
53 cm³/tr
ENGINE
P
M5 25 bar 0.32 ℓ
70 15 bar
PH
M4 350 bar
FR A P1
B P2 IC
S L1 MB 4.5 bar
B1 20µm
2 bar
B2 BRe
160 l/min
CA
135µm
R
647632EN
20 TRANSMISSION 49
20.1.5 HYDROSTATIC TRANSMISSION PRESSURE TEST PORT LOCATION
20
PP
Key:
–– Pressure test port PP (Hydrostatic engine)
PRESSURE TEST PORT VALUES
No. Correspondence Max. (bar) Comments

25 Static. Corresponds to boost pressure.
PP HP Pressure
350 Forward + reverse gear, maximum speed with maximum load.
647632EN
50 TRANSMISSION 20
20.1.6 TOWING PROCEDURE

Data obtained from Instruction Manuals: i 647628 of 02/02/2017
WARNING
If the lift truck is not on level ground, chock it so that it does not descend the slope.
The lift truck must be towed very slowly (less than 5 km/h) and for as short a distance as possible (less than 100 m).
20 - 1
For towing a lift truck, the high pressure limiters must be unlocked
20
1 to avoid damaging the hydrostatic transmission, and the parking

brake on the front axle must be released.
2
- Switch on lift truck ignition.
- Set the forward/reverse selector to neutral.
3 - Disconnect the parking brake.
UNLOCKING THE HIGH PRESSURE LIMITERS

- Open the engine bonnet.
- Remove the side cover (1, 020 - 1).
- Lift the latch (2, 020 - 1).
- Swivel the radiator.
20 - 2 - Hold it in position with the latch (3, 020 - 1).
- Loosen nuts (1, 0 20 - 2) on the hydrostatic pump by no more
than three turns.
RELEASING THE PARKING BRAKE

1 - Press several times on the button (1, 0 20 - 3) until pressing
1 becomes hard.
- This enables the brake disc to be released.
TOWING
- Switch on the hazard warning lights.
- Since there will be no steering or braking hydraulic assistance,
operate the steering and pedal slowly avoiding sudden or jerky
20 - 3 movements.
2
1
22 - After towing, retighten nuts (1, 020 - 2) 70N.m:
- Pressing the button (2, 020 - 3) will reactivate the parking brake.
1
2
647632EN
20 TRANSMISSION 51
20.1.7 TRANSMISSION TIGHTENING TORQUES
175 ± 17.5 N.m (x2)
20
95 ± 9.5 N.m (x4)
50 ± 5 N.m (x12) 50 ± 5 N.m (x8)
340 ±15 N.m (x6)
340 ±15 N.m (x6)
§ 00.4.1
§ 00.4.1
340 ±15 N.m (x6)
60 ±6 N.m (x8)
§ 00.4.1
340 ±15 N.m (x6)

647632EN
52 TRANSMISSION 20
20.2 TRANSMISSION REMOVAL - REFIT

PRECAUTION
20

When refitting, observe the special (620.1.7 TRANSMISSION TIGHTENING TORQUES, 5 51) and standard
tightening torques (600.4.1 STANDARD TIGHTENING TORQUES, 5 19).
20.2.1 HYDROSTATIC PUMP REMOVAL
The following operations must be performed:
(610.4.1 SIDE CASING AND ENGINE COVER REMOVAL, 5 31)

(610.4.6 COOLER REMOVAL, 5 33)
(610.4.7 EXHAUST PIPE REMOVAL, 5 35)
20 - 4

on either side of the axle.
1
Lift the rear axle and place blocks under the rear wheels (2, 020 - 4).
2 Repeat the operation on the front axle.
Drain the hydraulic oil.

2
20 - 5
Remove the 2 screws (1 , 0 20 - 5) et remove the access panel

(2, 020 - 5).
1 1
2
647632EN
20 TRANSMISSION 53
20 - 6
Disconnect connectors X291, X295, X298, X289 and X296 (1., 020 - 6).
1 1
20
20 - 7 6 6 Disconnect the hose from the hydraulic filter towards the T connector
4 of the hydrostatic pump (1, 020 - 7) and remove it.
7 5 Disconnect the hose from the hydraulic filter towards the bottom
of the hydrostatic pump (2, 020 - 7)(2, 020 - 8) and remove it.
4 4 Disconnect connect T from the hydrostatic pump (3, 020 - 7).

1
Disconnect the hoses (4, 020 - 7).

2 4
3 Disconnect the connectors X21 (5, 020 - 7)
Remove the screws (6 , 0 20 - 7) and remove the oil pre-filter

20 - 8
(7, 020 - 7).
Identify and disconnect the lower hydrostatic pump hoses (1, 020 - 8).
2
Loosen the lower clamp of the hydraulic pump (3, 0 20 - 8) and
3 disconnect the hose (4, 020 - 8).
1
1
Remove the screws (1, 020 - 9) fastening the hydraulic pump to
the hydrostatic pump.
20 - 9 1
20 - 10
Disconnect the hydraulic
1
pump (1 , 0 20 - 10 ) from
the hydrostatic pump
2 (2, 020 - 10).
Set down the hydraulic pump
(1 in the bottom of the engine
housing.
1
647632EN
54 TRANSMISSION 20
20 - 11
Attach a sling to the hydrostatic pump (1, 020 - 11) and pull tight.
1
20
20 - 12
Remove the screws (1, 020 - 12), attaching the hydrostatic pump
1 to the engine.
20 - 13
Disconnect the hydrostatic pump (1, 020 - 13) from the engine.
Lift, take out and remove the hydrostatic pump.

1
647632EN
20 TRANSMISSION 55
20.2.2 HYDROSTATIC MOTOR REMOVAL
The following operations must be performed:
(610.4.9 ENGINE REMOVAL, 5 38)
20 - 14
20
Identify and disconnect the hydrostatic pump lower hoses (1, 020 - 14)
20 - 15
Disconnect the lower flange (1, 020 - 15).
20 - 16
Disconnect the upper flange (1, 020 - 16).

1
PRECAUTION
Be sure to recover or replace the seals of each flange for refitting.
3 Disconnect the pressure measurement hose (2, 020 - 16).
2 Disconnect the hose (3, 020 - 16).

647632EN
56 TRANSMISSION 20
20 - 17
Identify and disconnect the electrovalve connectors X260 and
X261 (1, 020 - 17).
1 Disconnect the oil pressure connector X62 (2, 020 - 17).
2
20
20 - 18
Take off front left casing (1, 020 - 18).
20 - 19
Remove the 2 left-hand screws (1, 020 - 19).
20 - 20
Remove the 2 right-hand screws (1, 020 - 20).

1
Disconnect the hydrostatic motor (2, 020 - 20) from the reduction
gear box (3, 020 - 20).
2
3 Extract the hydrostatic motor via the right-hand access hatch and
remove.
1
647632EN
20 TRANSMISSION 57
20.3 SPECIFIC TRANSMISSION TOOLING
20.3.1 BASIC MANOMETER BOX
This box contains all the components required for measuring

pressure on all Manitou products.
20
6
2 3 5
1 3 4 5
Basis gauge kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549671
Consisting of:
1 - 1 gauge 1/9 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549882

2 - 1 gauge 0/40 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549883
3 - 2 gauge 0/60 bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549884
4 - 1 gauge 0/400 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549885
5 - 2 gauge 0/600 bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549886
6 - 4 standard hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549887
7 - 2 hoses for telehandler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549888
8 - 7 gauge tap connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 549889
647632EN
58 TRANSMISSION 20
20.3.2 DIGITAL MANOMETER BOX

20
Digital Manometer Set 0 to 600 bar (0 - 8,700 psi) allows:

- MIN and MAX values to be stored.
- Pressure peaks to be read.
Display units: mbar, bar, PSI, Mpa, kPa and kg/cm².
Digital Manometer Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947785
Consisting of:
1 - 1 Digital manometer 0 to 600 bar (0 - 8,700 psi)

2 - 1 Pressure connector adapter (M16x200)
3 - 1 Pressure connector hose 1,500 mm long
AXLE
TABLE OF CONTENTS
30.1 AXLE CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
30.1.1 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
30
MANUAL REFERENCE
DESIGNATION
NUMBER

647632EN
60 AXLE 30
AXLE
30.1 AXLE CONTROL AND ADJUSTMENT
30.1.1 TIGHTENING TORQUES

(620.1.7 TRANSMISSION TIGHTENING TORQUES, 5 51)
30
BRAKE
TABLE OF CONTENTS
40.1 BRAKE CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
40.1.1 SERVICE BRAKE / PARKING BRAKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
40.2 BRAKE CONTROLS AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
40.2.1 BRAKE AND INCHING PEDAL ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
ADJUSTING PROCEDURE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
BRAKE AND INCHING PHASES: REST, BRAKING AND ASSOCIATED VALUES FOR TRANSMISSION ECU: . . . . . . . . 64
40.2.2 BLEEDING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
LOCATION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
40
BLEED THE BRAKE CALLIPER: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
BLEED THE BRAKE MASTER CYLINDER: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
40.3 SPECIFIC BRAKE TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
40.3.1 BRAKE FLUID BLEEDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
MANUAL REFERENCE
DESIGNATION
NUMBER

647632EN
62 BRAKE 40 (14/09/2017)
40
647632EN
40 (14/09/2017) BRAKE 63
BRAKE
40.1 BRAKE CHARACTERISTICS AND SPECIFICATIONS
40.1.1 SERVICE BRAKE / PARKING BRAKE

Brake fluid
SHELL L.H.M S8 214 B Master cylinder ø 28.57 mm
Displacement: 19.68 cm3
Piston surface area: 641.30 mm2 Hydrostatic pump
Non-exhaustive illustrative diagram:
F1
(670.2 HYDRAULIC SCHEMATIC DIAGRAMS, 5 100) T
1,5cc
255 Pp
PDS/BPC PPC SAHR
PSAHR
PDS/LS
Y12
Y13
AM3 L2 MA
+ Battery
40
IN
12 cm3/tr 350 bar A
53 cm3/tr T
M5 25 bar
49
SBO
0.32 Litre
M4 15 bar
350 bar B
S L1 MB
Feed block
Negative parking brake operation:

P
- - If P = 0b -> Axle braked
- If P = 15b -> Axle not braked
Disc brake:
SERVICE BRAKE PARKING BRAKE
Total number of discs for the axle 1
Braking area per disc face 41 cm2
Total braking area 82 cm2
Recommended operating pressure 120 bars max.
Friction material EN-GJL-250
Dynamic friction coefficient 0,72
Static friction coefficient 0,60
Brand KNOTT
Disc diameter 266 mm
REAR AXLE
Disc thickness 20.4 mm
VDAR
Action radius 108 mm
FDAR Number of pistons 1
REAR AXLE
Wear compensation Mechanical

VDAR
Dynamic application:
FN
Maximum tangential force 19,800 N
Maximum braking torque 2,140 N.m
Static application:
FN Maximum tangential force 11,300 N
Maximum braking torque 1,220 N.m
647632EN
64 BRAKE 40 (14/09/2017)
40.2 BRAKE CONTROLS AND ADJUSTMENT BRAKE AND INCHING PHASES: REST, BRAKING AND ASSOCIATED VALUES FOR TRANSMISSION ECU:
40.2.1 BRAKE AND INCHING PEDAL ADJUSTMENT
ADJUSTING PROCEDURE:
+35 °
-35 °
5 (4.5 V) 0°
(0.5 V)
4
3
40
X139 S
Start the truck, move forward approx. 2 meters braking until the pedal is in the bottom position.
P
12 11 10 9 8 7
S
6 P
5
Leave the engine running during the control operations.
6 5 4 3 2 1
4
1
2
3
CORRELATION TABLE - FORCE ON PEDAL / VOLTAGES / BRAKING CIRCUIT PRESSURE / PEDAL ANGLE
Braking circuit pressure

Pedal position Force on pedal (N) Potentiometer voltage (V) Pedal angle (°)
(Bar)
Pedal released 0 1,2 0 0
(rest position)
Start the truck, move forward approx. 2 meters braking until the pedal is in the bottom position. 1 40 1,9 0,1 5
Leave the engine running during the control operations. 2 11 2,4 0,1 10
Connect a spark gap box (1) (680.6 SPECIFIC ELECTRIC TOOLING, 5 182) between the connector (X139)
3 48 2,8 1,8 15
and the brake pedal angle sensor (3).
Connect a voltmeter between pins 1 "earth" and 3 "angle signal channel 1" of the spark gap box (1). 4 900 3,2 75 20
Loosen the lock nut (4).
Screw or unscrew the stop (5) to obtain a value of 1.2 V on the voltmeter.
Tighten the lock nut (4).
647632EN
40 (14/09/2017) BRAKE 65
40.2.2 BLEEDING PROCEDURE

LOCATION:
1
2
4
3
6
Key:
7
1 - Brake fluid tank 8
2 - Master cylinder
40
3 - Service brake pedal 9
4 - Accumulator block
5 - Manual brake release block
6 - Negative brake actuator
7 - Control unit
8 - Parking brake cable
9 - Brake calliper
40 - 1
BLEED THE BRAKE CALLIPER:
2
Take out the brake fluid tank plug and fit the adapter (1) of the
bleeder (2) (640.3 SPECIFIC BRAKE TOOLING, 5 68).
Operate the bleeder.
40 - 2
Bleed the calliper by undoing the screw (1).
1 Wait until the oil is out then do up the screw (1).
647632EN
66 BRAKE 40 (14/09/2017)
BLEED THE BRAKE MASTER CYLINDER:
40 - 3 1
10
2 4
3
13
8 X30
X30 9
2
X29
4
X31
X31 1
X31 5
40
X31 4
X31 3
2
X30
8
6
647632EN
40 (14/09/2017) BRAKE 67
Unclip 2 heating outlets (1, 040 - 3).

Remove the 2 screws (2, 040 - 3) located behind the 2 outlets (1, 040 - 3).
Unclip the set of 3 switches (3, 040 - 3).
Remove the screw (4, 040 - 3) located behind the set of 3 switches (3, 040 - 3).
Remove steering column casing (5, 040 - 3), after removing the 2 screws (6, 040 - 3).
Unclip temperature button (7, 040 - 3).
Remove the 2 screws from the heating valve (8, 040 - 3) located behind the temperature button (7, 040 - 3).
40 - 4 Disconnect the 4-position ventilation switch (1, 040 - 4).

Disconnect air-conditioning on/off connector (2, 040 - 4).
Remove the air hose (9, 040 - 3) to dashboard (10, 040 - 3).
2 Disconnect the set of 3 switches (3 and 13, 040 - 3)
Remove the dashboard (10, 040 - 3).
40
40 - 5
Remove the brake fluid tank plug and fit the adapter (1, 040 - 5)
of the bleeder (2, 040 - 5).
2 Operate the bleeder.
40 - 6
Bleed the master cylinder by undoing the screw (1, 040 - 6).
Wait until oil is out then do up screw.
1
647632EN
68 BRAKE 40 (14/09/2017)
40.3 SPECIFIC BRAKE TOOLING
40.3.1 BRAKE FLUID BLEEDER
Bleed valve supplied with all the components required for

bleeding the brake circuits of Manitou products.
Operating instructions included.
40
MANITOU Reference
BRAKE BLEED KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .554019
SPARE PARTS:
– TOP MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719980
– BOTTOM MANOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 719981
– Membrane. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661913
– HOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 661914
– FLEXIBLE BRAKE (ORANGE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 720693
– VALVE RETRACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 744747
– SET OF 6 CAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 787147
BOOM
TABLE OF CONTENTS
50.1 BOOM REMOVAL - REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
50.1.1 TELESCOPIC CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
50.1.2 TELESCOPE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
50.1.3 TELESCOPE REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
50.1.4 COMPLETE BOOM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
50
647632EN
70 BOOM 50 (22/02/2017)
50
647632EN
50 (22/02/2017) BOOM 71
BOOM
50.1 BOOM REMOVAL - REFIT

–– Place the boom in the horizontal position
–– Switch on the ignition and operate the joystick to decompress the hydraulic circuit.
PRECAUTION
Before starting work;
Deactivate the battery power supply by means of the battery cut-off no less than 30 seconds after
turning off the ignition with the ignition key.
When refitting, observe the standard tightening torques (600.4.1 STANDARD TIGHTENING TORQUES, 5 19).
50.1.1 TELESCOPIC CYLINDER REMOVAL

50 - 1
Remove the boom rear cover plate (1, 050 - 1)
1
50
50 - 2
3 1 2 3 Identify and disconnect X134 and X91 (1, 050 - 2).
Identify and disconnect the 6 hoses (2, 050 - 2) and insert plugs.
2
1
647632EN
72 BOOM 50 (22/02/2017)
50 - 3
11 External leak return option:
3
Identify and disconnect the hose (1, 050 - 3).
3 3
4
Undo the tube (2, 050 - 3), the clamps (3, 050 - 3) and swivel the
2
leak return tube (4.
1
50 - 4
Remove the 2 screws (1, 050 - 4) from the leak return tube support
2
(2, 050 - 4) on the boom head.
1
1
50
50 - 5
Remove the boom head front plate (1, 050 - 5).
50 - 6
Unscrew and remove the nut (1, 050 - 6) and the bushing (2, 050 - 6).
1
2
647632EN
50 (22/02/2017) BOOM 73
50 - 7
Pull back the telescope cylinder (1, 050 - 7) to gain access to the
1
tube connections (2, 050 - 7).
2
4 4 Place the end of the cylinder on a prop (3, 050 - 7).

5
3
Remove the 2 clamps (4 from the harness (5, 050 - 7).
Identify and disconnect the 4 tubes (2, 050 - 7).
50 - 8
Clear the 4 hoses (1, 050 - 8) and attach them.

1
Pass a sling through the telescope cylinder (2, 050 - 8) flush with
2
3 the gutters (3, 050 - 8) and pull the sling tight (2, 050 - 8).
50
50 - 9
2
Free the telescope cylinder (1, 0 50 - 9) keeping it steady, and
remove it.
1
WARNING
When refitting, remember to refit the washer (2, 0 50 - 9) on the rod of the
telescope cylinder.
50 - 10 50.1.2 TELESCOPE REMOVAL

Carry out operation (650.1.1 Telescopic Cylinder Removal, 5 71)
2
1
Unscrew and remove the tilting cylinder head pin (1, 050 - 10) while
at the same time inserting a bar (2, 050 - 10) in the place of the pin.
647632EN
74 BOOM 50 (22/02/2017)
50 - 11
4
Sling with a bar (1, 050 - 11), pass a connecting bar (2, 050 - 11)
3 and sling in line with the inside of the boom (3, 050 - 11).
2
Pull the slings tight (4, 050 - 11).
1 1
50 - 12
1 1
Remove the 8 rear slide pad end stops (1, 050 - 12).
1 1
1 1
1
50
50 - 13
Note the colours and the locations of the pads.
1 3 1
1
Remove the 8 rear slide pads (1, 050 - 13).
2
1
2
Place the hoses and the wiring harness (2, 0 50 - 13) inside the
telescope tube (3, 050 - 13).
2
50 - 14
1
Extend the telescope approximately 400 mm.
Remove the upper and lower front deflectors (1, 050 - 14).
400 mm
1
647632EN
50 (22/02/2017) BOOM 75
50 - 15
3 3 Note the colours and the locations of the pads.

2
Raise the boom head slightly by re-tensioning the slings (4, 050 - 11).
Take out bottom pads (1, 050 - 15) then the side pads (2, 050 - 15).
Re-lower the boom head slightly by slackening the slings (4, 050 - 11).
2
Remove the upper slide pads (3, 050 - 15).
1
50 - 16
Place a prop (1, 050 - 16) and free the telescope (2, 050 - 16).
1 2
50
50.1.3 TELESCOPE REASSEMBLY
Insert the telescope into the base of the boom and remove the prop.
Pad summary tables:
Upper and lower pads Side pads
Colour Part No. Width Length Thickness Colour Part No. Width Length Thickness
52562497 60 180 12 52516690 40 80 10
52509955 60 180 13 52509958 40 80 11
52509956 60 180 14 52509959 40 80 12
52509957 60 180 15 52509960 40 80 13
52516691 60 180 16 52516694 40 80 14
52516692 60 180 17
647632EN
76 BOOM 50 (22/02/2017)
PAD INSTALLATION AND GREASING AREA RECOMMENDATIONS
50 - 24
Procedure with reduced clearances
80 80 1 - Grease the glide tracks over the entire length of the tube in
the specified areas ( , 0 50 - 24) the applied grease spread
is 0.2 kg/m².
50
50 2 - Grease slip face of each pad before installation.

3 - Install the front and rear lower horizontal pads at the nominal
fit (60 x 180 x 15).
4 - With the boom head resting on the above pads, install the
other pads in the following order:
50
50
A) upper front and rear horizontal pads.

80 80 B) lower front and rear side pads.
C) upper front and rear side pads.
Note:
–– For each of these fits, the pads chosen will be of the maximum thickness that can be inserted by
hand without using impact tools.
–– The symmetry of fit is 1mm, i.e. the allowable difference in thickness between the left-hand and the
right-hand pads.
5 - Re-attach the rear pad stops and the upper and lower front deflectors.
6 - Mark the heads of the screws (with ink) once they have been tightened to the correct torque (600.4.1
50
STANDARD TIGHTENING TORQUES, 5 19).

647632EN
50 (22/02/2017) BOOM 77
50.1.4 COMPLETE BOOM REMOVAL

–– Retract the telescope.
–– Raise the boom slightly to gain access to the lifting cylinder head pivot pin.
–– Switch on the ignition and operate the joystick to decompress the hydraulic circuit.
Weight of complete boom ≈ 900 kg
PRECAUTION
Before starting work;
Deactivate the battery power supply by means of the battery cut-off no less than 30 seconds after
turning off the ignition with the ignition key.
When refitting, observe the standard tightening torques (600.4.1 STANDARD TIGHTENING TORQUES, 5 19).
50 - 17 Boom removal
Unclip the ball joint (1) from the boom angle sensor.
50
1
50 - 18
Place a block between the cylinder and the boom shaft (1, 050 - 18).
Unscrew and remove the compensating cylinder head pivot pin

(2, 050 - 18).
2
1
647632EN
78 BOOM 50 (22/02/2017)
50 - 19
1
Remove the boom rear cover plate (1, 050 - 19).
50 - 20
1
1 2
2 Identify and disconnect X134 and X91 (1, 050 - 20).
Identify and disconnect the 6 hoses (2, 050 - 20) and insert plugs.
2
2
3
3
Identify and disconnect the hose (3, 050 - 20) and insert plugs.
1
50
50 - 21
Attach a sling to the front right slinging point of the boom (1, 050
- 21) and pull the sling tight.
50 - 22
4 Place a block (1, 050 - 22) between the frame and the lifting cylinder.

(2, 050 - 22).
3
2
Unscrew and remove the boom hinge pin (3, 050 - 22) and recover
1 the washer (4, 050 - 22).
647632EN
50 (22/02/2017) BOOM 79
50 - 23
Lift the boom (1, 0 50 - 23) keeping it steady (2 , 0 50 - 23) and
1 remove it.
WARNING
When refitting, remember to refit the washer (4, 050 - 22) on the boom hinge pin.
2
50
647632EN
80 BOOM 50 (22/02/2017)
50
HYDRAULICS
TABLE OF CONTENTS
70.1 HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
70.1.1 HYDRAULIC COMPONENT SHEETS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
DISTRIBUTOR 5000 (INLET ELEMENTS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
DISTRIBUTOR 5000 (TILTING ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
DISTRIBUTOR 5000 (TELESCOPING ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
DISTRIBUTOR 5000 (LIFTING ELEMENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
CONTROL ACCUMULATOR BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
STEERING PUMP/STEERING UNIT OSPC 160 LS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
3-POSITION STEERING SELECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
FAN CONTROL UNIT + (FAN REVERSE OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
COUNTERBALANCE VALVE VBSN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
COMPENSATION INSULATION VALVE VIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
70.2 HYDRAULIC SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
70.2.1 KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
70.2.2 DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
70
70.3 HYDRAULIC COMPONENT LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
70.3.1 KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
70.4 HYDRAULICS REMOVAL - REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
70.4.1 HYDRAULIC PUMP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
70.4.2 MAIN HYDRAULIC TANK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
70.4.3 SUCTION STRAINER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
70.4.4 ACCUMULATOR BLOCK REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
70.4.5 CONTROL UNIT AND DISTRIBUTOR ASSEMBLY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
70.4.6 LIFTING CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
70.4.7 COMPENSATING CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
70.4.8 TILTING CYLINDER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

647632EN
82 HYDRAULICS 70
70
647632EN
70 HYDRAULICS 83
HYDRAULICS
70.1 HYDRAULIC CHARACTERISTICS AND SPECIFICATIONS
70.1.1 HYDRAULIC COMPONENT SHEETS

DISTRIBUTOR 5000 (INLET ELEMENTS)
Values indicative only
Role:
- To direct the hydraulic flow to each section.
- To limit the maximum pressure.
- To return the flow when the manipulator is in neutral.
- To divide the flow and give priority to steering.
LS P2 1b 1A 1B 2b 2A 2B 3b 3A 3B 4b 4A 4B
D 245 245 180 245
70
bar bar bar bar
1 235 bar
P1
8 bar
Pp EE VPD VS C+
EI C-
EA D+
ET D-
EL EF
2 3
1. Main relief valve. - LS : Signal Line.

2. Dynamic flow priority valve. -T : Tank Return.
3. Safety valve. - P1 : Main pressure.
- P2 : Steering pressure.
- Pp : Pressure test port.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
84 HYDRAULICS 70
LS P2 The hydraulic flow arrives at P1.

D
At start-up, the flow passes through the dynamic flow
priority valve VPD and reaches the orbitrole.
T
235 bar
P1
8 bar
Pp EE VPD VS
LS P2 As the orbitrole is closed, the pressure increases and
D the VPD spool moves to direct the oil towards the safety
valve (VS) that is open to the tank.
T
235 bar
P1
8 bar
70
Pp EE VPD VS
LS P2 When the operator turns the steering wheel, an LS
D signal is sent from the orbitrole to the VPD, forcing it
to give priority of flow towards the steering system.
T
235 bar
P1
8 bar
Pp EE VPD VS
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
70 HYDRAULICS 85
DISTRIBUTOR 5000 (TILTING ELEMENT)

Values for information purposes only
Role:
- Enables several actuators to be supplied according to pilot-
operated distribution spool position.
A B
3 4
2 5 1 2
1. Distribution spool
2. Pilot head
3. Secondary valve
4. Secondary valve
5. Non-return valve
5 3 4
70
D 245
bar
245
bar
180
bar
245
bar
T
235 bar
P1
8 bar
Pp EE VPD VS C+
EI C-
EA D+
ET D-
EL EF
1 2 2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
86 HYDRAULICS 70
1b 1A 1B The spool is in neutral.

245 245
bar bar
The flow passes through the spool and returns to the tank.
P1
C+
EI
70
The spool moves downwards under the effect of a pilot pressure at 2b. 1b 1A 1B
245 245
bar bar
The flow is directed to 2B and the pressure on the lifting movement
increases.
T
P1
C+
EI
647632EN
70 HYDRAULICS 87
DISTRIBUTOR 5000 (ATTACHMENT ELEMENT)

Role:
A B
2 3 1 2
2. Pilot head
3. Non-return valve
70
D 245
bar
245
bar
180
bar
245
bar
T
235 bar
P1
8 bar
Pp EE VPD VS C+
EI C-
EA D+
ET D-
EL EF
1 2 2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
88 HYDRAULICS 70
P1
C-
EA
70
The flow is directed to2B and the pressure on the tilting movement
increases.
T
P1
C-
EA
647632EN
70 HYDRAULICS 89
DISTRIBUTOR 5000 (TELESCOPING ELEMENT)

Role:
A B
3 4
2 5 1 2
2. Pilot head
3. Relief valve
4. Non-return valve
5. Non-return valve
5 3 4
70
D 245
bar
245
bar
180
bar
245
bar
T
235 bar
P1
8 bar
Pp EE VPD VS C+
EI C-
EA D+
ET D-
EL EF
1 2 2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
90 HYDRAULICS 70

180
bar
P1
D+
70
180
bar
The flow is directed to 3B and the pressure on the tilting movement
increases.
T
P1
D+
647632EN
70 HYDRAULICS 91
DISTRIBUTOR 5000 (LIFTING ELEMENT)

Role:
A B
3 4
2 5 1 2
2. Pilot head
3. Non-return valve
4. Anti-shock valve
5. Non-return valve
5 3 4
70
D 245
bar
245
bar
180
bar
245
bar
T
235 bar
P1
8 bar
Pp EE VPD VS C+
EI C-
EA D+
ET D-
EL EF
1 2 2
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
92 HYDRAULICS 70

245
bar
P1
D-
EL
70
245
bar
The flow is directed to 4B and the pressure on the lifting movement
increases.
P1
D-
EL
647632EN
70 HYDRAULICS 93
CONTROL ACCUMULATOR BLOCK

Role:
Provide a reserve of pressurised oil to:
- Feed the negative parking brake.

- Feed the distributor SV pilot line.
- Feed the distributor electrovalve control block.
- BA : Feed block. - CAR : Check valve.

- AC : Membrane accumulator. - Y12 : Hydraulic cut-off electrovalve (SV).
- Pp : Pressure test port. - Y13 : Negative parking brake electrovalve.
- SAHR : Negative parking brake supply. -F : Filter.
- PSAHR : Negative parking brake pressure switch. - CAR : Check valve.
- IN : Supply.
-T : Tank return.
- PDS/BPC : SV control.
- PPC : Distributor electrovalve control block supply.
PDS/BPC PPC SAHR

PSAHR
Pp
Y12
70
X269
CAR Y13
F CAR X92
IN
BA
SBO
AC
0.32 ℓ
15 bar
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
94 HYDRAULICS 70
STEERING PUMP/STEERING UNIT OSPC 160 LS

Role:
- Direct and dose the flow in order to supply the steering circuit.
- It is a rotating valve.
1. Secondary relief valve (200b)

L R 1 2. Pump valve (200 cm3/tr)
3. Main pressure relief valve (140b)
70
-P : Supply pressure.
-T : Return to tank.
2 -R
-L
: Exit towards the right side.
: Exit towards the left side.
- LS : Pilot line.
3
Détail 2
P T LS
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
70 HYDRAULICS 95
L R
When the driver turns the steering wheel towards the right, he passes
the flow rate from P to R and sends pilot pressure towards the divisor
to get priority.
P T LS
L R
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.
70
P T LS
L R
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.
P T LS
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?

647632EN
96 HYDRAULICS 70
3-POSITION STEERING SELECTOR

Role:
A T
P B - Allows the selection of 3 steering modes, depending on
the steering alignment switch position (See instructions).
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).
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
70 HYDRAULICS 97
FAN CONTROL UNIT + (FAN REVERSE OPTION)

Role:
– To adjust the speed of the engine cooling fan.
– (Option) To reverse air flow direction temporarily in order

to clean the engine cover grill and radiator cores.
Key:
CAR - One way valve.
MV - Hydraulic fan motor. PPfan - Pressure test port.
BRV - Fan control unit. Cooler OUT.
Y19 - Fan speed control solenoid valve. Cooler IN.
Y20 - Fan direction reversal solenoid valve. S - Hydraulic oil temperature sensor.
Y23 - Warm-up solenoid valve (hydraulic oil heater). F - Filter
70
PPfan BRV
F X386 Y20
Fan In A
Loop A
CAR T 11 cm³/tr
138 bar
B
Cooler 3 bar Y23 MV
Out X199 B
Y19
X385
T
Cooler
In
t° S
X18
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
98 HYDRAULICS 70
COUNTERBALANCE VALVE VBSN

On lifting cylinder On telescoping cylinder
V1
VE 3 1
210 bar
1 V1 V2 2
210 bar
VT
VL V2 2
VE
70
Operation:
Pilot-assisted counterbalance valves are a combination of two valves; a non-return valve and a pressure
relief valve. The non-return valve allows free flow from the distributor (chamber 2) to the load (chamber 1),
while a pilot-assisted direct acting pressure relief valve controls the flow from chamber 1 to chamber 2.
The effective pressure relief valve setting is lowered by the pilot pressure at port 3 to a value determined
by the pilot ratio.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
70 HYDRAULICS 99
COMPENSATION INSULATION VALVE VIC

On compensation cylinder
VIC
VC V1
2
V2 3
70
2
3
3
2
Operation:
Pilot-assisted counterbalance valves are a combination of two valves; a non-return valve and a pressure
relief valve. The non-return valve allows free flow from the distributor (chamber 2) to the load (chamber 1),
while a pilot-assisted direct acting pressure relief valve controls the flow from chamber 1 to chamber 2.
The effective pressure relief valve setting is lowered by the pilot pressure at port 3 to a value determined
by the pilot ratio.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
100 HYDRAULICS 70
70.2 HYDRAULIC SCHEMATIC DIAGRAMS
70.2.1 KEY
Position on
Item Designation
diagram
BA Feed Block + Accumulator (AC) H7
BLR (O) Valve block (option) A12
LP 8 EV control block I11
BRe Breather plug H8
BRV Ventilation control block D3
CA Suction strainer J5
D Distributor F14
Steering distributor
Position 1: short turning
D3 B6
Position 2: front wheel steering
Position 3: crab position
EA Attachment element H12
EE Inlet element H10
EF Closing element H14
EI Tilting element H12
EL Lifting element H14
ET Telescope element H13
EVTF (O) Boom head electrovalve (option) B13
FDAR Rear disc brake B7
FN Negative brake C7
FR Return filter I5
IC Clogging indicator I6
M Kubota V2607 2607-DI-E3B engine H1
MA Manipulator I2
MC Master cylinder B2
MH Hydrostatic motor B3
MV Fan motor E4
P Hydraulic pump H4
70
PAAV Front attachment connector A12

A10, B11, B12,
PAAV(O) Front attachment connector (option)
B13
PDD Dynamic steering pump D6
PDF Brake release pump E7
PH Hydrostatic pump H4
PP Pressure test port A10, B10, D3, H10
R Main hydraulic tank J6
R3V 3-way valve A12, B14
S Oil temperature sensor F2
R1 Secondary hydraulic tank I8
R3V 3-way valve A12, B14
Re Breather I6
RF Cooler F1
RLF Brake fluid tank A3
VIC Compensating isolation valve A10
VC Compensating cylinder A10
VE Balancing valve A9, C14, E14
VDAR Rear steering cylinder B7
VDAV Front steering cylinder B2
VI Tilting cylinder B9
VL Lifting cylinder D13
VPD Dynamic flow priority valve H11
VS Safety valve H11
VT Telescope cylinder C14
VVT (O) Carriage locking cylinder (option) A11, A12, A13
647632EN
70 HYDRAULICS 101
70.2.2 DIAGRAM
1 2 3 4 5 6 7 8 9 10 11 12 13 14
VIC BOOM HEAD ELECTROVALVE OPTION BOOM HEAD ELECTROVALVE OPTION HYDRAULIC LOCKING OPTION
AND HYDRAULIC LOCKING AND HYDRAULIC LOCKING
PP
2
3 1
RLF VC VVT (O) VVT (O) VVT (O)
A V1
AV AR PAAV (O) P1 P2 P1 P2 P1 P2
B2 B1 3 2 1 V2 R3V
PAAV (O)
VE PAAV (O) PAAV (O) PAAV (O) PAAV
MC A B T VI
R3V
D3 V2 PAAV (O) PAAV (O) PAAV (O) PAAV
MH L2 270 bar
A 3 2 1 C3 C4 C2 C1 C3 C4 C2 C1
V1
B PP
Y12 Y12
Y6 P
VDAV VDAR EVTF (O) EVTF (O)
80 cm³/tr
AXLE
Y7 P2 P1 P2 P1
AXLE
FORWARD AXLE
FDAR
REAR AXLE
FORWARD
REAR
min max V1
L1
FN
C 210 bar
V2 VT
B
M5 M4
L PDD R
VE
PP
200 bar 200 bar
210 bar
V1 VL V2
PPfan BRV
X386 Y20
Fan In A
160 cm³/tr VE
Loop A
11 cm³/tr
E 138 bar T
B
Cooler 3 bar Y23 MV
Out X199 B PDF
Y19 140 bar
X385
T T
1.5 cc
RF Cooler F
In
70
t° S
X18 P T LS
F
245
245
bar
245
bar
180
bar bar D
PDS/BPC PPC SAHR

PSAHR
Pp
T
Y12 235 bar
G X269
Y13
X92
IN
P1
8 bar
Y4 Y3 T
AM3 L2 MA BA
M PP C+ C- D+ D-
12 cm³/tr
26.7 14.5 SBO EE VPD VS EI EA ET EL EF
350 bar A cm³/tr cm³/tr
F00B F00A
ENGINE
53 cm³/tr
AC
H
P
M5 25 bar 0.32 ℓ
15 bar
Re
PH A+ A- B+ B- BP
M4 350 bar
FR A P1 3.8±0.5 bar
B P2 IC Y31 Y32 Y33 Y34
S L1 MB 4.5+0.5
-0.2 bar
IN
I B1
1.5±1.5 bar T
R1
MA
B2 BRe Y35 Y37 Y38
Y36
4 C+ C- D+ D-
1
160 ℓ/min
J 3 CA R
2
647632EN
102 HYDRAULICS 70
70.3 HYDRAULIC COMPONENT LOCATIONS

VI
VE
70.3.1 KEY
Item Designation
VT BA Feed block + Accumulator
LP Control unit & electrovalve
D Distributor
FR Return Filter
MV Fan Motor
P Hydraulic pump
PDD Dynamic steering pump
R Main hydraulic tank
R1 Secondary hydraulic tank
VC Compensating cylinder
VE Balancing valve
VI Tilting cylinder
VIC Compensating isolation valve
VL Lifting cylinder
VT Telescope cylinder
VC
BP
VIC
VE
D
BA PDD
70
VL
FR
MV R
R1
647632EN
70 HYDRAULICS 103
70.4 HYDRAULICS REMOVAL - REFIT

PRECAUTION
When refitting, observe the standard tightening torques (600.4.1 STANDARD TIGHTENING TORQUES,
5 19);
70.4.1 HYDRAULIC PUMP REMOVAL
To remove the hydraulic pump, it is essential to first carry out the operation (620.2.1 HYDROSTATIC
PUMP REMOVAL, 5 52).
70.4.2 MAIN HYDRAULIC TANK REMOVAL

70 - 1
on either side of the axle.
70
1
Lift the rear axle and place blocks under the rear wheels (2, 070 - 1).
Repeat the operation on the front axle.

2
70 - 2
Disconnect the 3 hoses under the main hydraulic tank (1, 070 - 2).
Disconnect the 2 hoses (2, 070 - 2).

2
3 For refitting, perform the removal operations in the reverse order,

1 1 observing the tightening torque of the clamp (3, 070 - 2) on the
1 2
suction strainer hose
647632EN
104 HYDRAULICS 70
70 - 3
Remove the cab floor mat (1, 070 - 3).
70 - 4
Remove the access panel (1, 070 - 4).
70 - 5
Place a pallet (1, 0 70 - 5) and raise the pallet truck so that it is

70
bearing against the underside of the main hydraulic tank (2, 070 - 5).
2
70 - 6
1 Remove the 2 front fastening screws (1, 070 - 6).

1
2
2 Remove the 2 rear fastening screws (2, 070 - 6).
647632EN
70 HYDRAULICS 105
70 - 7
Lower the pallet truck slightly and remove the main hydraulic tank
(1, 070 - 7).
1
70 - 8
70.4.3 SUCTION STRAINER REMOVAL
Carry out operation (670.4.2 Main hydraulic tank removal, 5 103).
1 Unscrew the suction strainer, part no.: 52522593 (1, 070 - 8).
For refitting, perform the removal operations in the reverse order,

observing a tightening torque of 25 (+5/0) N.m. on the suction
strainer.
70.4.4 ACCUMULATOR BLOCK REMOVAL
70
70 - 9
2
Carry out operation ( 6 10.4.1 SIDE CASING AND ENGINE COVER
2 3
REMOVAL, 5 31).
4 Carry out operation (610.4.7 EXHAUST PIPE REMOVAL, 5 35).
4
1
1 Identify and disconnect (X269, X92, X133-1 and X133-2) (1, 070 - 9).
1
2 1 Identify and disconnect the hoses (2, 070 - 9) and the T connector
2
(3, 070 - 9).
Remove the 2 screws (4, 0 70 - 9) and remove the accumulator

block (5, 070 - 9).
647632EN
106 HYDRAULICS 70
70 - 10
2 1 70.4.5 CO N T RO L U N I T A N D D I S T R I B U TO R
1 ASSEMBLY REMOVAL
3 Open the rear cover.
Disconnect (X66 and X390-A)(1, 0 70 - 10) and unclip (X66) from

the support (2, 070 - 10).
Identify and disconnect all the upper hoses (3, 070 - 10) from the
distributor.
70 - 11
1
Disconnect the hoses (1 , 0 70 - 11) from the control unit and
(2, 070 - 11) at the front of the T connector.
70 - 12
70
1
Disconnect the hose (1, 070 - 12) from the accumulator block.
70 - 13
2 1 1
Remove the 4 nuts (1, 070 - 13).
Remove the 2 front pins (2, 070 - 13).
Push the assembly slightly forward, lift the rear.

1
Remove the control unit and distributor assembly from the rear,
2
1 being careful for the boom angle potentiometer.
647632EN
70 HYDRAULICS 107
70.4.6 LIFTING CYLINDER REMOVAL
Carry out the operation (610.4.7 EXHAUST PIPE REMOVAL, 5 35), up to removal of the exhaust casing.
70 - 14
1 Remove the 3 upper screws (1, 0 70 - 14) and the 2 side screws
1 1
4
(2, 070 - 14).
3 3
Remove the 3 screws (3, 070 - 14) from the oil filter support and
remove the engine housing structure (4, 070 - 14).
70 - 15
Disconnect the lifting cylinder base pivot pin lubrication hose
(1, 070 - 15).
70
70 - 16
Raise the boom and extend the telescope so that the fork clamp
is in front of the lift truck.
1 Hold the boom and lift it (to free the pressure on the lifting cylinder
head pin) (1, 070 - 16).
647632EN
108 HYDRAULICS 70
70 - 17
3
Attach a sling to the body of the lifting cylinder and pull the sling
tight (1, 070 - 17).
Place a block (2, 070 - 17) between the frame and the lifting cylinder.
1 Unscrew and remove the compensating cylinder head pivot pin

(3, 070 - 17).
2
Start the truck and retract the lifting cylinder rod.
Stop the engine, leave the ignition switched on and operate the
joystick to decompress the hydraulic circuit.
70 - 18
Identify and disconnect the lifting cylinder supply hoses (1, 070 - 18).
1
1
70 - 19
Unscrew and remove the lifting cylinder base pivot pin (1, 070 - 19).
70
70 - 20
Lift and remove the lifting cylinder (1, 070 - 20).
1
647632EN
70 HYDRAULICS 109
70.4.7 COMPENSATING CYLINDER REMOVAL
Carry out the operation (610.4.7 EXHAUST PIPE REMOVAL, 5 35), up to removal of the exhaust casing.
70 - 21
Switch on the ignition and operate the joystick to decompress the
hydraulic circuit.
2
2
Place a container (1, 070 - 21).
3
Identify and disconnect the compensating cylinder supply hoses
1 (2, 070 - 21).
Disconnect the compensating cylinder base pivot pin lubrication

hose (3, 070 - 21).
70 - 22
Open the rear cover (1, 070 - 22).
1 Protect the boom (2, 070 - 22) of the floor crane.

2
Attach a sling to the body of the compensating cylinder and pull

the sling tight (3, 070 - 22).
3

(4, 070 - 22)
4
70
70 - 23
Remove the circlip from the compensating cylinder base pivot pin
(1, 070 - 23) and remove the pin (2, 070 - 23).
1
Lift and remove the compensating cylinder via the rear of the
truck (1, 070 - 24).
70 - 24
1
647632EN
110 HYDRAULICS 70
70 - 25
70.4.8 TILTING CYLINDER REMOVAL
Take the load off the tilting cylinder with a prop (1, 0 70 - 25) or
blocks.
1
2 Unscrew and remove the tilting cylinder head pivot pin (2, 070 - 25).
70 - 26
Identify and disconnect the tilting cylinder supply hoses (1, 070 - 26)
and insert plugs.
1 1
70 - 27
Hold the tilting cylinder by the body (1, 070 - 27).
70
2
Unscrew and remove the tilting cylinder base pivot pin (2, 070 - 27).
To refit, perform the operations in the reverse order.

1
TIP
When refitting the tilting cylinder head pivot pin (2, 0 70 - 25) start-up the
truck and perform tilt-up or tilt-down movements to align the tilting cylinder
head pivot pin.
ELECTRICITY
TABLE OF CONTENTS
80.1 ELECTRICITY CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
80.1.1 LOCATION OF RELAYS AND FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
80.1.2 ELECTRICAL NETWORK ARCHITECTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
80.1.3 ECU INPUTS/OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
X13 - DASHBOARD MODULE (BAUSER) - A1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
X291 / X295 / X298 / X299 - TRANSMISSION ECU - A2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
X55 - MAIN ECU SPU 40-26 (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
X56 - MAIN ECU SPU 40-26 (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
X57 - MAIN ECU SPU 40-26 (A3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
X400 - ENGINE ECU - EVG - A13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
80.1.4 TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X1 / X2 - STARTER IGNITION SWITCH (S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X6 - LIGHTING COMMUTATOR SWITCH (E15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
X11 / 12 - WINDSCREEN WIPER COMMUTATOR SWITCH (S28) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X14 - LIGHTING COMMUTATOR SWITCH (S26) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
X22-1 / X22-2 - BRAKE FLUID LEVEL SWITCH (S11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X38 - REVERSING BUZZER (B1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
X39 / HORN (B2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X62 -TRANSMISSION SPEED SENSOR (B13) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
X63 - FUEL GAUGE (B34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
80
X65 / X66 - WHEEL ALIGNMENT SENSOR (B12 / B24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
X67 / X68 - JSM (A4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
X77A / X77B - BMEP (A14) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
X100 - TELESCOPE ANGLE POTENTIOMETER (B11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
X134 - BOOM RETRACTED SWITCH (S34) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X139 - INCHING BRAKE PEDAL ANGLE SENSOR (B9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
X199 - WARM UP ELECTROVALVE (OIL HEATER) (Y23) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
X295 - FORWARD AND REVERSE ELECTROVALVE (Y3 / Y4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
X325 - AIR-CONDITIONING THERMOSTAT SENSOR SUPPLIED WITH THE THERMOSTAT (Y17) . . . . . . . . . . . . . . . 133
X385 - VENTILATION CONTROL ELECTROVALVE (Y19) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
X386 - VENTILATION REVERSAL ELECTROVALVE (OPTIONAL) (Y20) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
80.2 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
80.2.1 ELECTRICAL DIAGRAM CODIFICATION EXAMPLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
80.2.2 CABLE IDENTIFICATION ON A WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
80.2.3 POSITIONS BY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

647632EN
112 ELECTRICITY 80
80.2.4 ELECTRICAL DIAGRAMS BY FUNCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
DIAGRAM 1 – STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
DIAGRAM 2 - NETWORKS (CAN & LIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
DIAGRAM 3 – TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
DIAGRAM 4 – HYDRAULIC MOVEMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
DIAGRAM 5 – VENTILATION, WIPERS AND AIR-CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
DIAGRAM 6 – OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
DIAGRAM 7 - LIGHTS AND SIGNALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
80.3 ELECTRICITY LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
80.3.1 KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
80.3.2 CAB 3D HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
80.3.3 CAB 2D HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
80.3.4 8 ELECTROVALVE HYDRAULIC BLOCK 2D HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
80.4 ELECTRICAL CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
80.4.1 "BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
ON-TRUCK ADJUSTMENT PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
80.4.2 LONGITUDINAL STABILITY INDICATOR (LLMI) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
STRAIN GAUGE RECALIBRATION (CLIENT PROCEDURE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
"AGGRAVATING" HYDRAULIC MOVEMENTS CUT-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
80.4.3 DASHBOARD CALIBRATION MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
CALIBRATION MODE: ACTIVATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

80
CALIBRATION SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
LIFT TRUCK SERIAL NUMBER DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
RESETTING THE PARTIAL HOUR METER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
INCHING BRAKE PEDAL CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
TELESCOPING SPEED CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
ATTACHMENT FLOW RATE CALIBRATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
FORCED OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
MAINTENANCE HOUR METER RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
SELECTION OF SPEED UNIT KM/H OR MPH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
80.5 ELECTRICITY REMOVAL -REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
80.5.1 STRAIN GAUGE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
AXLE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
CHARACTERISTICS OF PRODUCTS USED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
CHARACTERISTICS OF FASTENING SCREWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

647632EN
80 ELECTRICITY 113
STRAIN GAUGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
80.5.2 REMOVAL - REFIT OF JSM ON BMEP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
80.5.3 ELECTRICAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
80.5.4 DASHBOARD ERROR CODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
DTC DASHBOARD MODULE ECU (BAUSER) - (X13 ECU-A1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
DTC TRANSMISSION ECU (X291 / X295 / X298 / X299 - ECU A2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
DTC ENGINE ECU (X400 - EVG) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
80.6 SPECIFIC ELECTRIC TOOLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
80.6.1 DIAGNOSTIC TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
VERSION 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
VERSION 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
ENGINE ADAPTATION KIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
80.6.2 BREAKOUT BOXES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
80
647632EN
114 ELECTRICITY 80
ELECTRICITY
80.1 ELECTRICITY CHARACTERISTICS AND SPECIFICATIONS
80.1.1 LOCATION OF RELAYS AND FUSES
In the cab under the armrest
N°52567753
N°52567464
F51
Camera kit OPTION

80
In he engine compartment. In the battery compartment.

K21 F52
K22
F50
647632EN
80 ELECTRICITY 115
80.1.2 ELECTRICAL NETWORK ARCHITECTURE
MMI
Stability display
Seat sensor
Strain gauge
SPU
Hydraulics
ECU
Transmission
+
-
Boom angle sensor
Control 80
accumulator block
Inching potentiometer STOP
Hydrostatic motor
Hydrostatic pump
Transmission CAN Bus Brake lights

Hydraulic function Stability control Operator presence
647632EN
116 ELECTRICITY 80
80.1.3 ECU INPUTS/OUTPUTS

X13 - DASHBOARD MODULE (BAUSER) - A1
Key:
NC: Not Connected
A1
PIN
Designation Function on truck Comments
No.
Engine coolant temperature indicator lamp ON (If r
01 Temperature resistance analogue input Engine coolant temperature analogue gage
> 0.118 KΩ)
02 Fuel resistance analogue input Analogue fuel gage Reserve indicator lamp ON and buzzer (If r > 170 Ω)
Clogging indicator lamp ON and buzzer
03 Hydraulic filter pressure switch logic input Clogged hydraulic filter (Indicator lamp)
(If pressure > 2 bar)
Level indicator lamp ON and buzzer
04 Brake fluid level logic input Brake fluid level (Fault indicator lamp)
(If NO switch closed)
05 Engine oil pressure switch logic input Engine oil pressure (Fault indicator lamp) Indicator lamp ON and buzzer (If oil pressure < 10 bar)
06 Rxd Not used Plug
07 Txd Not used Plug
Battery charge indicator lamp and hour Indicator lamp ON and buzzer (If voltage < 4v and
08 Logic input D+ alternator
meter power supply hour meter running if u>4v)
09 Brake hydraulic pressure switch logic input (Parking brake on indicator lamp) Indicator lamp ON if brake applied (No circuit pressure)
10 Headlight logic input Main beam indicator lamp Indicator lamp ON if main beam headlights enabled
11 Indicator lamp logic input Right or left indicator lamp Lit with lighting stalk switch and warning switch
80
Engine coolant temperature indicator lamp Lit if NO temperature switch and buzzer closed
12 Engine coolant temperature logic input
/ switch (If temperature > 110°)
13 NC Air filter clogging Indicator not fitted on MT (plug)
Start of preheat info (time delay / temperature
14 Preheat logic input Preheat control information
probe)
15 Dashboard LCD lighting logic input Dimmed dashboard backlight Only LCD / no buttons or indicator lamps
16 Nc Not used Plug

17 Nc Not used Plug
18 Clock power supply + battery Clock power supply + battery Consumption in standby mode (1mA)
19 Nc Not used Plug
20 Nc Not used Plug
21 CAN high CAN H J1939 Twisted shielded cable 1 (red cable 0.6 mm²)
22 CAN low CAN L J1939 Twisted shielded cable 1 (green cable 0.6 mm²)
23 NC Not used Plug
24 NC Not used Plug
25 Bauser ground Bauser ground
26 Power supply + after ignition key Power supply + after ignition switch Bauser alert
647632EN
80 ELECTRICITY 117
X291 / X295 / X298 / X299 - TRANSMISSION ECU - A2

Key:
NC: Not Connected
ECU: Electronic Control Unit
A2
C1
C2
C3
C4 C5
C6
PIN No. Designation Function on truck Comments

01 Weight Transmission ECU ground
Transmission ECU 12V or 24V power supply (fuse
02 Power supply
F4)
03 Hydr. engine speed sensor power supply Hydrostatic engine speed sensor power supply Cable on MLT version
04 Hydr. engine speed sensor ground Hydrostatic engine speed sensor ground Cable on MLT version
X295
Hydrostatic engine speed sensor frequency
C1 05 Hydr. engine speed sensor frequency input Cable on MLT version
input (rpm)
06 Forward gear logic input Data input
07 Reverse gear logic input Data input
08 to 11 NC Not used Plug
12 Neutral logic input Neutral input (seat NO sensor) - driver presence
01 CAN H CAN bus high

X299
02 CAN L CAN bus low
C2
03 Ground CAN CAN bus shielding
X298 01
NC Not used Plug
C3 to 06
80
01 Forward gear power supply Forward gear power supply
02 Reverse gear power supply Reverse gear power supply
C4 03 to 04 NC Not used Plug
05 Reverse gear ground Reverse gear ground
06 Forward gear ground Forward gear ground
01 Hydr. pump speed sensor power supply Hydrostatic pump speed sensor power supply Wired by ECU supplier
C5 Hydrostatic pump speed sensor frequency input

02 Hydr. pump speed sensor frequency input Wired by ECU supplier
(rpm)
03 Hydr. pump speed sensor ground Hydrostatic pump speed sensor ground Wired by ECU supplier
01 Pedal analogue input 2 Inching pedal analogue input 2 (0.5V to 4.5V)
NO sensor closed when pedal
02 NC Accelerator pedal sensor info (driver presence)
released
03 Analogue output Proportional engine control valve
04 Hydr. engine speed sensor analogue input Hydrostatic engine speed sensor analogue input Only used on agricultural version
05 Sensor power supply Inching sensor 5V power supply

X291 06 Sensor ground Inching sensor ground
C6
07 Analogue input Inching pedal analogue input 1 (4.5V to 0.5V)
08 ON/OFF output 3A Direction selection valve on engine
09 PWM - / ON/OFF output 3A Stop light relay ground
10 NC Not used Plug
11 Digital in mode 1 Slow/fast speed switch input
12 NC Accelerator pedal sensor info (driver presence) NC sensor open when pedal released
647632EN
118 ELECTRICITY 80
X55 - MAIN ECU SPU 40-26 (A3)
Key:
APC: Power supply after contact NO: Normally Open
+BAT: Fixed power supply NC: Normally Closed
GND: Ground S.P.U.: Safety Power Unit
1
8
14 7
20 13
19
26
Pin Active
Type Function on truck Comments
N° state
1 Logic input GND Not used
2 Proportional output 0 to 12 V Solenoid valve spill (I-)
3 Proportional output 0 to 12 V Solenoid valve spill (I+)
4 Proportional output 0 to 12 V Solenoid valve Descending boom (L-)
5 Proportional output 0 to 12 V Solenoid valve Ascending boom (L+)

8 Power supply APC 12 V Power Supply
9 Power supply APC 12 V Power Supply
10 Logic input APC JSM button -
11 Analog input 0 to 5 V Angular sensor arrow track 2
80
12 Analog input 0 to 12 V JSM potentiometer roller 1 analogue track

13 ECU wake-up input GND Not used
15 Analog input 0 to 12 V JSM potentiometer roller 2 analogue track
16 Identification input GND Battery ground
17 Logic input APC JSM Button 1
18 Logic input APC NC seat switch
19 Analog input 0 to 5 V Carriage angle sensor track 1
20 Logic output APC Safety valve (VS)
21 Logic output APC Horn relay control
22 Logic output APC Start relay control
23 Logic output APC Not used
24 Analog input 0 to 5 V Carriage angle sensor track 2
25 Logic output APC Forced operation indicator lamp
26 Weight GND Battery ground
647632EN
80 ELECTRICITY 119
Key:
1
8
14 7
20 13
19
26
Pin Active
N° state
1 Analog input 0 to 12 V Not used
2 Proportional output 0 to 12 V Fan Drive proportional solenoid
3 Logic output GND

Boom head electrovalve (option 2nd front attachment)
4 Logic output GND
5 Logic output GND Ground Safety valve
6 Logic output GND Not used
7 Power supply +BAT ECU power supply
8 Logic input APC Fan Drive button
Electroproportional manipulator block - Lift Ascending
9 Analog input 0 to 5 V
track 1
10 Logic input GND Forced operation button
Electroproportional manipulator block - Lift Inclination
track 2
12 Analog input 0 to 5 V Angular sensor arrow track 1
80
13 ECU wake-up input APC Power supply
14 Proportional output 0 to 12 V Attachment way- proportional electrovalve
15 Logic input APC Contact telescope retracted NO

16 Logic input GND Overload input
17 Logic input GND Attachment button Off
18 Logic input APC JSM Button +
Power supply for electro-proportional block manipulator
19 Power supply 5V
and manual accelerator
21 Power supply 10 V Strain gauge supply
22 Logic input GND Neutralisation button of hydraulic movements
23 Logic input GND Easy Connect System
24 Logic input APC Tilt motion lock
25 Logic input APC JSM potentiometer roller 1 digital track
647632EN
120 ELECTRICITY 80
Key:
1
10
18 9
26 17
25
34
Pin Active
N° state
1 CAN 1 High CAN High
2 CAN 1 Low CAN Low
3 Power supply APC Power supply 12 V after contact Cut-off by emergency stop
4 Power supply APC Power supply 12 V after contact Cut-off by emergency stop
5 Proportional output 0 to 12 V Telescope retraction solenoid valve (T-)
6 Proportional output 0 to 12 V Warm up electrovalve
7 Logic output APC Solenoid valve Fan Drive inversion
8 Power supply APC Power supply 12 V after contact
9 Power supply APC Power supply 12 V after contact
10 CAN 2 High CAN open High
11 CAN 1 120 Ω Not used
12 Logic input APC Fuel level gauge
13 Logic input APC NC telescope retracted contact
Electroproportional manipulator block - Lift Inclination
80
track 1
15 Logic input APC JSM potentiometer roller 2 digital track
16 Logic input APC NO seat switch
17 Proportional output 0 to 12 V Telescope extension solenoid valve (T+)
18 CAN 2 Low CAN open Low
19 Logic input GND Parked regeneration button
20 Logic input APC Oil temperature sensor
Deactivation switch of the “aggravating” hydraulic
21 Logic input APC Support valid only for 1 min
movement cut-off (NO)
22 Analog input 0 to 10 V Attachment selector
23 Logic input APC Emergency stop input
Electroproportional manipulator block - Lift Ascending
track 2
25 Proportional output 0 to 12 V Not used
26 LIN interface Not used
27 CAN 2 120 Ω CAN open 120 Ohms (connected to CAN 2 LOW) CAN Shielding
28 Weight Battery ground
29 Logic output APC Attachment way + electrovalve
32 Logic output APC Hazard warning light control
34 Weight GND Battery ground detection
647632EN
80 ELECTRICITY 121
X400 - ENGINE ECU - EVG - A13
Key:
APC: Power supply after contact GND: Ground
+BAT: Fixed power supply NC: Not Connected
A13
23
22
44
Pin Active
N° state
1 Analog output GND Coolant liquid temperature sensor ground
2 Analog input 0V to 12V Engine speed sensor signal
6 Analog input Coolant temperature sensor signal
13 Logic output GND Preheating indicator lamp
15 Logic input GND Oil pressure switch
16
17
Weight GND ECU ground
18
19
20 Analog input GND Engine speed sensor ground
21 Logic input 12V Starter control
22 Power supply +BAT Computer supply
25 CAN High CAN H J1939
26 CAN Low CAN L J1939
80
36 Logic output GND Injection pump solenoid
39 Logic output 12V Preheat relay coil
40 Logic output GND Starter relay coil
41 Logic output 12V Injection pump solenoid
43 Logic output 12V Engine speed sensor power supply
44 Logic input APC Key contact
647632EN
122 ELECTRICITY 80
80.1.4 TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
X1 / X2 - STARTER IGNITION SWITCH (S2)
PIN Function
1 + Battery
2 + Battery
4 3 Un used
2 1
3 4 Shunt preload
OP
5 + After contact (+APC) 30 30 17 17 50a 19 19 54 15 58
1 2 3 4 7 8 9 5 6 10
6 + After contact (+APC)

5 7 Starter
6
7 8 Shunt preheating
8 Diagram
9 9 Preheating control relay
10 POS
10 Un used PIN
ITIO
N O P Maxi - 12 V
7 (50a) x 18 A / 1min
Corresponding connector
8 (19) x x 70 A / 3.5min
9 (19) x x 70 A / 3.5min
Note : 5 (54) x x x 65 A / ∞
Voltage drop : 300 mV 6 (15) x x x 65 A / ∞
10 (58) x 8A/∞
x -> PIN = 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X6 - LIGHTING COMMUTATOR SWITCH (E15)
PIN Function
1 Power supply
80
2 Ground
1
M
Diagram
Typical
Voltage 12 V
Resistance (10%) 2,82 Ω
Current 5A
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
80 ELECTRICITY 123
X11 / 12 - WINDSCREEN WIPER COMMUTATOR SWITCH (S28)

PIN Function
F
0
Rear windscreen wiper and
0
1
1
2
windscreen washer power supply 0
2
2 Rear screen wiper control
1
1 3 Front windscreen wiper power supply

2
3 4 Rear screen washer
7 5 Front screen washer supply
4 8
1
5 6 9 6 Front screen washer control 0
9
7 Front screen wiper speed 1 8
7
8 Front screen wiper speed 2 6
5
9 Intermittent 4
1
1 Rear screen wiper parking 2
2 2 Front windscreen wiper parking 1
Corresponding connector Diagram
Typical
Voltage 12 V
Consumption As per outputs
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
S5 LIGHT COMMUTATOR
X14 - LIGHTING SWITCH
COMMUTATOR SWITCH (S26)
PIN Function 2
4
1 Light power supply
3
Dipped beam
0
2 9
headlights
1 8
2 3
Headlight 57/58 56a 56b 54s 54d 49
6
L 0 R
3 signal 0 1 2
5
80
7 4 Main beam headlights
4 8
7
5 6 9 5 Horn 30 L 31 1
6 Horn power supply

Indicator lights
7 Diagram
power supply
Right-hand
8
indicator light
Left-hand
9
indicator light
PIN Min Typical Max

Voltage 12 V 24 V
Consumption 3A 5A 7A
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
124 ELECTRICITY 80
X22-1 / X22-2 - BRAKE FLUID LEVEL SWITCH (S11)

PIN Function A
1 Module A1 info (dashboard)
2 Cab Front Ground

N
Diagram
Note : contact closed = Level OK
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X38 - REVERSING BUZZER (B1)
PIN Function 1 2
1 1 Buzzer power supply
2 2 Rear cab ground

80
Diagram
PIN Minimum Typical Maximum

Resistance (10%) 19,5 Ω 21,7 Ω
Average current 0,60 A 0,75 A
Voltage 12 V
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
80 ELECTRICITY 125
X39 / HORN (B2)
PIN Function
1 Buzzer power supply
Diagram
Typique
Supply voltage 12 V
Resistance 2,17 Ω
Consumption 6,00 A
Nominal frequency 500 ± 20 Hz
Sound level 107 dB(A) / 13V
Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X62 -TRANSMISSION SPEED SENSOR (B13)
PIN Function
1 PLUG 1 2 3 4 5 6
6 2 Speed sensor direction

5 3 Speed sensor frequency
4
80
1 4 Power supply
2
3 5 Ground
CF
6 PLUG
Diagram
PIN Minimum Typical Max

Supply voltage 4 4.9 V 5V 6.1 V
Low level voltage 0.3 V 0.45 V 0.6 V
High level voltage 4.4 V 4.55 V 4.7 V
Teeth frequency 3 0 Hz
Remarques :
MLT version only.
The speed sensor is excited by a ring of 78 teeth.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
126 ELECTRICITY 80
X63 - FUEL GAUGE (B34)
PIN Function 1
1 Level info
2 1
2 Cab rear ground
Diagram
PIN Min level Typical Max level

Supply voltage 12 V
Resistance range 240 Ω 33 Ω
Level range 46. mm >466. mm
Height (mm) Resistance (Ω) Height (mm) Resistance (Ω)

>466 33 256 112.5
466 39.2 235 120
445 45.4 214 127.5
424 51.6 193 135
403 57.8 172 142.5
382 65 151 150
361 72.2 130 168
340 80.4 h 109 186
319 88.6 88 204
298 96.8 67 222
277 105 46 240
80
Note: Reserve indicator lamp lit and buzzer if R > 170Ω
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
80 ELECTRICITY 127
X65 / X66 - WHEEL ALIGNMENT SENSOR (B12 / B24)
PIN Function A B C
A Signal
C B Power supply
B
A
C Ground +
Diagram
PIN Typical
Supply voltage A 12 V
Direct current A 10 mA
Outlet logic Switch closed = wheels aligned
Type of outlet PNP at Vbat

Note :
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80
647632EN
128 ELECTRICITY 80
X67 / X68 - JSM (A4)
(Joystick Switch and Move)
R
PIN Function
N
F
1 Power or ground supply
R1 2 Roller 1 direction A (+)
12
11
3 Roller 1 direction B (-)
R2
4 Roller 2 direction A (+)
−
6
+
5 5 Roller 2 direction B (-)
8
4 7
1
3 8 6 Signal Roller 1
9
7
FNR 2
– 10 7 Signal Roller 2
1
5
11
8 Power or ground supply
D+ D-
BP2 12
4
R2
+ 9 BP1
6
BP1
3
10 BP2 Option
D+ D-
R1
2
11 Forward
BP2
10
12 Reverse
9
PIN Function
BP1
1 1 Speed +
2
2
2 Speed –
1
Correspondent connectors Diagram
12 pins connectors PIN Mini Typical Maxi

Current ± 10% 1 mA 2 mA
Potentiometers Supply voltage 1 5V
under 5 V (10% at
90%) 6-7 0.5 V 2.5 V 4.5 V
Outlet voltage
2-3-4-5 0V 5V
Current ± 10% 1 mA 2 mA
Potentiometers Supply voltage 1 12 V
under 12 V (25% at
75%) 6-7 3V 6V 9V
Outlet voltage
2-3-4-5 0V 12 V
2 pins connectors PIN Mini Maxi

80
1 0V 5 or 12 V
Outlet voltage
2 0V 5 or 12 V
Remarks :
* Depending on the range of machines, pins 1 and 8 can be a ground or a power.
Determine both possibilities e Groupe 80 - ELECTRICAL SCHEMATIC DIAGRAMS - ELECTRICAL DIAGRAMS
BY FUNCTION.
** Depending on the machine range, the supply voltage can be 5V or 12V. Check on the power pin.
Note : ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
80 ELECTRICITY 129
X77A / X77B - BMEP (A14)
5
4
3
2
6
1
5
8
6
7
7
8
PIN Function
1
1 Ascending signal 2
4
2 Power supply 5V
3 Ground
3
4 Lift Ascending signal 1
2
5 Inclination signal 1
1
6 Ground
7 Power supply 5V
2
8 Inclination signal 2
Correspondent connectors Diagram
PIN Mini Typical Maxi

Supply voltage 1 5V
Outlet voltage 6-7 0.5 V 2.5 V 4.5 V
80
647632EN
130 ELECTRICITY 80
X100 - TELESCOPE ANGLE POTENTIOMETER (B11)
PIN Function
1 Ground
2 12 V Power Supply
Track 1 angle signal

3
6 (0.5 to 4.5V)
5
4 2 3 1 5 6 4
1
4 Ground
2 + S 0 + S 0
3 5 12 V Power Supply
Track 2 angle signal

6
(4.5 to 0.5 V)
Diagram
Typical
Supply voltage 12 V
Direct current 10 mA
Output voltage See notes and diagrams
Load resistance 20 kΩ
Angular range 0° - 90°

Remarks:
An adjustment of the angle sensor and a calibration (min. angle, max. angle) are required on each
machine, after each new calibration.
These two procedures are detailed in the following chapter:
e Group 80 - Electrical control and adjustment
Voltage (V)
S1 S2 Centering of the adjustment range
5V
80
4,5 V
S1
S2
0,5 V
-45° 0° 45°
Potentiometer angle (°)
Representation of a track of the potentiometer (the other track is of

the same value but inverted).
⇒ In black the operating range of the potentiometer.
⇒ In red, the range and the setting options.
⇒ α represents the working angle of the cart.
The angular sensor setting is detailed in the following chapter:
e Group 80 - Electrical control and adjustment
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
80 ELECTRICITY 131
X134 - BOOM RETRACTED SWITCH (S34)
PIN Function
Power supply 1 4 3 2
1
BF2/M1-F6
1
2 NC Switch
2 4
3 Power supply
3
BF2/M1-F6
4 NO Switch
Diagram

Supply current 4 mA 6 mA
Note :
When the boom is retracted, the NO switch is closed and the NC switch is open.
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X139 - INCHING BRAKE PEDAL ANGLE SENSOR (B9)

PIN Function
2 3 1 5 6 4
1 Common earth
6 2 Common 5 V power supply
5
80
4 3 Track 1 angle signal
1
2 4 Common earth
3
5 Common 5 V power supply
6 Track 2 angle signal Pedal Inching 5V

output 0.5 to 4.5V
Diagram

Supply voltage 4,5 V 5V 5,5 V
Direct current 8 mA
Outlet voltage 0,5 V 2,5 V 4,5 V
Load resistance 20 000 Ω
Angular range 0° - 50°

Note :
Each machine should be calibrated (min. angle, max. angle) at km 0 (0 mileage), see part 40
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
132 ELECTRICITY 80
X199 - WARM UP ELECTROVALVE (OIL HEATER) (Y23)
PIN Function 1 2
1 1 ECU A3 power supply
2 2 Cab rear ground
Min.
Supply voltage 12 V
Power supply current 1.7 A
Coil resistance (at 20°C) 7.1 Ω
Power 20.5 W
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X295 - FORWARD AND REVERSE ELECTROVALVE (Y3 / Y4)
PIN Function 1 2
1 ECU A2 power supply

1
80
2 2 Ground
Diagram
Typical
Voltage 12 V
Current 2,3 A
Resistance 6,3 Ω
Note :
Measurements taken at 20°C
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
80 ELECTRICITY 133
X325 - AIR-CONDITIONING THERMOSTAT SENSOR SUPPLIED WITH THE THERMOSTAT (Y17)
PIN Function
1 1 Power supply Thermostat
2 2 Ground 1 2
T
Thermostatic
sensor connector
Diagram
Values (K Ohm) Temperature (°c)

1,25 26
1,64 22
2,8 11
3,8 0
11,35 -3
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
X385 - VENTILATION CONTROL ELECTROVALVE (Y19)

PIN Function 1 2
80
2 2 Cab rear ground
Diagram
Mini
Supply voltage 12 V
Supply current 1.7 A
Coil resistance (at 20°C) 7.1 Ω
Power 20.5 W
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
647632EN
134 ELECTRICITY 80
X386 - VENTILATION REVERSAL ELECTROVALVE (OPTIONAL) (Y20)
PIN Function 1 2
2 2 Cab rear ground
Min.
Supply voltage 12 V
Power supply current 1.7 A
Coil resistance (at 20°C) 7,1 Ω
Power 20.5 W
Notes: ____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80
647632EN
80 ELECTRICITY 135
80.2 WIRING DIAGRAMS
80.2.1 ELECTRICAL DIAGRAM CODIFICATION EXAMPLE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
S2
V
M -M
Ca - M2
Ch
Ba
ot 3
1
b
as
t
-M
1
2
III II I O P
A 4
30 30 17 17 50a 19 19 54 15 58
7
3 X1 1 2 3 4 7 8 9 5 6 10 X2
769 X151 5
669
444
719
713
705
+ APC 6
71 739
X150
BF1 / M1 02
Version H
238
F3 8 3
CN2-P2
11 237 40
421 2
K21
C F4 15
13 7 2
269 EP6 236 09
12 169 1
8
30
87
5 666
4
Y40
11 25
12 235 169
72 X162
85
86
421
234 55 420
Version Standard
4
5 369
F5 6 1 233 16 A2 10
X201 X116 MP 22 9 421 2
555 69
420 1
BF2 / M3
CN1-P2
CAN A H
Y16
CAN A L
E F3 469
X161
EP7
719
71 72 10
15
14
666
412
369
G 13 412 2
12 11 41 42
1
69
58
569 EP12 420
69
CN1-P1
Masse CAN A
CAN A H
CAN A L
Sch.3
59
X161 Y15
77
91
90 76
89 47 X38-7 X168
EP5 M1
Sch. 8 Sch. 5 9 X76B
88 46
I
17
87 17
X166A X166B
R 16
86
S25 N
12 183 30 P
F
11 182 59
A1 B06
8 82
179
JSM 1 34 MP 12
172
K 7 178 49
80
X149
5 176 88 58
440 440
B16
-
4 175 87
CN2-P1
Option ETDF Version EP/RC

+
6 177 19
B15 3 174 86 58
449 2 Y28
-
EP68
16
+
2 173 85 1
S16 10 232 89
X160
M
A12 S15 9 180 56
X67 X148
Example of marking on cables and components on an electrical diagram
Key:
1 - Marking grid
2 - + Permanent 10 - Electrical component name
3 - + After ignition 11 - Splice
4 - Grounds 12 - Version choice
5 - Wire N° 13 - Other diagram reference
6 - Electrical connector 14 - CAN
7 - Electrical connector name 15 - CAN Shielding
8 - Electrical connector PIN N° 16 - Option
9 - Electrical component
647632EN
136 ELECTRICITY 80
80.2.2 CABLE IDENTIFICATION ON A WIRING HARNESS

MARQUAGE DES CÂBLES SUR UN FAISCEAU ÉLECTRIQUE
The electrical harnesses installed on the truck are composed of connectors.
In order to identify the connectors and their wires, each wire carried a marking.
X32/88/X64
Joins
Wire N° End points X64
X32 / 88 / X64 X32 / 88 / X64
X32
80
647632EN
80 ELECTRICITY 137
80.2.3 POSITIONS BY DIAGRAM Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7
X77B B5
Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 X91 D11
C1 F7 X92 G6
C3 F8 X93 H3
C4 G9 X94 H4
C5 G8 X95 G6
C6 F7 X99A I7
X01 B3 X99B J7
X02 B4 X100 B4
X04 I11 X101 C14
X05 I13 X102 C14
X06 I13 B9, B10 X103 B4
X09 H12 X104 B4
X10 A11 I7 X105A B4
X11 C3 X105B B4
X12 C4 X106A E4
X13 C10 X106B D4
X14 F11 X106C D5
X15 G9 X106D D5
X16 G11 X107 H2
X17 H13 X108 D6
X18 B7 X109 D7
X21 G7 X110 D8
X22-1 D2 X111 D9
X22-2 D3 X112 C5
X25 E5 X115 J5
X26A D3 X118A B7
X26B D3 X118B B7
X27 E3 X118C A7
X28 E4 X133-1 E6
X29 C8 X133-2 E7
X30 H5 X134 B3
X31 I10 X138 B9
X32 I10 X139 H7
X34A E8 X153 H6
X34B E8 X154 H7
X34C E9 X155 D6
X35 I11 X159 B1
X36 I12 X160 I13
X37
80
I14 X167 A2
X38 D6 X199 B6
X39 H12 X200A A1
X42 D11 X200B B1
X43 D5 X201 G1
X46 C3 X202 B14
X50-1 I1 X203 B14
X50-2 I1 X204-1 H4
X55 D6 E6 X204-2 H3
X56 J3 D6 E6 D11 X205-1 H4
X57 J4 D7 E8 D10 X205-2 H4
X58 F7 X260 I6
X59 I4 X261 I7
X60 G5, I5 X268 B5
X62 G5 X269 E6
X63 B7 X274 D5 F1
X65 J8 X276A F4, J5 B9
X66 J8 X276B F5, J5 B9
X67A C9 X277A G2, J3 A8
X67B B9 X277B G2, J3 A8
X67C C9 X286 B7
X67D B9 X289 I12
X68 B8 X290 I12
X77A B5 X291 F6
647632EN
138 ELECTRICITY 80
Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7 Item Diag. 1 Diag. 2 Diag. 3 Diag. 4 Diag. 5 Diag. 6 Diag. 7
X292 A5 X395 H6
X295 F7 X396 H9
X296 G9 X397 H8
X297 G8 X398 H5
X298 F8 X400 F4 I2
X299 G4 X401 F5
X301 A14 X402 E3
X303A F14 J14 B14 D6 E14, H14, J14 X403 E11
X303B C14 C14 D14 D6, J6 C14 G14, J14 X404 H5
X304A B14 H14 C14, G14 D14, E14, J14 X405 G5
B14, E14, G14, X406 G5
X304B B14, G14 E14 E14 J6 C14, I14
J14 X407 C5
B14, D14, F14, X408 C5
X304C J14 B14, F14 F6 B14
G14
X305 I10
X308 E12
X309 D11
X311 B10
X312 B12
X313 B8
X314 B5
X315 B6
X316-1 B7
X316-2 B7
X322 B12
X323 F5
X324 G5
X325 D4
X326 B6
X327 C6
X328 G5, H5
X329 G6, H6
X330A G5, H5
X330B G5, H5
X331 G4
X332 G5
X358 B4
X360 E3
X362 D2
X363 I13
80
X365A C2
X365B C2
X366 B14
X367 B1
X368 B7, B8
X369 B7
X370 J5
X371 J5
X372 I12
X373 A1
X375 A10
X378 H10
X379 H11
X380 I14
X383 A9
X385 E10
X386 E10
X390A G4
X390B G4
X391 H7
X392 H4
X393 H8
X394 H5
647632EN
80 ELECTRICITY 139
80
647632EN
140 ELECTRICITY 80
80.2.4 ELECTRICAL DIAGRAMS BY FUNCTION

DIAGRAM 1 – STARTING
CONNECTORS FUSES AND RELAYS
Item Harness Component Designation Position Item Current Designation Position
X01 Main S2 Ignition switch B3 F1 5A Bauser + Martin Technologie module C5
X02 Main S2 Ignition switch B4 F2 5A Alternator excitation / LLMI + ECM alarm C5
X03 Main Preheat I11 F3 5A Digicode(+apc) + diagnostics plug (+apc) + Easy Manager (+apc) C5
X04 Main M Starter excitation I13 F7 10 A Main ECU SPU 40-26 + APC SPU (12VE) via Emergency Stop S50 C5
X05 Cable M Starter cable / alternator fuse (80A) I13 Starter key information on engine ECM + coil K22 power supply (starter
F27 5A D4
X10 Main Easy Manager predisposition A11 control relay)
X15 Main Sealed starter mini-relay holder G9 F28 3A Dashboard preheat indicator via engine ECM E4
X16 Main Sealed preheat mini-relay holder G11 F33 5A OBD II diagnostic plug + Digicode E4
X17 Additional 80A Fuse holder kit for 80 mm2 cable H13 F40 10 A Engine ECM bat+ power supply E4
X21 Main B7 Hydraulic filter clogging G7 F42 60 A IGNITION SWITCH F1
X101 Cable Cab / frame earth cable C14 F43 40 A Preheat relay power supply G1
X102 Cable Cab / frame earth cable C14 F44 50 A Power supply BF1 / M2 (F31 to F40) G1
X118A Main Digicode predisposition B7 F45 30A Starter relay power supply G1
X118B Main Transponder or Digicode anti-theft connector shut B7 F50 80A Alternator protection (in the engine housing) H13
X118C Option Transponder or Digicode A7 Dashboard and Easy Manager battery (+) power supply (in battery
F51 5A B2
compartment)
X138 Main S50 Emergency stop button B9
F61 2A Dashboard battery (+) power supply D8
X159 Main S1 Starter (bat+) / fuse box B1
X160 Cable M Starter (bat+) / battery cut-off I13 F62 2A Easy Manager battery (+) power supply + Easy Manager starter relay D8
X167 Main G1 SPU direct earth A2
K21 12V-70A Preheat relay (70A) G11
X200A Cable S1 Battery cut-off (+BAT) A1
12V
X200B Cable S1 Battery cut-off (+BAT) B1 K22 Starter solenoid 20/30A relay G9
20/30A
X201 Main STUD BF1/M5 G1
X202 Cable Frame / engine ground cable B14
Splices
X203 Cable Frame / engine ground cable B14
Item Position
X289 Main G2 Alternator IG / L I12
EP16 B2
Additional
X290 G2 Alternator B+ I12 EP24 D10
harness
X292 Main Easy Manager anti-start option A5 EP25 D12
X301 Cable Cable + battery 70 mm2 / frame A14 EP31 I5
X304A Main Cab rear ground B14 EP32 J5
X304B Main Cab rear ground B14, G14 EP71 E12
X304C Main Cab rear ground J14
Dashboard and Easy Manager permanent + power
X373 Main G1 A1
supply (module + relay)
80
X400 Main A13 Engine ECU 36kw F4

X401 Main B8 Engine speed sensor F5
X404 Main B3 Oil pressure switch H5
X405 Engine B4 Engine temperature sensor G5
X406 Engine Y5 Injection electrovalve G5
647632EN
80 ELECTRICITY 141
Diagram 1 - Starting
1 2 3 4 5 6 7 8 9 10 11 12 13 14
436
- X57-34
Ca 1( e X ca /C
+
M ass M5 AR A/B r
b X3 Ch 30 bi )
X373 Sch. 4
M 3- se 04 eu
fr 03 as 1- ne
714
on A s X
M as X3 ot
t G /B is 20
M 2( c M
713
X167
M lo 3
ro )
B+ B-
B 20
G1
un
X
S2 A6 S50
d
A EASY Manager Option
RECM
DEM
SPU
X292 Transponder or Digicode anti-theft connector shut
2
X118C X10 12 11 9 4 3 1
713
X200A 1 2 3 4 5 6 7 8 9 10 12 1 2 1 2 1 2
412
411
410
414
433
431
1 2 3 4 1 2 3 4 1 2 3 4
OP
311
410
413
416
Anti-start Option EP06 X305-1 714 X301
F51
30 30 17 17 50a 19 19 54 15 58 EASY Manager X138 3 4 2 5 1 6 Sch. 3 Sch. 4

S1 X01 1 2 3 4 7 8 9 5 6 10 X02
266
265
736
X118B 1 2 3 4 5 6 7 8 9 10 12
45
82
X304A
7
414
51
52
X118A
273
EP76
279
278
277
280
1 2 3 4 5 6 7 8 9 10 12
Sch. 4
EP16
X203
B X159 X200B
271
269
266
265
268
413
274
BF1/M1 X202
186
712
711
B
280
274 X304B
278
X102
277
X101
A
F7 B 7
272
C F3 271
X115 - 1
Sch. 2
A B 323
99 X58 - 2
725 F2 Sch. 2
F64 -8 A B 268
Sch. 4
279 A
F1 B 171 171 X13 -26
A Sch. 2 X13 -18
169 X60 -13 Sch. 2
Sch. 7
431
45
X13 -8 93
416
433
172
803 EP25
D EP24 Sch. 2
12
BF1/M2
660
BF1/M3
6
5
F62
F61
273
F27 311
A B
1
667
F28 X60 -14
1
A 668
18
B
186
Sch. 7
736
54
F33 667
D 269 9
A B EP71
270 X115 - 16
802
E Sch. 2
53 A
F40 B 799
F
BF1/M5
X400
X401 X13-3
F42
51
20 806 806 1 B8 Sch. 2
02 807 807 2
60A 52 CF
165 X304B
F43 43
43 808 808 3
80
166
165
ENGINE SPEED
711 40A SENSOR
X201 F44 A13 X405 X21 1 2

53
EVG 6 810 810 2 B4 X16
G
50A 54 KUBOTA
F45 X15 3
728 P 43
1 809 809
1 t° K21
30A 1
COOLANT TEMP
SENSOR B7 87a
K22
728
87 5
3
2 41 41 X304B
30
X406 4 2 804 1
36
811 811 1 Y5 87
5
3 30 85 2 1
86
801
5 660 4
85
2 1 86
4
41 812 812 2 727 5
12V 70A 2
ACTUATOR
SOLENOID 12V 20/30A 3
Preheat relay
H F50
Starter relay
X60-4 80A
13 70
Sch. 7
X404 X17
B3
B A
P
15
813 813
2
OIL PRESSURE
712
SWITCH
X03
12
9
21 803 X289 X290
I L IG B+
X05 X160
39 801 B+
22 800 800 799 G2 727 M
+BP (12V) EP31 3~
44 802 X04
R4 U
40 804
19 709
GND
18 708
GND
J GND
17 707
16 706 700 700 X304C
GND EP32
647632EN
142 ELECTRICITY 80
DIAGRAM 2 - NETWORKS (CAN & LIN)
CONNECTORS
Item Harness Component Designation Position
Main X10 Easy Manager predisposition I7
Main X13 A1 Dashboard module C10
Main X56 A3 SPU 40-26 CN1-A J3
Main X57 A3 SPU 40-26 CN1-B J4
Main X58 A5 LLMI safety module F7
Main X99A Redundant strain gage I7
X99B A11 J7
Main X106A Main harness / electrical predisposition / camera kit interconnection E4
Option X106B Boom electrical predisposition harness D4
Option X160C Front / rear camera kit D4
Option X160D Ready for telescope head electrical connector harness D4
Option X108 A17 Colour camera 1 (rear) C5
Option X109 A18 Colour camera 2 (front) C6
Option X110 Colour camera 3 (NC) C7
Option X111 Colour camera 4 (NC) C7
Option X112 Reversing information (displayed on JSM) C4
Main X115 Diagnostic plug J5
Option X268 A16 Front / rear camera kit monitor B4
Main X299 A2 CAN C2 transmission ECU G4
Main X303A Front cab ground F14
Main X303B Front cab ground C14
Main X304A Cab rear ground H14
Main X304B Cab rear ground E14
Option X360 Telescope head electrical plug harness E3
Main X362 S32, H32 Boom head pre-wiring D2
Main X400 A13 Engine ECM 36 kW I2
Option X402 Telescope head electrical connector option E3
Option X407 A19 Front / rear camera kit ecu C5
Option X408 A19 Front / rear camera kit ecu C5
FUSES AND RELAYS

Item Current Designation Position
F19 7,5A Telescope head electrical connector + front / rear camera kit E2
F52 2A Camera ecu C6
80
Splices
Item Position
EP17 H4
EP18 I4
EP19 I4
EP21 H7
EP22 H7
EP28 C12
EP60 H4
647632EN
80 ELECTRICITY 143
Diagram 2 - Networks (CAN & lin)
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ca 2( fro 03A
AP
Vb
M b 3
b X3 nt /B
at
C
A16
re 04 Gr )
Ca 1(
ar A
M
Gr /B/ und
X
ou C)
nd
A
o
MENU CH1 CH2 MODE
Info commut. CAM 1
Info commut. CAM 2
Info commut. CAM 3
Info commut. CAM 4
Audio CAM 1
Vidéo CAM 1
Vidéo CAM 2
Vidéo CAM 3
Vidéo CAM 4
0V CAM 1 à 4
+12V
GND
X268 3 8 6 12 11 5 2 1 7 9 10 4 13 RPM E1 A1
H1 H3 H4 H5 H9 H10 H25 H26 H28 H29 H30 H37 H38 H49 H40 P3
B
HOUR METER
MICROCONTROLLER B6 P1
P2
BP1 BP2
CAN L
CAN H
NC
NC
NC
X13 1 26 18 15 23 8 13 10 11 12 14 9 3 4 25 24 5 2 22 21
166
172
107
176
171
170
14
13
90
67
93
68
X407 X309-1 EP30 X21-1
X60-10
C Sch. 7 Sch. 3 Sch. 7 Sch. 1
X408
X112
+12DC
+12DC
+12DC
+12DC
Audio
Audio
Audio
Audio
Vidéo
Vidéo
Vidéo
Vidéo
X303B
GND
GND
GND
GND
BROWN CAM 1 170
171
107
93
EP14 GREEN CAM 2
F52
176
2A
Sch. 3 F1-B EP20 EP25
Yellow
Yellow
Yellow
Yellow
172
White
White
White
White
BLUE CAM 3
Black
Black
Black
Black
05 X60-3
EP28
Red
Red
Red
Red
Sch. 1 Sch. 7 Sch. 1
WHITE CAM 4 X108 X109 X110 X111 Sch. 7
461
F61-5
462
464
06
X362 1 2 3 4 1 2 3 4 1 2 3 4 1 2 3 4 Sch. 1
H32
1 7 10
PAIR 01
0
A19
1
dispo CAM 3 dispo CAM 4 X22-1
RED DC12-24V
Sch. 5
BLACK GND
X106C 1 2
D
S32 5 9
A17 A18
345
466
465
2mm² 343
2mm² noir
465
463
464
X106D 1 2 CAM1 CAM2

X106B
1 2
X106A Additional wiring harness between X106A
and X106B if camera option
461
462
463
313
312
X360
A B C 312 X304B
E
502
501
475
61 X304C
X402
BF1/M1 A C B
F19 + - +
Sch. 1 A B 313
F30-A 350
Sch. 7
A5/LLMI
X58 2 3 4 1
141
142
140
X303A
99
140
F2 - B
Sch - 1
A2
PAIRE 05
80
CAN GND
CAN L
CAN H
C2
G X299 1 2 3
64
60
59
141
142
88 68
EP22
61
PAIR 02 PAIR 01
87 67
EP60 EP21
CABLE 03
64
X60-16
H Sch. 7 129 X304A
EP12 403
86
Sch. 3
402
EP17
84
64
A13 X400
60
EVG CAN H
401
25 694 694 348

EP19
120 Ω 1/2 W
KUBOTA
I PAIR 09
59
401
405
26 695 347
404
695
402
403
CAN L
EP18
346
345
PAIR 08
EASY Manager 0ption
X10
432 2
X99A 1 4 5 2 3
408 5
X99B
409 8
F3-B F33-B
346
345
Sch - 1
84
Sch - 1
432
88
348
129
401
404
408
347
87
405
409
272
270
X56 21 01 02 X57
J
BLACK
CAN L
CAN H
130
RED
406 407
CAN1 H
CAN1 L
X115 1 3 4 5 6 11 14 16 A11
PAD R120
A3
CAN VISHAY gauge
647632EN
144 ELECTRICITY 80
DIAGRAM 3 – TRANSMISSION
CONNECTORS
C1 Main A2 Transmission ECU CC1 (X295) F7
C4 Main A2 Hydrostatic pump sensors G9
C5 Main A2 Hydrostatic pump speed sensor (X2977) G8
X18 Main B26 Oil temperature sensor B7
X34A Main Low speed adjustment potentiometer E8
R1, R2,
X34B Main Speed limiter shunt E8
EP80
X34C Option B23 Low speed adjustment option E9
X55 Main A3 SPU 40-26 CN2-C D6
X56 Main A3 SPU 40-26 CN1-A D6
X57 Main A3 SPU 40-26 CN1-B D7
X62 Main B13 Hydrostatic engine speed sensor G5
X63 Main B34 Fuel gauge B7
X67A Main A4 JSM C9
S4, S7, B15,
X67B Main JSM B9
B16
X67C Option A4 Recovery of reversing information on JSM for front / rear cameras C9
X67D Option A4 Recovery of reversing information on JSM for front / rear cameras B9
X68 Main S8, S9 High low speed JSM B8
X92 Main Y13 Negative Brake electrovalve G6
X139 Main B9 Redundant brake pedal potentiometer (inching) H7
X199 Main Y23 Warm Up electrovalve (hydraulic oil heater) B6
X260 Main Y6 Y6 hydrostatic motor I6
X261 Main Y7 Y7 hydrostatic motor I7
X269 Main Y12 Hydraulic cut-off electrovalve (VS) E6
X274 Main S5, S6 Seat switch + pneumatic seat option D5
X291 Main A2 CC2 C6 transmission ECU F6
X296 Main Stop switch control via SAUER G9
X297 Engine B14 Hydrostatic pump speed sensor G8
X303A Main Front cab ground J14
X303B Main Front cab ground C14
X304C Main Cab rear ground B14, F14
80
X309 Main H15, S15 Parking brake switch S15 D11
FUSES AND RELAYS

F4 10 A Transmission ECU (Sauer), JSM, parking brake E2
F6 10 A Seat switch + angle sensor + telescope retraction sensor E2
Splices
Item Position
EP06 E7
EP08 D10
EP09 H8
EP10 H7
EP11 D9
EP12 C8
EP13 D10
EP14 C11
EP80 E8
647632EN
80 ELECTRICITY 145
Diagram 3 - Transmission
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ca 2( ro 3A
AP
Vb
M b f 30
b X3 nt /B
A4
at
C
re 04 G )
Ca 1(
ar A ro
M
Gr /B un
B15 B16
ou /C) d
nd
A S9 S8 S7 S4
BP+ BP- EVTdF

F N R
+ - -
B34 B26
699
698
X199 T°c 699 X304C
B 1 2
X68 X67B 10 9 2 3 6 4 5 7 1 8 11 12
1 2
X63
426
X67D
427
10 2 3 6 4 5 7 1 8 11 12
1 2 X18 1 2 9
187
Y23
185
679
680
X99A-3 X112
EV Warm Up Sch. 2 EP14 Sch. 2
403
X67C 10 9 2 3 6 4 5 7 1 8 11 12
187 183
284 EP12 160 X303B
X67A 10 9 2 3 6 4 5 7 1 8 11 12
X13-14
330
C Sch. 2 X311-6
31
264
69
183
258
261
76
257
260
267
263
X77A-3 Sch. 7
159
Sch. 4
160
90
H15
1 7 10
127
281
267
263
264
427
1 0
20 18 10 17 12 15
K2 -1
EP11 EP08
83
X55 Sch. 7
X274 1
A3
259
262
X56 X57
S15 5 9
X309 79 SWF 525024 +
80
SWF 586371S1
D 20
204
5 18 25 16 15 20 12 6
76
seat 81
679
185
698
426
259
316
80
262
128
284
EP13
X311-9
S5 S6 Sch. 7
X274 3 2
281
282
127
128
OPTION SPEED LIMITER
EP80
B23
316
X269 1 2 282 412 X10-12
câble 02 noir
EP06
R1: 2.2 KΩ
R2: 3.9 KΩ
Sch. 1 OU
E BF1/M1
39
F6 58 EP15
1 2 3
1
Sch. 4 X34B 2 3
83
Y12 VS
X34C
X34A
Sch. 1 F4 81
1 2 3
339
340
341
38 K2 - 1
Sch. 7
40 X304C
339
341
340
564
565
563
40
38
39
31
30
F X295 4 3 5 1 2 12 6 7 X298 1 2 3
C1 C3
X291 C6
562 4
A2
27 10
9
28
C4
80
C5
3 8 5 7 1 6 1 2 3 1 6 2 5 3 4
27
28
562
563
564
565
22
26
17
21
20
16
X62 X92 1 2
2 3 4 5
X296
G 1 2
X297
37
36
4 3 5
CF
K3-1 K3-2
B13 Y13 EV FN
Sch. 7 Sch. 7
CF
Hydrostatic motor CV
B14
16
72 Pump CV
EP09
17
75
EP10
H
73
72
20
75
21
C2 C1
74
1 2 1 2
X139 2 3 1 5 6 4
F R
B9 B9 Y3 Y4
Electronic pomp control
Pedal Inching 5V
output 0.5 à 4.5V
I
22
23
24
26
X260 1 2 X261 1 2
2P BDP
Y6 Y7
Electronic mot hydro control 24 X303A
J
23 X303A
647632EN
146 ELECTRICITY 80
DIAGRAM 4 – HYDRAULIC MOVEMENTS
CONNECTORS
X55 Main A3 SPU 40-26 CN2-C E6
X56 Main A3 SPU 40-26 CN1-A E6
X57 Main A3 SPU 40-26 CN1-B E8
X77A Main A14 BMEP connector B5
X77B Main A14 BMEP connector B5
X91 Main Y17 Telescope head electrovalve D11
X100 Main B11 Telescope angle redundant potentiometer B4
X134 Main S34 Telescope bottom switch B3
X303A Main Front cab ground B14
X303B Main Front cab ground D14
X304A Main Cab rear ground C14, G14
X304B Main Cab rear ground E14
B14, D14,
X304C Main Cab rear ground
F14, G14
X305 Main S31 Hydraulic movement cut-off shunt switch I10
X322 Main S12 Forced operation switch B12
X363 Main S22 Telescope head electrovalve ON/OFF switch I13
X368 Main Main harness/attachment decompression harness interconnection. B7, B8
X369 Option S46 Attachment decompression NO/NC pushbutton B7
X372 Main S33 Attachment locking switch I12
X375 Main S52 Tilting neutralisation switch A10
X383 Main S53 Ventilation control switch A9
X385 Main Y19 Ventilation speed control electrovalve E10
X386 Main Y20 Fan drive direction reversal electrovalve E10
X390A Main Main harness / distributor harness interface G4
X390B Distributor Distributor harness / main harness interface G4
X391 Distributor Y31 Proportional electrovalve I- Tilt Up H7
X392 Distributor Y32 Proportional electrovalve A- Attachment direction - H4
X393 Distributor Y33 Proportional electrovalve T+ Telescope Extension H8
X394 Distributor Y34 Proportional electrovalve L- Boom Down H5
X395 Distributor Y35 Proportional electrovalve I+ Tilt Down H6
X396 Distributor Y36 Proportional electrovalve A+ Attachment direction + H9
X397 Distributor Y37 Proportional electrovalve T- Telescope Retraction H8
X398 Distributor Y38 Proportional electrovalve L+ Boom Up H5
X403 Option Y17 Telescope head electrovalve E11
80
FUSES AND RELAYS

F8 5A Override + Telescope Head Electrovalve + switch indicators X305 + X372 + X363 + X375 G2
F20 10 A Fan G2
F36 3A SPU40-26 bat+ power supply H2
F63 10 A SPU 40-26 supply (12VD lines) + SPU wake-up D4
F64 10 A SPU 40-26 supply (12VC lines) D4
Splices
Item Position
EP05 D8
EP07 D7
EP15 C3
EP68 D10
EP76 F6
EP78 C7
EP81 I5
EP82 I5
647632EN
80 ELECTRICITY 147
Diagram 4 - Hydraulic movements
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Vb
AP
Ca 2( ron 3A
at
M
C
b X3
re 04 Gr B)
Ca 1(
ar A
M
b X3
289
290
Gr /B und
161
365
289
f 0
94
283
ou /C)
t /
nd
A 1 0 1 10
H53 1 0 1 10
H52
o
E.C.S.
1 0 1 10
H12
A14 S46
X(2) X(1) Y(1) Y(2)
L+/L- L+/L- I+/I- I+/I-
S53 5 9 S52 5 9
2 1 1 2
X383 367 SWF 525005 +
X375 S12 5 9
366
92 SWF 525005 +
X322
91
SWF 586373S10 SWF 586374S12 SWF 525010 +
1 0 SWF 586374S5
X304C
203
161
291
290
B11 X369
S34 4 1
X77B
125
137
B X77A 2 1 3 4 7 8 6 5
X368
X368 4 137 X303A
378
1 137
330
374
373
331
375
125
2 3 1 5 6 4
X100 EP12
Sch. 3
X134 1 4 3 2
47
55
49
48
56
50
X304A
327
50
328
138
139
327 48
47 X304A
EP15 55
58
C
F6 - 1
Sch. 3
324 304
EP78
329
BF1/M3 435 X304C
F2 - A 725 8
F64 4 355 355 354
EP05
304
305
Sch. 1
D X91 2 1
286
7
F63 3 740 740 285
EP07 361 364 364 X303B
EP68
331
374
375
125
362
351
324
329
435
283
287
365
285
286
353
354
49
94
361
363
12 19 9 11 23 2 17 3 4 26 10 13 24 8 3 4 8 9
305
360
362
310
328 15
X386 X385 1 2
124 14
X56 X57
7 363
1 2
X403 2 1
71 7
13 139
417 5 24 373
415 4
A3 14 378
E 3 Y19 Regulation
126
34 436 X167 Y20 Inversion
120 2
Sch. 1 EV tdf Y17
56 11 X55 28 360 360 X304B
8 9 25 16 26 17 5 29 23 21
356
357
203
717
434
274
423
421
123
739
196
434 X304C
717 X304C
X138-1 82
Sch. 1
EP76
F
739
202 X304C
80
201 X304C
BF1/M1
421
120
126
423
415
417
124
202
123
201
G X390A
A
F20 B 366 371 X304A
2 8 4 5 1 3 7 6 10 9
X390B
202
421
123
201
124
417
423
415
126
120
Sch. 1 A
F8 B 91
359
BF1/M2
Sch. 1 A
F36 B 71
421
123
422
132
423
122
124
424
418
126
131
417
120
121
416
415
H X392 1 2 X398 1 2 X394 X395 1 2 X391 1 2 X393 1 2 X397 1 2 X396 1 2

1 2 X10-11
Sch. 1
370
135
371
291
368
411
351
196
305
35
Y32 Y38 Y34 Y35 Y31 Y33 Y37 Y36
A- L+ L- I+ I- T+ T- A+ 1 0 1 10
H31 1 0 1 7 9
H33 1 0 1 10
H22
122
I 201 131 S31 5 9 S33 5 10

S22 5 9
EP81 X305 SWF 525010 + X372 369 SWF 525024 + X363 358 EVTDF
136 SWF 586371S3 SWF 586374S4
135
418
368
SWF 525005 +
359
370
132
SWF 586374S4
35
202 416
EP82
121
424
422
J
647632EN
148 ELECTRICITY 80
DIAGRAM 5 – VENTILATION, WIPERS AND AIR-CONDITIONING
CONNECTORS
X11 Main S28 Wiper stalk switch C3
X12 Main S28 Wiper stalk switch C4
X22-1 Main S11 Brake fluid level D2
X22-2 Main S11 Brake fluid level D3
X25 Main M6 Front windscreen wiper engine E5
X26A Main Main harness/front windscreen washer pump harness interconnection D3
X26B Cab Main harness/front windscreen washer pump harness interconnection D3
X27 Cab M5 Front windscreen washer pump E3
X28 Cab M8 Rear windscreen washer pump E4
X50-1 Cab S25, E16 Roof light I1
X50-2 Cab S25, E16 Roof light I1
X59 Cab M7 Rear windscreen wiper I4
X107 Cab Roof windscreen wiper H2
X274 Main S44 Seat switch + pneumatic seat option F1
X276A Main Main harness/front cab harness interconnection F4, J5
X276B Cab Main harness/front cab harness interconnection F5, J5
X277A Main Main harness/rear cab harness interconnection G2, J3
X277B Cab Main harness/rear cab harness interconnection G2, J3
X303A Main Front cab ground D6
X303B Main Front cab ground D6, J6
X304B Main Cab rear ground J6
X304C Main Cab rear ground F6
X328 Option E18 Front right working light G5, H5
X329 Option E18 Front left working light G6, H6
X330A Cab Front working light harness interface G5, H5
X330B Option Front working light harness interface G5, H5
X331 Cab Rear right working light G4
X332 Cab Rear left working light G5
FUSES AND RELAYS

F17 15 A Rear windscreen wiper + rear windscreen washer + roof windscreen wiper control B1
F18 15 A Front windscreen wiper + front windscreen-washer control B2
F29 10 A Pneumatic seat D1
F34 7.5 A Horn and roof light 5W or 10W bulb D1
80
F37 10 A Rear windscreen wiper motor reset bat+ power supply D1

F38 15 A Front windscreen wiper motor reset bat+ power supply D2
Splices
Item Position
EP39 H3
647632EN
80 ELECTRICITY 149
Diagram 5 - Ventilation, wipers and air-conditioning
1 2 3 4 5 6
Vb
AP
at
C
Ca 2( ron 3A
M
b 3
re 04 Gr B)
Ca 1(
X
ar A
M
b X3
Gr B und
f 0
A
ou /C)
/
nd
t /
o
Sch. 1
0 1
0
BF1/M1
B
B S28
A
F
F17
F18
B
B
247
246
249
250
X11 1 2 3 4 5 6 7 8 9 X12 1 2
249
246
251
245
244
252
248
250
254
253
C
Sch. 1
243 243 X303B

244
245
242
Sch. 1 EP28
BF1/M2 Sch. 2
X26A 1 2 3
D X26B
C
D
244
569
570
242
242
6
A
A
A
X22-1 X22-2
F37
F29
F38
F34
256 X303A
B
B
B
N
242
X27
244
570
569
S11 X28
255
254
252
251
256
255
398
148
319
149
1 2 1 2
X25 1 3 4 2 6
X14-6 M M
E Sch. 7
+perm vit1
vit2
M5 M8 raz
M
-
M6
399 X304C
X314-1 X314-2
399
398
Sch. 7 Sch. 7
F X274 4 5
253
229
319
248
225
X276A
S44
6 2 5 3 7
X276B
253
319
248
80
229
X331 X332 X330A

M11 1 1 1 3
G X330B
X316-2
X329
247
X328
X277A Sch. 7
149
1 1
1 3
X277B
247
149
E17
E17
E18
E18
408
407
174 322 X329
EP39 X328
247
174
2 2
H X107 1 2
X331 X332 X330B

2 2 2 4
1
X330A
320
S29
0
1 2
3
407
149
I
253
319
248
406
X50-1 X50-2
1 2 3 X59 1 3 2 4
S25 X06-2
+perm vit +perm Sch. 7
M4 M M7
vit1
raz
E16 raz
M 321 X303B
-
X303B
406
320
320
322
Roof wiper X276B

J CAB HARNESS X277B 4
4 8 322 X304B
X277A X276A
320
321
322
647632EN
150 ELECTRICITY 80
DIAGRAM 6 – OPTIONS
CONNECTORS
X29 Main Heating / air-conditioning fan C8
X30 Main Air-conditioning compressor H5
X46 Main S17 12V connector C3
X93 Main Car Radio power supply H3
X94 Main Car radio loudspeaker H4
X95 Main Main harness / air conditioning condenser harness interconnection. G6
X153 Cab M10 Air-conditioning condenser fan H6
X154 Cab B20 Air conditioning condenser pressure switch H7
X155 Main A9 Main harness / air conditioning harness interconnection D6
RH
X204-1 Main + Right loudspeaker H4
loudspeaker
RH
X204-2 Main - Right loudspeaker H3
loudspeaker
LH
X205-1 Main + Left loudspeaker H4
loudspeaker
LH
X205-2 Main + Left loudspeaker H4
loudspeaker
X286 Main S24 Heating / air conditioning fan control B7
X303B Main Front cab ground C14
B14, E14,
X304B Main Cab rear ground
G14, J14
X323 Main A15 Air-conditioning module power supply connector F5
X324 Main A15 Air-conditioning module output connector G5
X325 Option B17 Air-conditioning thermostat sensor supplied with the thermostat D4
X326 Cab H23, S23 Air-conditioning control switch B6
X327 Cab B18 Air conditioning thermostat C6
X378 Option R7 Engine preheat rod connector H10
X379 Option 3-way connector extension 230V H11
X380 Option Preheat rod earth terminal on frame I14
FUSES AND RELAYS

F5 15 A 12V connector + car radio (+apc) B2
F35 10 A Car radio (power) H2
F41 20 A Heating E2
F46 30A Air conditioning (fan + compressor) E2
80
K7 20A / 35A Heating relay F4

K9 Air conditioning compressor control relay F5
K10 Fan motor time delay relay (air-conditioning) F6
K11 Fan motor time delay relay (air-conditioning) F6
Splices
Item Position
EP05 D8
EP07 D7
EP15 C3
EP68 D10
EP76 F6
EP78 C7
EP81 I5
EP82 I5
647632EN
80 ELECTRICITY 151
Diagram 6 - Options
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ca 2( fro 03A rou

AP
Vb
M b 3 g
b X3 nt /B nd
at
C
re 04 G )
Ca ( sis 0
ar A ro
M as X38
Gr /B un
1
Ch 5
ou /C) d
M
nd
A
M
5
235 X304B
AIR CONDITIONING UNIT A9 HEATING UNIT A8
B BF1/M1
H23
Sch. 1 A
F5 B 234
233
S23 X326
432
3
S24 X286
275
431
2
off
L
429 M 293 X303B
1
B H
C
C 430
388
235
234
X46
293
387
386
385
1 2
X327 3 4 2 1
432
B18
1
431
X29
12V
2
Thermostat 430
X325 428
S17
3
D
T
M9
430
428
429
X155 1 2 3
428
429
430
B17
E BF1/M5 309 X304B

F46 303
30A
303
Sch. 1 F41 292

20A EP23
309
428
306
307
308
X323 1 2 4 5 6
F
K3-3 30 30 30
86 86 86
Sch. 7 A15
292
276
87 87a 87 87
85 85 85
BF1/M3
K7 1 3
30 K9 K10 K11
86
87 87a
2 85 5 4 C B A
80
X324
301
389
K6-2 299
275
Sch. 7
G K8-5 300
390 X304B
Sch. 7
HPD HPG
429
388
390
389
X95
4 3 2 1
BF1/M2
429
388
390
389
X204-2 X204-1
Sch. 1
F35
238
237
301
A
239
B
X205-2 X30
X205-1
429
388
H X154
237
2 1
X153 X378 X379
390
389
240
241
X93 1 3 5 7
2 1
RADIO-SUPPLY
238
240
X94
2 4 6 8
1 3 5 7
EC
233
236
LOUDSPEAKER
2 4 6 8 C
239
241
Y16
I +
R7 Preheat rod option
_
M10 B20
A7 X380
CONDENSER UNIT A10
236 X304B
J
647632EN
152 ELECTRICITY 80
DIAGRAM 7 - LIGHTS AND SIGNALS

CONNECTORS FUSES AND RELAYS
Item Harness Component Designation Position Item Current Designation Position
X06 Cab M3, E15 Rotating beacon light B9, B10 K2+K3 power supply (reversing lights+buzzer+stop lights) + coil K7
F9 10 A F2
X09 Main B2 Front horn earth terminal H12 power supply (heating)
X14 Main S26, S27 Light commutator switch F11 F10 2A Wheel alignment sensors + indicator lamps F2
X31 Main E3, E8, E10 Rear left headlight I10 F11 15 A Flashing light unit (power + apc) G2
X32 Main E3, E9, E11 Rear right headlight I10 F12 5A Rear fog light switch G2
E8, E10, F13 15 A Boom working headlight switch via K4 F2
X35 Main Front left headlight I11
E12, E13 F14 7.5 A Rotating beacon light G2
E9, E10, F15 10 A Rear windscreen defrost F2
X36 Main Front right headlight I12
E12, E14 F21 3A Left side lights power supply H13
X37 Main E7 Rear number plate light I14 F22 3A Right side lights power supply H13
X38 Main B1 Reversing buzzer D6 F23 15 A Dipped headlights power supply H13
X39 Main B2 Front horn H12 F24 15 A Headlights power supply H13
X42 Main E4 Fog light D11 F25 7.5 A Right indicator lights supply H13
X43 Main E2 Reversing light D5 F26 7.5 A Left indicator lights supply H13
X56 Main A3 SPU 40-26 CN1-A D11 F30 20 A 2 front working lights and 2 rear working lights or blue light option via K5 H2
X57 Main A3 SPU 40-26 CN1-B D10 Light commutator switch: dashboard + dipped headlights + main
F31 20 A C1
X60 Main A12 Dashboard indicator lamps PCB connector G5, I5 headlights + front and rear side lights
X65 Main B21 Front wheel alignment sensor J8 F32 15 A Warning switch + flashing light unit (+bat power supply) C1
X66 Main B12 Rear wheel alignment sensor J8 K1 Free D3
X103 Option E19 Telescope head right working light B4 20A /
K2 Reverse light and buzzer relay D3
X104 Option E19 Telescope head left working light B4 35A
Main harness / Telescope head working light harness 20A /
X105A Main B4 K3 Stop light relay D3
interconnection 35A
X105B Option Telescope head working light harness B4 10A /
K4 Working lights on telescope option E4
20A
X133-1 Main B10 Negative brake pressure switch E6
20A /
X133-2 Main B10 Negative brake pressure switch E7 K5 Blue working light option D4
35A
X276A Main Main harness/front cab harness interconnection B9 K6 Free D5
4x
X276B Cab Main harness/front cab harness interconnection B9 K8 21W + Flashing unit C13
indicator
X277A Main Main harness/rear cab harness interconnection A7
Splices
X277B Cab Main harness/rear cab harness interconnection A7
Item Position
E14, H14, EP01 G13
X303A Main Front cab ground
J14 EP02 G14
X303B Main Front cab ground G14, J14 EP03 E4
D14, E14, EP04 F4
X304A Main Cab rear ground
J14
80
EP20 I13
X304B Main Cab rear ground C14, I14
EP30 E6
X304C Main Cab rear ground B14
EP72 H13
X308 Main S16 Warning switch E12
X311 Main S14 Hydraulic movement neutralisation switch B10
X312 Main S18 Rear fog light switch B12
X313 Main S19 Revolving light switch B8
X314 Main S20 Cab front + rear working lights switch B5
X315 Main S21 Rear window defrost switch B6
X316-1 Cab F6 Rear windscreen defrost B7
X316-2 Cab F6 Rear windscreen defrost B7
X358 Option Telescope head working light harness B4
Main harness / blue headlight harness
X365A Main C2
interconnection
Main harness / blue headlight harness
X365B Option C2
interconnection
X366 Option Blue light option harness ground B14
X367 Option S36 Blue headlight switch B1
X370 Option A12 Attachment line flow selector / electric plate J5
X371 Option S45 Selector for attachment line flow J5
647632EN
80 ELECTRICITY 153
Diagram 7 - Lights and signals
1 2 3 4 5 6 7 8 9 10 11 12 13 14
Ca (
AP
Vb
M b fr 30
b X3 nt GA/B
at
C
2
re 04
Ca 1(
ar A rou
M
Gr /B/ nd
X
o 3
ou C)
nd
A
)
397
394
230
X277A 2
1 0 1 10
H36 X276A-7 X276A-3
208
E19 E19
209
198
212
197
Sch. 5 Sch. 5 X277B
205
X276B-8
230
223
Sch. 5
212
210
211
211
223
210
209
230
229
X103
224
225
X104 H18
H14
7 8
X316-1 1 0 1 2 10
1 0 5 10
X276A 1
S36 5 9 E20 2
H20 H21
1 10 1
0 10
X367 396
1 2 1 2 1 1 0
1 0 1 10
H19 X276B 397 X366
395
R6
SWF 525138 +
SWF 585977S2 X358 X06 1 2 X06
3 S14 5 6 9 S18 1 9
B
1 2 4
X311 SWF 525110 + X312 SWF 525005 +
E20 S20 6 3 9
S21 5
S19 SWF 586374S3 SWF 586374S6
219
9 220
204
5
159
197
9
X314 X315 232 SWF 525005 +
X313
231
SWF 525138 + 222 SWF 525005 +
221
227 228 SWF 586374S2 X316-2
226
SWF 596610S6 SWF 586373S9
M3
X309-10 X309-9 310 X304C
X105B
395
E15 Sch. 3 Sch. 3 K7-2

394
EP39 408
X105A 1 2
Sch. 5 Sch. 6
300
310
218
Gyrophare
X365B X304B
315
314
314
BF1/M2 1 3 2 X365A
BF1/M3
394
395
391
F32 215
5 (-) 4 (+)
C F31 CL
(R2)
Sch. 1 144
K8
8(R) 6(C)
177
158
X296-2 294 X304B
Sch. 3
37
199 X304A
298
BF1/M4
297
295
188
189
226
37
296 K7-2
182
190
2 5 K3 2 5 K5 2 5 Sch. 6
D
4
194
192
205
X43
198
199
215
213
217
4 3
85
208
157
K1
158
296
297
182
194
X57 X56 22 X42
298
299
295
294
315
22 2 3
1 3 1 X38 1 2
H16
3 1 3 2 8 5 10
1 0
K2
394
393
2 5 2 5 2 5
36
276
A3
180
K6
E2
1 3 X296-1 1 3 1 3
B1 S16
Sch. 3 K4 REVERSING LIGHT E4 6 3 1 7
318
156
X308 SWF 525192 +

FOG LIGHT
218
216
214
213
180 SWF 586371S2
179
30
69
X295-7
Sch. 3
K7-1 192 X304A
E X67A-12
Sch. 3 Sch. 6
190 X304A
133 X303A
156
134
133
134
224
EP03 15
EP30 X133-1 X133-2
14
BF1/M1 V2
155
Sch. 1 A A F9 B 179 X13-9

P
Sch. 2
EP04
A F10 B 164 B10
57/58 56a 56b 54s 54d 49
S26
F 335 0 1 2 L 0 R
155
Sch. 1 B A
F13 318
S27 31
B 30 L
A
F15 B 231 X14 9 3 4 2
1 7 5 6 8
F14
155
A 221
B
V1
80
157
153
151
216
145
148
150
119
214
147
144
146
153
A
F12 B 219 EP01 EP02
F34-B
154
F11 217 Sch. 5
G A B
F28-B X400-13 F1-B EP28 X13-23

Sch. 1 Sch. 1 Sch. 1 Sch. 2 Sch. 2 317 X303B
119
668
169
177
162
334
146
317
X60
70
15
13
BF1/M2
5
145
147
150
151
X39
154
395 JP1
152
Sch. 1 A
F30 B 393
14 4 13 2 12 3 5 10 6 7 8 9 11 1
F19-A 350
BF1/M2
A
A
A
A
A
Sch. 2
H44
F22
F24
F21
F26
F23
F25
H B2
B
B
B
B
B
X09
H27 H2 H45 H6 H11 H13 H43 H8 H24 H35 H7 118
117
106
104
111
114
112
101
102
109
98
97
168
96
EP72 96 X303A
116
reserve
106
H27 H2 H45 H6 H44 H11 H13 H43 H8 H24 H35 H7 108 107 X13-15 4 X304B
I EP20 Sch. 2
188
112
104
193
111
100
102
118
114
101
108
98
109
191
189
116
97
95
168
X60 85
4
15
3K X31 3 4 2 1
X32 1 2 4 3 X35 1 2 3 4 5 X36 X37 1 2
1 2 3 4 5
1K 16 86 EP17
1.5K Sch. 2
JP1
STOP
STOP
0.5K A12 E7
X370 4 3 1 2 JP2 E3 E8 E10 E11 E9 E3 E13 E12 E8 E10 E13 E12 E9 E11
336
162
164
167
334
335
REAR LEFT HEADLIGHT REAR RIGHT HEADLIGHT FRONT LEFT HEADLIGHT FRONT RIGHT HEADLIGHT 95 X303B
X65 A B C X66 A B C
100 X303A
460
459
457
458
193 X304A
J X371 L M B H C + +
191 X304A
B21 _ B12 _
167 X304A
336 X303B
S45
647632EN
154 ELECTRICITY 80
80.3 ELECTRICITY LOCATIONS
80.3.1 KEY
3D 2D 3D 2D
8 electrovalve 8 electrovalve
Pos. Description Frame Cab Engine Frame Cab Engine hydraulic Pos. Description Frame Cab Engine Frame Cab Engine hydraulic
block block
EP01 B9 X31 Left rear light C3 F4
EP02 B9 X32 Right rear light F1 H7
EP03 B5 X34-A Low speed setting C9
EP04 B5 X34-B Low speed resistor shunt C8
EP05 G8 X35 Front left headlight G12 D11
EP06 G8 X36 Front right headlight J8 D12
EP07 G9 X37 License plate light option E3 G7
EP08 E8 X38 Rear horn E3 G8
EP09 C5 X39 Front horn D9/I7 B13
EP10 C5 X42 Fog light C3 G4
EP11 E8 X43 Reversing light F1 G7
EP12 E9 X46 12V connector D4 G7
EP13 E8 X55 SPU cn2-c hydraulic system ECU C4 H10
EP15 H5 X56 SPU cn1-a hydraulic system ECU C4 H9
EP17 E9 X57 SPU cn1-b hydraulic system ECU C4 H10
EP18 G9 X58 LLMI safety module D8 B10
EP19 G9 X60 Dashboard electric plate I7 A7
EP20 D9 X62 Hydrostatic engine speed sensor J8 B13
EP21 C9 X63 Fuel gauge D5 G7
EP22 C9 X65 Front wheel alignment sensor I7 D12
EP23 G10 X66 Rear wheel alignment sensor D5 G7
EP24 E9 X67 Joystick Switch and Move (JSM) F4 D9
EP25 E8 X68 JSM button (+) / button (-) D9
EP28 C9 X77 Electro-proportional manipulator block (BMEP) G5 F6
EP30 C9 X89 Miscellaneous components F4
EP31 G10 X91 Boom head electrovalve option D2 G5
EP32 G10 X92 Negative brake electrovalve G4 G9
EP60 G9 X93 Car radio power supply D3 F6
EP61 B3 X94 Car radio loudspeaker D3 F6
EP62 B3 X95 Air-conditioning option F4 E5
EP68 J8 X99 CAN Strain gauge E7
EP71 G8 X100 Boom angle sensor C2 G6
80
EP72 F7 X105 Telescope head working lights option E3 E6

EP76 G9 X106 Boom foot electrical predisposition option E3 E6
EP78 G10 X115 Diagnostic plug D7 F9
X1 Ignition switch B13 D7 X118 Digicode F9
X2 Ignition switch B12 D7/D8 X133-1 Negative brake pressure switch F7 G9
X3 Preheat plugs H9 X133-2 Negative brake pressure switch F7 H9
X4 Starter excitation H7 X134 Retracted boom switch C2 G5
X9 Horn earth I9 B13 X138 Emergency stop button B12 D7
X10 Easy Manager predisposition D6 D8 X139-1 Redundant brake pedal potentiometer C5
X11 Wiper commutator switch G9 A9 X155 Air-conditioning optional harness E9 D6
X12 Front and rear windscreen wiper reset D9 A9 X159 BF1-M5/power supply/battery cut-off I11 F11
X13 Bauser dashboard module D8 B7 X167 Battery direct ground I11 C9
X14 Light commutator switch F9 A10 X199 Hydraulic preheat electrovalve J5 I11
X15 Starter relay G3 H2 X201 BF1-M5 power supply/fuse box E7
X16 Preheat relay G3 H3 X204-1 + Right loudspeaker C4 F5
X18 Oil temperature sensor J4 J11 X204-2 - Right loudspeaker D4 F5
X21 Hydraulic filter clogging G4 H9 X205-1 + Left loudspeaker B6 E4
X22-1 Brake fluid level H10 C4 X205-2 + Left loudspeaker B6 E4
X22-2 Brake fluid level H10 D4 X260 Y6 hydrostatic motor J7 B12
X25 Front windscreen wiper engine F9 A9 X261 Y7 hydrostatic motor J7 A12
X26-A Front windscreen washer G9 D4 X269 Hydraulic cut-off electrovalve (VS) F7 G9
X29 Heating / ventilation E9 E5 X274 Seat switch + pneumatic seat option F3 F6
X30 Air conditioner compressor I6 C12 X276-A Front cab harness interconnection F11 D5
647632EN
80 ELECTRICITY 155
3D 2D
8 electrovalve
Pos. Description Frame Cab Engine Frame Cab Engine hydraulic
block
X277 Rear cab harness interconnection E3 E7
X286 Fan control E9 E5
X289 Alternator J5 H8
X291 cc2 c6 transmission ECU I3 H4
X292 Easy Manager anti-start option D6 E8
X295 cc1 c1 transmission ECU H3 H3
X296 Transmission harness interface H5
X298 ppc c3 transmission ECU H3 H4
X299 CAN c2 transmission ECU H3 H5
X303-A Front cab ground I7 B10
X303-B Front cab ground I7 C10
X303-C Front cab ground G9
X304-A Cab rear ground C6 D7
X304-B Cab rear ground C6 D7
X304-C Cab rear ground C6 D7
X305 S31 movement cut-off shunt switch E7 D13
X308 S16 warning D13 A1
X309 S15 parking brake B13 A8
X311 S14 movement neutralisation relay (Germany) C13 A8
X312 S18 fog light D13 A1
X313 S19 Rotating beacon light D13 A1
X314 S20 front + rear + boom working lights (Option) D13 A1
X315 S21 rear windscreen defrost C13 A1

X322 S12 attachment forced operation E7 E14
X323 Air-conditioning module supply C5 G11
X324 Air-conditioning module output C5 G11
X363 S22 telescope head electrovalve on/off E7 F13
X365 Blue working light option D5/F4 D6
X368 Easy connect system option G12 D11
X372 S33 attachment locking option F4 E14
X373 Bauser & easy manager option dashboard permanent (+) supply I11 C9
80
X375 Easy Manager option D7 F13
X383 Fan drive control switch F7 F12
X385 Fan drive control electrovalve H5 H9
X386 Fan Drive reversal electrovalve H3 H10
X390A Distributor harness interface connector E3 G6
X390-B Distributor harness / main harness interface B1
X391 Proportional electrovalve I- tilt up B6
X392 Proportional electrovalve A- attachment direction - D5
X393 Proportional electrovalve T+ telescope extension D4
X394 Proportional electrovalve L- boom down D4
X395 Proportional electrovalve I+ tilt down B6
X396 Proportional electrovalve A+ attachment direction + D5
X397 Proportional electrovalve T- telescope retraction D4
X398 Proportional electrovalve L+ boom up D3
X400 Engine ECU B5 G12
X401 Engine speed sensor I3 H6
X404 Engine oil pressure I6 H7
X405 Engine coolant temperature probe H6
X406 Electrovalve actuator H8
647632EN
156 ELECTRICITY 80
80.3.2 CAB 3D HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14
X2 X1
B X138
X400 X205-1 X309

X205-2
X55 X56 X323
X134 X42 X31 X311
X57 X324
C
X304C X315
X304A X304B
X204-1
X100 X10 X314
X204-1 X115
X91 X313
X46 X292
X93 X365 X312
D
X94 X375
X63 X66 X58 X13
X308
X37
X38
X390A
E X305
X277
X322
X105 X12 X155 X286
X363
X106
X95 X383 X29
X43
X365 X372 X269
X32 X133-1
X67 X25
F
X133-2 X14
X276A
X274 X89
X21 X11
80
X92
X35
X16 C
G 03 X368
X3 39 A
X 26
X
X15 X77
X34 X22-2
X386
X22-1
X299
H
X295
X298 X385
X291 X303A
X303B
X404 X65 X373
I X09
X401 X30 X159
X60
X39-1 X167
X260
X261
X36
X18 X62
J
X199 X289
647632EN
80 ELECTRICITY 157
80.3.3 CAB 2D HARNESS

1 2 3 4 5 6 7 8 9 10 11 12 13 14
X261
2
4
3
X308
X60 X11 1
A 10 9 X311 X12
6
5
12 11 X309 X25
14 13 1
2
7 4 1
16 15 3 2 8 5 2
5 4
7 5 3 1
9 2 1 6 5 4
6
7
9 6 3
8
7 5 3 1
8 7
9
10 8 6 4 2 3 2 1
10 8 6 4 2
X14
10
9 7
4
8 1
5
2
6
9 3
X58
1
2
3
4
1
X260
X13 7
13 2 2 X09
4
19 26
3
EP01
5 1
X312 EP03 DIODE V2 DIODE V1
B
3 1
25
1 8
6
5
14
EP02
21
100 EP04 20
X303A X39
7
1
10
9
1
1
X303B 6
2
X62
X139 5
EP28 3
6 4
4
5
2
1 75 EP30 1
3
50
1
100
2
100
C 75
4
3
EP09 EP22 X373

EP10 EP80
6
5
X313 X22-2 40
1 X34B R2
EP21
7
1
R1 1
X34A 40 3 4 X30
X22-1 X167
10
9
2 5
EP20
1 6
2
1
1
X36 1
X304A X304B X02 2 3
X26A
1
3 1
1 4
X304C X01
5 9
1
6
2
3
6
5 9
8
X368
10 7
X305
D X155 8
3
1 5
7
4
1
2
3
2
10
3 6
4
3
3
X276A 8 4
3 4 4 1
X314 X01-X02 X65 2

X10 2 5
6
5
1
12 3 4 5
6
1 6
X365A
2 1
1
3 2
X35
2
7
3 6 3
4 12 1110 9 8
X138 X68
5
7
X29
4
X277A
2
2 X67
10
9
X292
3
X106A 1
4
1 10 9
2
2 3 3
4 1 4 7
EP24 8
1 5
2 12 6
11
X286
10
9
8
7 6 5 X372
X105A
1
2
4 3
50
50 1
X95
3 1 EP11 2
E EP25
4 2
25 EP17
1
X99A EP08 EP12

BUS-BAR: E BUS-BAR: D BUS-BAR: C BUS-BAR: B BUS-BAR: A
50 50
EP13
6
MTA
2 41 2 41 + B A A B B A A B
X205-2 X201 10
4
3
25
R
5 5 - +
5
3 3 C
9
K3 K6 8
4 2 41 2 41 K8 25 7
X315
5 5 86
6
6
3 3 5
5
87 87a 30
1
6
X322
3 K2 K5 7
2 4 1 2 4 1 85 5 4
8
X205-1 3
2 4
5 5 K7 9
1 3
2
X118A
1 3 3 10
F64
F63
F62
F61
K1 K4 F31 F21 F11 F1 2
1
7
11
1
1 MTA
1
MODULE 5 MODULE 4 MODULE 3 MODULE 2 MODULE 1 12
1
6 2
70
10
9
5 3
4
10
1 3 5 7 X274 6
8
7
9
2 4 6 8 1 3 5 7
8
7
6 4 5
EP72
16 5
X93
15 4
X400
2 4 6 8 2
X204-2 X204-1 X363
14 3
3
X115
1
13
F
2
12 1
X94
11
10
9 1
X159 2 10
23 1 8
4 6
1
6 4
2
3 8 2 9
8
7
4
1 10 7
27 5 3 5
X77A
6
5
5 3
7
40 40 40 40 40 40 40 40 40 40 40 75 9 1
1
32 10 X383 X375
X31 EP06 EP05 EP07 EP18 EP19 EP60 EP76 EP78
X91 X134 EP71 EP23 EP31 EP32
35 13
3 4
X42 X100
X37
1
+
2
1
X269
2
2 1
3
4
1 2 4 5
X46 - 40 18
80
6 1
1
2 1 1 2 1
1 4 3
2 3 2 44 22
1
7 1 1
2 1
8
9
6 10 2
X390A
5 11
4 1
X92 3
G
12
3
2
1
2
1
1 X38 5
4
1 1 1
1
1 1
25 21 32 28 25 21
A 6 X323
26 20 34 26 26 20
X43 3 2
X63
19 14 25 18 19 14 C
X66
3 13 8 17 10 13 8
4
7 1 9 1 7 1
2 5 3 7 5 3 5 3
1
B
X133-1
X324
X56 X57 X55
X404
EP15 X133-2
X32
2 3
1 4
X289 2
X16 1 X291 56 X298 75 1
34
12
1 2 3
X405 X21
H
3
5
2
10 9
87 6 5 4 X299 X385
1211
X15
1
1
X401 X04 X406 2

1
4
2 X295 1 X296
5
3
1 3
4
5
6 2
2
1 X386
2
1 7
8
12
10
11
9
1
1
1
X03
1 1
1 1
1 1
1
1
1
1 1
I
1
EP68 1 1
2 1
X199
60
2
J
1
2
X18
1
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158 ELECTRICITY 80
80.3.4 8 ELECTROVALVE HYDRAULIC BLOCK 2D HARNESS

1 2 3 4 5 6
1
2 X391
B 50 80
X390B 1 2
X395
EP82 EP81
2
1
2
2
1
X398
1
X396
X397
2
D
1
X392
2
2
1
1
X394 X393
F
80
J
647632EN
80 ELECTRICITY 159
80.4 ELECTRICAL CONTROL AND ADJUSTMENT
80.4.1 "BOOM ANGLE" ANGULAR SENSOR ADJUSTMENT

OPERATION
The «boom angle» sensor transmits information to the computer about the actual position of the boom
in relation to the frame. The potentiometer and all the links fitted between the boom and the frame have
the same operating angle as the boom in relation to the frame actually in operation. The boom angle
potentiometer is fitted with two tracks (two sensors whose range of adjustment is between 0,5 volts
and 4,5 volts reversed one in relation to the other). If the potentiometer is faulty, incorrectly connected
or badly adjusted, this leads to a fault on the overload indicator and hydraulic movement malfunction.
If there is a fault on the potentiometer, calibration is not possible.
The operating range must be centred in the acceptance range of the potentiometer (0,5 volts to 4,5 volts).
To consult the electrical characteristics of the angular sensor:
e Group 80 - Electrical characteristics and specifications – data sheets for electrical components.
(6X100 - TELESCOPE ANGLE POTENTIOMETER (B11), 5 130)
ON-TRUCK ADJUSTMENT PROCEDURE
Key:
A
A - Brake nut and bolt
B B - Potentiometer pin
C - Link
80
b
C
The adjustment must be made without altering the length

of the link (Item C).
1 - Switch on the PAD and connect the VCI.

2 - Select «Diagnostic» and then confirm.
3 - Select your machine, and then confirm.
Maxi
4 - Select the type of machine range and then confirm.
5 - Select the type of machine and then confirm.
6 - Switch on the ignition, start the machine and then confirm.
7 - If the truck is fitted with stabilisers, they must be placed on
the ground in order to increase the lifting angle.
8 - Place the boom in the top position.
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9 - Select «Diagnostic global (tous les calculateurs)» and then confirm.

10 - Select «Calulateur central SPU» and then confirm.
11 - Select «Lecture paramètre» and then confirm. If there are any faults, refer to them and delete them.
12 - Select «Hydraulique» and then confirm.
13 - Select «État des capteurs» and then confirm.
14 - Select «Capteur angle de flèche» and then confirm.
The PAD displays the voltages of each boom angle

potentiometer sensor.
15 - Loosen the brake nut and bolt (Item A) on the lever.
16 - Using a screwdriver, turn the potentiometer pin (Item B) to obtain the adjustment values defined
below.
Note: The adjustment is done by slightly turning the pin in the lever housing.
Adjustment values to be obtained:
Mini Maxi
Voltage 0.7 V 4.3 V
80
17 - Then tighten the brake nut and bolt (Item A).
18 - Place the boom in the down position (stabilizers retracted).

Mini
19 - Check that the values are similar to those found in the top boom position and are within the
recommended adjustment range.
20 - Calibrate the boom angle sensor.
e Group 80 - Electrical control and adjustment - Strain gauge and angle sensor calibration.
(6STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (DEALER PROCEDURE), 5 163)
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80.4.2 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.
Computer earth output fault.
Aggravating hydraulic movement cut-off disable fault.
80
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)
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TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE
– These tests are essential for checking the correct operation and adjustment of the different components of the device.
b
– Place the lift truck on fl at, level ground with the wheels straight.
Use the test button only when instructed, following the guidance for a short press (less than 1 second)
or a long press (5 seconds).
In case of doubt during the test procedure, a clean exit can be made by a short press on the “BUCKET” MODE
or “SUSPENDED LOAD” buttons .
Long press on the test button
TEST OK
Short - One audible beep and progresses to
press stage 2.
the test
STAGE 1 1 button. TEST NOT OK
- Two audible beeps and lighting of
- Place the lift truck without any
attachment, with the jib fully the fault warning light .
- An audible beep. retracted and raised. - Exit test mode.
- First green LED flashing. - On stabilizers if fitted. - Go to stage 4.
- Test button lit.
TEST OK
Short - One audible beep and progresses to
press stage 3.
2 the test
STAGE 2 button. TEST NOT OK
1 -- Lower the jib with the engine - Two audible beeps and lighting of
running at full revs and the
the fault warning light .
- First green LED continuously lit. hydraulic control at the maximum
- Exit test mode.
- Second green LED flashing. setting. Calibrated speed until
- Go to stage 4.
- Test button lit. movement is cut-off.
TEST OK
- Conformity of aggravating
Short movement cut-off.
press - Exit test mode. All the LEDs will light
3
the test for 2 seconds and an audible beep
STAGE 3 2 - Lower the jib until the movement is will be sounded.
button.
80
1 cut-off.
- 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.
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STRAIN GAUGE AND ANGLE SENSOR CALIBRATION (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)
MEASURING THE TIME OF DESCENT FROM MAXIMUM TO MINIMUM ANGLE:
STAGE
- Lower the boom to its stop with the engine running at maximum revolutions (boom retracted).
80
3
- Ensure that the boom is below 4° (boom retracted).

STAGE
4
RECORDING MINIMUM GAUGE STRAIN:
t
- 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.
t After this calibration, check that movement cut-offs work correctly.

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STRAIN GAUGE RECALIBRATION (CLIENT 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
80
2 - Two audible
STAGE 3 beeps will
1 / be sounded
- First green led continuously Keep the load as close to the ground as possible throughout this operation. and all the
LEDs will
lit.
- Hold down the disable the «aggravating» hydraulic movement cut-off flash twice to
- Second green led flashing.
button (indicator lamp lit), and extend the jib until the rear wheels are off the confirm the
- Flashing test button.
ground. end of the
NOTE: This stage consists of unloading the rear axle. It can be done using a jack procedure.
but without bearing on the rear axle..
STAGE 4
FINISH /
- After completing the resetting procedure, the telehandler is in an overloaded condition. Retract the
boom to restore the situation.
- All LEDs lit.
- A continuous audible beep
b When the reset is completed, check the operation of the longitudinal stability limiter and warning device (see:
TESTING THE LONGITUDINAL STABILITY LIMITER AND WARNING DEVICE (LLMC).
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"AGGRAVATING" HYDRAULIC MOVEMENTS CUT-OFF
Lift truck behaviour Work zone

Movement not restricted. A - stability
Gauge signal and speed of boom angle sensor monitored.
Rapid movements that may cause the lift truck to overturn are stopped pre-emptively.
B - Dynamic movement cut-off
Stopping a rapid movement suddenly could cause the lift truck to overturn.
Slow movements may lead to the lift truck's stability limit being reached.
Cut-off of all aggravating movements: boom extension and lowering. C - stability limit
If the lift truck is not behaving normally:
=> Check the movement cut-off by referring to the load charts and inspecting the sensors.
A B C
LED ILLUMINATION ACCORDING TO CHANGES IN GAUGE SIGNAL
80
Increasing value
of the gauge signal:
100% (L8)
92% (L7)
84% (L6)
76% (L5)
68% (L4)
60% (L3)
52% (L2)
0% (L1)
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80.4.3 DASHBOARD CALIBRATION MENU

CALIBRATION MODE: ACTIVATION
Switch on lift truck ignition.
Simultaneously press the buttons and for 10 seconds.
CALIBRATION SELECTION
Press on the key to select the calibration menu 1,2…, End.
Press on the key to validate the calibration choice.
LIFT TRUCK SERIAL NUMBER DISPLAY

Select the menu . Press the key .
When ordering spare parts or requesting technical information, always specify the lift truck serial number:
Example of 7-figure number appearing o the digital screen scrolling from right to left:
Press the key , return to calibration selection menu .
RESETTING THE PARTIAL HOUR METER

80
The digital screen indicates whether or not the operator can reset the partial hour meter:
The operator cannot reset the partial hour meter.
The operator can reset the partial hour meter.
NOTE: By default the parameter is .

Press the key to change the value or .
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80 ELECTRICITY 167
INCHING BRAKE PEDAL CALIBRATION
Press the menu . Press the Inactive Transmission key .
: "Brake pedal end of travel" position calibration.
Start the truck, move forward approx. 2 meters braking until the pedal is in the bottom position.
Leave the engine running.
Press down the brake pedal for 2 seconds at end of travel position.
If the value recorded at connector X139 is between 1150 and 1500 mV and the sand timer is displayed
.
Go to stage .
If the value recorded does not correspond to the authorised range tolerances, the sand timer is not
displayed and the stage remains active.
: "Brake pedal rest" position calibration.
Check that the brake pedal is in the rest position and the engine is running.
Hold the idle position for 2 seconds.
If the value recorded at connector X139 is between 2250 and 3800 mV and the sand timer is displayed
.
If the value recorded does not correspond to the authorised range tolerances, the sand timer is not
displayed and the stage remains active.
TELESCOPING SPEED CALIBRATION
Select the menu . Press the key (the telescope line remains active at 100 % in both directions
80
of movement, telescope retraction and extension).
Telescope extension speed limitation:
80 - 1 Push the telescope extension button (A) towards the front to

define the maximum telescope extension speed (resolution 5 %),
e.g. .
If the operator pushes the button (A) backwards the screen will
show .
A
NOTE: Below 10%, the adjustments are not recorded, the old values
remain memorised.
Press on the key to proceed to the next stage.

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168 ELECTRICITY 80
Telescope retraction speed limitation:
80 - 2 Push the telescope retraction button (A) towards the rear to define
the maximum telescope retraction speed (resolution 5 %), e.g.
.
If the operator pushes button (A) towards the front, the screen
A
will display .
remain memorised.
ATTACHMENT FLOW RATE CALIBRATION
WARNING
Take into account the attachment characteristics.
Select the menu . Press the button (the attachment line remains active at 100 % in both
directions of movement).
Attachment "+" direction flow rate limitation.
80 - 3 Push the attachment button (B) towards the rear to define the
maximum attachment flow rate in the "+" direction (resolution 5
%), e.g. .
If the operator pushes button (B) button towards the rear, the
screen will display .
80
B
remain memorised.
- Press on the key to proceed to the next stage.
Attachment "-" direction flow rate limitation.

Push the B attachment button backwards to define the maximum attachment flow in the "-" direction
(resolution 5 %), example .
If the operator pushes button (B) button towards the front, the screen will display .
NOTE: Below 10%, the adjustments are not recorded, the old values remain memorised.

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80 ELECTRICITY 169
FORCED OPERATION
FORCED OPERATION WITH OR WITHOUT THE PRESENCE OF THE OPERATOR ON THE DRIVER SEAT
If the option is not accessible or the adjustment is not available, the press on the validated button is
rejected by a confirmation beep.
Forbids the use of forced operation without the presence of the operator on the driver
seat.
Authorises the use of the forced operation without the presence of the operator on the
driver seat.

MAINTENANCE HOUR METER RESET
The digital screen indicates whether or not the operator can reset the maintenance hour meter:
The operator cannot reset the maintenance hour meter.
The operator can reset the maintenance hour meter.
80
SELECTION OF SPEED UNIT KM/H OR MPH
Select the CAL 8 menu . Press the key .

Press the key to change the value (km/h) or (mph).
END OF CALIBRATION MENU

NOTE: If the lift truck ignition is switched off during one of the calibration phases, previous or default
calibration values will remain active.
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80.5 ELECTRICITY REMOVAL -REFIT
80.5.1 STRAIN GAUGE REFIT

LOCATION
A
80
KEY:
A - Strain gage
b PREPARATION AND SAFETY INSTRUCTIONS
⇒ The wheels must be aligned and the rear axle free from any load (tipped truck).
⇒ The contact surface must be perfectly clean.
⇒ Do not apply any Loctite to the screws.
⇒ Replace the gauge if faulty.
⇒ Store the gauge and axle at the same temperature.
⇒ Wear a mask and gloves when applying adhesive.
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AXLE PREPARATION
The area in contact with the strain gauge (Item 1) has protective
painted film coating. Scrape this coating with a filling knife,
aiming to remove as much film as possible. Any remaining
1
adhesive traces can be removed with Soft Surface Cleaner
(aerosol degreaser).
Sand the area to be glued (Item 2) to roughen the surface and

achieve a good bond.
80
CHARACTERISTICS OF PRODUCTS USED
References
ACROBOND PU 284/30 (two-part polyurethane structural adhesive) ....................................273504
Mixer ...............................................................................................................................................................781596
Hand gun.......................................................................................................................................................781597
b
Handling time before start of polymerization and hardening phase is approx. 5 min.
If the product stays inside the mixer for more than 5 minutes, replace the mixer.
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172 ELECTRICITY 80
CHARACTERISTICS OF FASTENING SCREWS
The screws used are supplied with the strain gage.
e Refer to the spare parts catalog.

ASSEMBLY PRECAUTIONS AND TIGHTENING TORQUE
1 The two components (strain gauge and axle) must be

stored at the same temperature for at least four hours
before commencing assembly.
The strain gauge must be assembled with an axle that is

free from any load.
For this:
1 - Lift the rear axle off the ground with a suitable hydraulic
jack (Item 1).
1
2 - Secure the machine by placing a two suitable stands (Item

2), one on either side of the frame.
2
80
3 3 - Remove the jack to fully unload the rear axle.

647632EN
80 ELECTRICITY 173
STRAIN GAUGE
STEP 1:
– Note the month/year of the gauge and enter into the lift
truck date sheet.
STEP 2:
– Apply glue to the grooves of the strain gauge (a total of

8 daubs of glue).
STEP 3:
80
– Position the strain gauge and attach with the screws. The
two M10 screws should be tightened gradually, as follows:
⇒ Tighten screw No. 1 to a torque of 34 N.m

⇒ Tighten screw No. 2 to a torque of 34 N.m
⇒ Tighten screw No. 1 to the rated torque C = 67 N.m ± 5%
⇒ Tighten screw No. 2 to the rated torque C = 67 N.m ± 5%
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174 ELECTRICITY 80
⇒ Use a 1 kg hammer from a height of about 100 mm

to give 2 moderate blows to the 2 screws.
STEP 4:
1 2
– Place a red mark on the heads of the screws, the gauge
and the axle.
– Fit the protective casing.

80
– Attach the protective casing with the two screws and

the washers.
– After having checked the red marks, apply a green mark

to the heads of the screws.
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80.5.2 REMOVAL - REFIT OF JSM ON BMEP
80 - 4
PRECAUTION
2
When removing and refitting the JSM, it is important to retrain the shaft of the
BMEP, as the tightening torque of the shaft is less than that of the JSM.
22 Shaft (A) of BMEP (1): 10 Nm.
B
During tightening of the JSM handle (2), in order to avoid transferring
a torque of more than 10 Nm to the shaft, hold the shaft (A) with a
A wrench and secure the nut (B) with thread lock no. 243 .
12 N.m +
1
A
10 N.m
80
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80.5.3 ELECTRICAL TROUBLESHOOTING
80.5.4 DASHBOARD ERROR CODES
The appearance of the maintenance key on the hour meter screen together with the
sounding of an audible beep, indicate that a fault has been detected by one of the lift truck's Electronic
Control Units (ECU).
–– Press the button to display the information on the upper screen, as well as the error
code .
–– If there are several error codes, press the button to scroll through all the error codes.
–– Press the button again to return to the hour meter screen, the maintenance key will remain
displayed as long the as the required repairs have not been carried out.
NOTE: A faulty fuse can generate several error codes. When "error codes" and "maintenance interval"
are displayed together, the maintenance reminder time will appear at the end of the list.
PAD ERROR CODES

Fault codes are displayed on the PAD in the following format:
XXXXXX.YY
XXXXXX: Indication of the faulty component (SPN error code)
YY: Type of fault (FMI error code), only for Hydraulic System ECU (A3), equal to 0 for A1 and A2.
FMI error code - Hydraulic system ECU (A3)

FMI code Description
0 Upper sensor signal value at normal value
80
1 Lower sensor signal value at normal value

2 Incoherent signal value
3 Signal voltage too high: + battery short circuit
4 Signal voltage too low: ground short circuit
5 Circuit impedance too high: open circuit
6 Circuit impudence too low: Short circuit or short circuit
7 Faulty actuator (mechanical problem)
8 Signal frequency out of normal value range
9 Information not available on the CAN bus
10 Abnormal signal value variation for correct operation
11 Nature of problem not known
12 Faulty sensor or actuator
13 Out of range signal value defined by calibration: Calibration
14 Not used
19 Transmitted signal value on CAN bus invalid
647632EN
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DTC DASHBOARD MODULE ECU (BAUSER) - (X13 ECU-A1)

Hexadecimal Decimal
Problem description Machine response Repair actions
SPN SPN
7F0D0 520400 Network link fault RPM value - > "- - -" and LED 16 lit Check CAN network wiring
7F0D1 520401 Fuel gauge fault Incorrect fuel gauge display Check gauge wiring
7F0D2 520402 Engine temperature sensor fault Incorrect temperature display Check sensor wiring
Incorrect Hour meter value and LED 16

7F0D4 520404 Man-Frame interface fault Replace dashboard module
lit
Incorrect fuel gauge and temperature
display LED 16 lit
Incorrect Hour meter value and LED 16
lit
7F0D7 520407 Man-Frame interface fault LED 16 lit Replace dashboard module
7F0DA 520410 Man-Frame interface fault LED 16 lit Replace dashboard

7F0DB 520411 Man-Frame interface fault LED 16 lit Replace dashboard
Hydrostatic transmission controller
7F0DC 520412 RPM value - > "- - -" and LED 16 lit Check CAN network wiring
network connection fault
Electronic controller network
7F0DD 520413 LED 16 lit Check CAN network wiring
connection fault
Motor controller network
7F0DE 520414 LED 16 lit Check CAN network wiring
connection fault
DTC MAIN ECU (X55 - X56 - X57 - SPU 40-26-A3)

Hexadecimal Decimal
Designation
SPN FMI SPN FMI
A66 1 2662 1 JSM roller 1 fault. Inconsistency between analogue channel and roller 1 logic.
A66 0 2662 0 JSM roller 1 fault. Roller 1 out-of-range, analogue channel voltage greater than 95% VBatt.
A66 2 2662 2 JSM roller 1 fault. Roller 1 out-of-range, analogue channel voltage less than 5% VBatt.
A67 1 2663 1 JSM roller 2 fault. Inconsistency between analogue channel and roller 2 logic.
A67 0 2663 0 JSM roller 2 fault. Roller 2 out-of-range, analogue channel voltage greater than 95% VBatt.
A67 2 2663 2 JSM roller 2 fault. Roller 2 out-of-range, analogue channel voltage less than 5% VBatt.
7F06C 2 520300 2 Seat sensor fault. 2 contacts are inconsistent.
Raise/Lower electro-proportional manipulator block fault. Channel 1 out-of-range, analogue channel voltage
7F06D 2 520301 2
less than 0.25V or greater than 4.75V.
80
Raise/Lower electro-proportional manipulator block fault. Channel 2 out-of-range, analogue channel voltage
7F06D 10 520301 16
less than 0.25V or greater than 4.75V.
Raise/Lower electro-proportional manipulator block fault. Inconsistency between analogue channels
7F06D 13 520301 19
(difference > 250 mV).
Tilting electro-proportional manipulator block fault. Channel 1 out-of-range, analogue channel voltage less
7F06E 2 520302 2
than 0.25V or greater than 4.75V.
Tilting electro-proportional manipulator block fault. Channel 2 out-of-range, analogue channel voltage less
7F06E 10 520302 16
than 0.25V or greater than 4.75V.
Tilting electro-proportional manipulator block fault. Inconsistency between analogue channels (Difference >
7F06E 13 520302 19
250 mV).
Electro-proportional manipulator block power supply fault. Loss of 4 analogue channels of the electro-
7F06F 0 520303 0
proportional manipulator block.
Electro-proportional manipulator block earth fault. The 4 analogue channels of the electro-proportional
7F070 1 520304 1
manipulator block are 5V.
7F073 5 520307 5 Telescope extension valve fault (Pin B17). Short to earth detected.
7F073 4 520307 4 Telescope extension valve fault (Pin B17). Short to battery+ detected.
7F073 A 520307 10 Telescope extension control fault (Pin B17). SPU power supply problem.
7F076 5 520310 5 Telescope retraction valve fault (Pin B05). Short to ground detected.
7F076 4 520310 4 Telescope retraction valve fault (Pin B05). Short to battery+ detected.
7F076 3 520310 3 Telescope retraction valve fault (Pin B05). Open circuit detected.
7F076 A 520310 10 Telescope retraction control fault (Pin B05). SPU power supply problem.
7F07B 4 520315 4 Front attachment direction A valve fault (Pin B29). Short to ground detected.
7F07B 4 520315 4 Front attachment direction A valve fault (Pin B29). Short to battery+ detected.
7F07B 3 520315 3 Front attachment direction A valve fault (Pin B29). Open circuit detected.
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Hexadecimal Decimal
Designation
SPN FMI SPN FMI
7F07B A 520315 A Front attachment direction A control fault (Pin B29). SPU power supply problem (VBatE: Pin C08 and C09).
7F07E 5 520318 5 Front attachment direction B valve fault (Pin A14). Short to ground detected.
7F07E 4 520318 4 Front attachment direction B valve fault (Pin A14). Short to battery+ detected.
7F07E 3 520318 3 Front attachment direction B valve fault (Pin A14). Open circuit detected.
7F07E A 520318 10 Front attachment direction B control fault (Pin B29). SPU power supply problem (VBatE: Pin C08 and C09).
7F080 5 520320 5 Boom lifting valve fault (Pin C05). Short to ground detected.
7F080 4 520320 4 Boom lifting valve fault (Pin C05). Short to battery+ detected.
7F080 3 520320 3 Boom lifting valve fault (Pin C05). Open circuit detected.
7F080 A 520320 10 Boom lifting valve fault (Pin C05). SPU power supply problem (VBatD: Pin B03 and B04).
7F081 5 520321 5 Boom lowering valve fault (Pin C04). Short to ground detected.
7F081 4 520321 4 Boom lowering valve fault (Pin C04). Short to battery+ detected.
7F081 3 520321 3 Boom lowering valve fault (Pin C04). Open circuit detected.
7F081 A 520321 10 Boom lowering valve fault (Pin C04). SPU power supply problem (VBatD: Pin B03 and B04).
7F082 5 520322 5 Crowd valve fault (Pin C03). Short to ground detected.
7F082 4 520322 4 Tilt-up valve fault (Pin C03). Short to battery+ detected.
7F082 3 520322 3 Crowd valve fault (Pin C03). Open circuit detected.
7F082 A 520322 10 Tilt-up control fault (Pin C03). SPU power supply problem (VBatE: Pin C08 and C09).
7F083 5 520323 5 Dump valve fault (Pin C02). Short to ground detected.
7F083 4 520323 4 Tilt-down valve fault (Pin C02). Short to battery+ detected.
7F083 3 520323 3 Dump valve fault (Pin C02). Open circuit detected.
7F083 A 520323 10 Tilt-down control fault (Pin C02). SPU power supply problem (VBatE: Pin C08 and C09).
7F08A 0 520330 0 SPU ECU fault. Internal voltage out-of-range.
7F08B 0 520331 0 SPU ECU fault. Loss of ground.
7F08C 0 520332 0 SPU ECU fault. Overcurrent detected.
7F08D 0 520333 0 SPU ECU fault. ADC converter voltage out of range or ADC blocked.
7F08E 0 520334 0 SPU ECU fault. SPI fault.
7F08F 0 520335 0 SPU ECU overcurrent fault. Total current > 25.5 A for 5 seconds.
7F091 C 520337 12 ECU internal fault. Program error.
7F092 0 520338 0 SPU ECU high temperature fault. Temperature higher than 110°C for 30 seconds.
7F095 5 520341 5 Attachment selector fault. Open circuit or short circuit detected.
7F09E 5 520350 5 PWM FanDrive valve fault. Ground short circuit detected.
7F09E 4 520350 4 PWM FanDrive valve fault. Short to battery+ detected.
7F09E 3 520350 3 PWM FanDrive valve fault. Open circuit detected.
7F09E A 520350 10 PWM FanDrive valve control fault. SPU power supply problem.
7F09F 5 520351 5 On/Off FanDrive valve fault. Ground short circuit detected.
7F09F 4 520351 4 On/Off FanDrive valve fault. Short to battery+ detected.
7F09F 3 520351 3 On/Off FanDrive valve fault. Open circuit detected.
7F09F A 520351 10 FanDrive On/Off valve control fault. SPU power supply problem.
80
7F0A0 2 520352 2 Forced operation pushbutton fault. Button shorting to battery+ or button pressed when switching to APC.
7F0A9 4 520361 4 5V output fault. Short to earth detected
7F0A9 3 520361 3 5V output fault. Short to battery+ detected.
7F0A9 A 520361 10 5V output fault. Power supply problem.
7F0AA 4 520362 4 10V output fault. Ground short circuit detected.
7F0AA 3 520362 3 520362. 10V output fault. Short to battery+ detected.
7F0AA A 520362 10 10V output fault. Power supply problem.
7F0AB 4 520363 4 Forced operation LED fault. Short to earth detected.
7F0AB 3 520363 3 Forced operation LED fault. Short to battery+ detected.
7F0AB A 520363 10 Forced operation LED fault. Power supply problem.
7F0AC 2 520364 2 Pushbutton Bp1 fault. Button shorting to battery+ or button pressed when switching to APC.
7F0AD 2 520365 2 Pushbutton Ecs fault. Button shorting to battery+ or button pressed when switching to APC.
7F0AE 5 520366 5 Telescope head electrovalve fault. Open circuit detected.
7F0AE 4 520366 4 Telescope head electrovalve fault. Short to earth detected.
7F0AE 3 520366 3 Telescope head electrovalve fault. Short to battery+ detected.
7F0AF 5 520367 5 Telescope head electrovalve 2 fault. Open circuit detected.
7F0AF 4 520367 4 Telescope head electrovalve 2 fault. Short to earth detected.
7F0AF 3 520367 3 Telescope head electrovalve 2 fault. Short to battery+ detected.
7F0B2 7 520370 7 Fault during EN15000 test. Telescope not retracted.
7F0B3 1 520371 1 ECU output fault. Power supply fault.
7F0B8 C 520376 12 Llim fault. Internal Llim error.
7F0B8 9 520376 9 Llmi fault. No CAN frame.
7F0B8 2 520376 2 Llmi fault. Button pressed at start-up.
7F0BE 2 520382 2 Override button fault. Button shorting to battery+ or button pressed when switching to APC.
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80 ELECTRICITY 179
Hexadecimal Decimal
Designation
SPN FMI SPN FMI
7F0BF 5 520383 5 Safety valve ground fault. Open circuit detected.
7F0BF 4 520383 4 Safety valve ground fault. Ground short circuit detected.
7F0BF 3 520383 3 Safety valve earth fault. Short to battery+ detected.
7F0C0 2 520384 2 Telescope retracted sensor fault (Pin B14 and C14). The 2 contacts are inconsistent.
7F0C2 9 520386 9 Boom angle sensor fault. Loss of signals.
7F0C2 10 520386 16 Boom angle sensor fault. Signals outside high range.
7F0C2. 12 520386 18 Boom angle sensor fault. Signals outside low range.
Boom angle sensor fault (Pin A12, C11). Inconsistency between the 2 channels, difference greater than 5°
7F0C2 2 520386 2
(approx. 0.3V).
7F0C3 9 520387 9 CAN strain gauge fault. Loss of frame 0x0CFF0EEB end frame 0x0CFF0FEC. Check the electrical connection
7F0C3 13 520387 19 CAN strain gauge fault. Internal error.

7F0C3 0 520387 0 CAN strain gauge fault. Out of range, channel 1.
7F0C3 1 520387 1 CAN strain gauge fault. Out of range, channel 2.
7F0C3 2 520387 2 CAN strain gauge fault. Inconsistency between the 2 channels, difference greater than 20%.
7F0C3 7 520387 7 CAN strain gauge fault. Incorrect signal variation.
7F0C4 9 520388 9 CAN network fault. Loss of communication.
7F0C5 10 523389 16 Manual accelerator fault. Signal outside high range.
7F0C5 12 523389 18 Manual accelerator fault. Signal outside low range.
7F0C6 C 520390 12 Lowering time calibration fault. Lowering time outside range.
7F0C8 D 520392 13 Fault during EN15000 test. Angle calibration problem.
7F0C9 D 520393 13 Fault during EN15000 test. Gauge calibration problem.
7F0CA 3 520394 3 Safety valve fault. Ground short circuit detected.
7F0CA 4 520394 4 Safety valve fault. Short to battery+ detected.
7F0CA 5 520394 5 Safety valve fault. Open circuit detected.
7F0CA A 520394 10 Safety valve fault. SPU power supply fault.
7F0CB 7 520395 7 Fault during EN15000 test. Safety valve problem.
7F0CD 7 520397 7 Fault during EN15000 test. Lowering control problem.
7F0CE 2 520398 2 JSM + button fault. Button shorting to battery+ or button pressed when switching to APC.
7F0CF 2 520399 2 JSM - button fault. Button shorting to battery+ or button pressed when switching to APC.
7F05B 2 520283 2 Fault on speed limiter potentiometer connected to Danfoss ECU
80
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180 ELECTRICITY 80
DTC TRANSMISSION ECU (X291 / X295 / X298 / X299 - ECU A2)
Hexadecimal Decimal
SPN SPN Problem description Machine response Repair actions
Hydraulic transmission electronic
7F009 520201 ECU internal fault Change battery, check ECU supply voltage
control unit voltage fault
Hydraulic transmission electronic Change ECU. See Manitou specification for

7F016 520214 ECU internal fault
control unit fault inching pedal configuration and calibration
As the ‘PCOR’ also manages

low or high speed (servo No requirement. The replacement of
Hydrostatic engine regulator control
7F017 520215 piston), it is dangerous for the the component does not require special
fault
operator to leave the ECU in calibration
normal mode.
Hydrostatic engine plate electrovalve Transmission in degraded
7F018 520216 Check wiring and electrovalve.
control fault mode (reduced speed)
The stop lights are no longer
lit by the ECU. The braking Change ECU. See Manitou specification for
7F019 520217 Stop light control error
system pressure switch lights inching pedal configuration and calibration
the stop lights
Can be driven, limited
7F01A 520218 Hydraulic engine speed sensor fault Change sensor
performance
As the ‘BPD’ also manages
the low or high speed control
No requirement. The replacement of
Hydrostatic engine operating pressure (servo piston), it is
7F020 520224 the component does not require special
electrovalve control fault dangerous for the operator
calibration
to leave the ECU in normal
mode.




7F051 520273 Forward/reverse selector error Cannot be driven the component does not require special
calibration
Can be driven, limited Change inching sensor. Inching pedal
7F052 520274 Inching sensor error
performance calibration by MMI
Hydrostatic pump reverse operation
7F053 520275 Reverse gear unavailable the component does not require special
control fault
calibration
80

Hydrostatic pump forward operation
7F054 520276 Forward gear unavailable the component does not require special
control fault
calibration
Automotive driving mode no
7F055 520277 Hydrostatic pump speed sensor fault the component does not require special
longer possible
calibration
7F059 520281 Temperature outside operating range Machine shutdown
Transmission in degraded
7F05A 520282 Pedal high switch Check switch and harness
mode (reduced speed)
647632EN
80 ELECTRICITY 181
DTC ENGINE ECU (X400 - EVG)
Hexadecimal Decimal
COMPONENT PROBLEMS
SPN FMI SPN FMI
00064 01 100 1 Oil pressure switch Oil pressure error
0006E 00 110 0 Coolant temperature sensor Engine overheating, temperature higher than ≥ 120°C (248°F)
0006E 03 110 3 Coolant temperature sensor Voltage higher than normal, or short circuited to power supply source
0006E 04 110 4 Coolant temperature sensor Voltage lower than normal, or short circuited to power supply source
0009E 03 158 3 Battery Voltage higher than 18 V, or short circuited to power supply source
000BE 00 190 0 Engine speed Engine speed higher than normal
00DB5 04 3509 4 Power supply connector (44 pin) Power supply voltage of connector pin 22 lower than normal
7FDFB 02 523771 2 Starter electrovalve Circuit open or short circuited to power supply source
7FDFC 02 523772 2 Engine speed sensor Circuit open or short circuited to power supply source
80
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182 ELECTRICITY 80
80.6 SPECIFIC ELECTRIC TOOLING
80.6.1 DIAGNOSTIC TOOLS

VERSION 1
DIAGNOSTICS CASE
80
1 - PAD (Plug And Diag) (hardened PC set + case). . . . . . . . . . . . . . . . . . . . . . . . More supplied

2 - Styli (set of 3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745368
3 - VCI (Vehicle Communication Interface / PAD) . . . . . . . . . . . . . . . . . . . . . . . . More supplied
4 - OBD Diag. cable Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745245
5 - VCI portable cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745244
6 - Manitou RC2/RC4 Diag. Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745246
7 - Battery LI-ION 7.4V / 9.6AH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745367
8 - CE standard mains lead L: 3 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745247
9 - Diag Supply Unit 3G 60W . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745251
10 - Cigarette lighter power supply cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745240
11 - Black battery clip cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745242
12 - Red battery clip cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745241
13 - Power supply cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745243
14 - Reception station (battery charging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 745236
15 - Workshop area (trolley + station set) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . More supplied
647632EN
80 ELECTRICITY 183
CONNECTIONS TO THE LIFT TRUCK
CASE No. 1: MACHINE DIAGNOSTIC
PAD
VCI
Note: Cable P/N 745245 enables diagnostics to be carried out on the entire machine except for the engine.
CASE No. 2: ENGINE DIAGNOSTIC
PAD
EDL
USB
Note: Case P/N 894942 can be used to diagnose the engine, e ENGINE ADAPTATION BOX.
80
647632EN
184 ELECTRICITY 80
VERSION 2
DIAGNOSTICS CASE
80
Diagnostic case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947349

Diagnostic case (Russia specific) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .947350
Consisting of:
1 - Tablet (with accessories and cables). . . . . . . . . . . . . . . . 895845 / 947351 (Russia specific)
2 - Styli . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947208
3 - Stylus strap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947355
4 - VCI (Vehicle Communication Interface / PAD) (with USB cable and OBD) . . . . . 895986
5 - OBD Diag. cable Manitou . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947201
6 - USB cable/Ethernet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947202
7 - Battery (6 cells: 8h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947206
8 - Mains power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947353
9 - Transport case (not shown) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947345
Sold separately:
10 - Docking station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947354
11 - Legacy Diag. cable Manitou. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947204
12 - Battery (9 cells: 17h) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 947207
647632EN
80 ELECTRICITY 185
CONNECTIONS TO THE LIFT TRUCK
CASE No. 1: MACHINE DIAGNOSTIC
PAD
VCI
Note: Cable P/N 947201 enables diagnostics to be carried out on the entire machine.
CASE No. 2: ENGINE DIAGNOSTIC

PAD
EDL
USB
Note: Case P/N 894942 can be used to diagnose the engine, e ENGINE ADAPTATION BOX.
ENGINE ADAPTATION KIT
80
2
1
3
Adaptation kit for engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894942
Consisting of:
1 - EDL communication box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894937
2 - OBD electrical cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894940
3 - USB electrical cable. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 894938
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186 ELECTRICITY 80
80.6.2 BREAKOUT BOXES
Breakout box kit ...................................................................................................... 785503
Consisting of:
1 - 1 breakout box (DT connectors) ..........................................................................................785504

2 - 1 breakout box (DTM connectors) ......................................................................................785505
80
Solenoid adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662196

DRIVER'S CAB
TABLE OF CONTENTS
85.1 DRIVER’S CAB CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
85.1.1 TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
CAB SILENT BLOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
85.2 DRIVER'S CAB REMOVAL - REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
85.2.1 REMOVE THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
85.2.2 REFITTING THE CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
85
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188 DRIVER'S CAB 85 (22/08/2017)
DRIVER'S CAB
85.1 DRIVER’S CAB CONTROL AND ADJUSTMENT
85.1.1 TIGHTENING TORQUES

CAB SILENT BLOCK
140 ± 14 N.m
140 ± 14 N.m
80 N.m maxi
85

PRECAUTION
When refitting, observe the special tightening torques.

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85 (22/08/2017) DRIVER'S CAB 189
85.2 DRIVER'S CAB REMOVAL - REFIT
85.2.1 REMOVE THE CAB
Carry out the operation (610.4.1 SIDE CASING AND ENGINE COVER REMOVAL, 5 31).
Carry out the operation (670.4.2 MAIN HYDRAULIC TANK REMOVAL, 5 103)
85 - 1 Move the seat forward slightly and disconnect the seat connector
(X274).
Slide the seat all the way forward.
Remove the seat.
X274
85 - 2
Loosen the two screws and remove the rear cab cover (1).
6
1
7 Remove and disconnect the car radio (2).
5
Remove the 2 screws (3) from the rear bracket (4).
Remove the 4 screws (5) from the right speaker (6).
3
4 3
2
85 - 3
Remove the right speaker (1) and disconnect the two terminals (2).
4
Disconnect the connector (X46) from the 12V socket (3).
1
X46 Remove the screw (4).
85
3
2 Lift up the rear bracket slightly (4, 085 - 2).
Disconnect the two terminals on the left speaker (7, 085 - 2).
Remove the rear bracket (4, 085 - 2).
647632EN
190 DRIVER'S CAB 85 (22/08/2017)
X205-1
85 - 4 X205-2
X134 X42 X31
X204-1
X100
X204-1
X91 X46
X93
X94
X63 X66
X37
X38
X390A
X277
X105
X106
X95
X43
X365 X269
X32 X133-1
X133-2
X274
X21
X92
X35
X16 C
03 X368
X3 39
X
X15 X77
X34 X22-2
X386
X22-1
X299
X295
X298 X385
X291 X303A
X303B
X404 X65 X373
X09
X401 X30 X159
X60
X39-1 X167
X260
X261
X36
X18 X62
X199 X289
Disconnect the cab harness connectors outside the cab (engine compartment connectors, signals,
axles, etc.) (X... , 085 - 4)
85 - 5
1
Remove the battery tray cover (1).
85 - 6
1 2 1
Disconnect the battery (2) terminals (1).
Unscrew the battery fastener (3) and remove the battery (2).
3
85
85 - 7
1
2 Remove the 4 screws (1).
1
Remove the battery support bracket (2).
85 - 8
1
Identify and disconnect the front steering hoses (1) and insert plugs.
1
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85 (22/08/2017) DRIVER'S CAB 191
85 - 9
Identify and disconnect the LH (1) and RH (2) rear steering hoses
and insert plugs.
85 - 10
Disconnect the brake hose (1).
85 - 11
Disconnect the throttle cable (1).
85
85 - 12
Disconnect the hose (1) and the heating hose (2).

1
2
647632EN
192 DRIVER'S CAB 85 (22/08/2017)
85 - 13
Identify and disconnect the steering block supply hose (P) and
insert plugs.
P
Identify and disconnect the steering block hose (LS) and insert plugs.
LS
85 - 14 Air-conditioning option
Remove the condenser supply hose clamp (1).
85 - 15
Air-conditioning option
1 WARNING
Only operators who are certified to handle refrigerant fluids may work on the
air conditioning system, otherwise please contact a specialist air-conditioning
2 company.
Connect the charging station hoses (1, 085 - 15).

1 Drain down the air-conditioning circuit.
DANGER
The R134a fluid, in free air is a colourless and odourless gas, heavier than air, that
85
may be dangerous for human beings in certain conditions. Always recuperate the
85 - 16 refrigerant fluid using the charging station.
1
Remove the clamp (2, 085 - 15)
Disconnect the air-conditioning compressor hoses (3, 0 85 - 16)

1
and insert plugs.
When refitting, observe the safety measures ( 6 110.2.1 SAFETY

MEASURES FOR HANDLING AIR-CONDITIONING R134A, 5 199 ) and
the tightening torques (6 110.2.2 ASSEMBLY INSTRUCTIONS FOR
AIR-CONDITIONING CIRCUIT, 5 199).
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85 (22/08/2017) DRIVER'S CAB 193
85 - 17
Chock the underside of the cab (1).
Raise up by resting under the cab (2).
85 - 18
Remove the 4 cab silent block fastenings (1).

1
85 - 19
Raise the cab (1)
Release the cab assembly (2) taking care with the wiring harnesses
and hoses.
1
85
85.2.2 REFITTING THE CAB
Refitting is done by reversing the steps for removal. Take care not to trap the wiring harnesses and hoses.
Observe the special ( 6 85.1.1 TIGHTENING TORQUES, 5 188 ) and standard tightening torques
(600.4.1 STANDARD TIGHTENING TORQUES, 5 19).
For air-conditioning option cab (6110.2.2 ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT, 5 199).
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194 DRIVER'S CAB 85 (22/08/2017)
85
TABLE OF CONTENTS
110 AIR-CONDITIONING OPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

110.1 AIR CONDITIONING CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
110.1.1 DESCRIPTION OF AIR-CONDITIONING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
110.1.2 PRINCIPLE OF AIR-CONDITIONING OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
110.1.3 DESCRIPTION OF AIR-CONDITIONING COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
110.2 AIR CONDITIONING CONTROLS AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
110.2.1 SAFETY MEASURES FOR HANDLING AIR-CONDITIONING R134A . . . . . . . . . . . . . . . . . . . . . . . . . . 199
110.2.2 ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

110.2.3 AIR-CONDITIONING R134a REFRIGERANT FLUID CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . 201
110.2.4 REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . 201
110.2.5 AIR-CONDITIONING CHARGING METHOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
110.2.6 AIR-CONDITIONING OPERATIONAL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
110.3 AIR-CONDITIONING TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
110.3.1 AIR-CONDITIONING FAULT DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
FAULTY AIR-CONDITIONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
FAULTY VENTILATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
FAULTY HEATING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
110
647632EN
196 OPTIONS - ATTACHMENTS 110 (28/08/2017)
110 AIR-CONDITIONING OPTION
110.1 AIR CONDITIONING CHARACTERISTICS AND SPECIFICATIONS

WARNING
Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact
a specialist air-conditioning company.
110.1.1 DESCRIPTION OF AIR-CONDITIONING OPERATION
The air-conditioning system reduces 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 the gaseous state at low pressure and at low temperature is drawn in and compressed by
the compressor which sends it at high pressure and high temperature to the condenser.
Phase 2: condensation
The fluid passes through the condenser to transmit its heat to the outside of the vehicle, by means of
the fan.
As it passes through the condenser the fluid liquefies while maintaining a high temperature and pressure.
It is then filtered in a drier (or desiccator).
Phase 3: expansion
The fluid enters a pressure reducing valve (or expansion valve) so as to lower its pressure and temperature
considerably while remaining in liquid state.
Phase 4: evaporation
The fluid passes through the evaporator to absorb the cab interior heat and vaporises while maintaining
a low temperature and pressure.
In this way, the cab interior air propelled by the fan motor cools and releases its moisture when in
contact with the evaporator. The condensation of the air is then drained and evacuated to the outside
of the vehicle.
The high and low pressures in the system are monitored by a HP and LP pressure switch attached directly
on the drier filter.
It has the following safety functions:
Complete shutdown of the air-conditioning system if the pressure is lower than 2 bars or greater than
110
27 bars.
647632EN
110 (28/08/2017) OPTIONS - ATTACHMENTS 197
110.1.2 PRINCIPLE OF AIR-CONDITIONING OPERATION

Electromagnetic
clutch
Alternator
Compressor
Engine
Low pressure High pressure
steam circuit steam circuit
External
air
Axial fan
Condenser
Hot air
discharge
Drier Filter
Binary pressure
switch
Warm air
Indicator lamp
Filters High pressure
liquid circuit
Centrifugal fan
(Turbine) Pressure
reducing valve
Low pressure
liquid circuit
Evaporator
Thermostat
110
Condensation water
Diffusion of drainage
cold air
CAB INTERIOR
647632EN
110.1.3 DESCRIPTION OF AIR-CONDITIONING COMPONENTS

THE COMPRESSOR
The compressor circulates the fluid through the circuit, drawing it in as a low pressure and low
temperature gas from the evaporator and sending it to the condenser as a high pressure, high
temperature gas.
THE CONDENSER
The condenser is a thermal exchanger that transmits the heat recuperated from the evaporator
to the outside air by means of the fan and causes the condensation of the fluid at high pressure.
THE DRIER FILTER

The filter is the main protective component in the system. It performs the following functions:
- Filtering any solid particles carried by the fluid that could damage the compressor or
obstruct the reducing valve, for example.
- Dehumidifying the fluid and the oil to protect all the components to protect all parts
of the circuit from corrosive substances and freezing moisture at the outlet of the pressure
reducing valve.
- Storing the fluid in liquid state and thus constituting a buffer tank to compensate for
pressure variations. It therefore helps to absorb pressure differences generated by the
compressor.
THE "BINARY" PRESSURE SWITCH

Mounted on the drier filter, the pressure switch is the system's safety device which is sensitive to
pressure variations. It protects the system against both excessively low pressures and excessively
high pressures by directly controlling the compressor clutch:
- Acts against low pressures (below 2 bars) due to a lack of refrigerant, a leak or a downstream
circuit blockage.
- Acts against high pressures (greater than 27 bars) due to incorrect compressor cooling,
an excess of refrigerant or an upstream circuit blockage.
THE REDUCING VALVE

The pressure reducing valve is mounted on the evaporator inlet. By expansion, it lowers the
pressure and thus the temperature of the fluid in such a way as to cool the air passing through the
evaporator. It adjusts the flow to calibrate the quantity of fluid in such a way that it is completely
vaporised at the evaporator outlet.
THE EVAPORATOR
The evaporator is a heat exchanger fitted with a pressure reducing valve and a fan. The fan
draws air across the cold evaporator fins. As the air passes across the fins the moisture it contains
condenses and the air leaves the evaporator cooled. This heat exchange allows the coolant to
evaporate at low pressure.
ANTI-FROST THERMOSTAT
The electric thermostat is connected to a sensor located between two evaporator fins. Temperature
variations in the evaporator lead to changes in the resistance of the potentiometer in the preset
thermostat and this controls the compressor clutch relay.
110
647632EN
110.2 AIR CONDITIONING CONTROLS AND ADJUSTMENTS
110.2.1 SAFETY MEASURES FOR HANDLING AIR-CONDITIONING R134A

WARNING
Only operators who are certified to handle refrigerant fluids may work on the air conditioning system, otherwise please contact
a specialist air-conditioning company.
DANGER
The R134a fluid, in free air is a colourless and odourless gas, heavier than air, that may be dangerous for human beings in certain
conditions. Always recuperate the refrigerant fluid using the charging station.
Carry out the assembly operations in a dry and dust free area. Use PAG ISO SP20 oil for lubricating all
seals and seal surfaces before assembly.
1 - Individual protection: protective goggles and rubber gloves.

2 - Perform the operations in a ventilated space.
3 - First aid: After inhalation, breathe clean air, give oxygen or perform artificial respiration according
to the degree of urgency (medication contraindication). Consult a doctor. After contact with the
eyes, rinse thoroughly for 15 minutes and see a doctor. After contact with the skin, rinse thoroughly
and remove contaminated clothing.
4 - Storage conditions: keep R134a in a sealed container in a dry, cool and well ventilated place.
5 - Handling: only in ventilated areas.
6 - Measures to be taken in case of accident: wear self-contained breathing apparatus if R134a is
exposed to fire.
110.2.2 ASSEMBLY INSTRUCTIONS FOR AIR-CONDITIONING CIRCUIT
- Hose tightening torques.
Designation Type Tightening torque

Hose condenser output - filter input M6 16 N.m
Hose filter output - reducing valve input M6 16 N.m
Hose compressor output - cab input M8 25 N.m
Hose cab input - condenser input M8 25 N.m
Hose reducing valve output - cab output M10 33 N.m
Hose cab output - compressor input M10 33 N.m
- Connection to the compressor
Key:
3
1 - Compressor
1
2 - Hose cab output/compressor input
2 3 - Hose compressor output/cab input
110
647632EN
- Connection to heater valve
Heating valve
Heating hose
- Connection to HVAC block
Key:
4 - Inlet pipe
5 - Return pipe
6 - Pressure reducing valve
5
4 7 - Pressure reducing valve block
5 N.m
5 N.m
- Pressure switch connection to condenser
Key:
8 - Pressure switch
9 - Drier filter
2
16 N.m
110
647632EN
110.2.3 AIR-CONDITIONING R134a REFRIGERANT FLUID CHARACTERISTICS

DANGER
The R134a fluid, in free air is a colourless and odourless gas, heavier than air, that may be dangerous for human beings in certain
conditions. Always recuperate the refrigerant fluid using the charging station.
Designation Hydro fluorocarbon

Use Refrigerant
Chemical characteristics Tetrafluoroethane 134a
Chemical formula CH2F-CF3
Physical state Liquefied gas
Colour Colourless
Smell Slightly ethered
Boiling point (in atmospheric pressure) - 26,5 °C
Melting point - 101 °C
Density at 25°C 1.21 kg/l
Critical pressure 40.7 bar
Critical temperature + 101 °C
Weight in vapour state 5 times heavier than air
1 kg in liquid state under 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
With alkaline metals and alkaline earth metal salts in powder form (Al-Zn-
Dangerous reactions
Be, etc.)
Flash point No flash point (very stable)
Spontaneous combustion temperature Greater than 75 °C
Explosive limit Lower and higher none
Potential to destroy ozone layer None, ODP=0
110.2.4 REFRIGERANT FLUID LOAD FOR THE AIR CONDITIONING CIRCUIT

Refrigerant fluid: R134a
Charging equipment: Charging station
Quantity of fluid: 725 gr ± 25 gr
Oil PAG ISO 100 SP20: Compressor 125 mℓ; Hoses 5 mℓ/m; Condenser 30 mℓ; Drier filter;
15 mℓ; Evaporator 25 mℓ.
Change the cores in the event of leakage (plugs in the charging ports): Part no. 797464
110.2.5 AIR-CONDITIONING CHARGING METHOD
Prior to using the charging station, refer to the instruction booklet for the device.
Initial coolant charging (duration 56 minutes)
1. Connection phase of the circuit station (about 1 minute).

2. Refrigerant circuit evacuation phase (minimum duration 45 minutes).
110
Achieve a vacuum at a pressure of -0.75 bar in 10 minutes maximum,

Maintain the vacuum at a pressure of –0.99 bar maximum for dehumidifying in 30 minutes
minimum,
Check leaks within 5 minutes.
3. Load operation (maximum duration 10 minutes).
647632EN
Refrigerant charging after servicing and repair (duration 90 min)
1. Preparation phase (about 15 minutes).

Connect up circuit station,
Run vehicle engine at between 800 and 1200 rpm,
Simultaneously, switch on the air-conditioning at maximum speed (3rd notch),
Turn off vehicle ignition after 10 to 15 minutes.
2. Recuperation phase (15 minutes maximum).
Its aim is to recover and recycle the gas, oil and any impurities present in the circuit.
Launch the fluid recovery cycle on the station.
3. Waiting phase of 3 to 4 minutes to enable any micro-frozen granules of oil and moisture to be recovered.
4. Drain phase of recuperated oil (about 1 minute).
5. Phases 1, 2 and 3 can be redone if a formation pressure is observed during phases 2 and 3.
6. Evacuation phase of the fluid circuit (minimum duration 45 minutes).
Achieve a vacuum at a pressure of -0.75 bar in 10 minutes maximum,
Maintain the vacuum at a pressure of –0.99 bar maximum for dehumidifying in 30 minutes
minimum,
Checking leaks within 5 minutes maximum.
7. Charging phase (maximum 10 minutes).
Fluid top-up (duration 15 minutes) vehicle engine running
1. Preparation phase (about 10 minutes).

- Connect the station to the circuit,
- Run vehicle engine at between 800 and 1200 rpm,
- Simultaneously, switch on the air-conditioning at maximum speed (3rd notch).
2. Additional loading phase (about 5 minutes).
110.2.6 AIR-CONDITIONING OPERATIONAL CHECK

The following checks are carried out with the vehicle engine running.
1. Check the heating control

110 - 1
Use the switch (1) to select the maximum heater fan speed (3rd
notch).
1
Check that the LED (2) of the air-conditioning switch is turned off.
2 Use the switch (3) to check the increase in temperature between

the minimum heating position and the maximum heating position.
3
110
647632EN
2. Check the air-conditioning control
–– Connect the charging station

–– Start the vehicle
–– Switch on the air-conditioning as follows:
110 - 2 Use the switch (1) to select the slow heater fan speed (1st notch).
Press the air-conditioning switch with the LED (2) on.

1
Adjust the temperature to the maximum cooling position using

the manual control (3).
2
Open the 3 diffuser outlets.
3 Adjust the engine to idle speed (about 800 rpm)
Wait for at least 5 minutes for the circuit to stabilise.
Check that the LP and HP circuit pressures between two compressor

cut-offs are between:
0.5 bar and 2 bar in LP,
6 bar and 20 bar in HP.
3. Monitor anti-icing safety
–– Connect the charging station

–– Start the vehicle
–– Switch on the air-conditioning as follows:
110 - 3
Use the switch (1) to select the slow heater fan speed (1st notch).
Press the air-conditioning switch with the LED (2) on.

1
Adjust the temperature to the maximum cooling position using

the manual control (3).
2
Close all diffuser outlets.
3
Adjust the engine to idle speed (about 800 rpm)
heck that the LP and HP circuit pressures between two

C
compressor cut-offs are between:
0.5 bar and 2 bar in LP,
6 bar and 20 bar in HP.
Check that the compressor is cut-off after a few minutes:
110
LP ≥ 3 bar,
HP ≤ 5 bar.
647632EN
4. Complete the air-conditioning inspection form
Engine at idle, low fan speed (1st notch), air-conditioning ON and maximum cooling setting.
110 - 4
Open only the left-hand outlet (1):
Check the output air temperature and note:
Temperature Pressures
Date Machine No. Compressor cut-off
External Air output LP HP
110
647632EN
110.3 AIR-CONDITIONING TROUBLESHOOTING
110.3.1 AIR-CONDITIONING FAULT DIAGNOSTICS

FAULTY AIR-CONDITIONING
Faulty air-conditioning
Fan function YES
on 1st, 2nd or 3rd notch?
YES See "FAULTY
VENTILATION"
NO Air-conditioning indicator
lamp lit?
NO Operation YES
Pressure switch OK?
Replace pressure YES
switch
NO YES
Electrical harness OK?
Repair harness Connect a charging station
At shutdown NO
HP = LP ≥ 3 bar
YES
Load to 360 g and
check for leaks
NO In operation YES
with HP > LP?
NO Thermostat HP pressure NO
working correctly? reaches 28 bar?
YES YES LP pressure NO
Check and/or replace
the thermostat below zero bar?
NO YES Check temperature
Is the condenser fan at all HP couplings to
operating? detect blockage
NO YES
Fan working correctly?
YES NO
Replace fan Clean condenser fins Correct charge?
NO YES De-gas the

Electrical harness OK?
system
YES Replace the reducing
Repair harness
valve
NO Clutch working YES
Vacuum achievable?
correctly?
Change the YES NO
Charge with 725 g
compressor clutch ±25 g
NO Correct compressor Perform leak detection
belt tension? to determine the faulty
YES item
Re-tension or replace
the compressor belt
Recover the charge and
remove the cylinder
head
NO Compressor valves and YES

110
pistons OK
Replace If there are filings in the oil:
- compressor
- t he hoses from the 1 - Remove the compressor, the drier and the reducing valve
compressor output to the
reducing valve input 2 - Flush out the hoses, the condenser and the evaporator
- condenser
- pressure reducing valve
- dehydrator 3 - Replace the compressor, the reducing valve and the drier
647632EN
FAULTY VENTILATION
Faulty ventilation
YES All 3 turbine speeds NO
operating correctly?
NO Are ventilation ports At least one of the NO
open? 3 speeds operating
YES correctly?
Open the air outlet YES NO
12 volt supply OK?
nozzles
NO Inlet air YES Repair electrical
filter OK harness
Replace or YES Switch working NO
clean air filter correctly?
Electrical harness YES
Replace the switch
Check air diffusion
between HVAC and YES Inter-turbine wiring NO
dashboard harness OK?
Replace the Repair
HVAC turbine electrical harness
FAULTY HEATING
Faulty heating
NO Is heating mode YES
enabled?
Refer to the operator's Is the cooling fluid NO
instructions circulating in the
circuit?
YES NO
Is there a leak?
NO Is the fluid up to YES Add cooling fluid and

temperature (80 °C)? bleed the circuit
YES
Run the truck's engine Replace the faulty item
Heating valve NO
operation OK?
YES
Change the valve
See "FAULTY
VENTILATION"
110

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647632EN (11/01/2019)

MT 420 H 49K ST3A S1

PUBLICATION DATE COMMENTS

03 / 03 / 2017 - 1st EDITION

07 / 12 / 2017 - UPDATE GR80-04 + ADDITION: MT 425 H TI 49K and GR85 + GR110

23 / 04 / 2018 - Partial UPDATE: GR80-04

Manitou BF S.A Limited liability company with a Board of Directors.

INTERACTIVE REPAIR MANUAL

Ω Ohm: unit of electrical resistance, equal to V.A-1.

A Ampere: unit of measurement for electrical current intensity. It is one of the

AOC Ammonia Oxidation Catalysts: elimination of the excess ammonia (NH3)

BMEP Bloc Manipulateur ÉlectroProportionnel - Electro-proportional joystick unit:

CAN Controller Area Network: control communication network for inter-system

CO Carbon Monoxide: colourless, odourless and highly toxic gas.

CRC Comfort Ride Control: Boom suspension.

CVT Continuous Variable Transmission.

DPF Diesel Particulate Filter : o FAP.

DTC Diagnostic Trouble Code: fault codes

ECM/ECU Electronic or Engine Control Module/Unit : ECU making it possible to control

FMI Failure Mode Identifier: identifies the type of fault:

gr. Greek: signifies a word of Greek origin.

HS High Side: power side power supply.

HVAC Heating, Ventilation and Air-Conditioning: in-cab heating, ventilation and

HMI Human-Machine Interface: dashboard screens.

i.V. Interactive View: 2nd generation MANITOU machine diagnostics software.

lat. Latin: signifies a word of Latin origin.

LIN Local Interconnect Network.

LS Low Side: ground side power supply.

LSU Load Sensing Ultra: hydraulic load detection.

m Metre: unit of measurement for length. It is one of the basic International

NF = NC Normalement Fermé (= Normally Closed): normally closed contact.

NO Normally Open: normally open contact.

NOx Nitrogen Oxide: regulated air pollutants.

PAD Plug And Diag: MANITOU machine diagnostics software.

PS/PS+ Power Shift: semi-automatic gear box.

PWM Pulse Width Modulation: modulation of the pulse

s Second: unit of measurement for time. It is one of the basic International

SCR Selective Catalytic Reduction: reduction of nitrogen oxides (NOx) emitted by

SPU Safety Power Unit: machine controller.

USB Universal Serial Bus.

V Volt: unit of electromotive force and potential diﬀerence (or voltage).

00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

00.1.2 SERVICING POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

00.1.3 EXPLANATION OF SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

00.1.4 SERVICING RULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

00.2 GENERAL CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

00.2.2 LUBRICANTS AND FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

MT 420 H 49K ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

MT 425 H TI 49K ST3A S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

00.3 GENERAL LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

00.3.1 LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

00.4 GENERAL CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

00.4.1 STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

00.4.2 METRIC - IMPERIAL UNIT CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

GENERAL, CHARACTERISTICS AND SAFETY

00.1 GENERAL INSTRUCTIONS AND SAFETY NOTICE

In order to reduce accident risks, make sure to:

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

00.1.2 SERVICING POSITION

Before any intervention:

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

Indicates an imminent hazardous situation which, if not avoided