MI25D Exq Elect

647364EN (07/06/2018)
MI 15-18-20-25-30-35 D S1 E3
MI 20-25-30-35 D S2 E3
MI 20-25-30-35 D Y S3 E3
MI 15-18-20-25-30-35 G S1
MI 15-18-20-25-30-35 G S2
REPAIR MANUAL
647364EN
2
DATE OF ISSUE OBSERVATION
15 / 11 / 2011 - 1st ISSUE
21 / 03 / 2014 - 2nd ISSUE
03 / 12 / 2014 - 3rd ISSUE
07 / 06 / 2018 - 4th ISSUE : Add MI 20-25-30-35 D Y E3 S3
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
organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned
may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU-BF
and may not be used without express and formal authorization. All rights are reserved.
647364 3
HOW TO USE THIS REPAIR MANUAL ?

1GENERAL CHARACTERISTICS AND SAFETY 2
00
00
GENERAL, CHARACTERISTICS AND SAFETY
ENGINE
10
TRANSMISSION
20
- GENERAL INSTRUCTIONS AND SAFETY NOTICE
AXLE
30
BRAKE
40
BOOM
60
55
50
HYDRAULIC
70
ELECTRICITY
80
DRIVER’S CAB
85
FRAME - BODYWORK
90
110
OPTIONS - ATTACHMENTS
3 4 General instructions and safety

4 notice
00
00
RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.
Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.
GENERAL INSTRUCTIONS AND SAFETY NOTICE
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.
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Before carrying out any operation on an electrically powered

1
component, activate the battery cut-off.
2 If the telehandler does not have a battery isolation device, disconnect
the battery connecters then re-assemble them.
Before carrying out any welding operations, think about

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

specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.
00-M173EN (29/09/2011)
(29/09/2011) 00-M173EN
547982 : See the repair manual N° 547982.

M
R
70 - HYDRAULIC : See the group N° 70 called «Hydraulic».

GENERAL CHARACTERISTICS AND SAFETY
00
ENGINE
10
TRANSMISSION
20
AXLE
30
BRAKE
40
MAST
60
HYDRAULIC
70
ELECTRICITY
80
DRIVER’S CAB
85
FRAME - BODY
90
110
GENERAL CHARACTERISTICS AND SAFETY
00
- GENERAL INSTRUCTIONS AND SAFETY
NOTICE
- GENERAL CHARACTERISTICS AND

SPECIFICATIONS
- GENERAL COMPONENTS LOCATION
- GENERAL CONTROL AND ADJUSTMENT

00
00
GENERAL INSTRUCTIONS AND SAFETY NOTICE
pages
PREAMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAINTENANCE POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
RULES FOR MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(31/01/2014) 00-00-M183EN
2 GENERAL INSTRUCTIONS AND SAFETY NOTICE
00
00
PREAMBLE
This chapter deals with the general instructions and safety notice during inspection and maintenance
work.
Other instructions and warnings are indicated in each chapter concerned.
In order to reduce accident risks, make sure to:
–– Follow the instructions in the truck operating and maintenance manual.

⇒⇒ This manual should be found in all trucks.
–– Please follow all safety instructions.
–– Use the appropriate tools for any work to be performed.
–– Use original Manitou spare parts.
Any non-compliance increases the risk of accidents occurring which may lead to causing grievous bodily
harm and even death.
An efficient, dependable and profitable combination will be formed if the operator follows the safety
manual correctly and the machine is serviced properly.
When you see this symbol:
It means: Warning! Be careful! Your safety, somebody else’s or the safety of the lift truck itself
is at risk.
The manufacturer cannot predict all possible risky situations. Consequently, the safety instructions
given in the safety manual are not exhaustive.
At any time, as an operator, you must envisage, within reason, the possible risk to yourself, to others or
to the lift truck itself when you repair, service or drive it.
Manitou cannot be held responsible for the use of any lifting devices, tools or operating methods other
than those specified.
00-00-M183EN (31/01/2014)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 3
00
00
MAINTENANCE POSITION
2 4
1 3
Before any intervention:
1 - Place the machine on a flat surface and chock the wheels.

2 - Turn off the engine and remove the ignition key.
3 - Let the machine cool down.
4 - Take all the pressure out of the circuits concerned.
(31/01/2014) 00-00-M183EN
00
00
RULES FOR MAINTENANCE
Do not carry out any work on the machine unless you have followed
a suitable training course and have the knowledge required for it.
Make sure you have taken into consideration all the indicator plates
on the machine and in the instruction manual.
Be careful not to burn yourself when touching hot liquids or parts

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

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

specifically equipped. Moreover, local safety notices deal with
maintenance and repair work on such machines.
00-00-M183EN (31/01/2014)
GENERAL INSTRUCTIONS AND SAFETY NOTICE 5
00
00
Never step on a part of the machine that has not been designed for it.
Never wear clothes, jewelry or objects that could get caught during
work and cause accidents.
Always wear protection glasses, gloves, safety shoes as well as any

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

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

liquids, solids, gases that are harmful to the environment, make
sure the necessary precautions are taken to avoid contaminating
the environment.
(31/01/2014) 00-00-M183EN
00
00
When lifting or shoring a component of the machine, make sure

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

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

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

by the manufacturer.
MIN
00-00-M183EN (31/01/2014)
00
GENERAL CHARACTERISTICS AND SPECIFICATIONS
pages
MI 15 D / MI 18 D - S1 E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– CHARACTERISTICS AND FLUIDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MI 15 G / MI 18 G - S1
MI 15 G / MI 18 G - S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MI 20 D / MI 25 D - S1 E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MI 20 G / MI 25 G - S1
MI 20 G / MI 25 G - S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MI 30 D / MI 35 D - S1 E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
MI 30 G / MI 35 G - S1
MI 30 G / MI 35 G - S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
MI 20 D / MI 25 D - S2 E3
MI 20 D / MI 25 D - Y E3 S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MI 30 D / MI 35 D - S2 E3
MI 30 D / MI 35 D - Y E3 S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
–– DIMENSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
(07/06/2018) 00-01-M183EN
GENERAL CHARACTERISTICS AND
2 SPECIFICATIONS MI 15 D / MI 18 D - S1 E3
00
Data from the Operator’s Manuel :

CHARACTERISTICS AND FLUIDS l 647377 du 16/07/2013
Designation Value Designation Type Quantity
Kerb weight of MI 15 D 2905 kg Fuel Tank Diesel fuel 45 ℓ
truck MI 18 D 3100 kg Engine oil MANITOU Oil / API CH4 7.5 ℓ
Front 1325 kg Cooling circuit Cooling fluid (protection - 25° or -35°) 11 ℓ
MI 15 D
Axle load Rear 1580 kg Hydraulic oil tank MANITOU Oil / Hydraulic ISO VG 32 40 ℓ
unladen Front 1315 kg Brake system Mineral brake fluid / DOT3 1.5 ℓ
MI 18 D
Rear 1785 kg Transmission MANITOU Oil / DEXRON-III / Automatic transmission 4ℓ
Nominal towing MI 15 D 760 daN Differential MANITOU Oil / SAE80W90 / Mechanical transmission 5.8 ℓ
power unladen MI 18 D 795 daN
DIMENSIONS
Value
Item
MI 15 D MI 18 D
Q (t) 1,5 1,8
c (mm) 500 500
x (mm) 405 405
y (mm) 1 420 1 420
b10 (mm) 900 900
b11 (mm) 920 920
α (°) 6 6
β (°) 12 12
h1 (mm) 2 145 2 145
h2 (mm) 155 155
h3 (mm) 3 300 3 300
h4 (mm) 4 255 4 255
h6 (mm) 2 090 2 090
h7 (mm) 1 160 1 160
h10 (mm) 315 315
l1 (mm) 3 310 3 350
l2 (mm) 2 240 2 280
1 080 / 1 080 /
b1 (mm) (1)
1 500 1 500
s (mm) 35 35
e (mm) 100 100
l (mm) 1 070 1 070
b3 (mm) 1 000 1 000
m1 (mm) 115 115
m2 (mm) 150 150
Ast (mm) (2) 3 590 3 615
Ast (mm) (3) 3 790 3 815
Wa (mm) 1 985 2 010
b13 (mm) 55 55
(1)
Total width, wheels Single / dual wheels (overall)
(2)
Aisle width for palette 1000x1200 widthways
(3)
Aisle width for palette 800x1200 lengthways
00-01-M183EN (07/06/2018)
MI 15 G / MI 18 G - S1 SPECIFICATIONS 3
MI 15 G / MI 18 G - S2
00
Kerb weight of MI 15 G 2710 kg Gas cylinder Gas cylinder 13 kg
truck MI 18 G 2905 kg Engine oil MANITOU Oil / API CH4 3.8 ℓ
MI 15 G
MI 18 G
Nominal towing MI 15 G 770 daN Differential MANITOU Oil / SAE80W90 / Mechanical transmission 5.8 ℓ
power unladen MI 18 G 800 daN
DIMENSIONS
Value
Item
MI 15 G MI 18 G
Q (t) 1,5 1,8
c (mm) 500 500
x (mm) 405 405
y (mm) 1 420 1 420
b10 (mm) 900 900
b11 (mm) 920 920
α (°) 6 6
β (°) 12 12
h1 (mm) 2 145 2 145
h2 (mm) 155 155
h3 (mm) 3 300 3 300
h4 (mm) 4 255 4 255
h6 (mm) 2 090 2 090
h7 (mm) 1 160 1 160
h10 (mm) 315 315
l1 (mm) 3 310 3 350
l2 (mm) 2 240 2 280
1 080 / 1 080 /
b1 (mm) (1)
1 500 1 500
s (mm) 35 35
e (mm) 100 100
l (mm) 1 070 1 070
b3 (mm) 1 000 1 000
m1 (mm) 115 115
m2 (mm) 150 150
Ast (mm) (2) 3 590 3 615
Ast (mm) (3) 3 790 3 815
Wa (mm) 1 985 2 010
b13 (mm) 55 55
(1)
(2)
(3)
(07/06/2018) 00-01-M183EN
00

MI 20 D
MI 25 D
DIMENSIONS
Value
Item
MI 20 D MI 25 D
Q (t) 2 2,5
c (mm) 500 500
x (mm) 465 465
y (mm) 1 600 1 600
b10 (mm) 965 965
b11 (mm) 973 973
α (°) 6 6
β (°) 12 12
h1 (mm) 2 185 2 185
h2 (mm) 140 140
h3 (mm) 3 300 3 300
h4 (mm) 4 345 4 345
h6 (mm) 2 115 2 115
h7 (mm) 1190 1190
h10 (mm) 355 360
l1 (mm) 3 615 3 685
l2 (mm) 2 465 2 535
1 155 / 1 155 /
b1 (mm) (1)
1 595 1 595
s (mm) 40 40
e (mm) 122 122
l (mm) 1 150 1 150
b3 (mm) 1 038 1 038
m1 (mm) 115 115
m2 (mm) 175 175
Ast (mm) (2) 3 865 3 930
Ast (mm) (3) 4 065 4 130
Wa (mm) 2 200 2 265
b13 (mm) 145 145
(1)
(2)
(3)
00-01-M183EN (07/06/2018)
MI 20 G / MI 25 G - S2
00
MI 20 G
MI 25 G
DIMENSIONS
Value
Item
MI 20 G MI 25 G
Q (t) 2 2,5
c (mm) 500 500
x (mm) 465 465
y (mm) 1 600 1 600
b10 (mm) 965 965
b11 (mm) 973 973
α (°) 6 6
β (°) 12 12
h1 (mm) 2 185 2 185
h2 (mm) 140 140
h3 (mm) 3 300 3 300
h4 (mm) 4 345 4 345
h6 (mm) 2 115 2 115
h7 (mm) 1190 1190
h10 (mm) 355 360
l1 (mm) 3 615 3 685
l2 (mm) 2 465 2 535
1 155 / 1 155 /
b1 (mm) (1)
1 595 1 595
s (mm) 40 40
e (mm) 122 122
l (mm) 1 150 1 150
b3 (mm) 1 038 1 038
m1 (mm) 115 115
m2 (mm) 175 175
Ast (mm) (2) 3 865 3 930
Ast (mm) (3) 4 065 4 130
Wa (mm) 2 200 2 265
b13 (mm) 145 145
(1)
(2)
(3)
(07/06/2018) 00-01-M183EN
00

MI 30 D
MI 35 D
DIMENSIONS
Value
Item
MI 30 D MI 35 D
Q (t) 3 3,5
c (mm) 500 500
x (mm) 480 485
y (mm) 1 700 1 700
b10 (mm) 1 005 1 005
b11 (mm) 975 975
α (°) 6 6
β (°) 12 12
h1 (mm) 2 200 2 315
h2 (mm) 145 145
h3 (mm) 3 300 3 300
h4 (mm) 4 445 4 445
h6 (mm) 2 130 2 130
h7 (mm) 1 215 1 215
h10 (mm) 355 360
l1 (mm) 3 865 3 935
l2 (mm) 2 715 2 785
1 225 / 1 225 /
b1 (mm) (1)
1 725 1 725
s (mm) 45 50
e (mm) 122 122
l (mm) 1 150 1 150
b3 (mm) 1 100 1 100
m1 (mm) 130 130
m2 (mm) 200 200
Ast (mm) (2) 4 140 4 195
Ast (mm) (3) 4 340 4 395
Wa (mm) 2 460 2 510
b13 (mm) 160 160
(1)
(2)
(3)
00-01-M183EN (07/06/2018)
MI 30 G / MI 35 G - S2
00
MI 30 G
MI 35 G
DIMENSIONS
Value
Item
MI 30 G MI 35 G
Q (t) 3 3,5
c (mm) 500 500
x (mm) 480 485
y (mm) 1 700 1 700
b10 (mm) 1 005 1 005
b11 (mm) 975 975
α (°) 6 6
β (°) 12 12
h1 (mm) 2 200 2 315
h2 (mm) 145 145
h3 (mm) 3 300 3 300
h4 (mm) 4 445 4 445
h6 (mm) 2 130 2 130
h7 (mm) 1 215 1 215
h10 (mm) 355 360
l1 (mm) 3 865 3 935
l2 (mm) 2 715 2 785
1 225 / 1 225 /
b1 (mm) (1)
1 725 1 725
s (mm) 45 50
e (mm) 122 122
l (mm) 1 150 1 150
b3 (mm) 1 100 1 100
m1 (mm) 130 130
m2 (mm) 200 200
Ast (mm) (2) 4 140 4 195
Ast (mm) (3) 4 340 4 395
Wa (mm) 2 460 2 510
b13 (mm) 160 160
(1)
(2)
(3)
(07/06/2018) 00-01-M183EN
MI 20 D / MI 25 D - Y E3 S3
00

MI 20 D
MI 25 D
DIMENSIONS
Value
Item
MI 20 D MI 25 D
Q (t) 2 2,5
c (mm) 500 500
x (mm) 465 465
y (mm) 1 600 1 600
b10 (mm) 965 965
b11 (mm) 973 973
α (°) 6 6
β (°) 12 12
h1 (mm) 2 185 2 185
h2 (mm) 140 140
h3 (mm) 3 300 3 300
h4 (mm) 4 345 4 345
h6 (mm) 2 115 2 115
h7 (mm) 1190 1190
h10 (mm) 355 360
l1 (mm) 3 615 3 685
l2 (mm) 2 465 2 535
1 155 / 1 155 /
b1 (mm) (1)
1 595 1 595
s (mm) 40 40
e (mm) 122 122
l (mm) 1 150 1 150
b3 (mm) 1 038 1 038
m1 (mm) 115 115
m2 (mm) 175 175
Ast (mm) (2) 3 865 3 930
Ast (mm) (3) 4 065 4 130
Wa (mm) 2 200 2 265
b13 (mm) 145 145
(1)
(2)
(3)
00-01-M183EN (07/06/2018)
MI 30 D / MI 35 D - S2 E3 SPECIFICATIONS 9
MI 30 D / MI 35 D - Y E3 S3
00
MI 30 D
MI 35 D
DIMENSIONS
Value
Item
MI 30 D MI 35 D
Q (t) 3 3,5
c (mm) 500 500
x (mm) 480 485
y (mm) 1 700 1 700
b10 (mm) 1 005 1 005
b11 (mm) 975 975
α (°) 6 6
β (°) 12 12
h1 (mm) 2 200 2 315
h2 (mm) 145 145
h3 (mm) 3 300 3 300
h4 (mm) 4 445 4 445
h6 (mm) 2 130 2 130
h7 (mm) 1 215 1 215
h10 (mm) 355 360
l1 (mm) 3 865 3 935
l2 (mm) 2 715 2 785
1 225 / 1 225 /
b1 (mm) (1)
1 725 1 725
s (mm) 45 50
e (mm) 122 122
l (mm) 1 150 1 150
b3 (mm) 1 100 1 100
m1 (mm) 130 130
m2 (mm) 200 200
Ast (mm) (2) 4 140 4 195
Ast (mm) (3) 4 340 4 395
Wa (mm) 2 460 2 510
b13 (mm) 160 160
(1)
(2)
(3)
(07/06/2018) 00-01-M183EN
10 SPECIFICATIONS
00
00-01-M183EN (07/06/2018)
00
GENERAL COMPONENTS LOCATION
pages
LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(31/01/2014) 00-03-M183EN
2 GENERAL COMPONENTS LOCATION
00
LOCATION OF NAME AND IDENTIFICATION PLATE
Key :
1 - Lift truck manufacturer’s plate 5 - Chassis
2 - Engine (MI .. D) 6 - Mast
3 - Engine (MI .. G) 7 - Plate manufacturer of the attachment
4 - Hydraulic pump
6
1
MANITOU BF
44158 ANCENIS CEDEX
FRANCE
MODELE
N° dans la série
Année fabrication
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°241415
3 4
00-03-M183EN (31/01/2014)
00
CONTRÔLE ET RÉGLAGE GÉNÉRAUX
STANDARD TIGHTENING TORQUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

METRIC - IMPERIAL UNIT CONVERSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(07/06/2018) 00-04-M183FR
2 CONTRÔLE ET RÉGLAGE GÉNÉRAUX
00
STANDARD TIGHTENING TORQUES
b 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.
00-04-M183FR (07/06/2018)
CONTRÔLE ET RÉGLAGE GÉNÉRAUX 3
00
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
in (inch) (pouce) x 12 = ft (foot)
oz av (once avoirdupois) x 16 = lb (pound) (lat. libra)
mm (millimeter) x 1000 = m (meter)
µm (micrometer) x 1000 = mm (millimeter)
kg (kilogram) x 1000 = t (metric ton)
° (angle degree) x 57.2958 = rad (radian)
(07/06/2018) 00-04-M183FR
4 CONTRÔLE ET RÉGLAGE GÉNÉRAUX
00
00-04-M183FR (07/06/2018)
ENGINE
10
- ENGINE CHARACTERISTICS AND
SPECIFICATIONS
- ENGINE COMPONENTS LOCATION
- ENGINE CONTROL AND ADJUSTMENT
- ENGINE REMOVAL
- ENGINE REFIT
- ENGINE TROUBLESHOOTING
MI 15 TO 35 G S1
l 647106EN
(4TNE92 - 4TNE98
MI 15 TO 35 D S1 E3)
- CHARACTERISTICS AND SPECIFICATIONS l 647507EN
- CONTROL AND ADJUSTMENT (4TNV94L

MI 20 TO 35 D S2 E3)
- TROUBLESHOOTING
- SPECIFIC TOOLING l 647120EN
(K21 - K25 GAS ENGINE)

MI 15 TO 35 G S1
l 647471EN
(K21 - K25 LPG ENGINE)

MI 15 TO 35 G S2
10
ENGINE CHARACTERISTICS AND SPECIFICATIONS
pages
POWER SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MI 15 TO 35 G - S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MI 15 TO 35 G - S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MI 15 TO 35 D - S1 E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MI 20 TO 35 D - S2 E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– MI 20 TO 35 D Y E3 S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
K21 - K25 GAS ENGINE - LPG CARBURETION OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– OPERATING A CASOLINE CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– LPG ASSEMBLY DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(07/06/2018) 10-01-M183EN
ENGINE CHARACTERISTICS AND
2 SPECIFICATIONS
POWER SYSTEM
MI 15 to 35 G - S1 (UP TO MACHINE N°856887)

10
Gasoline (K21 - K25 GAS ENGINE)

K21 GAS K25 GAS
Parameter
MI 15 G / MI 18 G MI 20 G / MI 25 G / MI 30 G / MI 35 G
Rated output (kW) 37 44
Rated rotate speed (r/min) 2300 2500
Max. torque (N.m) 142 179
Speed (rpm) 1600 1600
Service weight (kg) 158 161
Combustion system IMPCO single fuel IMPCO single fuel
MI 15 to 35 G - S2 (FROM MACHINE N°856888)
LPG Single fuel (K21 - K25 LPG ENGINE)

K21 LPG K25 LPG
Parameter
MI 15 G / MI 18 G MI 20 G / MI 25 G / MI 30 G / MI 35 G
Rated output (kW) 29 35
Rated rotate speed (r/min) 2250 2400
Max. torque (N.m) 140 170
Speed (rpm) 1600 1600
Combustion system NIKKI single fuel NIKKI single fuel
MI 15 to 35 D - S1 E3 (UP TO MACHINE N°_____)
Diesel (4TNE92 - 4TNE98 DIESEL ENGINE)

4TNE92 4TNE98
Parameter
MI 15 D / MI 18 D MI 20 D / MI 25 D / MI 30 D / MI 35 D
Rated power (kW) 32.8 44.3
Rated rotate (r/min) 2450 2300
Max. torque (N.m) 149.4 206
Speed (rpm) 1600 1700
Service weight (kg) 194 194
(FROM MACHINE N°____)

Diesel (4TNV94L DIESEL ENGINE)
Parameter MI 20 D / MI 25 D / MI 30 D / MI 35 D
Rated power (kW) 35.5
Rated rotate (r/min) 2400
Max. torque (N.m) 208
Speed (rpm) 1500
Service weight (kg) 235
10-01-M183EN (07/06/2018)
SPECIFICATIONS 3
MI 15 to 35 G - S1
K21 - K25 GAS ENGINE - LPG CARBURETION OPERATION
OPERATING A CASOLINE CARBURETION
10
START-UP
uring the start-up phase, the depression recorded in the carburettor is transmitted to the secondary
D
diaphragm of the reducing valve via a vacuum pipe.
This diaphragm opens a check valve enabling the LPG gases to be drawn up to the carburettor.
The LPG gases are mixed with air in the carburettor and then enter the engine via the intake pipe.
OPERATION
While operating, the engine depression, transmitted to the carburettor, acts on the secondary diaphragm,
which regulates the gas flow depending on the value of the depression recorded.
Clogging of the air filter increase the depression. This depression transmitted by the compensator pipe
draws the reducing valve’s secondary diaphragm and limits the opening of the reducing valve’s check
valve which reduces the LPG flow and maintains the ideal Air/Gas ratio.
REMINDER
bb If gaseous capture phase

If liquid capture phase
---> C13 valve towards the top
---> C13 valve towards the bottom
(07/06/2018) 10-01-M183EN
4 SPECIFICATIONS
MI 15 to 35 G - S1
LPG ASSEMBLY DIAGRAM
1 2
10
3
5 4
7
10
9
8
11
11
Legend :
1 - Air filter
2 - C13 gas bottle
3 - Overpressure valve
4 - Compensator hose
5 - Carburettor
6 - VFF30 valve (Fuel lockoff and filter)
7 - Intake manifold
8 - Engine
9 - Cobra Reducing valve
10 - Overpressure hose
11 - To engine cooling
10-01-M183EN (07/06/2018)
10
ENGINE COMPONENTS LOCATION
pages
ENGINE COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– K21 - K25 ENGINE (MI 15 TO 35 G) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– 4TNE92 - 4TNE98 DIESEL ENGINE (MI 15 TO 35 D S1 E3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– 4TNV94L DIESEL ENGINE (MI 20 TO 35 D S2 E3 & MI 20 TO 35 D Y E3 S3) . . . . . . . . . . . 3
LPG CARBURETION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– K21 - K25 GAS ENGINE (MI 15 TO 35 G - S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– K21 - K25 LPG ENGINE (MI 15 TO 35 G - S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
INLET - EXHAUST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(07/06/2018) 10-03-M183EN
2 ENGINE COMPONENTS LOCATION
MI 15 to 35 G - S1
MI 15 to 35 G - S2
ENGINE COMPONENTS
K21 - K25 ENGINE (MI 15 to 35 G)

10
Carburetor
Starter
Alternator
Ignition
Oil filter
10-03-M183EN (07/06/2018)
MI 15 to 35 D - S1 E3
ENGINE COMPONENTS LOCATION 3
MI 20 to 35 D - S2 E3
MI 20 to 35 D Y E3 S3
4TNE92 - 4TNE98 DIESEL ENGINE (MI 15 to 35 D S1 E3)
(2)
10
(6)
(12)
(10)
(11)
(1)
(9)
(4)
(13) (15)
(8)
(3)
(14)
(7) (5)
KEY (4TNE92 - 4TNE98) :

4TNV94L DIESEL ENGINE (MI 20 to 35 D S2 E3 & MI 20
1 - Fuel Filter / Water Separator to 35 D Y E3 S3)
2 - Top Filler Port (Engine Oil)
3 - Governor Lever
4 - Fuel Injection Pump
5 - Side Filler Port (Engine Oil)
6 - Fuel Priming Pump
7 - Drain Plug (Engine Oil)
8 - Engine Oil Filter
9 - Dipstick (Engine Oil)
10 - e Coolant Pump
11 - Alternator
12 - Glow Plug
13 - V-Belt
14 - Crankshaft V-Pulley
15 - Starter Motor
(07/06/2018) 10-03-M183EN
MI 15 to 35 G - S1
MI 15 to 35 G - S2
LPG CARBURETION
K21 - K25 GAS ENGINE (MI 15 to 35 G - S1)

10
KEY :
2 1 - Overpressure valve
2 - Cobra Reducing valve
3 - VFF30 valve (Fuel lockoff and filter)
K21 - K25 LPG ENGINE (MI 15 to 35 G - S2)
KEY :
1 - Overpressure valve
2 - Solenoid valve and filter
3 - Vaporizer
10-03-M183EN (07/06/2018)
ENGINE COMPONENTS LOCATION 5
INLET - EXHAUST
10
Exhaust line (Option)
Air Filter Line
Cooling system
(07/06/2018) 10-03-M183EN
10
10-03-M183EN (07/06/2018)
10
ENGINE CONTROL AND ADJUSTMENT
pages
K21 - K25 ENGINE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1

4TNE92 - 4TNE98 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
MI 15 to 35 D - S1 E3
(14/06/2016) 10-04-M183EN
2 ENGINE CONTROL AND ADJUSTMENT
10
10-04-M183EN (14/06/2016)
ENGINE CONTROL AND ADJUSTMENT A1
MI 15 to 35 G - S1
MI 15 to 35 G - S2
K21 - K25 ENGINE

pages
10
K21 - K25 GAS ENGINE (MI 15 TO 35 G - S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
–– VFF30 VALVE DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
–– SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
–– VALVE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
–– VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
–– REPAIR KIT INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A5
–– TECHNICAL FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A12
–– COBRA REDUCING VALVE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A13
–– VALVE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A14
–– OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A17
–– TECHNICAL FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A18
–– DISMANTLING CARBURETTOR CA55 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A19
–– VALVE DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A20
–– PRINCIPLE OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A21
–– DISMANTLING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A24
–– DIS-ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A24
–– TECHNICAL FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A28
–– SETTING THE POLLUTION AND IDLE ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A29
K21 - K25 LPG ENGINE (MI 15 TO 35 G - S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . l 647471EN
(14/06/2016) 10-04-M183EN
A2 ENGINE CONTROL AND ADJUSTMENT
MI 15 to 35 G - S1
K21 - K25 GAS ENGINE (MI 15 to 35 G - S1)
VFF30 VALVE DISMANTLING

10
SPECIFICATIONS
The Model VFF30 is a combination fuel lockoff and filter, engineered for use with LPG (liquid or vapor)
or Natural Gas Vapor. It is available with hydrin, silicone and fluorosilicone diaphragms. A pressure of
0.5” Hg (1.69 kPa) is required to open the lockoff. The VFF30 is suitable for engines up to 325 hp (242
kW) at a maximum working pressure of 312 psi (21.51 Bar). The extra large capacity filter element is
fully serviceable.
Fuel Type.............................................................................................................. LPG Liquid/Vapor, Natural Gas Vapor

Inlet Pressure (maximum)................................................................................................................... 312 psi (21.51 Bar)
Flow Rate.................................................................................................................................................. 26.7 CFM (12.6 L/s)
Operating Temperature Range........................................................................... -40°F to +250°F (-40°C to +121°C)
Filtration Requirement..........................................................................................................................................40 Micron
Vacuum Activation.....................................................................................................................................................................
Minimum Opening................................................................................................................... 0.50” w.c. (0.12kPa)
Fully Opened............................................................................................................................. 11.5” w.c. (2.86 kPa)
Minimum Operating Opening................................................................................................2.0” w.c.(0.50 kPa)
Mounting Position...................................................................................................................Vertical (as shown above)
Certification........................................................................................UL (AU1502) Inquire for specific ECE approval
10-04-M183EN (14/06/2016)
MI 15 to 35 G - S1
VALVE DIAGRAM
10
Legend :
A - Chamber 8 - Valve spring

B - Gaz entry 9 - Seat
C - Gaz outlet 10 - Pin
1 - Screw of filter cover 11 - Washer
2 - Filter cover 12 - O-ring
3 - Filter cover gasket 13 - Screw
4 - Filter 14 - Diaphragm cover
5 - Screen backup filter 15 - Diaphragm
6 - Body 16 - Valve operating lever
7 - Screw 17 - Plug Depression
VALVE OPERATION
The LPG in liquid phase enters by the cover, through the felt filter which retains all the impurities.
The valve is held in place by the perforated plate.
The gas stops before the check valve and the gas pressure closes the check valve (positive safety).
By the depression plug (17), the carburettor creates a depression in chamber A which draws the
diaphragm (15).
This activates the lever (16) which moves the pin (10) and thus opens the check valve (9). Once open, the
check valve allows the gas to pass towards the filter valve outlet in the direction of the reducing valve.
(14/06/2016) 10-04-M183EN
MI 15 to 35 G - S1
Screw
Cover
10
Filter cover gasket
Filter
Seat
Screen backip filter
Pin
Screw
Washer
Valve spring
O-ring
Screw
Body
Valve operating lever
Fulcrum
Screw
Diaphragm
Diaphragm cover
Screw
10-04-M183EN (14/06/2016)
MI 15 to 35 G - S1
REPAIR KIT INSTALLATION INSTRUCTIONS
INSTALLATION SAFETY PRECAUTIONS:
1 - Do NOT use Teflon thread tape on any of the NPT pipe-thread fittings where fuel travels. Use a
10
suitable fuel-resistant joint compound.
2 - Be sure to leak-check all fittings and covers for fuel tanks, using a soapy solution.
3 - Be sure to use proper mounting bolts to secure the lockoff. Bolts which are too long may cause
severe damage to the lockoff.
1 - Kit includes: Gasket, Filter, Screen, Diaphragm Assy., Screws

8-32 x 5/8” (2), Screws 12-24 x 5/8” (2), Seal (Viton, bonded to
aluminum), Lip Seal, Valve operating pin, Retaining washer,
Instructions, Seal holder (tool) and Installation pin (tool).
2 - Remove 10 screws from cover which has the words “Fuel

In” cast into it.
3 - Remove the cover and the gasket.
(14/06/2016) 10-04-M183EN
MI 15 to 35 G - S1
4 - Remove the filter and screen.

10
5 - Remove screw holding valve screen in place.
6 - Remove valve spring.
7 - Remove valve seat.
10-04-M183EN (14/06/2016)
MI 15 to 35 G - S1
8 - Remove valve operating pin.
10
9 - Using a bent paper clip or wire, fashion a hook as shown.
10 - Cutaway shows the relationship of the valve spring, valve

seat, valve operating pin, seal retaining washer and o-ring.
Note that removal of valve pin allows retaining washer to
be removed through the “Fuel Out” (1/4” NPT) opening.
11 - Insert wire hook through “Fuel Out” threaded port to hook

the retaining washer, then...
(14/06/2016) 10-04-M183EN
MI 15 to 35 G - S1
12 - ...pull the retaining washer out of the body through the

jet hole.
10
13 - Using the same hook/wire, pull the o-ring seal through

the hole in the body from which you removed the valve
operating pin in step 7. Wash body, cover and jet area as
needed, using kerosene or equivalent petroleum solvent.
Do NOT use carburetor cleaner, as it will attack synthetic
rubber seals.
14 - Seal holder should be placed as shown in photo (bottom

tool). Note that the hole in the seal holder, which accepts
the O-ring lip seal, is tapered, and that the wider end of
the opening faces up. The replacement seal must be
coated with silicone grease prior to inserting into holder.
Place the greased O-ring seal into the holder, using the
installation pin (upper tool). Re-coat the seal with silicone
grease.
The seal must be in the position shown in the photo
groove facing up, and visible. Seal is tapered to match
the hole in the seal holder.
15 - Place the body with the filter side up, as shown.
10-04-M183EN (14/06/2016)
MI 15 to 35 G - S1
16 - With the O-ring lip seal in the holder, groove visible and
facing up, slide the holder into the body. Look through
the Fuel In port to check positioning of the seal, above the
cavity of the seal recess (see cutaway, step 10).
10
17 - Coat the installation pin with silicone grease and push the
seal through the holder and into the seat recess of the body.
Remove installation pin and check for proper installation by
looking into the Fuel In port. O-ring seal should be seated
in the seal recess and groove should be visible.
18 - Use needle nose pliers to insert seal retainer washer

through the Fuel In threaded port. Again, refer to cutaway
drawing, step 10.
19 - Lubricate valve operating pin with silicone grease and

insert in body as shown, so that pin passes through retainer
washer and o-ring lip seal. Rotate pin slowly to ease passage
through washer and o-ring.
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20 - Place valve seat on top of head of operating pin, with

aluminum side facing up and dark, Viton side against
head of pin.
10
21 - Add valve spring and secure with screw.
22 - Lift valve spring slightly to confirm its freedom of

movement.
23 - Insert screen and filter.
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24 - Place gasket on body and align with screw holes.
10
25 - Add filter cover and secure with screws. Alternate side to
side when tightening screws.
26 - Cover and diaphragm are removed. Clean parts as necessary,

using only kerosene or equivalent petroleum solvent. Do
NOT use carburetor cleaner.
27 - Check valve operating lever for freedom of movement.

Use silicone grease to coat the surface of the gasket which
will contact the body.
Note: gasket will only align with holes when installed correctly.
Rivet heads in diaphragm plate should be on the cover side, not
the body side.
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28 - Add diaphragm to body, then...

10
29 - ..add cover and secure with screws, alternating sides as

you tighten screws.
TECHNICAL FILE
CHECKING THE STATE OF THE FILTER VALVE
To see if the filter valve (VFF-30) is in good working order, it is necessary to:
- start the engine
- thread the hose between the filter valve (VFF-30) and the carburettor (CA55).
If the engine continues to run, the filter valve is not leaking.
If the engine chokes, that suggests that there is a leak within the filter valve.
The engine is receiving too much gas.
- Put new liner RK-VFF-30-2, ref. 550525 without forgetting to change the lipped seal and replace
the retaining washer.
PROBLEM WITH VALVE FILTER ICING
If the filter valve freezes, this could be due to a number of reasons:

- either the filter valve’s lipped seal is no longer waterproof (to check this, do the same as above),
- or the LPG tank has been assembled the wrong way round. Therefore, the dip tube inside of the
tank draws gas in the gas phase instead of in the liquid phase.
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COBRA REDUCING VALVE OPERATION
SPECIFICATIONS
10
COBRA SERIES
TWO STAGE CONVERTER FOR 3.7 TO 75 KW (5 TO 100 HP) FOR LP GAS ENGINES
The COBRA series converters deliver superior performance and very stable pressure output
through-out their service life. Three vapour outlet pressures are available.
Use of the standard blue secondary spring provides negative pressure of 0.37 kPa (- 1.5 inches w.c.).
The optional orange secondary spring provides negative pressure of 0.12 kPa (-0.5 inches w.c.) and the
red secondary spring, negative pressure of 0.05 kPa (- 0.2 inches w.c.).
Type of fuel.....................................................................................................................................Liquid/vapour propane

Max. inlet pressure ................................................................................................................................ 2151 kPa (312 psi)
Min. inlet pressure ...................................................................................................................................... 207 kPa (30 psi)
Primary pressure................................................................................................................6.9 to 13.8 kPa (1.0 to 2.0 psi)
Nominal outlet pressure .........................................................................................................................................................
....................................................................................................................standard (blue spring) – 0.37 kPa (- 1.5 w.c.)
.................................................................................................................. Cobra I (orange spring) – 0.12 kPa (- 0.5 w.c.)
.........................................................................................................................Cobra II (red spring) – 0.05 kPa (- 0.2 w.c.)
Horse power rating................................................................................................................. 3.7 to 75 kW (5 to 100 hp)
Temperature range..................................................................................................... - 40° to +121°C (-40° to +250° F)
Filtration requirement ......................................................................................................................................... 40 micron
Heating chamber source, cooling liquid, engine oil, exhaust heat may be used
with a B3-20 baffle
Vertical mounting position recommended (outlet down). The horizontal position (secondary cover up)
can be used when fuel contamination can be controlled with HD-5 propane fuel.
Weight ............................................................................................................................................................ 0.86 kg (1.9 lbs)
Applications .....................................................open loop, closed loop, forced induction up to 34.4 kPa (5 psi)
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VALVE DIAGRAM
10
Legend :
A - Inlet and outlet of cooling liquid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8˝ NPT

B - Inlet of liquid gaz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4˝ NPT
C - Plug for primary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8˝ NPT
D - Fuel vapor outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/2˝ NPT
E - Connection air purge / balanced . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/8˝ NPT
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Push button Secondary diaphragm
10
Spring
Secondary check valve
LPG gases towards

carburettor
LPG
liquid
Primary chamber
Cooling liquid passage P r i m a r y

Primary check valve diaphragm
High Pressure Low Pressure
Liquid gas pressure at inlet of reducing valve: from 5 to 6 bar

Gaseous gas pressure in the first chamber: 0.1 bar
Depression of gaseous gas at outlet of reducing valve: - 38 mm EC -depression
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Component parts :
1 - Screen, atmospheric vent

2 - Screw 8-32 x 5/8˝
10
3 - Cover assy, secondary

4 - Diaphragm assy, secondary
5 - Screw 8-32 x 3/8˝
6 - Lever secondary
7 - Pin secondary fulcrum
8 - Seat secondary
9 - Spring blue secondary (standard)
Spring orange secondary (option)
Spring red secondary (option)
10 - Body assy
11 - Screw 1/4 - 20 x 5/8˝ (2)
12 - Gasket, body to body cover plate
13 - Pin, valve primary
14 - Plate, body cover
15 - Plug, 1/8˝ NPT
16 - Spring, primary
17 - E ring, external
18 - Diaphragm assy, primary
19 - Cover primary
20 - Screw 8-32 x 1
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OPERATION
The liquefied gas must pass from a liquefied state to a gaseous state in order to be prepared as
a fuel mixture in the gas/air mixer with 1’ the drawn air.
This is obtained at 1 with the vaporiser heated by the engine cooling liquid.
10
The operating mode is as follows:
The vaporiser is a dual-phased combination regulator with vaporiser. Through the solenoid valve
fitted with a cleaning filter, it receives the liquefied gas held under pressure in the tank and reduces this
pressure in two phases to a pressure a little below that of atmospheric pressure (depression).
When the engine is in operation (the throttle valve of the gas/air mixer is open), a vacuum occurs
in the intake tube going to the carburettor, which opens the reducing valve’s secondary check valve
by which the gaseous gas can reach the carburettor by passing through the primary check valve. The
secondary check valve is driven by the secondary diaphragm.
In the rest position (engine is stopped), the primary check valve is open and the secondary check
valve is closed. The secondary check valve prevents the gas from escaping when the engine is stopped.
The spring situated under the lever assists the check valve with this process.
The control of the primary check valve is carried out by the pressure inside the vaporising chamber
which acts on the primary diaphragm. This pressure is reached by the port in the chamber situated in
front of the diaphragm. The needle valve transmits the movement to the primary check valve. The spring
positioned under the needle valve resists the movement. The face opposite the primary diaphragm is
subjected to atmospheric pressure transmitted by the ventilation hole.
The secondary check valve can be activated manually for cold starts.
While the engine is running (the mixer’s throttle valve is open), a vacuum is formed inside the
intake tube. This vacuum opens the secondary check valve which allows the liquid gas to escape into
the vaporiser via the primary check valve. The secondary check valve is controlled by the secondary
bb
diaphragm.
The fall in liquid gas pressure (approx. 6 bar inside of the tank) to atmospheric pressure releases
the liquid gas and initiates cooling. The vaporiser is heated to compensate for this cooling and to
accelerate vaporisation. For this reason, the cooling liquid is directed towards the vaporiser via the
heating channel. According to the position of the throttle valve (which depends on the position of the
acceleration pedal), the secondary diaphragm is more or less drawn, and thus controls the opening of
the secondary check valve.
According to the engine load and speed, the depression increases or decreases on the rear face of
the secondary diaphragm. The gas flow is then changed to the level of the secondary check valve.
If a clogged air filter initiates a depression increase, this increase resists the opening pressure of the
secondary diaphragm. The closing of the regulating check valve is accentuated, the gas flow is thus
reduced and the mixture is poorly maintained. When the engine is stopped, the secondary check valve
closes completely. The gas can no longer reach the carburettor.
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TECHNICAL FILE
CHECKING THE STATE OF THE REDUCING VALVE
To check the functioning of the reducing valve, it is necessary to:

10
- remove the hose between the reducing valve and the carburettor,
- create a vacuum in the filter valve (VFF30) by drawing into the hose using a vacuum pump. If
the reducing valve is operating correctly, there will be no gas at the reducing valve outlet.
2° CHECKS
If the starter button is pushed while drawing, there should be gas at the reducing valve outlet and as
soon as the button is released, the intake of gas should stop.
3° CHECKS
In order to check the primary pressure of the reducing valve:

- Empty the circuit of any gas,
- Unscrew cap no. 15,
- Connect a manometer with a pressure scale of 0 to 1 bar
- With the engine running at idle speed, the pressure should be 0.1 bar.
If the pressure is too high, the primary check valve no. 13, or the diaphragm no. 18, may be faulty.
If the reducing valve is faulty, take a reducing valve repair box:
RK_COBRA, Ref. 602091
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DISMANTLING CARBURETTOR CA55
SPECIFICATIONS
10
IMPCO’s CA55 model carburetors are offered in four design variations, providing proven, effective
solutions for optimum metering and delivery of either LPG Vapor or Natural Gas. The standard model
can be mounted in either an updraft, downdraft, or sidedraft orientation, supplying either LPG or Natural
Gas to engines up to 73 hp (1 to 54kW), with a flow rate of 118 CFM (55.7 L/s). Various SAE flanges and
air horn sizes are available.
Fuel Type.....................................................................................................................................LPG Vapor or Natural Gas

Inlet Pressure....................................................................................................................................... -1.5” w.c. (-0.37 kPa)
Operating Temperature Range...........................................................................-40°F to +250°F (-40°C to +121°C)
Mounting Position......................................................................................................................................................Vertical
Diaphragm Material.......................................................................................................................................................... N/A
HP/kW Rating......................Up to 73 hp (54 kW) @ 118 CFM (55.7 L/s) and 2.0” in Hg manifold depression
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VALVE DIAGRAM
Plug 1/5’’
Idle srew
10
Spring idle srew
Air horn Assy
Air valve Assy
Sealing ring
Spring air valve
Check valve plate Assy
Gasket
Piston, Idle cutoff
Spring, Idle cutoff
Screws
Throat SAE flange
Seal
Bearing
Screw Seal retainer
Fly Screw
Pin
Throttle stop Assy
Throttle shaft
Gasket
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PRINCIPLE OF OPERATION
ROLE
A good proportion of the gas / air mixture is essential for the perfect engine operation and reduced
10
pollutant emissions. The carburetor uses «metering valve» to obtain an optimized mixture.
IDLING FULL LOAD
LEGENDE CA50, 55 :
1 - Piston ring
2 - Piston
3 - Cone gas
4 - Channels
5 - Ball control (gas flow) in charge
6 - Idle adjustment screw
7 - Spring of the metering
8 - Plug depression
9 - Throttle valve
10 - . Screw 10-24x 16mm
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OPERATION
At Starting the engine (throttle (9) open), the chamber located below the piston is subjected to a vacuum
caused by the suction of the pistons of the engine. This depression, as opposed to the pressure of the
10
spring (7), moves the piston (2) down. By this movement, the piston (2) provides an opening of the
cone gas (3) complete.
Depression varies with engine speed and throttle position (9). The piston (2) dose the amount of air
sucked by the engine. The cone gas (3) is secured to the piston and designed to deliver the quantity of
gas from gas to the amount of intake air according to the position of the piston (2).
EVOLUTION
The carburetor CA55 replaces the carburetor CA50.
The carburetor CA55 improvements include:

–– A segmentation thicker material high tech Dupont
–– Enlargement of the guide plates, also in Dupont material
–– Manufacturing tolerances more stringent
–– Exhibition of the body of a CA55 corrosion resistant layer type Teflon
Thus we find a longer life, improved performance resulted in reduced emissions and reduced maintenance
costs.
Attention: For the carburetor CA50, use the repair kit 588670.
SETTING
On the carburetor, two mixing settings are provided on the mixer and an idle engine speed control on
its base.
IDLE ADJUSTMENT - AIR BY PASS
The quantities of air and gas flowing next to the closed throttle remain constant. During the idle
adjustment, part of the intake air is diverted from the air intake valve. The idle adjustment is made by
the adjusting screw (6) of the By-pass of air that can impoverish or enrich the gas / air mixture at idle.
MIXTURE ADJUSTMENT AT FULL LOAD
This setting adjusts the mixture when the cone gas (3) is stopped. The adjustment of the cone gas can
be performed only when the engine is fully loaded and the speed limit (rated speed) is reached.
The composition of the mixture for the intermediate phases at idle and full load is regulated by the
specific shape of the cone gas (3). This one is designed to low mixing at low load, and designed to
increased strength according to the increased engine speed and load.
SETTING IDLE ENGINE SPEED
On the axis of the throttle carburetor, you find a screw with a spring deadline. It is used to determine
the speed of motor rotation (speed) by simply tightening or loosening.
REPAIR POCKET CHANGE ALL 1000 HOURS, REF. 588670
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SETTING THE RATE OF CARBON DIOXIDE
⇒⇒ Prerequisites:
–– Starting the engine in good condition
–– The engine and hydraulic oil at operation temperature (Trigger fan motor)
10
–– The pressure the pressure limiter of the hydraulic work is set as indicated
–– the manufacturer.
–– The parking brake is locked in position brake applied.
1 - Set engine RPM
2 - Idle Speed Adjustment

–– Tighten the idle setting (6) to a stop and then loosen the 2.5 to 3 turns.
–– Connect the gas analyzer IMPCO TEC-898 (Measurement of carbon monoxide)
–– Engine running, measure the rate of CO at idle (950-1000 rev / min)
The CO should be measured between 0.1 and 0.5%

If the measured CO is greater than 1% vol, loosen the set screw (6), the engine must keep a normal
operating cycle.
3 - Setting the full load

–– Position the adjusting screw (5) of the carburetor at full load to (Item R)
–– Load up the engine to speed limit (rated)
–– Perform a hydraulic load and hold for the measures
–– Measure the CO
The CO should be measured between 0.1 and 0.5% vol. To make a correction to the rate of CO, turn the
adjustment screw (5) to (Item L)
Note: During the measurement phase, the engine must not fall below 2300 r / min
Item 5
REMINDER
Item 6 Screw = enrich = R

Unscrew = impoverish = L
Throttle stop
screw
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DISMANTLING INSTRUCTIONS
bb ARNING, before starting repairs on the CA55 carburettor, check that the repair box corresponds
W
with the references provided by the manufacturer. There are several types of CA55 carburettors,
and the incorrect box may cause serious engine problems.
10
Seals box reference: 588670
DIS-ASSEMBLY
1 - Unscrew the base of the carburettor
2 - Note that the seal holds up the piston, this being

the piston which cuts off idle movement.
3 - Remove the seal. The idle movement piston and

its spring will be freed.
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4 - Remove the guide plate and the air/gas piston

spring.
10
5 - Clean the carburettor’s body with petrol or
another gentle degreaser.
6 - The RK-CA55 box ref.588670 includes the following

parts:
1 – Air/gas piston
1 – Piston ring.
1 – Air/gas piston guide plate.
1 – Seal between base and body of carburettor.
4 - M 10 - 24 x 16 mm screw
1 – Idle speed change piston.
1 – Spring, idle speed piston.
1 - Repair manual
7 - In the case where the ring is still not in place

on the piston (in the repair box), proceed as
indicated in the photo.
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8 - Replace the gas/air piston in the carburettor’s

body. Carefully guide the ring to avoid any
scratches.
10
9 - Replace the air/gas piston spring and the piston’s

guide plate.
10 - View of the carburettor body with the air/gas

piston, spring and guide plate in place. Mount
the spring and the idle speed change piston on
to the base.
11 - Place the seal on the base while holding the idle

speed change piston under the thumb.
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12 - Position the carburettor’s body as shown in the

photo. Next place the base with the seal and the
piston in position of the carburettor’s body.
10
13 - Centre the base carefully on the carburettor’s
body, ensuring that the small piston remains
correctly in its place.
14 - Tighten the 4 screws.
15 - Check that the piston can move freely.
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TECHNICAL FILE
CHECKING THE CARBURETTOR

10
There is not really any method for checking the state of the carburettor, other than dismantling it and
simply looking at the state of the diaphragm or the piston.
DATE OF
250H 500H 750H 1000H 1500H 2000H
INSTALLATION
FUEL COMPONENT
Adjusting the mix of idle X X X X
Adjusting the mix at full load X X X X X
Checking the membrane air / gas X X X
Replacing the membrane air / gas X X
Maintenance of the air filter X X X X X X
Check the sealing between the air filter and carburetor X X X X X X
Clean inside the carburetor X X X X
Check the sealing on the intake side between the

carburetor and the engine
PART REDUCTING
Check the secondary membrane X X X X
Check the primary pressure (0.1 bar with the engine

X X X
idling)
Change the repair kit X X
PART VALVE FILTER
GENERAL MAINTENANCE
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SETTING THE POLLUTION AND IDLE ENGINE
Purpose : to ensure proper engine idle speed and the level of pollutant gas emissions.
10
1-1
Establish analyzer probe (1) in the exhaust.
1-2
Connecting the tachometer (2) on a motor plug power cable.
1-3
Adjust the engine speed to 825 +/- 25 r / min by adjusting the
idle screw (3)
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1-4
Controlling the emission of gases.
The CO value should be between 0.10% and 0.50%.

10
1-5
To do this, adjust the screw (4) of the vaporizer.

4
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ENGINE CONTROL AND ADJUSTMENT B1
MI 15 to 35 D - S1 E3
4TNE92 - 4TNE98 DIESEL ENGINE

pages
10
STARTER DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
ALTERNATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
FAN DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
RADIATOR DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B4
(23/07/2012) 10-04-M183EN
B2 ENGINE CONTROL AND ADJUSTMENT
MI 15 to 35 D - S1 E3
STARTER DISASSEMBLY
10
Open I.C. engine cover

Disconnect the battery
Disconnect the two connectors (foolproof devices) and undo
the supply cable (13 mm wrench)
Remove the two fixing bolts (17 mm wrench)
Remove the starter and identify the cause of breakdown.
ALTERNATOR DISASSEMBLY

1 Disconnect the battery
Loosen the two clips from the air filter hose, and then remove it.
Disconnect the alternator from harness : one connector, one
ground wire (cruciform screwdriver), one power wire (8 mm
wrench) and the temperature sensor above.
Unscrew the upper bolt (Rep.1) (12 mm wrench) for adjustment
the belt tension, and then on the fan side, unscrew the lower
nuts (12 mm wrench) from the alternator’s axle.
Remove the belt.
Loosen the bolt from the adjustment lug (Item 2), raise the lug
10-04-M183EN (23/07/2012)
ENGINE CONTROL AND ADJUSTMENT B3
MI 15 to 35 D - S1 E3
a little to free the alternator.

Remove the alternator and retrieve the shim.
2
10
Shim position on the engine crankcase.
FAN DISASSEMBLY

Disconnect the battery
Loosen the two clips from the air filter hose (Rep.1), and then
remove it.
2 Unscrew the upper adjustment bolt (12 mm wrench) from the
belt tension, and then on the fan side, unscrew the lower nuts
(12 mm wrench) from the alternator’s axle.
1 Slacken the belt.
Loosen the four fan bolts (Rep.2) (12 mm wrench).
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B4 ENGINE CONTROL AND ADJUSTMENT
MI 15 to 35 D - S1 E3
RADIATOR DISASSEMBLY
Start by lowering the fan as described above.

1 Place a collection container under the vehicle.
10
Disconnect the two water hoses from the radiator (adhesive

marks towards the engine) and the expansion tank’s hose (Item
2
1), and the two transmission oil hoses (Item 2).
bb
1
ake care to protect the ports in order to prevent any
T
2
clogging.
1
Loosen the four fixing bolts (10 mm wrench) from the fan’s
deflector, and then remove it.
Remove the two fixing bolts (Item 1) (16 mm wrench) from the
radiator, remove it by lifting it from its silent blocks.
10-04-M183EN (23/07/2012)
10
ENGINE REMOVAL
pages
K21 - K25 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1

4TNE92 - 4TNE98 DIESEL ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
MI 15 to 35 D - S1 E3
(20/11/2014) 10-06-M183EN
2 ENGINE REMOVAL
10
10-06-M183EN (20/11/2014)
ENGINE REMOVAL A1
MI 15 to 35 G - S1
MI 15 to 35 G - S2
K21 - K25 ENGINE

pages
10
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
REMOVING ENGINE K21-K25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
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A2 ENGINE REMOVAL
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MI 15 to 35 G - S2
PREPARATION AND SAFETY INSTRUCTIONS

Stabilize the machine on a horizontal floor.
Lower the mast to a maximum with the forks set on the ground.
10
Disconnect the battery.

Transmission weight: 105 kg
Specific tool:
- Lifting crane (minimum 1000 Kg)
Check that the engine lifting device goes under the lift truck, otherwise put blocks under the front and
rear wheels.
Ensure to remove the vehicle’s left rear wheel in order to be able to back the engine with the lifting
crane under the chassis.
bb efore any intervention, close the gas bottle and let the engine run until it stops to reduce the
B
pression in gas circuit to prevent any damage.
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ENGINE REMOVAL A3
MI 15 to 35 G - S1
MI 15 to 35 G - S2
REMOVING ENGINE K21-K25
10
Open I.C. engine cover.
Disconnect the battery and remove it.
Remove the rubber protector.

1
Remove the floor panel (Item 1) in front of the seat with its 2 bolts.
Remove the floor panel under the pedals (Item 2) with its 4 bolts.
Loosen the nut from the accelerator cable and remove the pin.
On the left door, on the end of the door’s compass (Item 3),
undo the pin (Item 4) from its housing in the swivel joint (Item
5), disassemble the swivel joint and open the door backward.
3
5
Hold the door open backward.

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A4 ENGINE REMOVAL
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MI 15 to 35 G - S2
Open the engine cover (Item 2) and disconnect the seat harness
behind the battery, remove the locking lug, unpin the top of
gas spring and lower it.
1
10
Unscrew 6 bolts from the 2 hinges of the engine cover (Item 1).
2
1
Lower the engine cover (Item 2), move it forwards and remove it.
Unscrew 2 clips from the air hoses and remove them.
3
Remove the battery holder (Item3) with fuses box, disconnect
4 connectors.
Place a collection container under the vehicle.
Drain the radiator (Item4).
Disconnect the oil pressure sensor, ignition coil connector.

4
Disconnect the water temperature (Item 1), the buzzer alarm

1
(Item 2), (warning identical connector).
3
Disconnect alternator (Item 3).

3
2 Unscrew the upper nut and lower nut of the alternator, remove
3 the belt.
Unscrew 4 screw from the fan, and remove it.
10-06-M183EN (20/11/2014)
ENGINE REMOVAL A5
MI 15 to 35 G - S1
MI 15 to 35 G - S2
Disconnect the gas hose from the lock and filter valve, and the
compensator hose from reducting valve.
1
Disconnect the water hose from the radiator (Item 1).
bb
2
10
2 2 ake care to protect the ports in order to prevent any
T
clogging.
2
3
Loosen 4 fixing bolts (Item 2) from the fan’s deflector, and then
remove it.
Disconnect the second water hose (Item3).
Remove the transmission oil hose from the tank oil (Item4) and
from the oil pump.
4
Disconnect the starter.
Disconnect the exhaust pipe near the engine and tie back close
to the air filter.
5 Remove 2 access grid screws of the converter (Item 5).
6
7 Unscrew 12 screws of converter’s flexible plate on flywheel (Item
6) 3 by 3.
5
Chock up the transmission and unscrew 8 screw around the

transmission (Item 7). Unplug the earth wire.
Be carefull to unscrew the fixing of the gas flexible (Item 8).

8
(20/11/2014) 10-06-M183EN
A6 ENGINE REMOVAL
MI 15 to 35 G - S1
MI 15 to 35 G - S2
For MI 15 to 35 G - S2
Disconnect the three hoses (Item1) between the vaporizer
and motor
10
1
1
Put chains on 2 engine’s lifting eyes, and start to lift engine:
2 Remove the left rear silent block to help the output :

–– 4 screws on engine block (Item 2)
–– 2 screws on body frame (Item 3).
Unscrew the right rear silent block on body frame.
3 3
Make sure the engine is balanced.
Protect the radiator, lift a little and disengage the engine to the
rear. Then remove engine.
Make sure you have the shim of the converter (Item 4).
4
5
Maintain the shim on the flywheel with grease (Item 5).
10-06-M183EN (20/11/2014)
ENGINE REMOVAL B1
4TNE92 - 4TNE98 DIESEL ENGINE

pages
10
PREPARATION AND SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
REMOVING ENGINE 4TNE92-98 (WITH TRANSMISSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
(20/11/2014) 10-06-M183EN
B2 ENGINE REMOVAL
MI 15 to 35 D - S1 E3
PREPARATION AND SAFETY INSTRUCTIONS

Place the machine on a horizontal floor and block the wheels.
Lower the mast to it’s maximum with the forks on the ground.
10
Disconnect the battery.
Engine weight: 194 kg

Transmission weight: 105 kg
Specific tool:
- Lifting crane (minimum 1000 Kg)
Ensure to put the vehicle’s front and rear wheels on shims in order to be able to pass the lifting crane
under the chassis.
10-06-M183EN (20/11/2014)
ENGINE REMOVAL B3
MI 15 to 35 D - S1 E3
REMOVING ENGINE 4TNE92-98 (WITH TRANSMISSION)

(2)
(6)
(12)
(10)
(11)
(1)
10
(9)
(4)
(13) (15)
(8)
(3)
(14)
(7) (5)
Open I.C. engine cover.
Disconnect the battery and remove it.
Remove the rubber protector.

1
Remove the floor panel (Item 1) in front of the seat with its 2 bolts.
Remove the floor panel under the pedals (Item 2) with its 4 bolts.
Loosen the nut from the accelerator cable and remove the pin.
Open the engine cover (Item 6) and disconnect the seat harness
behind the battery, remove the locking lug, unpin the top of gas
spring and lower it.
Unscrew 6 bolts from the 2 hinges of the engine cover (Item 3).
Lower the engine cover (Item 6), move it forwards and remove it.
3 On the top of the gas spring, undo the pin (Item 4) from its
housing in the swivel joint (Item 5).
5
6
3
4
(20/11/2014) 10-06-M183EN
B4 ENGINE REMOVAL
MI 15 to 35 D - S1 E3
Unscrew 2 clips (Item 1) from the air hoses and remove them.
1
Remove 2 fixing bolts (Item 2) from the air filter.

10
Disconnect the wiring harness from the alternator: 1 connector

(Item 3), 1 earth wire (Item 4), 1 live wire (Item 5) and the QGS
temperature sensor above (Item 6).
7
6 Slightly unscrew the upper adjustment bolt (Item 7) from the
belt tension, then on the fan side, slightly unscrew the lower
3
5 nut (Item 8) from the alternator’s axle (the lower bolt (Item 8)
is blocked by a welded lug).
Remove the belt.
Unscrew 4 bolts from the fan and remove it.
4 Place a collection container under the vehicle.
2
Disconnect the two water hoses from the radiator (Item 1)
(adhesive marks towards engine) and the expansion tank’s hose
(Item 2), and the two transmission oil hoses (Item 3).
bb
3
1
ake care to protect the ports in order to prevent any
T
clogging.
3
1
Loosen 4 fixing bolts from the fan’s deflector, and then remove it.
Remove 2 fixing bolts from the radiator, and remove it by lifting

it from its silent blocks.
1 Unscrew 2 bolts (Item 1) from the exhaust pipe :

–– undo the first bolt and then turn the clip
–– undo the second one.
10-06-M183EN (20/11/2014)
ENGINE REMOVAL B5
MI 15 to 35 D - S1 E3
Unscrew 4 bolts (Item 1) from the exhaust manifold and leave

1 the metallic joint on the engine.
10
2 Disconnect the hose on the hydraulic pump and the supply
hose (Item 2).
Disconnect the starter: 2 connectors (foolproof devices) (Items

5
3 and 4) and the supply (Item 5).
3
4
Disconnect 2 bolts from the converter’s ventilation plates (Item 6).

7
6
6
8 Disconnect the wiring harness from the FNR valve (Item 7).
Disconnect the temperature sensor from the transmission (Item 8).
Near the engine water pump, disconnect the temperature system

(Barograph) (Item 9), and the preheating system (Item 10).
Remove the fuel filter, disconnect the pipe from the injection
pump and the water presence sensor.
Remove the fuel return pipe.

9
10
On the injection pump, disconnect the engine stop solenoid
valve and the overflow valve (maintains constant temperature
in the pump chamber)
Disconnect the oil pressure sensor.
(20/11/2014) 10-06-M183EN
B6 ENGINE REMOVAL
MI 15 to 35 D - S1 E3
Disconnect 2 transmission oil cooling hoses by loosening their

clips (Item 1).
1
Loosen the adjustment nuts from the inching cable (Item 2)
and its pin and remove the cable.
10
Unscrew the earth (Item 3) on the transmission.
Under the vehicle, undo the 2 clips from the hand brake cable
(Item 2).
3 2
4 Unscrew 4 bolts (Item 4) from the universal joint on the

transmission side and leave them above.
Raise a vehicle wheel as needed to turn the universal joint.
4
Put chains on the engine’s lifting eyes (Item 1) and start to

unscrew the silent blocks:
1
1 - Relieve the silent blocks by slightly lifting the engine.
- U nscrew 2 bolts from the front silent blocks and 4 bolts
1 from the rear silent block’s support plates and position the
universal joint so that the bolt from the silent blocks on the
front right is freed.
Raise the engine and the transmission and place the transmission
on a stable support.
10-06-M183EN (20/11/2014)
10
ENGINE REFIT
pages
ENGINE REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
–– 4TNE92 - 4TNE98 (WITH TRANSMISSION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
–– K21 - K25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
(20/11/2014) 10-07-M183EN
B2 ENGINE REFIT
ENGINE REFIT
Proceed with the refit in the opposite direction of the operations described in the section «ENGINE
bb
REMOVAL» in recpect of torques.
10
The tightening torque in the Standard Torque Chart should be applied
o
bb
00 - GENERAL CONTROL AND ADJUSTMENT.
Apply 80% torque when tightened to aluminum alloy.
(6)
(2)
(12)
4TNE92 - 4TNE98 (WITH TRANSMISSION)
(10)
(11)
(1)
(9)
Fill in the cooling system, check the engine and hydraulic oil
levels, bleed the fuel system.
(4)
(13) (15)
(8)
Install the engine cover and its harness, connect the battery.
(3)
(14)
(7) (5)
K21 - K25
Ensure the alignment of centering pins on the housing and

keyed to the flywheel.
Fill in the cooling system and purge it (Item 1) on water pump,

check the engine and hydraulic oil levels.
Install the engine cover and its harness, connect the battery.
10-07-M183EN (20/11/2014)
10
ENGINE TROUBLESHOOTING
pages
K21 - K25 GAS ENGINE (MI 15 TO 35 G S1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– LPG CARBURETION MAINTENANCE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– OVERALL CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(11/09/2014) 10-08-M183EN
2 ENGINE TROUBLESHOOTING
MI 15 to 35 G - S1
K21 - K25 GAS ENGINE (MI 15 to 35 G S1)

LPG CARBURETION MAINTENANCE GUIDE
PROBLEMS PROBABLE CAUSE PROBABLE SOLUTIONS
10
It does not start Tank or C13 cylinder empty Change the C13 cylinder
Fill the tank up (80% max)
C13 cylinder valve or tank valve closed Open the valve
Flow relief valve malfunction Close the valve and then open the valve carefully.
Loop or line of LPG liquid phase is obstructed Remove the cap. Test seal
LPG filter solenoid valve or filter valve blocked Change the filter
Reducing valve primary check valve out Test the primary check valve with tool kit 984615
Use the repair box
Connection fault between the reducing valve and carburettor Check the connection between the reducing valve and
carburettor
Filter valve fault Check the depression line between the filter valve and
carburettor
Test the filter valve with tool kit 984615
Use the repair box if necessary
Solenoid valve fault Check the electric circuit
Check the safety relay
Test the solenoid valve with tool kit 984615
Replace the solenoid valve if necessary
Reducing valve malfunction Test the reducing valve with tool kit 984615
Carburettor malfunction Clean carburettor
Test the carburettor with tool kit 984615
Replace carburettor (wear) if necessary
Air filter blocked Replace air filter
Ignition failure Check ignition

Repair or replace if necessary
Start-up difficulties Tank or cylinder nearly empty LPG gaseous phase diffusion output tank or cylinder
Fill tank up (80% max)
Change cylinder
Flow relief valve malfunction Close the valve
Reducing valve primary check valve out Test the primary check valve with tool kit 984615
Use the repair box
carburettor
carburettor
10-08-M183EN (11/09/2014)
ENGINE TROUBLESHOOTING 3
MI 15 to 35 G - S1
10
Start-up difficulties Solenoid valve fault Check the electric circuit
Air filter blocked Replace air filter

Does not operate Tank or cylinder nearly empty LPG gaseous phase diffusion output tank or cylinder
continuously Fill tank up (80% max)
Change cylinder
Flow relief valve malfunction Close the valve
carburettor
Ice on reducing valve Check cooling circuit level
Check anti-freeze cooling circuit (Winter)
Check position of reducing valve below the top of the
water radiator
Check the cooling circuit hoses supplying the reducing
valve
Check the reducing valve with tool kit 984615
Incorrect idle speed Check and adjust the idling engine
Check the engine speed regulator
No acceleration Tank or C13 cylinder empty Change the C13 cylinder
carburettor
Carburettor shutter does not operate Check the carburettor base
Replace the base or carburettor if necessary
(11/09/2014) 10-08-M183EN
MI 15 to 35 G - S1

10
Engine shim Tank or C13 cylinder empty Change the C13 cylinder
carburettor
Vacuum seal fault Check the vacuum circuit
Check vacuum transmission between mixer and base
carburettor
Check speed regulator
Check intake manifold
carburettor
Solenoid valve fault Check the electric circuit
Ice on reducing valve Check cooling circuit level
Check anti-freeze cooling circuit (Winter)
Check position of reducing valve below the top of the
water radiator
Check the cooling circuit hoses supplying the reducing
valve
Check the reducing valve with tool kit 984615
carburettor
Idle speed too high Incorrect idle speed Check and adjust the idling engine
carburettor
Vacuum seal fault Check the vacuum circuit
Check vacuum transmission between mixer and base
carburettor
Check speed regulator
Check intake manifold
Overall checks Consult “overall checking” table
Incorrect idle speed Check and adjust the idling engine

Carburettor shutter seizing Check the shutter
Change base if necessary
10-08-M183EN (11/09/2014)
ENGINE TROUBLESHOOTING 5
MI 15 to 35 G - S1
10
Return of carburettor Incorrect full load adjustment Adjust the carburettor to full load
flame Adjust the idle speed
carburettor
Check front ignition
Check depression on ignition
Operational fault Loop or line of LPG liquid phase is obstructed Remove the cap. Test seal
full speed
carburettor
Carburettor throttle valve shutter opening fault Check the shutter
Change the base or the carburettor if necessary
Check front ignition
Check depression on ignition
Air filter clogging Check the air filter
Change if necessary
Brake on the exhaust gas Check the exhaust line
Check the exhaust line back-pressure
(11/09/2014) 10-08-M183EN
MI 15 to 35 G - S1
OVERALL CHECKS
ENGINE STOPPED ENGINE RUNNING

10
Checking Carburetion sealing circuit Checking Thermostat operation

Checking LPG level in cylinder or tank Checking Alternator load
Cleaning Battery Checking Transmission of engine depression
Checking Battery cable Checking Carburetion circuit in gaseous phase
Cleaning Battery connections Checking Ignition
Checking Battery voltage Checking Depression on ignition
Cleaning Earth battery Checking Solenoid
Cleaning Starter supply connections Checking Carburettor idle speed adjustment
Cleaning Earth between starter and engine block Checking Carburettor full load adjustment
Checking Water radiator Checking 3-way catalytic system
Checking Cooling water level
Checking Antifreeze radiator
Checking Internal radiator clogging
Checking Cooling circuit hoses
Checking Radiator fan
Checking Water pump
Checking Water pump belt
Checking Electric circuit
Checking Starter electric circuit
Checking Ignition coil
Checking Complete igniter
Checking Plug wires
Checking Plugs
Checking Alternator electric circuit
Checking Alternator load circuit
Checking Fresh air suction
Checking Air filter
Checking Intake circuit
Checking Cylinder or tank positioning
Checking LPG carburetion circuit
Checking Solenoid or filter valve filtration
Checking Solenoid valve electric circuit
Checking Depression circuit between filter valve and carburettor
Checking Reducing valve
Checking Carburettor
Checking Engine valves
Checking Engine compression
Checking Greasing circuit seal
10-08-M183EN (11/09/2014)
TRANSMISSION
- TRANSMISSION CHARACTERISTICS AND

SPECIFICATIONS
20
- TRANSMISSION CONTROL AND
ADJUSTMENT
- TRANSMISSION TROUBLESHOOTING
- CHARACTERISTICS AND SPECIFICATIONS
- SCHEMATIC DIAGRAMS l 647119EN
- COMPONENTS LOCATION (TRANSMISSION Y43160X

REDUCTION Y48130X
- CONTROL AND ADJUSTMENT Y48140X
Y48150X)
- COMPONENT DIAGRAMS AND CROSS
SECTIONS
- TROUBLESHOOTING
- SPECIFIC TOOLING
TRANSMISSION CHARACTERISTICS AND
20
SPECIFICATIONS
pages
DRIVING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– 1 - SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– 2 - HYDRODYNAMIC POWER TRANSMISSION GEAR-BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– 2.1 - SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– 2.2 WORKING PRINCIPLE OF POWER TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– 2.3 INTRODUCTION OF STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
GEAR-BOX HOISTING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(20/11/2014) 20-01-M183EN
2 SPECIFICATIONS
DRIVING SYSTEM
20
Fig. 2-1 Drive system (Okamura hydraulic transmission box)
20-01-M183EN (20/11/2014)
SPECIFICATIONS 3
1 - SUMMARY
Driving system is composed of drive axle, hydraulic transmission box, etc. The power from engine acts
on hydraulic transmission box, through cardan transfer to drive axle, and then the power come to half
shaft by differential, and half shaft drive tires to run. Hydraulic transmission box can change the rotated
direction of output shaft to drive truck to move forward and backward.
20
2 - HYDRODYNAMIC POWER TRANSMISSION GEAR-BOX
2.1 - SUMMARY
Hydrodynamic power transmission gear-box is an engineering mechanical power device, it consists of

hydraulic torque converter, power shift gearbox, (1 forward and 1 reverse), double reduction gear-box,
and they are connected by universal coupling.
Torque converter in hydrodynamic transmission gearbox has one single stage, two phase, three work
wheel. It has virtues as follows: hydrodynamic torque converter make the hydrodynamic transmission
gearbox have auto adaptability for hydrodynamic transmission output, it can change its output torque
and rotation speed according to the change of external load; it can absorb and remove the impact
liberation that the engine and external load brings to the transmission system; double reduction is adopted
in reduction gearbox, and power is outputted through differential side gear of differential ,universal
coupling is adopted in gearbox output and reduction box input. Shift type is power shift controlled by
electromagnetism, and it also has inching valve, cushion valve, so it can make the truck to remove a
little when the engine is in either low speed or high speed, make the operation easy, convenient, start
stable, reduce the labor intension of operators.
(20/11/2014) 20-01-M183EN
4 SPECIFICATIONS
2.2 WORKING PRINCIPLE OF POWER TRANSMISSION
Gear-box transmission sketch, see fig. 2-4, torque converter is driven by engine through a elastic plate
1 and rotates the impeller wheel 4, in this way, the fluid flows at high speed into the turbine wheel 2
which rotates the turbine wheel. Stator wheel 3 make the torque converter effective, Then transmit the
torque to input shaftıthrough turbine shaft 5. When at forward gear ratio, reverse clutch at idle motion,
transmit order is that 5→7→6→11→12→13→15→16→17, finally output through the driven bevel gear
17. When at reverse gear ratio, transmit order is that 5→8→18→19→9→10→11→12→13→15→16→
20
17, finally output through the driven bevel gear 17 also. Onward and reverse clutch are controlled by
shift control valve. Oil pump 20 is inne tem, after hydrodynamic torque converter works, the oil flows
into the radiator, then into gear-box-lubrication clutch disc, bearings and gears.
Fig. 2-4 Transmit principle for Y43160X hydraulic transmission
1 - Flexible coupling plate 11 - Driven gear

2 - Turbine 12 - Output shaft
3 - Guide wheel 13 - Driving gear
4 - Pump impeller 14 - Input shaft
5 - Turbine shaft input assembly 15 - Driven gear
6 - Forward gears 16 - Driving bevel gear
7 - Forward clutch assembly 17 - Driven bevel gear
8 - Backward clutch assembly 18 - Backward gear
9 - Intermediate shaft 19 - Transition gear
10 - Transition gear 20 - Inner gearing pump
20-01-M183EN (20/11/2014)
SPECIFICATIONS 5
2.3 INTRODUCTION OF STRUCTURE
The working principle is as above mentioned. Hydraulic transmission gearbox is consisted of hydraulic
torque converter, gear-box, universal coupling, reduction gearbox (differential). The engine power is
converted by torque converter, and then the power is transmitted from turbine of torque converter to
input shaft assembly of gearbox (forward shift clutch) by spline joint.
Forward or reverse is controlled by control valve, power from gearbox is controlled differentiated by
differential assembly 14, then acted on tires through differential side gear and half shaft. Gearbox and
20
reduction gearbox can also play as oil reservoir, they are fixed by bracket (absorption).
Gearbox consists of input shaft assembly (forward shift clutch) , intermediate shaft assembly (reverse
shift clutch), output gear, output flange, electromagnetism control valve, oil-supply pump, etc. Reduction
gearbox consists of input flange, driving gear, driven gear, driving spiral bevel gear, driven spiral bevel
gear, differential, gearbox and reduction gearbox are connected by universal coupling.
Fig. 2-3 Y43160X Hydraulic transmission box structure

1 - Torque converter housing, spoiler 21 - Differential housing(right)
2 - Output gear shaft, ball-bearing 22 - Tapered roller bearing
3 - Turning gear shaft,ball-bearing, jump spring 23 - Main transmission housing
4 - Input shaft assembly 24 - Bearing cap
5 - Turning gear, ball-bearing 25 - Adjusting bolt
6 - Gasket, seal 26 - Main transmission housing cap
7 - Gearbox housing, oil seal 27 - Oil seal
8 - Oil pump assembly, seal 28 - Ball-bearing
9 - Gasket, control oil pump, seal 29 - Output flange
10 - Oil pipe,ring, gasket 30 - Driving gear
11 - Output shaft flange 31 - Ball-bearing
12 - Oil filter 32 - Shim
13 - Fuel outlet valve, gasket, block 33 - Reduction driving gear, adjusting shim, tapered roller bearing
14 - Torqueconverter assembly 34 - Driven gear
15 - Differential housing(left) 35 - Tapered roller bearing
16 - Reducer gear 36 - Adjusting shim
17 - Bolt 37 - Clamp nut, seal ring, cap
18 - Differential gear,shim 38 - Locking sheet
19 - Differential shaft, driving gear diff, washer 39 - Truck body connecting bracket
20 - Differential gear, shim
(20/11/2014) 20-01-M183EN
6 SPECIFICATIONS
GEAR-BOX HOISTING DIAGRAM

Lifting hook can be used to lift the transmission box
20
Oil volume 4L
Oil type DEXRON—III (Caltex)
Weight 105 Kg
Chariot 1.5t-1.8t 2t-2,5 3t-3,5t

Dimension (L×W×H)
791×476×487 831×476×502 870×476×502
mm
20-01-M183EN (20/11/2014)
TRANSMISSION CONTROL AND ADJUSTMENT
20
pages
DISASSEMBLY SEQUENCY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(08/06/2018) 20-04-M183EN
TRANSMISSION CONTROL AND
2 ADJUSTMENT
UNCOUPLING PROCEDURE OF THE HYDRAULIC TORQUE CONVERTER
The step «engine removal» must be performed first, e 10 - «ENGINE REMOVAL»

A - Drain the oil from the gearbox.
B - Disengage the converter from the flywheel.

20
C - Disengage the gearbox from the engine.
bb Locate the depth (1) of the torque converter in relation to the gearbox housing before removal,
to be certain to reassemble it in the same position:
If the notches on the torque converter (2) are not properly seated on the gearbox shaft, they get damaged
and this causes a change in the torque converter.
D - Take out hydraulic torque converter.
E - Disassemble oil-supply pump, electro-hydraulic control valve, torque converter shell assembly,
forward shift clutch assembly, reverse shift clutch assembly, transition gear shaft assembly and
output shaft in turns.
Open end cap 37 , take off lock nut, disassemble reduction input shaft assembly, main transmission
housing 23 and differential assembly o 20 - «TRANSMISSION CHARACTERISTICS AND SPECIFICATIONS.»
Figure § 2-3.
F - Take off other parts and assembly.
Assembling procedures:
Please assemble with opposite procedures of disassembly.
20-04-M183EN (08/06/2018)
TRANSMISSION TROUBLESHOOTING
20
pages
CAUSE AND SOLUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(25/07/2012) 20-08-M183EN
2 TRANSMISSION TROUBLESHOOTING
CAUSE AND SOLUTIONS
Item Cause Solutions

Lack oil Fill oil
Efficiency of pump falls Disassemble, check, replace if necessary
Gasket ring wears Disassemble, replace
Insufficient power and
Bearing damage Disassemble, replace
over high oil temperature
Filter clogging Check and clean or replace
Pipe or connector damage Disassemble, replace
20
Inching valve lever reposit non-freely Check and clean or replace

Seal damage or hurt Disassemble, replace
Seal gasket damage Disassemble, replace
Oil leakage Rubber stiffen or distort Disassemble, replace
Bolt loosen, joint surface leak Screw down
Surface damage Disassemble, replace
Gear damage Disassemble, replace
Input elastic plate loosen or distort Screw down or replace
Bearing damage Disassemble, replace
Abnormal noise Bolt loosen Screw down or replace
Spline damage Disassemble, replace
Air suction because of oil pipe leaking Check ,replace
Air pocket because of oil lacking Fill oil
20-08-M183EN (25/07/2012)
AXLE
- AXLE CHARACTERISTICS AND

SPECIFICATIONS
- AXLE CONTROL AND ADJUSTMENT
- AXLE COMPONENTS DIAGRAMS AND

SECTIONS
30
- AXLE REMOVAL
- AXLE REFIT
- AXLE TROUBLESHOOTING
AXLE CHARACTERISTICS AND SPECIFICATIONS
30
pages
SUMMARISE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– HYDRAULIC POWER STEERING GEAR ASSEMBLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– HYDRAULIC POWER STEERING GEAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STEERING SYSTEM DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(25/07/2012) 30-01-M183EN
AXLE CHARACTERISTICS AND
2 SPECIFICATIONS
SUMMARISE
Steering system is composed of hydraulic power steering gear and steering cylinder.
HYDRAULIC POWER STEERING GEAR ASSEMBLE
Hydraulic power steering gear assemble include cyclical hydraulic power steering gear, column and
steering wheel.
When stop engine, you can turn the steering wheel with tight force about 1 kg. When loosen the steering
wheel, it can turn back to its original position about 10 degrees.
HYDRAULIC POWER STEERING GEAR

30
Principle : In load sensing steering systems, the oil for steering system and working circuit may be
supplied by a pump via priority valve of which can support extra amount of steering system oil into
operating system. A Ls inlet of load sensing steering unit is connected with a priority valve or with a Ls
inlet of pump with load reaction. Via the oil hose the pressure signal of the steering load transfers from
the steering unit to the priority valve or the pump with load reaction, so as to control the oil volume
which is supplied to steering unit. In addition, when uses a pump with which is connected load reaction,
energy of system will be saved.
When the power steering is working, pressure oil flows into rotor and stator pair through valve disk and
valve jacket pair, and to drive to rotor rotate along with steering wheel, and push oil into left and right
chamber of steering cylinder, and piston rod pushed steering tires to steer.
When the engine stops running, the pump does not supply oil, and the steering action will be realized
manually by turning the steering wheel to move valve disk , valve jacker, coupling block, and to actuate
the rotor to feed oil into steering cylinder, in this case, rotor and stator act as a hand pump, making
manual steering possible.
STEERING CYLINDER
Steering cylinder is of double-acting piston type. The two end of piston is connected with steering
spindle through rod. The pressure oil from hydraulic power steering gear makes piston rod to move
left and right so as to turn truck lift and right.
Structure and maintenance, please see front part drive axle.
STEERING SYSTEM DATA
Steering system type : Change direction rear wheel with full power steering
Connecting type : Direct-mounted
Performance : Load sensing
Oil port type : P T A B : M20×1.5 Fasten torque : 50N·m - 60N·m

LS : M12×1.5 Fasten torque : 30N·m - 36N·m
30-01-M183EN (25/07/2012)
AXLE CONTROL AND ADJUSTMENT
30
pages
DRIVING AXLE TIGHTEN TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REMOVAL WHEEL HUB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– KINGPIN AND STEERING SPINDLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– KINGPIN AND STEERING SPINDLE INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– WHEEL BEARING ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– STEERING CYLINDER DISASSEMBLE AND INSTALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(20/11/2014) 30-04-M183EN
2 AXLE CONTROL AND ADJUSTMENT
DRIVING AXLE TIGHTEN TORQUE
44-58 Nm (1,5t-1,8t) 260-347 Nm (1,5t-1,8t)

74-88 Nm (2,0t-3,5t) 475-598 Nm (2,0t-3,5t)
157-176 Nm (1,5t-1,8t)
441-588 Nm (2,0t-3,5t)
30
157-176 Nm (1,5t-1,8t) 76-107 Nm (1,5t-1,8t)

441-588 Nm (2,0t-3,5t) 178-235 Nm (2,0t-3,5t)
30-04-M183EN (20/11/2014)
AXLE CONTROL AND ADJUSTMENT 3
STEERING AXLE
REMOVAL WHEEL HUB
1 - Jack up and support forklift truck body with Wooden blocks.

2 - Remove tyre.
3 - Remove hubcap.
4 - Remove steering spindle nut.
5 - Pull off hub assembles.
6 - Remove bearing inner race.
bb . Do not drop the bearing inner ring.

a
b. Be careful not to damage oil seal.
30
KINGPIN AND STEERING SPINDLE REMOVAL
1 - Remove rod.
2 - Loose lock bolts.
3 - Remove grease nipples on kingpin.
bb
4 - Remove kingpin.
Hold kingpin to prevent it from dropping.
5 - Take off spindle, thrust bearing and shim.
INSPECTION :
1 - Replace spindle if cracked.

2 - Replace bearing if its rollers or roller surfaces are rusted or
nicked.
3 - Replace steel sleeve if it distortion, out of round, cracked.
4 - Replace thrust bearing and dust cap if them damaged.
(20/11/2014) 30-04-M183EN
4 AXLE CONTROL AND ADJUSTMENT
KINGPIN AND STEERING SPINDLE INSTALL
To install, reverse the order of removal. Careful observes the following.

1 - Always insert kingpin from lower side.
2 - Install thrust bearing, set the tighten-ring below the support and loosen-ring. Pack all grease
between dust proof inside, loosen-ring, and tighten-ring.
3 - Set the axial play less than 0.2 mm with washers.
4 - Place the seal tape with the letters on the outside. Apple grease to roller of roller bearing, also
apply grease between lip and groove of seal tape.
5 - Pack all grease nipple with a sufficient of grease.(10 oil cups)
WHEEL BEARING ADJUSTMENT

30
1 - Slowly rotate hub. Tighten steering spindle nut until it can no longer be rotated with one hand.
2 - From that position, turn back steering spindle nut 1/6 to 1/4 rotation. Measure hub bolt force is
10 to 30N.
3 - Make sure that hub rotates smoothly and that its axial play is within specification. Axial play is
less than 0.1mm.
STEERING CYLINDER DISASSEMBLE AND INSTALL
i «AXLE COMPONENTS DIAGRAMS AND SECTIONS» chapter for steering cylinder view
1 - Loose nut 11, remove screw 10;
2 - Remove guide sleeve 6 at left and right side;
3 - Remove LBH dust ring 2, protect ring 3, ISI gasket ring 4, compound bushing 5, O-ring 7 in turn;
4 - Remove piston rod, remove piston seals 9;
5 - Inspecting: if any component is damaged, please replace.
To install, reverse the order of removal, careful observes the following:

1 - Lubricate every component with clean hydraulic oil.
2 - Prevent dust , oil dirty entering cylinder.
3 - Prevent using linen yarn at cylinder port (input and output).
4 - ISI seal lip direct to inside, LBH dust proof port direct to outside.
5 - Pay attention to avoiding scratch O-ring at outside circle when installing.
6 - Carefully center, push guide sleeve into cylinder, pay attention to avoid scratch O-ring at outside
and inside circle when installing.
7 - Lubricated with the same hydraulic oil trademark between gaskets.
30-04-M183EN (20/11/2014)
AXLE COMPONENTS DIAGRAMS AND SECTIONS
30
pages
DRIVE AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
STEERING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
(24/11/2014) 30-05-M183EN
AXLE COMPONENTS DIAGRAMS AND
2 SECTIONS
DRIVE AXLE
30
30-05-M183EN (24/11/2014)
SECTIONS 3
30
1 - Left support plate 18 - Washer
2 - Shim plate 19 - Bolt
3 - Nut 20 - Washer
4 - Washer 21 - Wheel hub bolt
5 - Connected bolt 22 - Wheel hub nut
6 - Left brake 23 - Bearing
7 - Bolt 24 - Oil seal
8 - Nut 25 - Paper backing board
9 - Washer 26 - Compress bushing
10 - Tyre assembly 27 - Right brake
11 - Wheel hub 28 - Right support plate
12 - Pin 29 - Plug
13 - Half shaft 30 - Washer
14 - Oil seal 31 - Axle body
15 - Locknut 32 - Washer
16 - lock sheet 33 - Plug
17 - Bolt 34 - Air draught plug
(24/11/2014) 30-05-M183EN
4 SECTIONS
STEERING AXLE
30
A - Insert proper 0.1mm backing board between 2 back backing board to make axial clearance less
than 0.2mm.
B - Adjust backing board number to make the other side have no clearance,and adjust this side clearance
less than 1 mm.
C - This side has no clearance.
30-05-M183EN (24/11/2014)
SECTIONS 5
1 - Steering tire 25 - Steel bushing

2 - Bearing 26 - Nut
3 - Bearing 27 - Pin
4 - Oil seal 28 - Steel bushing
5 - Steel bushing 29 - Seal rubber backing board
6 - Bearing 30 - Connecting bolt
7 - Master pin 31 - Cone nut
8 - Bearing 32 - Adjust backing board
9 - Steering axle body 33 - Steering wheel hub
10 - Left steering knuckle 34 - End cover
11 - Steering cylinder 35 - Locking washer
12 - Shim plate 36 - Lock nut
13 - Steering buffer block 37 - Oil seal
14 - 38 - Oil cup
30
15 - 39 - Washer
16 - Seal backing board 40 - Bolt
17 - Pin shaft 41 - Shaft bushing
18 - Oil cup 42 -
19 - Top connecting rod 43 - Adjust washer
20 - Bottom connecting rod 44 - Right steering knuckle
21 - Shim plate 45 - Oil cup
22 - Cover plate 46 - Fixed bolt
23 - Bolt 47 - Nut
24 - Washer 48 - Bolt
(24/11/2014) 30-05-M183EN
6 SECTIONS
STEERING CYLINDER
30
1 - Piston rod
2 - LBH dust ring
3 - Protect ring
4 - ISI gasket ring
5 - Compound bushing
6 - Guide sleeve
7 - O-ring
8 - Steel cylinder
9 - Piston seal
10 - Screw
11 - Nut
30-05-M183EN (24/11/2014)
AXLE REMOVAL
30
pages
DRIVING AXLE ASSEMBLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DRIVING AXLE SHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(24/11/2014) 30-06-M183EN
2 AXLE REMOVAL
DRIVING AXLE ASSEMBLE REMOVAL
bb Be careful when removal and installation driving axle as it is heavy.
1 - Raise front end of forklift truck and support frame with wooden blocks.
2 - Remove mast assembles.
3 - Slightly raise axle with a hoist and place wooden blocks under differential gear carrier and
transmission case.
4 - After placing a pan under axle case, loosen oil plug, drain oil from axle case.
30
bb
5 - Disconnect brake nuts from left and right cylinders.
Plug brake tube openings to prevent oil from flowing out.
6 - Disconnect brake cable at hand brake lever.

7 - Remove front wheels.
8 - Remove axle shaft.
9 - Support driving axle with wire ropes and lifting device.
10 - Remove bolts securing axle mounting bracket to frame.
11 - Remove nuts securing axle case to differential gear carrier.
12 -
Remove driving axle assemble.
13 -
Remove locknut and lock sheet.
14 -
Remove wheel hub (together with brake drum).
15 -
Remove axle mounting bracket and brake component
from axle tube.
16 - Remove oil seal from axle tube.
30-06-M183EN (24/11/2014)
AXLE REMOVAL 3
DRIVING AXLE SHAFT
i «Brake removal» Chapter for removing brake drum.

Then remove oil seal and inner bearing as an assembly by evenly tapping on periphery of seal with a
wooden mallet and brass bar.
bb
Remove bearing outer race from wheel hub by evenly tapping on its periphery with a wooden mallet.
Be careful not to damage oil seal and outer race.
30
Inspection :
Stepped wear or cracks on axle shaft splines Replace
Seized, scratched, noisy or rusted bearing or improper rotation of rollers Replace
Cracked or damage wheel hub Replace
Damaged oil seal felt ring. Replace
(24/11/2014) 30-06-M183EN
4 AXLE REMOVAL
30
30-06-M183EN (24/11/2014)
AXLE REFIT
30
pages
STEERING SYSTEM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

DRIVING AXLE ASSEMBLE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(24/11/2014) 30-07-M183EN
2 AXLE REFIT
STEERING SYSTEM INSTALLATION
Careful observe the following:

1 - Hydraulic tie-in, blots and piping must be cleaned while installing.
2 - C heck the order of connection of hydraulic lines, whether it is reverse order of steering direction
or not, refer to steering system .
3 - Steer wheel to end left and right to make sure whether it is equably of steering force and smooth
of steering.
4 - Jack up rear wheel and steer slowing wheel left and right and repeat it. Purge air of hydraulic lines
and cylinder.
When engine stops running, rotate steering wheel with 1kg force slightly, after leaving hands, steering
wheel should return 10° auto return back.
30
DRIVING AXLE ASSEMBLE INSTALLATION
To install driving axle assemble in the reverse order of removal. Observe the following order :
1 - W hen installing axle mounting bracket and brake component, apply a coat of calcium grease to
axle tube.
2 - Apply 1/3 or 2/3 of volume of calcium grease to wheel hub, then install them on axle tube.
3 - Install oil seal with its part number facing to the inside of forklift truck.
4 - Attach seal tape (PVC, white) to drain plug then installed after cleaned it.
5 - Replenish axle case with gear oil. Tighten vent plug after clearing.
6 - Fabrication mill finish directs to bearing when installing locknut.
7 - When installing component 17, please smear LOCTITE 222 mucilage (or 242 mucilage ) at screw
thread position(above 2/3) and then loosen.
Fill in drive axle with 6,5L of gear oil GL-5 85W/90.
Vent plug should clear instantly to prevent pressure inside of wheel hub from rising.
30-07-M183EN (24/11/2014)
AXLE TROUBLESHOOTING
30
pages
TROUBLE DIAGNOSES AND CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– STEERING AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(25/07/2012) 30-08-M183EN
2 AXLE TROUBLESHOOTING
TROUBLE DIAGNOSES AND CORRECTIONS
FRONT AXLE
Condition Probable cause Corrective action

loose driving axle and body connecting blots Tighten
loose wheel nut Tighten
worn or damaged wheel hub bearing Replace
Abnormal noise
wheel hub bearing not properly adjusted Adjust
worn axle shaft spline Replace
insufficient lubrication Lubricate
loose wheel nut Tighten
deformed wheel Replace
30
worn or damaged wheel hub bearing Replace

Unstable driving
loose driving axle and body connecting blots Tighten
wheel hub bearing not properly adjusted Adjust
improper tire pressure Adjust
worn or damaged axle shaft oil seal Replace
Oil leakage final drive improperly installed Replace gasket
loose drain plug Tighten
STEERING AXLE
Condition Probable cause Corrective action

loose wheel nut. Tighten
wheel bearing out of adjustment. Adjust
Unstable driving
improperly adjusted shims. Adjust
faulty steering system. refer to turning system section
insufficient lubrication. Apply calcium grease
loose bolts and nut. tighten
Noises
Improperly adjusting shim for axle end shaft. adjust
Damaged joint bearing at two ends of rod. replace
Damaged or trouble of oil pump Replace
Failure to rotate steering
Priority valve(multi-way valve) is clogged or damaged. Clean or replace
wheel
Damaged hose or connector, block lines Replace or clean
Steering overflow value pressure too low. Adjust pressure.
Air in oil lines. Remove air
Control oil pipe is jammed Clean or replace
High effort for steering Priority valve(multi-way valve) itself fault Check or replace
The steering fails to turn to its natural position, broken lock spring or
Replace spring flat
insufficient spring pressure
Too much internal leakage in steering cylinder. Check piston for sealing
Track travel zigzag or
Too much oil flow to steering cylinder. Adjust divide value.
wobbly
Oil is not sufficient in oil tank. Add oil.
Abnormal noise
Suction piping or filter clogged. Clean or replace.
Damaged sealing of oriented bush of steering cylinder or hose or
Oil leakage Replace
connector.
30-08-M183EN (25/07/2012)
BRAKE
- BRAKE CHARACTERISTICS AND

SPECIFICATIONS
- BRAKE COMPONENTS LOCATION
- BRAKE CONTROL AND ADJUSTMENT
- BRAKE REMOVAL
- BRAKE REFIT
40
- BRAKE TROUBLESHOOTING
BRAKE COMPONENTS LOCATION
pages
MASTER CYLINDER STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40
FORKLIFT BRAKE STRUCTURE MI 15/18 - MI 30/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
FORKLIFT BRAKE STRUCTURE MI 20/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(07/06/2018) 40-03-M183EN
2 BRAKE COMPONENTS LOCATION
MASTER CYLINDER STRUCTURE
1 2 6
3
8 9 10 11
5 7
4
40
1 - Lock nut
2 - Rod
3 - Duct cover
4 - Clamp spring
5 - Gasket ring
6 - Piston
7 - Primary cup
8 - Spring
9 - Raffinate valve
10 - Valve seat
11 - Cylinder body
40-03-M183EN (07/06/2018)
BRAKE COMPONENTS LOCATION 3
FORKLIFT BRAKE STRUCTURE MI 15/18 - MI 30/35
1
2 5
20 3
40
6
7
21 27
25
26 24 19
23
13
14 22 17
8 16
9 11 13
10
9 12 18
1 - Screw 15 - Cable
2 - Washer 16 - Return spring
3 - Plug 17 - Cable guide
4 - Rod 18 - Right spring
5 - Plate 19 - Guide
6 - Pin 20 - Left brake assembly
7 - Right handbrake lever 21 - Wheel cylinder
8 - Right brake lining 22 - Pin
9 - Spring seat 23 - Right conrod
10 - Spring 24 - Clip
11 - Spring 25 - Snap ring
12 - Right lever 26 - Spring
13 - Spring 27 - Brake cable
14 - Setting screw
(07/06/2018) 40-03-M183EN
4 BRAKE COMPONENTS LOCATION
FORKLIFT BRAKE STRUCTURE MI 20/25
20 22
21 23
19
18
17
24
16
25 3
15
40
14
13
12
11
10
9 4
7 2
8
5
6
1 - Cover 14 - Spring
2 - Brake lining 15 - Stop
3 - Plug 16 - Spring seat
4 - Handbrake lever 17 - Spring
5 - Rod 18 - Spring
6 - Spring seat 19 - Tie rod
7 - Spring 20 - Washer
8 - Spring seat 21 - Right wheel cylinder
9 - Spring 22 - Screw
10 - Setting screw 23 - Washer
11 - Right lever 24 - Brake cable
12 - Shim 25 - Right brake assembly
13 - Lever pin
40-03-M183EN (07/06/2018)
BRAKE CONTROL AND ADJUSTMENT
pages
INCHING AND BRAKE PEDAL SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40
REPLACE BRAKE SHOE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
HAND BRAKE DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(24/11/2014) 40-04-M183EN
2 BRAKE CONTROL AND ADJUSTMENT
INCHING AND BRAKE PEDAL SETTING

40
1 Make the adjustment from the initial position of brake and

2
inching pedals using the screws (Item 1 and 2).
3
Dimension A = 140mm.
bb
Dimension B = 140mm.
The dimensions are taken from the top of the pedal
A B (without pad) to the floor (without carpet)
Adjust the length of master cylinder pusher to ensure the idle

stroke is 1 to 3 mm (Item 3) and ensure that the brake light switch
is on when the brake pedal is pushed down by 10 to 20 mm, the
switch is off when the brake pedal is return to initial position.
40-04-M183EN (24/11/2014)
BRAKE CONTROL AND ADJUSTMENT 3
4
After a displacement of 50 mm (dimension A = 90 mm), the
inching pedal actuates the pedal brake.
Set the run with a wrench (Item 4) :
Dimension A = 90mm.
At the beginning of braking the dimensions are :
A B Dimension A = 80mm.
At maximun braking the dimensions are :
Dimension A = 50mm.
Lift the front wheel by putting blocks under the mast.
Place a pressure gauge on the orifice (hex key 5mm) (Item 5).
Connector thread : R(PT) 1/8 with a connector
5 - Ref. 177239 (knee)
40
- Ref. 180971 (straight)
- Ref. 605816 (pressure plug)
Switch forward gear
The initial pressure is 9 to 11 bar.
Press the pedal gradually inching until the dimension indicated

(80mm) and check that the pressure is at 0 bar at the start of
braking (to prevent slippage of the clutch).
(24/11/2014) 40-04-M183EN
REPLACE BRAKE SHOE
1 - Place the forklift truck on level ground.
2 - Raise forks about 100mm.
3 - Place chocks behind rear wheels to prevent movement of forklift truck.
4 - Loosen wheel nuts two or three turns each.
5 - Tilt mast fully backward, and place a wooden block under each side of outer mast.
bb Do not allow wooden blocks to touch front tires.
6 - Tilt mast forward until front tyres are raised from ground. WARNING: Do not unscrew the wheel
nut before the wheel rise from the ground.
40
7 - Support forklift truck by putting additional wooden blocks under each side of front-end frame.
8 - Stop engine.
9 - Remove wheel tire nuts and brake drum. Remove half-shaft, lock nut, and washer.
10 - Remove wheel hub and brake drum.
11 - Replace brake shoes with new ones.
12 - Install brake drum.
13 - Adjust shoe to drum clearance: rotate wheel anticlockwise and at the same time press down brake
pedal several times.
14 - Take out every chocks in the reverse direction of the installation procedure.
15 - Make sure nobody or obstacles are around the forklift, then operate it in reverse at 2 or 3 km/h,
push on brake pedal 2 or 3 times.
40-04-M183EN (24/11/2014)
BRAKE CONTROL AND ADJUSTMENT 5
HAND BRAKE DEVICE
40
Gear box
Make sure that drive system is working normally before adjusting hand brake.
1 - Adjust nut B to make the length is 68mm, and then lock nut B.
2 - Adjust nut A to adjust hand brake pull force, the pull force of point P in Q direction is in the range
of 147N to 196N when locking hand lever.
3 - After adjusting hand brake lever correctly, loosen hand brake lever, make sure brake loose completely.
4 - Make sure hand brake device work normally by adjustment above.
Notice : wipe lithium lubricating grease on guide rail C, and do it usually.
(24/11/2014) 40-04-M183EN
40
40-04-M183EN (24/11/2014)
BRAKE REMOVAL
pages
DISMANTLING FRONT WHEEL BRAKE MI 20/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40
DISMANTLING FRONT WHEEL BRAKE MI 15/18 - MI 30/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(07/06/2018) 40-06-M183EN
2 BRAKE REMOVAL
DISMANTLING FRONT WHEEL BRAKE MI 20/25
bb ake sure you place the machine on a level surface and

M
block the rear wheels.
Loosen the parking brake.

1
Lift truck with a hydraulic jack near the front wheel and support
frame with wooden blocks.
Unscrew the six nuts (Rep.1) of the wheel rim.

40
2 Unscrew the 9 screws (Rep.2) from the wheel shaft.
Screw back 2 screws (Rep.3) on the flange to remove the half-

3 shaft, and take off the seal with a screwdriver (Rep.4).
5 Pull the half-shaft and unscrew the 2 screws (Rep.5) on the lock
6 washer. Remove the lock washer (Rep.6).
40-06-M183EN (07/06/2018)
BRAKE REMOVAL 3
screw back the 2 screws on the lock nut (Rep.1)

Remove the lock nut using a spanner slot or a screwdriver then
unscrew by hand.
Remove the brake drum by turning slowly in both directions.
Backward, the adjusting hole plug (Rep.1)
40
1
If it is dufficult :
- use a rubber mallet by evenly tapping nuts (Rep.2) and remove

the bearing with it (Rep.3).
- or remove adjusting hole plug, then with flat-blade screwdriver

extend adjusting nut, turn adjusting ratchet wheel by 10 notches
to contract the brake shoe lining
(07/06/2018) 40-06-M183EN
4 BRAKE REMOVAL
Disengage the rod (Rep.3) then the spring (Rep.4).
Disengage the 2 spring (Rep.5).

5 3 5
Remove the washer (Rep.6).
7 Remove the 4 washers (Rep.7).

7
40
7
7
Disconnect the handbrake cable (Rep.1)
2
Remove the brake shoe (Rep.2)
2
The adjusting hole plug (Rep.3)
1
40-06-M183EN (07/06/2018)
BRAKE REMOVAL 5
DISMANTLING FRONT WHEEL BRAKE MI 15/18 - MI

30/35
1
bb ake sure you place the machine on a level surface and

M
block the rear wheels.
Loosen the parking brake.

Lift truck with a hydraulic jack near the front wheel and support
frame with wooden blocks.
« DISMANTLING FRONT WHEEL BRAKE MI 20/25t» for

dismantling brake drum.
40
2 2
Disconnect the handbrake cable
Unhook the two springs (Rep. 2).
Remove the brake fluid pipe (Rep.3) and the two screws of the
4 slave cylinder (Rep.4)
4
Remove the slave cylinder

7
(07/06/2018) 40-06-M183EN
6 BRAKE REMOVAL
8 6 Remove the springs (Rep.5) and cable of self-adjustment and

support (Rep.6), the strut and spring (Rep.7), washer (Rep.8).
5
7
6
Remove the cups and springs (Rep.9).
9
40
Remove the pawl (Rep.10) spring (Rep.11) and the adjusting

bolt (Rep.12).
11
10
12
Remove the brake shoes.
13
Remove the circlips (Rep.13) and take the parking brake rod
(Rep.14).
14
7
40-06-M183EN (07/06/2018)
BRAKE REFIT
pages
REMOUNTING FRONT WHEEL BRAKE MI 20/25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40
REMOUNTING FRONT WHEEL BRAKE MI 15/18 - MI 30/35 . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
REPLACE THE BRAKE DRUM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
(24/11/2014) 40-07-M183EN
2 BRAKE REFIT
REMOUNTING FRONT WHEEL BRAKE MI 20/25
2 Reconnect the handbrake cable (Item1)
2 Remount the brake shoe (Item 2)

1
The adjusting hole plug (Item 3) to shorten the adjusting nut

(Item4), by removing the rubber cap.
3
40
The mecanisme of self-adjustment (Item 5).
40-07-M183EN (24/11/2014)
BRAKE REFIT 3
REMOUNTING FRONT WHEEL BRAKE MI 15/18 - MI

30/35
bb
1
Watch for position of the springs and hooks (item 1)
- Position hook and spring. (Item 2)
40
Purge the system:
- Remove the the rubber cap and loosen the bleed screw (Item 3).
- Repeatedly press the brake pedal, has until the air bubbles
disappear from the brake fluid.
- When the operation is complete, tighten the bleed screw (Item3)
3 put the rubber cap.
- Complete the level of brake fluid.
REPLACE THE BRAKE DRUM
Replace the brake drum and lubricate it on taper roller bearing.

Tighten roller bearing lock nut in wheel hub until it can’t be
rotated with one hand.
4
In this position, turn back lock nut approx. 60°.
Turn back wheel hub two or three rotations so that bearing
settles down.
Tighten again lock nut until it can’t be rotated with one hand;
then turn back approx.60° to have the axle of screw with the
hole of lock washer (item 4).
Unscrew the 2 screw.
(24/11/2014) 40-07-M183EN
4 BRAKE REFIT
Install lock washer so as to set its hole in the tapping of lock

nut (Item1).
1
Screw lock washer .
(Centering pin (Item2) for half-shaft)

1 2
Turn wheel hub back and forth two or three rotations to see if
rotation starting torque is within specifications.
3
Rotation starting force : 10 to 29N (Item3)

40
Measure axial play of wheel hub to see if it is within specification.
Axial play is less than 0.08mm (Item4).

4
Guide half-shaft with the centering pin (Item5).
Tighten the 6 screws.
Adjust brake shoes to drum clearance by pressing down brake

pedal several times while rotate wheel counterclockwise.
Remove hydrolic jack and wooden blocks. Start engine.

5
Make sure no person or obstacle is around forklift, then operate

forklift in reverse at 2 km/h to 3 km/h, set foot on brake pedal
2-3 times.
40-07-M183EN (24/11/2014)
BRAKE TROUBLESHOOTING
pages
TROUBLE DIAGNOSES AND CORRECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
40
(27/07/2012) 40-08-M183EN
2 BRAKE TROUBLESHOOTING
TROUBLE DIAGNOSES AND CORRECTIONS

Conditions Probable cause Corrective action
Oil leakage in brake lines. Correct and replenish.
Air in brake lines. Bleed air.
Water or oil on linings. Clean or replace.
Insufficient brake force
Uneven wear or contact of brake linings. Grind or replace.
Improper functioning of master cylinder or wheel cylinder. Correct or replace.
Clogged oil lines. Clean.
Uneven tire pressure. Adjust.
Brake out of adjustment. Adjust.
Water or oil on brake linings. Clean or replace.
Foreign particles in brake drum. Clean.
Deteriorated lining surface. Grind or replace.
Improper contact of linings. Grind or correct.
Unequal braking (forklift Worn lining. Replace.
truck veers to one side) Worn, warped, rusted or damaged brake drums. Correct or replace.
Improper operation of wheel cylinder. Correct or replace.
Improper sliding shoes. Adjust.
Loose back plate blots. Tighten or replace.
Warped back plates. Replace.
Improperly adjusted wheel bearing. Adjust or replace.
No free play of brake pedal. Adjust.
Improper shoe sliding. Adjust.
Improper operation of wheel cylinder. Adjust or replace.
Faulty piston cup. Replace.
Brake dragging
40
Weak or broken return springs. Replace.

Clogged master cylinder returns port. Clean.
Wheel bearing out of adjusting. Adjust or replace.
Lining surface harden or foreign particles on it. Repair or replace.
Warped back plates or loosed blots. Repair or replace.
Brake noise Brake shoes warped or improper install. Repair or replace.
Worn linings. Replace.
Loose wheel bearing. Repair.
40-08-M183EN (27/07/2012)
MAST
- MAST CHARACTERISTICS AND

SPECIFICATIONS
- MAST COMPONENTS LOCATION
- MAST CONTROL AND ADJUSTMENT
- MAST SECTIONS AND DIAGRAMS
- MAST REMOVAL
- MAST REFIT
- MAST TROUBLESHOOTING
60
MAST CHARACTERISTICS AND SPECIFICATIONS
pages
PRESENTATION OF MASTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– HIGH VISIBILITY DUPLEX MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DUPLEX MAST WITH FREE-ACTING LIFT AND WITH MAST FOR CONTAINER . . . . . . . . 2
60
–– TRIPLEX MAST WITH FREE-ACTING LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
(07/06/2018) 60-01-M183EN
MAST CHARACTERISTICS AND
2 SPECIFICATIONS
PRESENTATION OF MASTS
SUMMARY
The lift truck's lifting system consists of masts, a fork carriage, forks, a tool carriage, a lifting chain, rollers,
a lifting and lowering cylinder and a tilting cylinder.
Along with the hydraulic system, it constitutes the truck's working system and enables loading and
unloading operations to be performed. The lifting systems are generally categorised according to the
type of mast structure (single, double or triple). The trucks produced by Manitou have double masts
with a wide field of vision, total lift double masts (including masts for containers) or even total lift triple
masts, with CL type side to side uprights.
HIGH VISIBILITY DUPLEX MAST

The duplex mast with wide field of vision is made up of a fixed outer mast and a top to bottom mobile telescopic
inner mast. The bottom of the lifting cylinder is fixed to the lower crossbeam of the outer mast, a pin is put in
place, the end of the piston rod is connected to the upper crossbeam assembly of the inner mast. The cylinder
clamps attach the cylinder to the left and right vertical panels of the upper crossbeam of the outer mast. In
general, the free-acting lift range is 100 mm to 145 mm (3.93 to 5.7 in) depending on the tonnage. The two rear
lifting cylinders (6FREE-ACTING LIFTING CYLINDER, 5 2), the left lifting cylinder) installed at the back of the
mast enable the wide field of vision.
The forks are hooked onto the carriage. The carriage has rollers, assembled rollers (side rollers fitted in the middle
of the rollers side) and the side rollers. The inner mast is under the assembled rollers.
The pressurised oil from the distributor passes through the priority flow divider valve(6MAIN DIAGRAM OF THE
60
HYDRAULIC SYSTEM (DETECTION SYSTEM), 5 2) and enters the lowering cylinder. It pushes the piston and the
piston rod rises, thus lifting the inner mast. The end of the chain on the chain pinion mounted on the inner mast
is fixed on the outer mast that does not move. The other end is connected to the carriage. If the inner mast is
lifted, the carriage is pushed and the forks lift, until the products are lifted to the required height.
Most of Manitou's lift trucks have a lift height of 3 m (9.84 ft). The other lift heights (2 m to 6 m (6.56 to 19.68 ft))
concern specific trucks.
DUPLEX MAST WITH FREE-ACTING LIFT AND WITH MAST FOR CONTAINER
Like the high visibility duplex mast, the total free-acting lift duplex mast (6HIGH VISIBILITY DUPLEX
MAST, 5 2) consists of an inner mast, an outer mast and a fork carriage. Unlike standard models, the
right and left rear lifting cylinders are plunger piston cylinders. Their structure is slightly different, a
piston rod is hollow to let fluid into the front cylinder. The upper end of the piston rod of these two left
and right lifting cylinders is connected to the upper seat of the inner mast. In addition, in the centre of
the inner mast is a short lift cylinder, the free-acting lift cylinder.
If the free-acting lift cylinder is lifted, the inner mast cannot be removed, the forks can be used above
1,400 mm (55.11in). Depending on the specifications for 2 m, 2.5 m, 2.7 m, 3 m, 3.3 m and 4 m (6.56, 8.2,
8.85, 9.84, 10.82 and 13.12 ft)high, the free-acting lift varies between 1,050 mm and 2,100 mm (41.33 in
and 82.67 in).
The truck masts for containers are equipped with forks that have lateral movement devices, the minimum
height of the mast is 2,200 mm (86.61 in), the lift height is 3 m (9.84 ft), the free lift is approximately
1,500 mm (59.05 in) (6 DUPLEX MAST FOR CONTAINERS, 5 2). If the required position cannot be
reached to put the products away, the lateral movement cylinder of the trucks for containers enables
lateral movement to reach the required position, then it returns to neutral position. The free-acting lift
cylinder structures of the two mast configurations above are identical. Left and right lifting cylinder
structure (6LIFTING CYLINDER - TYPE B, 5 2)
60-01-M183EN (07/06/2018)
SPECIFICATIONS 3
TRIPLEX MAST WITH FREE-ACTING LIFT

The triple mast with free-acting lift (6TRIPLEX MAST WITH FREE-ACTING LIFT, 5 3) consists of an outer
mast, an intermediate mast and an inner mast. The inner mast and the intermediate mast are retractable.
The specifications differ for each of the following heights: 4 m, 4.3 m, 4.5 m, 4.8 m, 5 m, 5.5 m, 6 m, 6.5 m,
7 m (13.12, 14.1, 14.76, 15.75, 16.4, 18.04, 19.68, 21.32, 22.96 ft). It is different from the total free-acting
lift double mast primarily because of the intermediate mast, but also because the two left and right
lifting cylinders at the back are piston cylinders (6 LIFTING CYLINDER - TYPE A, 5 3) and the oil circuit
system is complex.
The free-acting lift cylinder structure is presented in Figure (6FREE-ACTING LIFTING CYLINDER, 5 3).
4
1
2
60
3
No. Designation
1 Outer mast
2 Inner mast
3 Lifting cylinder
4 Chain
5 Tilting cylinder
6 Fork carriage
7 Fork
(07/06/2018) 60-01-M183EN
4 SPECIFICATIONS
60
60-01-M183EN (07/06/2018)
MAST COMPONENTS LOCATION
pages
MAST COMPONENTS LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– HIGH VISIBILITY DUPLEX MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– DUPLEX MAST WITH FREE-ACTING LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DUPLEX MAST FOR CONTAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
60
–– TRIPLEX MAST WITH FREE-ACTING LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
(07/06/2018) 60-03-M183EN
2 MAST COMPONENTS LOCATION
MAST COMPONENTS LOCATION

HIGH VISIBILITY DUPLEX MAST
60
1 - Outer mast 6 - Chain

2 - Inner mast 7 - Left lifting cylinder - Type A
3 - Back 8 - Right lifting cylinder - Type A
4 - Fork arm support 9 - Tilting cylinder
5 - Fork arm 10 - Roller
60-03-M183EN (07/06/2018)
MAST COMPONENTS LOCATION 3
DUPLEX MAST WITH FREE-ACTING LIFT
60
1 - Outer mast 6 - Fork arm
2 - Inner mast 7 - Left lifting cylinder - Type B
3 - Chain 8 - Right lifting cylinder - Type B
4 - Free-acting lifting cylinder 9 - Back
(07/06/2018) 60-03-M183EN
DUPLEX MAST FOR CONTAINERS

60

2 - Inner mast 7 - Side-shift cylinder
3 - Chain 8 - Left lifting cylinder - Type B
4 - Free-acting lifting cylinder 9 - Right lifting cylinder - Type B
5 - Fork arm support 10 - Back
11 - Tilting cylinder
60-03-M183EN (07/06/2018)
MAST COMPONENTS LOCATION 5
TRIPLEX MAST WITH FREE-ACTING LIFT
60
2 - Middle mast 8 - Chain
3 - Inner mast 9 - Left lifting cylinder - Type A
4 - Front cylinder chain 10 - Right lifting cylinder - Type A
5 - Free-acting lifting cylinder 11 - Back
(07/06/2018) 60-03-M183EN
60
60-03-M183EN (07/06/2018)
MAST CONTROL AND ADJUSTMENT
pages
MAST CONTROL AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– INSPECTION AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– TILT ANGLE OF DUPLEX AND TRIPLEX MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– WEIGHT OF MAST FOR BASIC MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
60
REMOVE THE FORKS AND THE MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– REMOVE THE LIFTING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– REMOVE THE ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– REMOVE THE INNER MAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ASSEMBLY AND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– LIFTING ROLLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
–– ADJUSTING THE CLEARANCE BETWEEN THE LIFTING ROLLER AND THE MAST . . . . . 6
–– CLEARANCE OF THE GUIDE PLATE AND THE METAL PROFILE OF THE MAST . . . . . . . 7
–– MAST REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
INITIAL ADJUSTMENT OF THE HEIGHT OF THE LEFT AND RIGHT CYLINDER. . . . . . . . . . . 8
LIFTING CHAIN ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
FORK ARM SUPPORT CLEARANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LIFTING CYLINDER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
INSTALLING AND REPLACING THE FAULTY PARTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
TILTING CYLINDER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– REMOVAL OF PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
–– INSTALL THE TILTING CYLINDER AFTER REPLACING THE RING . . . . . . . . . . . . . . . . . . . . . 13
NOTE ABOUT TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
(07/06/2018) 60-04-M183EN
2 MAST CONTROL AND ADJUSTMENT
MAST CONTROL AND ADJUSTMENT

INSPECTION AND ADJUSTMENT
Components
Free space for assembly Free space for repair
Location
(mm / in) (mm / in)
Mast towards lifting roller 0.1 to 0.8 / 0.003 to 0.03 0.2 to 1 / 0.007 to 0.04
Shims 0.5 - 1.0 - 2.0 / 0.02 - 0.04 - 0.08
Mast towards metal back 0.1 to 0.8 / 0.003 to 0.03 0.2 to 1 / 0.007 to 0.04
Shims 0.5 - 1.0 - 2.0 / 0.02 - 0.04 - 0.08
Inner mast towards lateral support roller 0.1 to 0.6 / 0.003 to 0.02 0.2 to 1 / 0.007 to 0.04
Shims 0.5 - 1.0 - 2.0 / 0.02 - 0.04 - 0.08
Lifting chain deflection 25 to 30 / 0.98 to 1.18
Shims
Setting screw
2 shims
60
2 setting screws Setting screw
60-04-M183EN (07/06/2018)
MAST CONTROL AND ADJUSTMENT 3
TILT ANGLE OF DUPLEX AND TRIPLEX MAST

Forward tilt angle Backward tilt angle
Mast type and lifting height Carriage rollers
of mast of mast
Standard type and 2 to 4 metres (6.56 to 13.12 ft) 6 12
4 to 5 metres (13.12 to 16.4 ft) 6 6 Uses longitudinal and lateral rollers
5 to 6 metres (16.4 to 19.68 ft) 3 6
WEIGHT OF MAST FOR BASIC MODEL

Model of vehicle Mast weight
1.5t - 1.8t (3,306.9 - 3,968.3 lbs) 5145
2 t - 2.5 t (4,409.2 - 5,511.55 lbs) 652
3 t (6,613.8 lbs) 731
3.5 t (7,716.17 lbs) 836
TIGHTENING TORQUE FOR MAIN PARTS

Position (1.5 t - 1.8 t / 3,306.9-3,968.3 lbs) N.m / ft-lb (2 t - 3.5 t / 4,409.2-7,716.17 lbs) N.m / ft-lb
60
Lift chain locknut 193-257 (M16) / 142.3-189.5 245-314 (M20) / 180.7-231.6
Mast support bolt 124-165 (M14) / 91.4-121.7 176-216 (M18) / 129.8-159.3
Tilting cylinder locknut 89-118 (M14) / 65.6-87 89-118 (M14) / 65.6-87
Lifting cylinder upper bolt 76-107 (M12) / 56-78.9 76-107 (M12) / 56-78.9
Lifting cylinder lower bolt 22-30 (M8) / 16.22-22.12 44-58 (M10) / 32.45-42.7
Lifting cylinder attachment bolt 76-107(M12) / 56-78.9 76-107(M12) / 56-78.9
(07/06/2018) 60-04-M183EN
bb
REMOVE THE FORKS AND THE MAST
Pay attention to the weight of the masts during disassembly.
FORKS
Remove the adjusting cylinder (8t-10t) and the connecting hose.
First mark the position of the forks if necessary.
Unlock the forks.
Tilt the bottom of the fork to release it and remove it by sliding

it on the sides.
FORK CARRIAGE
Attach a steel cable and use a tool to lift up the assembly.
Fork carriage
Unscrew the ends of the chain from the nut and the fork carriage
to remove the chain.
60
Nut
Remove the carriage.
Remove the hydraulic hoses.
Lift up the inner mast assembly and outer mast with a steel cable.
Pull the pin of the shaft and the locator screws on the front end
of the tilting cylinder.
60-04-M183EN (07/06/2018)
Undo the bearing support bolts
Bearing
support Remove all of the masts
For assembly, reverse the disassembly procedure
REMOVE THE LIFTING CYLINDER
1 - Place the mast flat on the floor. Remove the attachment

bolts from the lifting cylinder and tighten the screw.
2 - Slide the inner mast along, then remove the lifting cylinders.
60
REMOVE THE ROLLER
1 - Slide the inner mast until the rollers are exposed and
remove them using a bearing extractor. Make two discs
approximately 10 mm (0.39 in) thick and 53 mm (2.08 in)
and 58 mm (2.28 in) in diameter to cover the seat of the
roller. Extract the rollers using a bearing extractor.
2 - Carefully loosen the rollers.
Discs
REMOVE THE INNER MAST
Attach a rope to the middle of the inner mast and take it out
with a lifting device.
INSPECTION
1 - Check the lifting rollers, the roller axes and the associated
parts for wear and damage.
2 - Replace the damaged parts if necessary.
(07/06/2018) 60-04-M183EN
ASSEMBLY AND ADJUSTMENT
bb Pay attention when disassembling the masts as they are heavy.
LIFTING ROLLER
Inner mast
Slide the inner mast into the outer mast and attach the lifting
rollers securely.
Outer mast
ADJUSTING THE CLEARANCE BETWEEN THE LIFTING ROLLER

AND THE MAST
L
1 - Adjust the height of the roller from the inner and outer
masts over dimension "L". Then make the following
Inner adjustment.
60
Outer
Unit of dimension "L": mm
Max. lift height (mm) Model 2t - 3.5t Model 3t
2,500 to 3,300 328 368
3600 348 388
4000 378 418
4500 403 443
Adjusting nut
A 2 - Adjustment range "A" with shims:

Shim
- 1.5 t to 2 t, Dimension A: 0.1 to 0.6 mm.

- 2.5 t to 3 t, Dimension A: 0 to 0.5 mm.
Possible use of one or two without rubber pad;
Dimension: 0.1 mm to 0.6 mm if there is no rubber pad.

A
Sidedesroller
Groupe
rouleaux latéraux
The orientation pin ensures the vertical position of the lateral
roller in relation to the inner mast rail.
A
Mât extérieur
Outer mast Mât intérieur
Inner mast
60-04-M183EN (07/06/2018)
3 - The adjustment of the roller and the outer mast must be approximately 0.8 mm to 1 mm
(0.031 to 0.039 in). Replace the roller if it is too worn.
4 - Apply a lubricant (grease) between the inner and outer masts and between the rollers and the
steel guide groove. To prevent sand from sticking to the mast, decide whether or not to apply
grease in dusty areas.
CLEARANCE OF THE GUIDE PLATE AND THE METAL PROFILE OF THE MAST
Adjust clearance "B" between 0.1 mm and 0.8 mm (0.0196 in ~ 0.0393 in) by using shims between the
guide plate and the upright of the inner mast.
The shim is 0.5 mm or 1 mm thick.
Guide plate
Roller
B
60
B
Roller
Outer mast
Inner mast
MAST REFIT
Apply a layer of grease to the metal reinforcements.
Install the mast and the lifting cylinder on the forklift truck.
Connect the circular tube and the high pressure tube.
(07/06/2018) 60-04-M183EN
INITIAL ADJUSTMENT OF THE HEIGHT OF THE LEFT AND RIGHT CYLINDER.

1 - Install the left and right cylinders on the mast. The pin
must be installed in the guide hole of the outer mast's
crossbeam.
U bolt
Steel tube 2 - Fit the top part of the cylinder in its seat on the inner mast.
Adjust the position of the inner mast uniformly to the left,
right, top and bottom. If necessary, put washers between
Washer the cylinder support hole and the top part of the cylinder.
Bolt Damper
3 - Fit the "U bolt" to the cylinder and tighten it by hand
using the nuts. Relock it using the nuts. Tighten the bolt
to stop it loosening.
LIFTING CHAIN ADJUSTMENT

Install the fork arm support on the inner mast and fit the lifting
chain, then fit two nuts on the end of each side.
With the mast in the RH position, completely lower the support.

60
Temporarily adjust the clearance to 74 mm-76 mm (2.91-2.99 in)

above the ground.
If necessary, adjust the chain's adjusting nut.
74 mm
To adjust the tension of the lifting chain, lower the lifting cylinder
until the forks are on the ground and adjust the chain using the
adjusting nuts (three on each side) for dimension C: 25 mm-
C 30 mm, pressing in the middle of the chain with your finger.
Adjusting
nuts
60-04-M183EN (07/06/2018)
FORK ARM SUPPORT CLEARANCE
1) Measure the internal width "A" between the inner masts. Take
the measurements on the upper, lower and central sections
(crossbeam).
A
A
2) Measure the left and right heights B, B' and B'' of the lateral
B support roller, the support roller and the metal stop.
Fork carriage
Roller
Adjusting shim
3) Calculate A-B, A-B' and A-B". Each of the results indicates the
Guide roller Adjusting shim clearance between each roller and the inner mast. Adjust the
Roller Adjusting washer shims of each roller uniformly to the left and right and obtain
B’’ the clearance between the smallest part of the inner mast and
the side roller of the support.
60
Adjusting washer
Roller
B’ A- B' = 0.2 mm to 1 mm (0.007 to 0.04 in)
A- B' = 0.1 mm to 0.8 mm (0.004 to 0.031 in)
A- B" = 0.1 mm to 0.8 mm (0.004 to 0.031 in)
Guide roller
Shims: 0.5 mm to 1 mm (0.019 to 0.04 in)
a. The number of shims must be the same to the right and left
when the shims are used.
Roller
Roller b. After the clearance has been adjusted, push the whole support
to check that it is working correctly.
(07/06/2018) 60-04-M183EN
LIFTING CYLINDER REMOVAL AND INSTALLATION
bb Keep away from the equipment
Remove the mast.
i 60 (6 MAST REMOVAL, 5 10)

Attach a rope to the inner mast and remove
the left and right lifting cylinder using a lifting device.
DISASSEMBLY
If the rated capacity is less than 2.5t (5,511.55 lbs), remove the
cylinder head and the guiding sleeve.
If the rated capacity is greater than 3 tonnes (6,613.86 lbs), remove

60
the screws and the nylon hood and remove the cylinder head.
1 - Remove the O-ring dust seal.
2 - Remove the Y ring using a screwdriver.
bb o not reuse the dust seal, the O-ring or the Y ring.

D
Replace them with new parts.
3 - Pull out the piston rod and remove the Y ring on the end
of the piston.
60-04-M183EN (07/06/2018)
INSTALLING AND REPLACING THE FAULTY PARTS.
1 - Clean the parts with clean oil before installation.
2 - Then clean the guiding sleeve and the piston using hydraulic oil of the same brand used in the box.
3 - Do not get dust or dirt in the lifting cylinder.
4 - The order for installation is the reverse of the order for disassembly.
5 - Fit the Y ring on the piston.
6 - Install the piston rod assembly in the body of the clean cylinder.
bb he end of the cylinder body must be smooth and clean. The installation must be centred. Avoid
T
scratching the Y ring.
7 - Fit the O-ring dust seal and the Y ring in the guiding sleeve and the cylinder head.
PLEASE NOTE: use hydraulic grease of the same brand as the grease in the tank of the guide sleeve
installed with the O-ring.
8 - Push the head of the cylinder into the piston rod and screw on the cylinder body.
60
(07/06/2018) 60-04-M183EN
TILTING CYLINDER REMOVAL AND INSTALLATION
bb Information for removing cylinders.
- Attach a rope to the outer mast to prevent the mast falling after the tilting cylinder
is removed.
- Keep your body away from the equipment. Do not stand under the fork arm
support.
1 - Lower the fork arm support completely.
2 - Remove the bolt from the left and right supports of the
outer mast and remove the shaft (Item 1).
3 - Remove the oil pipe from the tilting cylinder inlet.
4 - Remove the bolt from the chassis mount and remove the
pin, then move the tilting cylinder.
5 - The order for installation is the reverse of the order for

disassembly.
60
Removal of parts
1 - Clamp the tilting cylinder in a vice, then move the piston

rod with a to-and-fro movement in the tilting cylinder to
get rid of any oil that is still in the tilting cylinder.
2 - Loosen the eye bolts (Item 2) and unscrew the eye (Item 1).
3 - Remove the guiding sleeve from the cylinder head (Item 3).
4 - Remove the piston rod assembly (Item 4).
5 - Remove all of the dust seals, O-rings and the Y ring.
60-04-M183EN (07/06/2018)
Remove any dust from the O-ring in the cylinder head in

6 -
the same way as for the lifting cylinder.
(6LIFTING CYLINDER REMOVAL AND INSTALLATION, 5 10)
7 - Remove the outer O-ring from the guiding sleeve.
Remove the O-ring and the Y ring from the inside hole of
8 -
the guiding sleeve
(6LIFTING CYLINDER REMOVAL AND INSTALLATION, 5 10)
bb IMPORTANT: do not reuse the O-ring dust seal and the Y ring that have been removed.
Install the tilting cylinder after replacing the ring
Refit in the reverse order to removal, taking care of the following:
Lubricate the parts using clean hydraulic oil.
60
1 -
2 - Do not get dust or dirty oil in the tilting cylinder.
3 - Avoid scratching the end of the cylinder head and the hydraulic oil inlet and outlet.
4 - Push the piston rod into the cylinder body when it is correctly centred, making sure not to scratch
the Y ring.
5 - Before installing the guide bush, wipe the old hydraulic oil with new hydraulic oil in the middle
of the O-ring and the Y ring in the inside hole of the guiding bush.
6 - Do not scratch the outside of the O-ring on the guiding sleeve during installation.
7 - Remember to fit the nylon stop and tighten the screw after screwing on the cylinder head.
(07/06/2018) 60-04-M183EN
NOTE ABOUT TROUBLESHOOTING

1. Adjust the forward and backward position of the mast
Place the forklift truck on flat ground and activate the control lever to tilt the mast all the way forward
and all the way back.
If information is required to resolve assembly problems, adjust the thread length of the screw based on
the information for tilting backward, then lock the eyelet firmly.
i Tilt angle of duplex and triplex mast (6INSPECTION AND ADJUSTMENT, 5 2)

i Tightening torques table for section (6INSPECTION AND ADJUSTMENT, 5 2)
2. R
eadjust the installation position of the left and right lighting cylinders
a. Adjust the washer in the middle of the piston rod and the inner mast support if the lifting
cylinders are not synchronized during lifting or lowering and if a lifting cylinder is a different
height from the others.
b. Loosen two nuts on the U bolt. Do not raise or lower the mast when the relative position of
the U bolt and the lifting cylinder is not appropriate. Then tighten the nuts and the fastening
60
screw on the U bolt. This operation extends the usage time of the lifting cylinder and reduces
wear on the piston rod.
i Tightening torques table for section (6INSPECTION AND ADJUSTMENT, 5 2)
60-04-M183EN (07/06/2018)
MAST SECTIONS AND DIAGRAMS
pages
MAST SECTIONS AND DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– LIFTING CYLINDER - TYPE A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– LIFTING CYLINDER - TYPE B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– FREE-ACTING LIFTING CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
60
(07/06/2018) 60-05-M183EN
2 MAST SECTIONS AND DIAGRAMS
MAST SECTIONS AND DIAGRAMS

LIFTING CYLINDER - TYPE A
60
1 - Piston 7 Piston
-
2 - Dust protection ring 8 Support ring
-
3 - Gasket ring 9 Protection ring
-
4 - O-ring seal 10 Gasket ring
-
5 - Guiding sleeve 11 Oil nozzle assembly
-
6 - Cylinder (with no left lifting cylinder)
12 - O-ring seal
60-05-M183EN (07/06/2018)
MAST SECTIONS AND DIAGRAMS 3
LIFTING CYLINDER - TYPE B
60
1 - Dust protection ring 7 - O-ring seal
2 - Cylinder cover 8 - Bolt
3 - Protection ring 9 - Piston rod
4 - ISI ring 10 - Cylinder
5 - O-ring seal 11 - Wearing ring WR
6 - Pad 12 - Piston
(07/06/2018) 60-05-M183EN
4 MAST SECTIONS AND DIAGRAMS
FREE-ACTING LIFTING CYLINDER

60
1 - Dust protection ring 7 - Support ring

2 - Cylinder cover 8 - Piston
3 - Guiding sleeve 9 - Retaining ring
4 - O-ring seal 10 - Cylinder
5 - Stop 11 - ISI ring
6 - Piston rod assembly
60-05-M183EN (07/06/2018)
MAST REMOVAL
pages
MAST REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– REMOVE THE FORKS AND THE MAST ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
60
(07/06/2018) 60-06-M183EN
2 MAST REMOVAL
MAST REMOVAL
bb Pay attention when removing and installing the forks, the support and the mast as they are
heavy (600 to 900 kg).
REMOVE THE FORKS AND THE MAST ASSEMBLY
After unscrewing the captive bolts (1), unlock the fork pins by
1 pulling them and moving the forks (2) to the middle of the
support assembly.
Pull the lower portion of the fork to remove its lower jaw, then
lift up the fork.
bb
2
A - Ke e p yo u r h a n d s a n d f e e t a wa y f r o m t h e
forks. When removing and installing the forks,
pay attention and keep your hands and feet away.
60
B - Do not remove the forks from the end of the fork bar.
If the fork falls, it can cause serious injury.
Support the mast assembly with ropes (3).
3
bb Place a shim under the support to hold it firmly in position.
If all of the mast components are removed separately, remove

Fork carriage the chain attachment nuts (4) and detach them from the support
assembly.
Nut (4)
60-06-M183EN (07/06/2018)
MAST REMOVAL 3
Undo the screw (5) from the tilting cylinder pivot pin.
Take out the pin (6).
Put a collecting pan in place (7).

Detach the hoses (8) and close them off using plugs (9).
8
60
Detach the central hose (10) and the collar (11) from the hose (12).
12
10
11
Disconnect the flexible circuit accessories, where appropriate.
12
(07/06/2018) 60-06-M183EN
4 MAST REMOVAL
Flanges (13)
Remove the support flanges (13) from the mast.
Remove the mast assembly (14).
14
60
Truck without mast and hoses disconnected (15).
15
15
15
60-06-M183EN (07/06/2018)
MAST REFIT
pages
MAST REFIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
60
(07/06/2018) 60-07-M183EN
2 MAST REFIT
MAST REFIT
Carry out the operations in reverse order, paying attention to the tightening torques.
(6MAST CONTROL AND ADJUSTMENT, 5 2)

60
60-07-M183EN (07/06/2018)
MAST TROUBLESHOOTING
pages
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
60
(07/06/2018) 60-08-M183EN
2 MAST TROUBLESHOOTING
TROUBLESHOOTING
Condition Likely cause Corrective action
The fork arm support 1. Excessive abrasion of the tilting cylinder and the ring Replace the tilting cylinder piston ring.
or the mast tilts on
its own. 2. The hydraulic control valve spring is not working correctly. Replace.
The fork arm support 1. Piston jammed or piston rod bowed. Replace defective parts.
goes up and down
slowly. 2. Excessive dirt built up in the cylinder. Remove and clean.
Adjust the clearance with the metal stop and the

1. The support assembly must be adjusted.
lateral support roller.
2. Inadequate clearance between the inner and outer masts or between
Adjust the clearance with the rollers.
the rollers and the mast.
The forks go up and
down unevenly. 3. Dirt between the moving parts. Eliminate the foreign matter
Apply grease to the contact surfaces of the sliding
4. Insufficient lubrication.
part.
5. Support assembly or inner mast bowed. Repair or replace.
The forks go up
1. Lifting chains not adjusted correctly. Adjust the lifting chains.
unevenly
1. Grease hardened or dirt built up on the lifting roller and the mast's
The lifting roller does sliding surfaces. Clean and lubricate the lifting rollers.
not pivot
2. Lifting rollers not adjusted correctly. Adjust.
1. Insufficient lubrication. Lubricate.
2. Lateral roller not adjusted correctly; the fork support is struck by the
Adjust.
metal profile of the mast.
Excessive mast noise
By adjusting the shims and rubber pads, the piston
60
3. The rubber pad at the bottom of the outer mast cannot be used for the
rod touches the bottom of the cylinder body after the
forklift truck for containers.
mast has touched the rubber pad.
1. Excessive wear between the oil pump body and the gears, creating too
Replace the worn parts of the oil pump.
great a clearance.
2. The Y ring of the lifting cylinder is worn and causes excessive internal
Replace the Y ring.
leaks.
3. The multiple control springs and their relief valves are not working
Replace.
because of oil leaks.
4. Excessive wear of the hydraulic control valve, causing excessive oil leaks. Replace.
Insufficient lifting
power or no lifting Disassemble to correct the sealing surfaces and refit
movement. 5. Oil leaks between the sections of the hydraulic control valve.
the valve.
6. Leak in the hydraulic pipe. Tighten the seal nuts and check the seal for damage.
Replace the hydraulic oil or stop the work to reduce

7. The hydraulic oil temperature too high. The viscosity of oil too low and
the oil temperature. Determine the reasons for the
the ratio insufficient.
high oil temperature and eliminate the problem.
8. The transport load exceeds the rated capacity. Respect the lifting capacity limit.
60-08-M183EN (07/06/2018)
HYDRAULIC
- HYDRAULIC CHARACTERISTICS AND

SPECIFICATIONS
- HYDRAULIC SCHEMATIC DIAGRAMS
- HYDRAULIC CONTROL AND ADJUSTMENT
- HYDRAULIC TROUBLESHOOTING
70
HYDRAULIC CHARACTERISTICS AND
SPECIFICATIONS
pages
MAIN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MAIN PUMP DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
–– 1.5T-1.8T (3,306.93-3,968.31 LBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– 2T TO 3.5T (4,409.24 LB TO 7,716.17 LBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
–– MAIN PRESSURE RELIEF VALVE AND STEERING PRESSURE RELIEF VALVE . . . . . . . . . . . 6
–– OPERATION OF THE TILTING SPOOL LOCKING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– HYDRAULIC PIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
70
DISTRIBUTOR DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
–– 1.5T TO 3.5T (3,306.93 - 7,716.17 LBS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
(07/06/2018) 70-01-M183EN
2 SPECIFICATIONS
MAIN PUMP
The hydraulic system work pump is a CBHZG gear pump. This gear pump is an automatic play compensation
pump with radial hydraulic balancing.
The difference between the pumps with left or right rotation is the seal in 3 forms. This part is specific
to each pump.
70
CBHZG gear pump with anticlockwise rotation (left)
1 - Snap ring 8 - Driven gear

2 - Seal 9 - Drive gear
3 - Front cover 10 - Intermediate body
4 - Seal washer 11 - Rear cover
5 - Seal in 3 forms 12 - Washer
6 - Pressure plate 13 - Mounting screw
7 - Bush
70-01-M183EN (07/06/2018)
SPECIFICATIONS 3
CBHZG gear pump with clockwise rotation (right)
70
1 - Snap ring 8 - Driven gear
2 - Seal 9 - Drive gear
3 - Front cover 10 - Intermediate body
4 - Sealing plate 11 - Rear cover
5 - Seal in 3 forms 12 - Washer
6 - Pressure plate 13 - Mounting screw
7 - Bush
(07/06/2018) 70-01-M183EN
4 SPECIFICATIONS
MAIN PUMP DATA
1.5t-1.8t (3,306.93-3,968.31 lbs)
Model CBHZG-F20-AFΦL CBHZG-F23-AFΦ

Type Gear
Drive Type of engine power take-off: gear
Movement (ml/r) 20/23
Speed (rpm) 500 to 3000
Output pressure (rated/max) MPa 20/25
2t to 3.5t (4,409.24 lb to 7,716.17 lbs)
Model CBHZG-F28.2-AFΦL CBHZG-F30-AFΦ

Type Gear
Drive Type of engine power take-off: gear
Movement (ml/r) 28.2/30
Speed (rpm) 400 to 3,500
Output pressure (rated/max) MPa 20/25
70
70-01-M183EN (07/06/2018)
SPECIFICATIONS 5
DISTRIBUTOR
The distributor consists of a body with 4 locations:

–– 2 spools,
–– a main pressure relief valve,
–– a steering pressure relief valve.
The body with 4 locations is assembled by 3 studs and nuts.
The tilting spool consists of a tilt locking valve.
Depending on the device's requirement, it is possible to add a locking valve and a rotating valve.
Main pressure relief valve Lifting spool Tilting spool
P
to the pump
70
to steering box
B1 B2
to steering box
A1 A2
PF
Steering pressure relief valve
P
T
Distributor for forklift truck 1.5t to 3.5t (3,306.93-7,716.17 lbs)
(07/06/2018) 70-01-M183EN
6 SPECIFICATIONS
MAIN PRESSURE RELIEF VALVE AND STEERING PRESSURE RELIEF VALVE
Main pressure relief valve
The main pressure relief valve controls the system pressure. Under normal operating conditions, the
rod of the main relief valve does not open. When a hydraulic system overload results in a stoppage
by reaching the pressure limit, the main pressure relief valve operates. The hydraulic system pressure
therefore stops increasing and safety is guaranteed.
Steering pressure relief valve
The steering pressure relief valve is adjusted to a lower pressure than the main pressure relief valve.
When a steering system fault occurs, or when the load is too high, the pressure increases, exceeding
the spring's force. This increase results in closure of the spool and guarantees the safety of the steering
system.
To steering box
Oil inlet Control valve

70
PF P
Main pressure
relief valve
Steering
pressure
relief valve
Main pressure relief valve and steering pressure relief valve
70-01-M183EN (07/06/2018)
SPECIFICATIONS 7
OPERATION OF THE TILTING SPOOL LOCKING VALVE
The tilting spool has an automatic locking valve to avoid:

–– Vibration caused by the negative pressure inside the tilting cylinder
–– Injuries caused by a handling error
–– The mast tilting when the engine is off
Tilting cylinder
Tilting spool
A2 B2
Locking
Spring valve Spool
Tilting spool
The holes (A2) and (B2) are connected to the front and rear chambers of the tilting cylinder piston.
70
When the spool is removed, the high pressure oil (P) enters through the hole (A2) and the oil in the rear
chamber returns to the tank (T) through the hole (B2). The mast then tilts backwards.
When the spool is pushed back, the high pressure oil enters through the hole (B2). The locking valve is
triggered by the oil's action, the hole (A2) communicates with the low pressure.
If the engine stalls or is off, there is no high pressure oil to activate the tilt locking valve, the hole (A2)
can no longer communicate with the low pressure. The mast can no longer tilt and a negative pressure
can no longer be generated in the tilting cylinder.
(07/06/2018) 70-01-M183EN
8 SPECIFICATIONS
HYDRAULIC PIPES
The high pressure oil from the main pump is distributed by the distributor towards 2 flows:
–– the lifting cylinder or the tilting cylinder,
–– the steering box to control the steering cylinder.
When the lifting and tilting spool is in neutral, the high pressure oil returns directly to the oil tank.
When you pull on the lifting spool, the high pressure oil passes through the logical valve then pushes
the piston rod under the lifting cylinder piston.
When you push on the lifting spool, the bottom of the lifting cylinder piston connects to the low pressure
pipe and then the piston rod drops under the weight of the load. At this moment, the lifting cylinder
oil passes through the one-way speed limitation valve to control the lowering speed.
The stopcock serves under the right lifting cylinder. Its function is to prevent goods falling suddenly
when the oil pipe goes down.
When the tilting spool is operating, the high pressure oil goes to the front box of the tilting cylinder and
another connects to the low pressure pipe so that the mast tilts forwards or backwards.
DISTRIBUTOR DATA
1.5t to 3.5t (3,306.93 - 7,716.17 lbs)
2 spools
Model 3 spools
4 spools
70
Type Double spool valve with pressure relief valve and automatic tilt locking valve
1.5 t / 3,306.93 lbs (bar/psi) 155 ±0.25/2,249 ±3.62
Pressure
1.8 t-3.5 t / 185 ±0.25/ can lift 110% of the rated load, cannot lift 125% of the rated load
adjustment (bar)
3,968.31-7,716.17 lbs (bar/psi) 2,684.35 ±3.62
Nominal flow rate (L/min/gpm) 65/17.19
Steering pressure relief valve pressure (bar/psi) 100 ±5/1451 ±72.55
70-01-M183EN (07/06/2018)
HYDRAULIC SCHEMATIC DIAGRAMS
pages
MAIN DIAGRAM OF THE HYDRAULIC SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

MAIN DIAGRAM OF THE HYDRAULIC SYSTEM (DETECTION SYSTEM) . . . . . . . . . . . . . . . . 3
–– SCENARIO 1: MOVEMENT STOPPAGE IS DEACTIVATED AND THERE IS NO MOVEMENT REQUEST . . . 4
–– SCENARIO 2: MOVEMENT STOPPAGE IS DEACTIVATED AND THERE IS A MOVEMENT REQUEST (LIFTING) . . . . . 4
–– SCENARIO 3: MOVEMENT STOPPAGE IS ACTIVATED AND THERE IS A MOVEMENT REQUEST (LIFTING) . . . . . 5
–– SCENARIO 4: MOVEMENT STOPPAGE IS ACTIVATED AND THERE IS A MOVEMENT REQUEST (DOWNWARDS) . . 5
MAIN DIAGRAM OF THE HYDRAULIC SYSTEM (DETECTION SYSTEM) (WITH THE 3RD AND 4TH HYDRAULIC
COMPONENT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
70
(07/06/2018) 70-02-M183EN
2
70
70-02-M183EN
T Multiway valve
B2
A2 Steering cylinder
Tilt cylinder B2
A2
Steering
Pt
gear
Flow divider
MAIN DIAGRAM OF THE HYDRAULIC SYSTEM
Lift cylinder valve

Pressure
limiter
PT Pressure
limiter
Speed P1 P PF
limiting valve
Gear pump Engine

P2
Oil suction strainer Oil return strainer
UP TO THE MACHINE
(07/06/2018)
N°855581
Key:
1 - Stopcock
T 2 - Logical valve
(07/06/2018)
Distributor
3 - Priority flow divider
valve
B2 4 - Directional pressure
relief valve
A2
5 - Main pressure relief
Tilting cylinder valve
Steering cylinder
1
2
A1
Lifting cylinder 2
3
Steering
Pt box
88±5 bar
Lifting cylinder 4 (1276.88±72.55 psi)
1 155±5 bar /1.5 t (2,249.05±72.55 psi/3,306.93 lbs)

5 185±5 bar /1.8 t-3.5 t (2,742.39±72.55 psi/3,968.32 lbs-7,716.17 lbs)
PT
Speed limitation P1 P PF
valve
MAIN DIAGRAM OF THE HYDRAULIC SYSTEM (DETECTION SYSTEM)
Gear pump Engine P2
Oil suction strainer Oil flow strainer

70-02-M183EN
3
70
4 HYDRAULIC SCHEMATIC DIAGRAMS
SCENARIO 1: MOVEMENT STOPPAGE IS DEACTIVATED AND THERE IS NO MOVEMENT REQUEST
T Distributor
B2
A2
Tilting cylinder
Steering cylinder
A1
Steering
88±5 bar
Pt box
(1276.88±72.55 psi)
Lifting cylinder
PT 155±5 bar /1.5 t (2,249.05±72.55 psi/3,306.93 lbs)

185±5 bar /1.8 t-3.5 t (2,742.39±72.55 psi/3,968.32 lbs-7,716.17 lbs)
valve
Engine
Gear pump
In operation
P2
Oil suctionstrainer Oil flow strainer
SCENARIO 2: MOVEMENT STOPPAGE IS DEACTIVATED AND THERE IS A MOVEMENT REQUEST (LIFTING)

70
T Distributor
B2
A2
Tilting cylinder
Steering cylinder
A1
Steering
Pt box
88±5 bar
(1276.88±72.55 psi)
Lifting cylinder
155±5 bar /1.5 t (2,249.05±72.55 psi/3,306.93 lbs)

PT 185±5 bar /1.8 t-3.5 t (2,742.39±72.55 psi/3,968.32 lbs-7,716.17 lbs)
valve
Engine
Gear pump
In operation
P2
Oil suctionstrainer Oil flow strainer
70-02-M183EN (07/06/2018)
HYDRAULIC SCHEMATIC DIAGRAMS 5
SCENARIO 3: MOVEMENT STOPPAGE IS ACTIVATED AND THERE IS A MOVEMENT REQUEST (LIFTING)
T Distributor
B2
A2
Tilting cylinder
Steering cylinder
A1
Steering
Pt box
Lifting cylinder
PT
valve
Engine
Gear pump P2
running
Oil suction strainer Oil flow strainer
SCENARIO 4: MOVEMENT STOPPAGE IS ACTIVATED AND THERE IS A MOVEMENT REQUEST (DOWNWARDS)
70
T
Distributor
B2
A2
Tilting cylinder
Steering cylinder
A1
Steering
Pt box
88±5 bar
Lifting cylinder (1276.88±72.55 psi)
PT 155±5 bar /1.5 t (2,249.05±72.55 psi/3,306.93 lbs)

185±5 bar /1.8 t-3.5 t (2,742.39±72.55 psi/3,968.32 lbs-7,716.17 lbs)
valve
Gear pump Engine
running
P2
Oil suction strainer
Oil flow strainer
(07/06/2018) 70-02-M183EN
6
70
Distributor
B4
70-02-M183EN
A4
Steering cylinder
B3
A3
Tilting cylinder
B2
A2
2
3RD AND 4TH HYDRAULIC COMPONENT)
A1
Lifting cylinder
2
88±5 bar
PT Steering
(1276.88±72.55 psi) box
4
Speed limitation
1
valve
Key:
PT 5
1 - Stopcock 155±5 bar /1.5 t (2,249.05±72.55 psi/3,306.93 lbs)
185±5 bar /1.8 t-3.5 t (2,742.39±72.55 psi/3,968.32 lbs-7,716.17 lbs)
2 - Logical valve
3 - Priority flow divider PF
valve Gear pump
4 - Directional pressure P1 Engine
relief valve Oil suction strainer Oil flow strainer
5 - Main pressure relief
MAIN DIAGRAM OF THE HYDRAULIC SYSTEM (DETECTION SYSTEM) (WITH THE
valve
(07/06/2018)
HYDRAULIC CONTROL AND ADJUSTMENT
pages
MAIN PRESSURE RELIEF VALVE PRESSURE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
70
(07/06/2018) 70-04-M183EN
2 HYDRAULIC CONTROL AND ADJUSTMENT
MAIN PRESSURE RELIEF VALVE PRESSURE ADJUSTMENT
The main pressure relief valve pressure is adjusted in the factory and generally it cannot be modified.
Here is a 3t truck example to explain how to adjust the pressure.
1 - Place 125 percent of the rated load (3,750 kg/8,267.25 lbs) on the fork in a stable fashion.
2 - Press right down on the acceleration pedal and check the lifting amount. If the fork can reach
the height of 0 mm-300 mm (0 in-11.81 in), the main pressure relief valve is working. Otherwise,
adjust it according to step (3).
3 - If the fork cannot lift the load, to increase the pressure in the main pressure relief valve, remove
the front shoe, tighten the retaining nut, turn the adjusting screw clockwise. If the lifting height
is greater than 300 mm (11.81 in), turn the setting screw anticlockwise to reduce the pressure.
4 - Press right down on the acceleration pedal so that the fork is in the height range 0 mm-300 mm
(0 in-11.81 in). Otherwise, adjust it according to step (3).
bb
5 - Retighten the retaining nut and attach it to the front shoe.
Place the load in a stable fashion.
Reference connection: 744804

70
70-04-M183EN (07/06/2018)
HYDRAULIC CONTROL AND ADJUSTMENT 3
P1 Main pump pressure: P1.
P2 Steering unit pressure: P2.
Adjust the main pressure relief valve (1).

1
70
(07/06/2018) 70-04-M183EN
4 HYDRAULIC CONTROL AND ADJUSTMENT
TIGHTENING TORQUE
ATTACHMENTS TO THE CHASSIS & COMPONENTS
25~32 N.m
(18.44~23.60 ft-lb)
27,1 N.m
(20 ft-lb)
48~58 N.m
(35.40~42.78 ft-lb) 65~80 N.m
(47.95~59 ft-lb)
100~120 N.m
(73.76~88,55 ft-lb)
65~80 N.m
(47.95~59 ft-lb)
70
TIE ROD ATTACHMENT
[M10] 50 N.m
(36.88 ft-lb)
[M8] 40 N.m
(29.50 ft-lb)
70-04-M183EN (07/06/2018)
HYDRAULIC TROUBLESHOOTING
pages
MAIN PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
DISTRIBUTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
70
(07/06/2018) 70-08-M183EN
2 HYDRAULIC TROUBLESHOOTING
MAIN PUMP
Problem Likely cause Corrective action

Low oil level in oil tank. Add oil to the level indicated.
No oil from oil pump Clean the oil circuit and the tank.
Blocked inlet pipe or strainer.
If the oil is dirty, change it.
Worn bearing, damaged support ring or O-ring seal. Replace the damaged parts.
Pressure relief valve not adjusted correctly. Adjust to the pressure specified using the manometer.
Low oil pump discharge Retighten the lateral inlet pipe.
pressure. Add oil to the tank.
Air in the oil pump. Check the pump's oil-tight seal.
Do not run the pump until the bubbles in the tank have
disappeared.
Cavitation due to a clogged inlet pipe or strainer. Adjust or replace the clogged pipe and clean the strainer.
Air is taken in by a loose lateral suction seal. Retighten each seal.
Noisy oil pump replace with new oil with the correct viscosity for the
Cavitation due to excessively high oil viscosity. temperature at which the pump operates.
·operate when the oil temperature is normal.
Bubbles in the hydraulic oil. Determine the cause of the bubbles and correct.
Oil leak from the oil Defective oil-tight seal on the pump, defective O-ring seal or sliding
Replace defective parts.
pump surfaces worn on the pump.
DISTRIBUTOR
Problem Likely cause Corrective action

Loosen the pressure adjustment screw. Adjust again and retighten.
The pressure relief valve Deformed or damaged pressure adjustment spring. Replace.
pressure is unstable or
Worn or blocked pressure relief valve core. Replace or clean.
70
too low.
Pump reduced. Examine and repair the pump.
Replace the relief valve core and the blocking tilt valve
Worn or damaged blocking tilt valve.
Mast tilt forwards when as a whole.
the control lever is used
and the engine is off. Broken blocking spring. Replace the spring.
Damaged tilt valve piston O-ring seal. Replace the O-ring seal.
The mast is unstable in
The tilt pressure relief valve is not working correctly. Replace the tilt pressure relief valve assembly.
forward tilt
The valve body and the spool valve lever are worn and the gap
Replace the spool valve with a specified gap.
The support is towards between them is too great.
the bottom when the The spool valve lever is not centred. Stay in the centre.
lever up and down is in
neutral. The cylinder seal is reduced. Examine and repair the cylinder.
The overload valve is worn or jammed with dirt. Replace or clean the taper valve.
Damaged or deformed repositioning spring. Replace the spring.
The spool valve does not Presence of dirt between the valve body and the valve lever. Clean.
return to neutral. Control system jammed. Adjusted.
No coaxial parts repositioned Reinstall.
Damaged O-ring. Replace.
Seal not leak-tight. Check and retighten.
Leak Loose sealing plate. Clean the sealing plate and retighten the bolts.
Pressure relief valve locknut loose and connection nut between two
Tighten.
plates.
70-08-M183EN (07/06/2018)
ELECTRICITY
- ELECTRICAL CHARACTERISTICS AND

SPECIFICATIONS
- ELECTRICAL SCHEMATIC DIAGRAMS
- ELECTRICAL COMPONENTS LOCATION
- ELECTRICAL CONTROL AND ADJUSTMENT
80
ELECTRICAL CHARACTERISTICS AND
SPECIFICATIONS
pages
WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A
ELECTRICAL COMPONENT TECHNICAL FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B

2 SPECIFICATIONS
80
80-01-M183EN (07/06/2018)
SPECIFICATIONS A1
WIRING
pages
FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2

–– RELAYS AND FUSES HOLDER PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
–– POWER FUSES ON STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
–– BULB SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
CABLE COLORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
80
(07/06/2018) 80-01-M183EN
A2 SPECIFICATIONS
FUSES AND RELAYS
RELAYS AND FUSES HOLDER PLATE
F1 5A
X21 F2 5A
F3 5A
F4 10A
F5 10A
F6 10A
F7 5A
F8 5A
F9 5A
F10 5A
F11 15A
F12 15A
F13 20A
Section Rep. Current Designation Description
F14 15A
F1 20 A Light HEAD LAMP, WIDTH LAMP
F2 10 A Horn
F15 5A HORN, CONTROLER SECURITY
F3 10 A Signal light LEFT AND RIGHT SIGNAL LAMP, BRAKE LAMP
F4 10 A Control circuit CONTROLLER POWER, DIRECTION SWITCH, FUEL SHUT OFF (MI D)
F5 10 A Instrument INSTRUMENT MESURE, INSTRUMENT INDICATOR LAMP
F6 X20
10 A Engine control circuit ALTERNATOR CONTROL, QGS CONTROL (MI D), IGNITION COIL (MI G)
FUSES JD1 JD3 JD5
F7 15 A Warning lamp ROTATING WARNING LAMP, REAR WORK LAMP
80
F8 F120 A Reserved
5A fused 30 30 30
87a 87a 87a
F9 10 A Reserved fuse 86 85 86 WIPER (OPTION)
85 86 85
F2 10A 87 87 87
F310 A Reserved fuse (MI G S1 E3)
F10 10A
Heater (MI30
G S2) HEATER
F4 10A 86 30
49
F11 10 A Reserved fused 87a
F5 86 85 49a
R1 50 A
20A
STARTER 85 87
STARTER, 31 (MI D)
GLOW PLUG
POWER 87
F6
FUSES R2 50 A TRUCK ALL LITTLE FUSE
JQ8 IGNITION RELAY JD2 JD4 JD6

JQ1 STARTER RELAY
JQ6 WIDTH LAMP RELAY
JQ7 HEAD LIGHT RELAY
RELAYS JQ2 START CONTROL RELAY
JQ3 FORWARD RELAY
SG FLASHER RELAY
JQ4 REVERSE RELAY
JQ5 SOLENOID VALVE RELAY RESERVED
80-01-M183EN (07/06/2018)
SPECIFICATIONS A3
POWER FUSES ON STARTER
Fusible wire 55A (Rep.A).
LIGHTING SYSTEM
BULB SPECIFICATIONS
Lamp Specification
Headlight
Front lighting 12V-35W
Steering lamp 12V-21W
Width lamp (LED) (3.2V-20mA)×2
Combined back lamp (LED)
Brake and width lamp (3.2V-20mA)×15
Steering lamp (3.2V-20mA)×15
ReTowardse lamp (3.2V-20mA)×15
CABLE COLORS
Cable colors are indicated by one or two alphabetical letters:
B: black
80
BR: brown
G: green
L: blue
LG: Light green
R: red
W: white
Y: yellow
S: gray,
P: purple
O : Orange
The main cable is generally coded with a single color.
The others are coded with a two-tone color as below :
B/W Black with white stripe

G/Y: Green with yellow stripe
(07/06/2018) 80-01-M183EN
MI 20 to 35 D S2
A4 SPECIFICATIONS MI 20 to 35 D Y E3 S3
80
80-01-M183EN (07/06/2018)
SPECIFICATIONS B1
TECHNICAL SHEETS FOR ELECTRICAL COMPONENTS
Rep.
Désignation Pages
Électriques
Instrument meter B2
G2 Engine water temperature probe B3
G3 Fuel level gauge B4
Combination switch B5
Brake lamps B6
QK Pre-heat & start B6
BJ1 / BJ2 Reverse warner / Backup buzzer B7
K8 Hand-brake switch B7
Reversing solenoid valve B8
Oil pressure sensor B8
80
(10/10/2014) 80-01-M183EN
B2 SPECIFICATIONS
Instrument meter X2
Schematic representation
PIN Min Typical Max

Voltage 11 V 12 V 15 V
Current 1,5 A
Position Function
1 Power of timer
2 Indicator of right turning light
3 Indicator of left turning light
4 Indicator of neutral position
5 parking brake indicator
6 Power of panel
7 Charge battery indicator

80
8 Engine oil pressure indicator
1 9 Water oil separator indicator +

11 10 Preheating indicator
10 11 Oil temperature transmission indicator
20 12 Fault indicator -
13 Accumulator indicator
14 Engine water temperature indicator
15 fuel gauge signal +
16 Ground of panel
17 Water oil separator indicator -
18 fuel gauge signal -
19
20 Fault indicator +
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M183EN (10/10/2014)
SPECIFICATIONS B3
G2 Engine water temperature probe X28
PIN Fonction 1 2
1 1 Water temperature info

2
2 Engine Earth
Corresponding connector
PIN Min Typical Max

Supply voltage 12 V
Resistance range 10 000 Ω
Temperature range 50 °C 120 °C
80
NOTE: Resistance tolerance ± 3%
TEMPERATURE SENSOR RESISTANCE TABLE
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(10/10/2014) 80-01-M183EN
B4 SPECIFICATIONS
G3 Fuel level gauge X43
PIN Fonction 1 2
1 1 Fuel level info

2
2 Engine Earth
PIN Typical
Supply voltage 1 12 V
Empty reservoir resistance 1 11 kΩ
Full reservoir resistance 1 1 kΩ
Input type Analogue input

80
NOTE: Resistance tolerance ± 3%
FUEL SENSOR RESISTANCE TABLE
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M183EN (10/10/2014)
SPECIFICATIONS B5
Combination switch X8 / X9
PIN Fonction
1 Forward signal
B
2 Reverse signal
3
6 3 Control power
1 4 Horn signal (+)

B
4 5 Horn signal ground wire
A 6
Steering lamp switch
1
3 2 power
A
1 2 Left steer signal
3 Right steer signal
6 4 Lighting switch power

5
4 5 Width lamp signal
6 Headlamp signal
PIN Typical
Note :
Voltage drop ≤ 50mV
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Combination switch B
Connector
Combination switch (direction) A
Connector
80
position position
1 2 3 4 6 6 1 2 3 4 5
Handle Handle
position position
Headlight X X Forward X X
Horn
Width lamp X X N X
Contactor
OFF X Reverse X X
Turn left X X
Off X
Turn right X X
(10/10/2014) 80-01-M183EN
B6 SPECIFICATIONS
Brake lamps X10
PIN Fonction
1 1 Power signal
2
Brake lamps the input
2
signal
PIN Typical
Power 1 120 W
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
QK Pre-heat & start X7
PIN Fonction
1 1 Connection B1, B2
3 2 ACC
2
80
4 3 C
4 R2
Note : Preheat start switch QK

Contacts load : ACC : 240 W connector
B1 B2 Acc C R1 R2 Explain
C : 480 W position
preheat X X X OFF
R1 : 1200 W Preheat run
ON
OFF (close) X X
R2 : 1200 W
run X X X start and preheat
are short working
ON (start) X X X X X automaticallt return
Note : «X» mans ON
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M183EN (10/10/2014)
SPECIFICATIONS B7
BJ1 / BJ2 Reverse warner / Backup buzzer X31 / X29
PIN Fonction
1 1 input Signal 1 2
2
2 Ground wire
PIN Typical
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
K8 Hand-brake switch X11
PIN Fonction
1 Power signal (COM)

1
2 NO
2
80
Hand-brake input Signal
3 3
(NC)
PIN Min Typical Max

Voltage 12 V
Current 15 A
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
(10/10/2014) 80-01-M183EN
B8 SPECIFICATIONS
Reversing solenoid valve X35
PIN Fonction
1 Forward
2 2 Reverse
4 1
3 Grounding
3
4 Grounding
PIN Typical
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
Oil pressure sensor X24
PIN Fonction
1 Oil pressure alarm signal

80
Note :
Alarm pressure value of 0.5 MPa
Notes: _____________________________________________________________________________________
___________________________________________________________________________________________
___________________________________________________________________________________________
80-01-M183EN (10/10/2014)
ELECTRICAL SCHEMATIC DIAGRAMS
pages
MI 15 TO 35 G - S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
MI 15 TO 35 G - S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
MI 15 TO 35 D - S1 E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MI 20 TO 35 D - S2 E3 & Y E3 S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
80
(07/06/2018) 80-02-M183EN
2 ELECTRICAL SCHEMATIC DIAGRAMS
80
80-02-M183EN (07/06/2018)
ELECTRICAL SCHEMATIC DIAGRAMS 3
MI 15 to 35 G - S1
Battery 12V DC
Alternator
Starter
Key
Symbol Name Remark
FD Distributor Supplied by engine
Sparking plug F3 - F13 Fuse (Little fuse) Supplied by control box
F1 - F2 Power fuse
Carburetor JQ8 Ignition relay 12V Supplied by control box
Dual fuel option Gas valve JQ7 Hand lamp rely 12V Supplied by control box
Fuel valve
JQ6 Width lamp relay 12V Supplied by control box
Engine control circuit Oil pressure indicator lamp
Oil temperature indicator lamp JQ5 Multiple valve control relay 12V Supplied by control box
Water temperature sensor JQ4 Reversing relay 12V Supplied by control box
Instrument Timer JQ3 Forward relay 12V Supplied by control box
Neutral indicator lamp
Malfunction warning lamp JQ2 Starting control relay 12V Supplied by control box
Parking brake lamp JQ1 Start relay 12V Supplied by control box
A5 B3 Buzzer SG Flasher 12V Supplied by control box
B4
B8 A6 Multiple valve down solenoid valve (reserve) DL Horn 12V
A10 Multiple valve movements solenoid valve (reserve)
Security BJ2 Buzzer 12V
A4
A14 module A9 BJ1 Reverse warner 12V
A15 Forward solenoid valve
A18 D7 - D8 Front side lamp 21W 4W
A17 A8
Control circuit D5 - D6 Combination tail lamp
A1 A2 Reverse solenoid valve
21W21W/5W10W
Left reversing lamp
Right reversing lamp D3 - D4 Front head lamp 35W
Reverse warner
D2 Rear work lamp 55W
Left indicator lamp D1 Rotating warning lamp 21W
Left turn signal lamp-front HX Carburetor Supplied by engine

Left turn signal lamp-rear HS1 - HS4 Spark plug M14x1.25 Supplied by engine
Right turn signal lamp-rear
G5 Oil temperature warner
80
Right turn signal lamp-front
G2 Water temperature sensor Supplied by combination meter
Reserved Right indicator lamp
Security module Input/Output G1 Oil pressure warner Supplied by engine
Signal light Left brake lamp ZD1 - ZD8 Warning lamp 12V 2W Supplied by combination meter
Right brake lamp Symbol Name
Reserved
A1 Controller Power B3 Timer 12V Supplied by combination meter
A2 Controller grounding B1 Water temperature inducator Supplied by combination meter

Reserved
A4 Battery + DQ Ignition coil Supplied by engine

Reserved
A5 Parking brake indicator K11 Rotating Warning lamp switch
A6 Multi-way valve control valve K10 Rear work lamp switch

Horn Horn
output K9 Seats switch
Left head lamp
Right head lamp A8 Reverse solenoid valve output K8 Hand braking switch
A9 Forward solenoid valve output K5 Combination switch (lamplight)
Rear-left width lamp A10 Starting signal output K4 Horn button Supplied by steering whell
Light Rear-right width lamp A14 Seat switch signal K3 Braking switch
A15 Hand braking swith signals K2 Combination switch (steering)
A17 Direction switch reverse gear K1 Combination switch (direction)
Front-left width lamp
A18 Direction switch forward gear QK Preheat & start switch Supplied by combination meter
Front-right width lamp
B3 Alarm output QD Starter 12V 1.2kW Supplied by engine
Warning lamp Rear work lamp
B4 Malfunction warning lamp JF Alternator 12V 50A Supplied by engine
Rotating Warning lamp
B8 Neutral indicator lamp XDC Battery 12V 60Ah
(07/06/2018) 80-02-M183EN
MI 15 to 35 G - S2
Battery 12V DC
Alternator
Starter
Spark plug
Carburetor
Charge indicator lamp Key
Oil pressure indicator lamp Symbol Name Remark

Engine control circuit
Oil temperature indicator lamp FD Distributor Supplied by engine
Water temperature sensor F3 - F13 Fuse Supplied by control box
Instrument Timer
JQ9 Carburetor Relay 12V Supplied by engine
Mid-position indicator lamp
Falut alarm lamp JQ8 Ignition relay 12V Supplied by control box
Parking brake lamp JQ7 Front big lamp relay12V Supplied by control box
A5 B3 Buzzer
B4 JQ6 Width lamp relay 12V Supplied by control box
B8 A6 Lowering control valve (spare)
JQ5 Multi-way valve control relay 12V Supplied by control box
A10 Motion control valve (spare)
Security JQ4 Reverse relay 12V Supplied by control box
A4
A14 module A9 JQ3 Forward relay 12V Supplied by control box
A15 Forward solenoid valve
A18 JQ2 Starting control relay 12V Supplied by control box
A17 A8
A1 A2 JQ1 Start relay 12V Supplied by control box
Reverse solenoid valve
Left reversing lamp SG Flasher 12V Supplied by control box
Right reversing lamp DL Electrical horn 12V
Reverse warner
Control circuit BJ1 Reverse alarm 12V
D7 - D8 Front small lamp 21W 4W
Left turn signal lamp-front
Left turn signal lamp-rear D5 - D6 Combination rear lamp 21W21W/5W10W
Right turn signal lamp-rear D3 - D4 Front big lamp 35W
Right turn signal lamp-front
D2 Rear work lamp 55W
80
Signal light Left brake lamp D1 Warning lamp 21W

Right brake lamp HX Carburetor Supplied by engine
Reserved
Front wiper Security module Input/Output
HS1 - HS4 Spark plug M4x1.25 Supplied by engine
Front wiper sprinkler Symbol Name
Reserved
G4 Oil temperature alarm
A1 Controller Power
Option Rear wipe and rear wipe sprinkler G2 Water temperature sensor Supplied by combined meter
Heater Heater A2 Controller ground
G1 Oil pressure warning unit Supplied by engine
A4 Battery +
Reserved
ZD1 - ZD8 Warning lamp 12V 2W Supplied by combined meter
A5 Parking brake indicator
B3 Timer 12V Supplied by combined meter
A6 Multi-way valve control
Horn Horn solenoid valve output B2 Fuel gauge meter 12V Supplied by combined meter
Left head lamp A8 Reverse solenoid valve output DQ Ignition coil Supplied by engine
Right head lamp
A9 Forward solenoid valve output K5 Combination switch (laghting)
A10 Starting output K4 Horn button Supplied by steering whell
Rear-left width lamp
Light A14 Seat switch signal K3 Brake lamp switch
Rear-right width lamp
A15 Hand brake swith signal K2 Combination switch (steering lamp)
A17 Reverse gear K1 Combination switch (direction)
Front-left width lamp A18 Forward gear QK Preheat start switch Supplied by combined meter
Front-right width lamp B3 Alarm output QD Starter 12V 1.2kW
Warning lamp Rear work lamp B4 Fault indicator JF Alternator 12V 50A Supplied by engine
Warning lamp B8 Mid-position indicator XDC Battery, Maintenance low 12V 60Ah Supplied by engine
80-02-M183EN (07/06/2018)
ELECTRICAL SCHEMATIC DIAGRAMS 5
MI 15 to 35 D - S1 E3
Battery 12V DC
Alternator
Key
Symbol Name Remark
F3 - F13 Fuse (Little fuse) Supplied by control box
F1 - F2 Power fuse
Starter JQ8 Ignition relay 12V Supplied by control box
JQ7 Head lamp relay12V Supplied by control box
Glow plug
JQ5 Multiple valve control relay 12V Supplied by control box
Water temperature sensor (Only MI 20 to 35 D)
JQ4 Reversing relay 12V Supplied by control box
JQ3 Forward relay 12V Supplied by control box
Timer solenoid (Only MI 20 to 35 D)
Preheat indicator lamp JQ2 Starting control relay 12V Supplied by control box
Charge indicator lamp
Oil pressure indicator lamp JQ1 Start relay 12V Supplied by control box
Fuel-water separation indicator lamp SG Flasher 12V Supplied by control box
Engine control circuit
Oil temperature indicator lamp
Water temperature sensor DL Horn 12V
Fuel quantity sensor BJ2 Buzzer 12V
Instrument Timer
BJ1 Reverse alarm 12V
Malfunction warning lamp QGS QGS Control box 12V Supplied by engine
Parking brake lamp
DR Preheat plug Supplied by engine
A5 B3 Buzzer
B4 D7 - D8 Front side lamp 21W 4W
B8 A6 Multiple valve down solenoid valve (reserve)
D5 - D6 Combination tail lamp
A10 Multiple valve movements solenoid valve (reserve)
21W21W/5W10W
A4
Security
A14 module A9
D3 - D4 Front head lamp 35W
A15
Forward solenoid valve D2 Rear work lamp 55W
A18
A17 A8 D1 Rotating warning lamp 21W
A1 A2
G6 Water temperature sensor Supplied by engine
Left reversing lamp
Right reversing lamp G5 Oil temperature warner
Reverse warner G4 Fuel-water separate warner Supplied by engine
G3 Fuel quantity sensor Supplied by combination meter
Control circuit Fuel shut off switch
G2 Water temperature sensor Supplied by combination meter
Left indicator lamp G1 Oil pressure warner Supplied by engine
Left turn signal lamp-front ZD1 - ZD8 Warning lamp 12V 2W Supplied by combination meter
80
Left turn signal lamp-rear
B3 Timer 12V Supplied by combination meter
Right turn signal lamp-rear
Right turn signal lamp-front B2 Fuel quantity gauge 12V Supplied by combination meter
Reserved Security module Input/Output
B1 Water temperature indicator Supplied by combination meter
Right indicator lamp Symbol Name
Signal light Left brake lamp K11 Rotating warning lamp switch
A1 Controller Power
Right brake lamp K10 Rear work lamp switch
Reserved A2 Controller grounding
K9 Seats switch
Reserved A4 Battery +
K8 Hand braking switch
Reserved A5 Parking brake lamp
K7 Timer solenoid valve Supplied by engine
A6 Multi-way valve control valve
output K6 Fuel shut off switch Supplied by engine
Horn Horn
A8 Reverse solenoid valve output K5 Combination switch (laghting)
Left head lamp
Right head lamp A9 Forward solenoid valve output K4 Horn button Supplied by steering whell
A10 Starting signal output K3 Braking switch
Rear-left width lamp A14 Seat switch signal K2 Combination switch (steering)
Light Rear-right width lamp A15 Hand braking swith signals K1 Combination switch (direction)
A17 Direction switch reverse gear QK Preheat & start switch Supplied by combination meter
A18 Direction switch forward gear QD Starter 12V 2.3kW Supplied by engine
Front-left width lamp JF Alternator 12V 40A Supplied by engine
B3 Alarm output
Front-right width lamp
B4 Malfunction warning lamp Battery 12V 60Ah MI 15 and 18 D
Warning lamp Rear work lamp XDC
B8 Neutral indicator lamp Battery 12V 90Ah MI 20 to 35 D
Rotating Warning lamp
(07/06/2018) 80-02-M183EN
MI 20 to 35 D - S2 E3 & Y E3 S3
Battery 12V DC
Alternator
Key
Symbol Name Remark
F1 - F11 Fuse (Little fuse) Supplied by control box
JQ10 Flameout control relay 12V
JQ9 Start relay 12V Supplied by control box
Starter JQ8 Ignition relay 12V Supplied by control box
JQ7 Headlamp relay12V Supplied by control box
Glow plug
JQ5 Multiple valve control relay 12V Supplied by control box
JQ4 Reversing relay 12V Supplied by control box
Preheat indicator lamp JQ3 Forward relay 12V Supplied by control box
Charge indicator lamp
JQ2 Starting control relay 12V Supplied by control box
Oil pressure indicator lamp
Fuel-water separation indicator lamp JQ1 Start relay 12V Supplied by control box
Oil temperature indicator lamp
Water temperature sensor SG Flasher 12V Supplied by control box
Fuel quantity sensor DL Horn 12V
Timer
BJ1 Reverse alarm 12V
Malfunction warning lamp RK Pre-heat timer 12V Supplied by control box
Parking brake lamp DR Glow plug Supplied by engine
A5 B3
Buzzer
B4 D7 - D8 Front side lamp 21W 4W
B8 A6 Multiple valve down solenoid valve (reserve)
A10 D5 - D6 Combination tail lamp
Multiple valve movements solenoid valve (reserve)
21W21W/5W10W
A4 Security
A14 module A9 D3 - D4 Front head lamp 35W
A15
A18
Forward solenoid valve D2 Rear work lamp 55W
A17 A8
D1 Rotating warning lamp 21W
A1 A2
Left reversing lamp D Diode
Right reversing lamp G5 Oil-water separator indicator Supplied by engine
Reverse warner lamp
Fuel shut off switch G4 Oil temperature alarm
Left turn signal lamp-front G3 Fuel quantity sensor Supplied by combination meter
Left turn signal lamp-rear
Right turn signal lamp-rear G2 Water temperature sensor Supplied by combination meter
Right turn signal lamp-front G1 Oil pressure warner Supplied by engine
80
ZD1 - ZD8 Warning lamp 12V 2W Supplied by combination meter

Left brake lamp
B3 Timer 12V Supplied by combination meter
Right brake lamp
Security module Input/Output
Front wiper B2 Fuel quantity gauge 12V Supplied by combination meter
Front wiper sprinkler Symbol Name
B1 Water temperature indicator Supplied by combination meter
A1 Controller Power
Rear wipe and rear wipe sprinkler TC Flameout solenoid valve Supplied by engine
Heater A2 Controller grounding
K6 Fuel shut off switch Supplied by engine
A4 Battery +
K5 Combination switch (lighting)
A5 Parking brake lamp
K4 Horn button Supplied by steering whell
A6 Multi-way valve control valve
K3 Braking switch
Horn output
K2 Combination switch (steering
Left head lamp A8 Reverse solenoid valve output
lamp)
Right head lamp
A9 Forward solenoid valve output
K1 Combination switch (direction)
A10 Starting signal output
QK Preheat & start switch Supplied by combination meter
Rear-left width lamp A14 Seat switch signal
Rear-right width lamp QD Starter 12V 2.3kW Supplied by engine
A15 Hand braking swith signals
JF Alternator 12V 40A Supplied by engine
A17 Direction switch reverse gear
XDC Battery 12V 90Ah MI 20 to 35 D
A18 Direction switch forward gear
Front-left width lamp
Front-right width lamp B3 Alarm output
Rear work lamp B4 Malfunction warning lamp
Rotating Warning lamp B8 Neutral indicator lamp

80-02-M183EN (07/06/2018)
ELECTRICAL COMPONENTS LOCATION
pages
KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
MI 15 G TO MI 35 G . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– 2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MI 15 D TO MI 35 D S1 E3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– 2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
–– MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
MI 20 D TO MI 35 D S2 E3 & Y E3 S3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– 2D LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
–– MAIN HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
80
(07/06/2018) 80-03-M183EN
2 ELECTRICAL COMPONENTS LOCATION
KEY
MI 15 to 35 G MI 15 to 35 D S1 E3 MI 15 to 35 D S2 E3
MAIN HARNESS MAIN HARNESS MAIN HARNESS
Item Designation 2D 2D 2D
LOCATION LOCATION LOCATION N°855
N°854349 N°854350 N°854306 N°854307 ___
X1 front right head light O28 A7 A6 O28 A7 A6 O28 A6
X2 connector to display O27 C5 C5 O27 C5 C5 C5
X3 drop down valve M27 E7 E6 M27 G6 E6 M27 E5
X4 action valve M27 G7 G6 M27 I7 G6 M27 G5
X5 warning light switch M27 G12 G12 M27 G12 G12 M27 G13
X6 rear working light switch M27 I12 I11 M27 I12 I12 K27 I13
X7 ignition switch K27 I5 I5 K27 I5 I5 K27 I5
direction & turning switch
X8 K27 K5 K4 K27 K5 I5 K27 I5
plug
direction & turning switch
X9 K27 M5 K4 K27 M5 K5 K27 K5
socket
X10 brake light switch K26 K11 I11 K26 K11 I11 K26 K13
X11 hand brake switch I27 O5 O5 I27 O5 O5 I26 Q5
X12 horn ground G28 Q9 Q8 G28 Q9 Q9 G28 Q9
X13 front left head light I28 Q13 Q14 I28 Q13 Q14 I28 Q13
CARBURETOR RELAY (MI G) I24 Q17 Q17
X14
Engine off relay (MI D) I24 Q20 Q19 I24 Q17
X15 Electrical card I23 M16 M16 I23 M16 M16 I23 M16
X16 Electrical card I23 M18 M18 I23 M18 M18 I23 M18
(MI G) I22 Q22 Q21
X17
Time relay (MI D) I22 Q15 O15 I22 Q15
X17A QGS (2) (MI D) I22 Q18 Q18
X18 Relay & fuse box plug I21 Q24 Q26 I21 Q24 Q25 G21 S24
X19 Relay & fuse box socket I21 M23 I22 I21 M23 K22 I21 K22
X20 7.8 connector I20 M20 M20 I20 M20 M20 G20 M21
X21 9.5 connector I20 M24 M24 I20 M24 M25 I20 M23
X22 Diode 1 I20 M27 M27 I20 M27 M27 I20 M27
X23 Diode 2 I19 M29 M28 I19 M29 M28 I19 M28
X24 Engine oil pressure sensor K18 Q27 O27 K18 Q26 Q25 K18 Q26
X25 IGNITION COIL (MI G) K20 M32 M32
X26 Generator K17 I32 I31 M17 E30 E32 M17 E32
X27 Generator K17 I33 I33 M17 E29 E30 M17 E30
X28 Water temp. sensor K15 K37 I35 K15 K36 K34 K15 K34
X29 warning buzzer I17 M35 M35 I17 M35 M35 I17 M35
X30 To ground I16 Q33 Q33 I16 Q33 O33 I15 O33
X31 Buzzer I15 M38 M38 I15 M38 M38 I15 M38
X32 Seat switch I15 Q38 Q38 I15 Q38 Q38 I15 Q37
X33 Rear light I14 O41 M41 I14 O41 M41 I14 M41
Signal light(warning light
X34 I14 K41 I41 I14 K41 I41 G14 I41
80
and rear working light)

Transmission valve(F/R
X35 K24 G22 G22 K24 G22 G22 K24 G22
valve)
Transmission oil temp.
X36 M25 G22 G21 M25 G21 E21 E21
sensor
X37 Starter M19 C24 C24 M19 C24 C26 M19 C26
X38 Starter M18 C26 / G31 G33 M18 G36 G40 M18 C23 / E41
CARBURATOR (MI G) O17 C28 C27
X39 WATER TEMPERATURE
K15 A30 A32 K15
SENSOR (MI D)
X40 Starter M20 G27 G29 M20 G32 G36 E38
X41 SEPARATOR ALARM (MI D) I21 Q29 Q28 I16 Q35
X42 Diode (MI D) K17 Q30 Q30 K17 Q29
X43 Fuel Gauge sensor (MI D) I18 Q31 Q32 I18 Q32
X44 Pre-heater plug (MI D) K33 K32 K17 K31
X45 Fuel supply pump (MI D) O31 M31 I21 M31
X46 VALVE (MI G) O31
X47 Front wiper washer motor C11 A11 C13
X48 Front wiper washer switch E12 E12 E13
X49 Front wiper switch E12 E12 G13
X50 front wiper I6 G6 G6
X51 Heater C35 C36 C36
X52 Rear wiper A40 A39 O15 A40
X53 Standby for cabin C40 C39 C39
X54 Engine off valve K20 Q28
EP1 SPLICE 1 O12 O12 O12
80-03-M183EN (07/06/2018)
ELECTRICAL COMPONENTS LOCATION 3
MI 15 to 35 G MI 15 to 35 D S1 E3 MI 15 to 35 D S2 E3
MAIN HARNESS MAIN HARNESS MAIN HARNESS
Item Designation 2D 2D 2D
LOCATION LOCATION LOCATION N°855
N°854349 N°854350 N°854306 N°854307 ___
EP3 SPLICE 3 K8 K8 K7
EP6 SPLICE 6 O38 M38 M37
EP7 SPLICE 7 O36 O36 M35
EP9 SPLICE 9 M22 M22 I6
EP10 SPLICE 10 I7 G7
80
(07/06/2018) 80-03-M183EN
MI 15 G to MI 35 G 2D LOCATION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Key :
A Main harness A
Light & seat Harness
Power harness
Connection between harnesses

C C
E E
G G
- X12
+
X34 X20 X18
X31 X21 X19

X13
X33 X30 X29 X23 X22 X17 X15 X14 X11
I X32 X16 I
X24 X25 X9
X26
X27
X28
K X8 K
X35 X10
X7
K21-K25 X6
X5
X4
80
X36 X3
M X38 X40 M
X37
X2
X39
X1
O O
Q Q
S S
Forward
80-03-M183EN (07/06/2018)
MI 15 to 35 G
MAIN HARNESS Up to machine N°854349
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
A A
X1
C X37 C
X2 X39
X38
E E
X3
Fusible wire
(standby)
X36
X40 X38
G (standby) X5
G
X35
X4
X6
I X7 I
X26
X27
X28
X10
X34
X8
K K
X9 X19
80
X15 X16 X22 X23
X21
M X31 M
X20 X25 X29
X33
O O
X11
X13
X30
X17
X14
X24
X18
Q X12 X32 Q
S S
(07/06/2018) 80-03-M183EN
MI 15 to 35 G
From machine N°854350
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
X52
X1
A A
From machine N°855213 and for N°855203

X47
X53
X37
X2 X39
X38 X51
C C

X48
X3
E E
X49
Fusible wire
X36
X40 X38
X35
X4
G X5 G
N°855213 Up to machine N°855212
and for exept for N°855203
N°855203 EP10
X50
X6 X28
X7
I X27 I
X10 X34
X26
X19
X8
EP3
EP4
K K
X9 EP5
X22 X23
X15 X16
80
X31
X20 X21 X29
X25
M M
EP9 X33
EP6
EP7
EP1 EP2
O O
EP8
X46
X11 X24
X17 X30
X14
X32
X13 N°855213
X12
N°855213 Valve
and for
Q and for Q
N°855203
N°855203 X18
N°855213 and for N°855203

N°855213 and for N°855203
S S
80-03-M183EN (07/06/2018)
MI 15 D to MI 35 D S1 E3 2D LOCATION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Key :
A Main harness A
Power harness

C C
E E
G G
- X12
+
X34 X20 X18
X31 X43 X21 X19

X13
X33 X30 X29 X23 X22 X41 X17 X15 X14 X11
I X32 X17A X16 I
X24 X9
X42
X28
K X44 X8 K
X39 X10
X35
X7
4TNE92-98 X6
X5
X4
80
X26
X36 X3
X27
M X38 X40 M
X37
X2
X1
O O
Q Q
S S
Forward
(07/06/2018) 80-03-M183EN
MI 15 to 35 D S1 E3
Up to machine N°854306 MAIN HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
A X39 A
X1
C C
X37
X2
X38
X26
E E
X27
X3 Fusible wire
(standby) X40 X38

X36
G G
(standby) X5
X35
X4
X6
I I
X7
X28
X10 X44
X34
X8
K K
X9 X19
80
X15 X16 X23

M X21 X22 M
X20 X29 X31
X45
X33
O O
X11
X13
X17 X30
X24
Q X17A X18 X42 Q
X14
X12 X41 X32
X43
S S
80-03-M183EN (07/06/2018)
MI 15 to 35 D S1 E3
From machine N°854307
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
X1
X52
X39
A From machine N°855213 and for N°855203 A
X47
X2
X53
X37
C C
X38 X51
X3
X48
Up to machine N°855212 X26
exept for N°855203 X27

E X49 E
X36
Up to machine N°855212
X4 Fusible wire
X35
exept for N°855203
X50 X5
N°855213 X40 X38
G and for G
N°855203 EP10
X6
X7
X10
I X34 I
X8
X44 X28
X19
EP3
EP4
X9
K EP5 K
N°855213
X15 X16 X22 X23
and for
N°855203
X29 X31
80
X20 X21
X45
X33
M EP9 M
EP6
EP1 EP2 EP7
O
EP8 O
X11 X30
X17
X17A X24 X42

X14 N°855213
X13 and for X41 X32
X12 N°855213
N°855203
and for
N°855203
Q X43 Q
X18
N°855213 and for N°855203
N°855213 and for N°855203
S S
(07/06/2018) 80-03-M183EN
MI 20 to 35 D S2 E2 E3 & Y E3 S3
MI 20 D to MI 35 D S2 E3 & Y E3 S3 2D LOCATION From machine N°85____
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
Key :
A Main harness A
Power harness

C C
E E
G G
- X12
+
X34 X20 X18
X31 X43 X21 X19

X13
X33 X30 X29 X23 X22 X17 X15 X14 X11
I X32 X17A X16 I
X41
X45 X9
X24
X42
X54
X28
K X44 X8 K
X39 X10
X35
X7
4TNV94L X6
X5
X4
80
X26
X36 X3
X27
M X38 X40 M
X37
X2
X51
X1
O O
Q Q
S S
Forward
80-03-M183EN (07/06/2018)
MI 20 to 35 D S2 E2 E3 & Y E3 S3
From machine N°85____ MAIN HARNESS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42
X52
X1
A A
X53
X47
X2
C C
X37
X38 X51
X26
X27
X40
E X48
E
X38
X3 Fusible wire
X36
X49
X4
X35
G G
X50
X5
EP 9
X7
X6
I I
X34
X8
X10
X19 X44 X28
EP3 EP4
K K
X9
EP5
X20 X21 X22
X15 X16 X23
80
X29 X31
X45
M M
X33
EP6
EP7
O EP1 O
EP2
EP8
X11 X30
X42
X17 X14
X24
X12 X13
Q X54 Q
X43
X41 X32
X18
S S
(07/06/2018) 80-03-M183EN
80
80-03-M183EN (07/06/2018)
ELECTRICAL CONTROL AND ADJUSTMENT
pages
ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– CABLE COLORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– INSPECTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– INSPECTION: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
COMBINATION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– REMOVAL DIRECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– INSPECT DIRECTION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– LIGHTING SWITCH AND STEERING SWITCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . 3
INSTRUMENT,SENSOR AND RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– DISASSEMBLY AND INSTALLATION COMBINATION METER ASSEMBLY . . . . . . . . . . . . 4
80
KEY (START) SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
–– INSPECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
(25/11/2014) 80-04-M183EN
2 ELECTRICAL CONTROL AND ADJUSTMENT
ELECTRICAL SYSTEM
INSPECTION:
Inspect all electrical circuit, referring to wiring diagrams. Circuits should be tested for continuity or short
circuit with a conventional test lamp or circuit tester.
Before inspecting circuit, ensure that :
1 - Each electrical component or cable is properly fastened to its connector or terminal.
2 - Each connection is properly fastened and free of rust and dirt.
3 - There’re no cracks, deterioration or other damage to the cable coating.
4 - Each terminal is at a safe distance from metal parts.
5 - The wiring is kept away from sharp edges nearby parts.
6 - The wiring is kept away from all rotating or moving parts.
7 - Cables between fixed and moving parts are not too taut to withstand shocks and vibrations.
8 - The wiring is spaced from high temperature elements.
CONTROL BOX
COMPONENT REMOVAL
1 - Turn key switch «OFF»;

2 - Press lock buckle on control box and open the cover;
3 - Remove fuse and relay from box.
INSPECTION:
If fuse is broken, replace with new one.

Refer to figure as follow: (Specific see a forklift control box inner)
A - If fuse is blown, be sure to eliminate cause of problem before installing new fuses.
80
B - Never use fuse higher than specified rating.
The 2 power fuses of 50 A, that supply the electrical system, are on the positive pole of the battery in
wires.
80-04-M183EN (25/11/2014)
ELECTRICAL CONTROL AND ADJUSTMENT 3
COMBINATION SWITCH
LIGHTING AND STEERING

SWITCH
DIRECTION SWITCH
REMOVAL DIRECTION SWITCH
1 - Remove switch cover;

2 - Unscrew bolt, disconnect connector.
80
INSPECT DIRECTION SWITCH
Disconnect switch connector and test the continuyty of these positions (Forward , N, Reverse) with
multimeter.
LIGHTING SWITCH AND STEERING SWITCH DISASSEMBLY
1 - Remove switch cover;

2 - Unscrew bolt, disconnect connector and ground wire.
(25/11/2014) 80-04-M183EN
4 ELECTRICAL CONTROL AND ADJUSTMENT
INSTRUMENT,SENSOR AND RELAY
DISASSEMBLY AND INSTALLATION COMBINATION METER ASSEMBLY
1 - Remove 4 fixed bolt from combination meter. Notice that when installing and removing ,please
make instrument surface tilt an angle to avoid damaging the screw thread of fixed parts on truck.
2 - Take out wiring harness from sleeve, and then instrument can be brought out.
3 - The transparent plastic cover prevents dust and water to enter, it is fixed by 6 plastic clip, press
on it to take out the plastic cover.
4 - To install, reverse removal procedures.
80
KEY (START) SWITCH

3
1 - Remove combination meter.

2 1
2 - Disconnect connector of wring. 4
3 - Remove nuts, washers, spacers and instrument

plate.
4 - To install, reverse removal procedures.
Adjust ledge of switch to proper length when
installing.
INSPECT 1 - Ring nut 3 - Panel Meter

2 - Washer 4 - Spacer
Use multimeter (with ohm) to check key switch
whether it is on at each position.
80-04-M183EN (25/11/2014)
DRIVER’S CAB
- DRIVER’S CAB COMPONENTS REMOVAL
85
DRIVER’S CAB REMOVAL
pages
TRUCK BODY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

–– DRIVER'S CAB (OPTION) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
–– FRONT AND REAR FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
–– DASHBOARD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
85
(07/06/2018) 85-06-M183EN
2 DRIVER’S CAB REMOVAL
TRUCK BODY SYSTEM
DRIVER'S CAB (OPTION)
2
4
1 - Front window
2 - Top glass
3 - Left door
4 - Rear window
bb
5 - Right door
To start lifting with the fork, the left and right doors must be properly locked.
85
Move the gas cylinder in the following situation:

1 - When opening the rear window to ventilate the driver's cab;
bb
2 - When opening the engine cover to avoid contact with the rear window.
Move the gas cylinder back to its original position.
85-06-M183EN (07/06/2018)
DRIVER’S CAB REMOVAL 3
FRONT AND REAR FLOOR
7
1 8
9
7 7
8 8
9 9
4 6
12 14
3 10
2
5 12 17 11
16
15
13
1 - Floor mat 10 - Rear floor

2 - Floor plate 11 - Profiled seal
3 - Profiled seal 12 - Profiled seal
4 - Casing 13 - Right running board
5 - Left housing 14 - Left running board
6 - Right housing 15 - Screw
7 - Screw 16 - Washer
8 - Washer 17 - Screw
Washer
85
9 -
bb
1
Before disassembly:
- Park the truck on level ground and put it in neutral
2 - Apply the handbrake;
3 - Turn off the engine;
4 - Make sure that the left and right doors can be opened fully,
5 - Open the left and right doors fully.
6 - Remove all of the pedals.
(07/06/2018) 85-06-M183EN
4 DRIVER’S CAB REMOVAL
DASHBOARD
13
12
7
15
16
11 9 17
*
10
14
15 6
16 23
*
5
8
21
2 4
3
18
1
20 * Only for cab
19
25 22 Option
1 - Left housing 13 - Lower steering column trim

2 - Attachment 14 - Screw
3 - Rear housing 15 - Sleeve
4 - Screw 16 - Collar
5 - Bracket 17 - Plastic collar
6 - Right housing 18 - Cover
7 - Storage tray 19 - Washer
8 - Screw 20 - Washer
9 - Front housing 21 - Cotter pin
10 - Screw 22 - Screw
85
11 - Screw 23 - Right housing

12 - Upper steering column trim
85-06-M183EN (07/06/2018)
FRAME - BODY
- FRAME REMOVAL
90
FRAME - BODY REMOVAL
pages
COUNTERWEIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
90
(07/06/2018) 90-06-M183EN
2 FRAME - BODY REMOVAL
COUNTERWEIGHT
2
Pay attention to the counterweight during assembly and

disassembly.
Make sure that slings are designed for the lifting capacity.
Weight of counterbalance weight (kg/lbs)
1 Model 1.5 t/3,306.31 lb 1.8 t/3,968.31 lb 2.0 t/4,409.24 lb 2.5 t/5,511.55 lb 3.0 t/6613.86 lb 3.5 t/7,716.17 lb
Weight 800/1,763.68 800/1,763.68 800/1,763.68 1450/3,196.67 1450/3,196.67 1450/3,196.67
Tightening torque for bolts: 490-620 N.m (361.42-457.31 ft-lb)
Disconnect the hose from the gas cylinder (1).
Remove the cylinder (2).
Disassemble the gas cylinder holder (3).

3
Loosen the 2 counterweight screws (4).
5
Attach the counterweight by feeding the straps through the
holes (5).
Apply tension to the straps (6).

6
90
Remove the 2 counterweight screws (7).
90-06-M183EN (07/06/2018)
FRAME - BODY REMOVAL 3
Remove the cap from the tank (8).

8
Guide the counterweight using a tool (9) when handling the

counterweight.
9 Move the counterweight onto a stable surface.
90
(07/06/2018) 90-06-M183EN
4 FRAME - BODY REMOVAL
90
90-06-M183EN (07/06/2018)
TABLE OF CONTENTS
110 OPTIONAL MINI LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

110.1 MINI LEVER CHARACTERISTICS AND SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
110.1.1 SAFETY NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
110.1.2 NAME PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
110.2 HYDRAULICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
110.2.1 HYDRAULIC DIAGRAM WITH OPTIONAL MINI LEVERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
110.2.2 OPTIONAL MINI LEVER CONTROL VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
110.3 ELECTRICAL DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
110.3.1 CODES ON THE ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
110.3.2 DIAGRAM KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
110.3.3 MINI LEVERS OPTION WIRING DIAGRAM ONLY FOR: ME 418 - 420 - 425 C 48V S3 & US . . . . . . . 9
110.4 LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
110.4.1 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
ORDERING ATTACHMENTS WITH PIN ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
EMERGENCY STOP BUTTON WITH PIN ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
STEERING SWITCH WITH PIN ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
HORN SWITCH WITH PIN ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
MFA DEVICE WIRING HARNESS WITH PIN ASSIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
110.5 CONTROL AND ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
110.5.1 REMOVAL AND ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
COMPLETE MFA DEVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MFA CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MFA LIFT TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
FRONT PART OF THE MFA CONSOLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
FORWARD/REVERSE AND HEIGHT ADJUSTMENT HANDLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
FINGERTIP JOYSTICK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
BLIND COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
BOWDEN FORWARD/REVERSE ADJUSTMENT TRACTION WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
BOWDEN FORWARD/REVERSE ADJUSTMENT TRACTION WIRE: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
BOWDEN HEIGHT ADJUSTMENT TRACTION WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
BOWDEN HEIGHT ADJUSTMENT TRACTION WIRE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

110
EMERGENCY STOP BUTTON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
STEERING SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
HORN SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ARMREST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
647364EN
2 OPTIONS - ATTACHMENTS 110 (08/06/2018)
SEAT ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LOWER COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
LOWER PART WITH MFA DEVICE WIRING HARNESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
110.6 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
110.6.1 POTENTIAL FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
110.6.2 FAULT LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
DIAGNOSIS PRECONDITIONS FOR EACH TEST: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
1 ATTACHMENT CONTROL INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
2 EMERGENCY STOP BUTTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3 STEERING SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4 HORN SWITCH INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

110
647364EN
110 (08/06/2018) OPTIONS - ATTACHMENTS 3
110 OPTIONAL MINI LEVERS
110.1 MINI LEVER CHARACTERISTICS AND SPECIFICATIONS
110.1.1 SAFETY NOTICE

Inspections, testing and repairs should only be carried out by specifically trained personnel.
All of the stages and procedures described must be followed in line with the applicable guidelines and
regulations stipulated by the competent local authorities and in accordance with the provisions relating
to health, accident prevention and protection of the environment.
The observations in this repair manual are indicated as follows:
WARNING:
indicates potential risks concerning people and prevention thereof.
IMPORTANT:
indicates a risk of damage or deterioration of equipment and prevention thereof.
Comment:
introduces an additional explanation to enable better understanding of the work to be done.
Installation note:
introduces an additional explanation to enable better understanding of how to carry out installation.
Before starting a repair, disconnect the MFA Device on the vehicle's power supply.
Follow the appropriate safety instructions in the event of oil, grease or other chemicals being handled.
110.1.2 NAME PLATE

The name plate appears on the MFA truck.
The name plate gives the following
information (example):
A
Multifunktions- (A) BENENNUNG (NAME)
Armlehne
BENENNUNG
Multi-purpose armrest
(B) SACH-Nr. (INVENTORY NO.)
1327866
B 1327866
SACH-NR.
(C) Year / CW / Assembly
C 1710 061 1710 061
Year of manufacture = 17 (2017)
D DE 4284430008
Manufactured in week = 10 (March)
AUFTRAGS NR. Assembly = 061
(D) AUFTRAGS NR. (ORDER NO.)
DE 4284430008
Comment:
For claims or orders concerning the MFA
Device, always quote the inventory number
(B).
110
647364EN
110.2 HYDRAULICS
110.2.1 HYDRAULIC DIAGRAM WITH OPTIONAL MINI LEVERS
Lifting cylinders Tilting

cylinders
Steering cylinders
R H
Steering
pump 160 A A1 B1 A2 B2 A3 B3
bar
Relief
(2321.6 psi) valve
150b
125 cm3 Main pressure
FT (7.63 cu.in.) valve
V 2.5t/3.0t: 180±0.5bar
(5511.55 lb/6613.86 lb:
2611.8±7.255 psi)
10
3.5t: 190±0.5bar
(7716.17 lb:
2756.9±7.255 psi)
LSM
PP
DD
190b (2756.9 psi) T
T LS P
Hydraulic control valve
EF
LS
Priority valve
P
Hydraulic pump
30 mL/r (1.014 fl
oz/r)
Return filter 16μm Suction strainer

(0.62939216 mil) 100μm (3.933701 mil)
Tank
110
647364EN
110.2.2 OPTIONAL MINI LEVER CONTROL VALVE
14
15
12
16 1
13
2
19 5
9 10
2
17 5
8
11 4
6 7 5
3 4
4 5
A A1 B1 A2 B2 A3 B3
18
12
17 17
16 4 4 4
15 14 14
3
LSM
11
PP
T P
1 - Distributor 12 - Proportional control

2 - One way valve 13 - Two-way discharge valve
3 - Flow control valve 14 - Attachment proportional electrovalve control
4 - Integral shuttle valve valve
5 - One way valve 15 - Tilting proportional electrovalve control valve
6 - Logic unit 16 - Flow proportional electrovalve control valve
7 - Head connection hex. socket 17 - Counterbalance valve
8 - Head connection hex. socket 18 - Relief valve
110
9 - Pressure test port 19 - Plug

10 - Hex. socket head plug
11 - Discharge valve
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110
647364EN
110.3 ELECTRICAL DIAGRAM
110.3.1 CODES ON THE ELECTRICAL DIAGRAMS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
1 11
A 5
S1
III II I O P
30 30 17 17 50 19 19 54 15 58 R R
F21
J J V BC BC
7
C
R
4 C
F27
9
5 9
F23 F25 F26 F4 S15

1 0
E
G1
1 10
K1 BC BC
N J N
5 OR
8
S12 V 7
F
Y1 6
J L
10
G K7
N 3 M1 G2 M
N
M8 8
M
3 7
K7
R1 R1 R1 R1 E15 E16
10 7
I
Example of marking on cables and components on an electrical diagram
Key:
1 - Vbat supply 10 - Earths
2 - Post contact supply (APC) 11 - Marking grid
3 - Electrical component
4 - Electrical connector
110
5 - Electrical component designation
6 - Electrical connector designation
7 - Splice
8 - Wire colour
9 - Electrical connector PIN No. designation
647364EN
110.3.2 DIAGRAM KEY

Connectors 25 Lifting potentiometer
26 Display
Item Designation Position on diagram Hydraulic equivalence code
27 Traction motor controller and variable speed drive
P1 Diagnostic plug F10
28 Pump motor speed controller
S1 Ignition switch B10
Electrical components
S2 Sidelight / working light stalk switch D2
Item Designation Position on diagram Hydraulic equivalence code
S3 Forward/reverse shuttle D6 / C10
ACS23P Pump motor speed controller C13
S4 Indicator light stalk switch D5
ACS35P Wheel motor speed controller C11
S5 Seat switch C10
E1 Rear left position light E2
S6 Brake pedal switch D6 / C10
E2 Rear right position light E2
S7 Handbrake switch C10
E3 Front left position light E2
S8 Road sound alarm switch D7
E4 Front right position light E3
S9 Revolving light switch D8
E5 Front left working light E4
S10 Accelerator null position *. E10
E6 Rear right working light E4
S11 Steering Pressure switch D10
E7 Front left indicator light E4
S12 Tilting switch D10
E8 Rear left indicator light E5
S13 Carriage side-shift switch d10
E9 Front right indicator light E5
S14 4th element switch D10
E10 Rear right indicator light E5
S15 Emergency stop switch A10
E11 Left hand reverse light E6
S19 Lowering cut-off valve control switch D10
E12 Right hand reverse light E6
S20 Forward gear switch H7
E13 Left hand brake light E6
S21 Reverse gear switch H7
E14 Right hand brake light E7
S22 Horn switch I7
E15 Rotating beacon light E8
G1 Battery F1
Electrical components
Color codes M1 Reverse warning indicators E6
Item Designation
Item Colours M2 Road sound alarm F7
1 Battery
BC White M3 Accelerator Potentiometer E10
2 Rear left position light
BL Blue M4 Lifting potentiometer E10
3 Rear right position light
G Gray M5 Fan D8
4 Front left position light
J Yellow M6 Traction motor D12
5 Front right position light
M Brown M7 Pump motor D14
6 Front working headlight relay
N Black M8 Seat cut-off time delay C10
7 Front left working light
O Orange M9 Pre-charging circuit A10
8 Front right working light
R Red OPT100 Display G10
9 Front left indicator light
RO Pink Y1 Mast lowering cut-off electrovalve C12
10 Rear left indicator light
11 Flashing unit VT Green
12 Front right indicator light V Purple
13 Rear right indicator light

14 Left hand reverse light FUSES RELAYS
15 Right hand reverse light Item Designation Position on diagram Item Designation Position on diagram
16 Road sound alarm FP1 Hydraulic control motor (250A) for ME 418 / 420 / 425 C A13 K1 Start-up authorization relay Not on drawing ??
17 Left hand brake light FP2 Transmission motor (300A) for ME 418 / 420 / 425 C A11 K2 Reverse warning relay D7
18 Right hand brake light FP1 Hydraulic control motor (250A) for ME 425 / 430 A13 K3 Front working light relay E3 / D4
19 Reverse warning indicators FP2 Transmission motor (300A) for ME 425 / 430 A11 K4 Flashing unit C5
20 Reverse warning relay F1 Control circuit (10A) B10 K5 Line switch A11 / C12
110
21 Fan F2 Main circuit (10A) B10

22 Rotating beacon light F3 Lighting (10A) C2
23 Emergency stop button F4 Spare (10A) A10
24 Accelerator potentiometer
647364EN
110.3.3 MINI LEVERS OPTION WIRING DIAGRAM ONLY FOR: ME 418 - 420 - 425 C
48V S3 & US
1 2 3 4 5 6 7 8 9 10 11 12 13 14
K5
A S15
F P2 F P1
M9
F4
F1 F2
B
S1
F3
r/bc
3 KEY
B+
ACS35P
S5 12 DI1 HIGH SIDE IN 28
C r/bc r/bc r/bc r/bc r/bc r/bc r/bc r/bc

19 DI2
HIGH SIDE OUT 29
Open Drain Out 1 4 K5

23 DI3
K4 K2
S6
Open Drain Out 2 16 Y1 1
KEY
B+
ACS23P
11 DI4 Open Drain Out 3 25
bl/o S7 Open Drain Out 4 24

18 DI5
Open Drain Out 5 27
S2 K3 S4 S3 S6 K2 S8 S9 Open Drain Out 6 13
M5 30 ID6
0 1 2 L 0 R Motor temp 26 1
34 ID8
2
D m bl/n r bl bc vt r bc/n bl/bc
35 ID9 Encoder 12v 5 1
Encoder CH1 7
M6 16
2 Motor temp 1
2 ID10 17
Encoder CH2 8 3 Motor temp GND 2
6 3
1 Encoder GND 4 Encoder 12v 1
Delay Controller ID11
U
5 M7
Encoder CH1 2
2 6
V Encoder CH2 3
3
4
r 4
S10 W Encoder GND 4
5 17 ID7 23
6 CAN_H2 33 CAN_H1 U
DC-DC M3 32 Alim ANA CAN_L2 21 15 CAN_L1
E M3 8
V
20 INANA1 CAN_GND2 10
+ 48V
120 Ω
CAN_120 15
CAN_GND1
9 CAN_120
120 Ω W
M4 9
M4 INANA2
- B-
31 GNDANA
E1 E2 E3 E4 K3 E5 E6 E7 E8 E9 E10 M1 E11 E12 E13 E14 E15
Beeper
G1 M2 B-
6
CAN_H
4 7
F - P1 2
CAN_L
CAN_GND
1 3
5 9
n n n n n n n n n n n n n n n n n n n n
B+
1
0v
2
CAN_GND
OPT100 3
G 5
CAN_L
CAN_H
6
1 2 3 4 5 6 7 8 9 10 11 12 13 16 14 15 17 18 19 20 . 21 22 23 26 24 25 27 28
H V-
....
CAN 5V 2
3 VM C 30
OPEN A In1
A In2 15
lift
tilt
POUT_PROP1A ZC
POUT_PROP1B 6C
lift
down
S20 22 D In1 A In3
4 shift
Forword POUT_PROP2A 5C for- tilt
A In4 16 4th
3C back- tilt
Reverse
S21 10 D In2 A Gnd 14
POUT_PROP2B
2C left-shift
POUT_PROP3A
Horn
S22 21 D In3 Can_H 24 POUT_PROP3B
1C right-shift
Can_L 12 POUT_PROP4A 19C 4 th

I 19
Can_Gnd 11 POUT_PROP4B 18C 4 th
110
V+
Can_H 23A
Can_L
Can_Gnd 8A
J
647364EN
110.4 LOCATION
110.4.1 COMPONENTS
2 CONNECTOR VERSION ORDERING ATTACHMENTS WITH PIN ASSIGNMENT
2 1
1
B
2
3
(1) PC board plug (14 pins)
Switch:
1 Voltage
4
B 2 (Signal) Fingertip Joystick 9
3 (Signal) Fingertip Joystick 8
1 4 (Signal) Fingertip Joystick 7
7 5 5 5 (Signal) Fingertip Joystick 6
6 6 Not assigned
14 Earth
E
(2) PC board
N° DESCRIPTION
1 Horn Active 9
2 Driving direction switch FNR
3 Analogue value FTC 1
(4) MFA Device wiring harness (delivery
4 Analogue value FTC 2 8
5 Analogue value FTC 3 option)
7
6 Analogue value FTC 4
7 Emergency Switch 6
4 3 5
(5) MFA Device wiring harness plug (37 pins)

Pin:
1 Voltage 3 (Signal) Fingertip Joystick 9 5 (Signal) Fingertip Joystick 7
2 Earth 4 (Signal) Fingertip Joystick 8 6 (Signal) Fingertip Joystick 6
(6) Fingertip Joystick (FTC 4)

110
647364EN
10
(10) Fingertip Joystick plug

Switch:
4 3 2 1 1 Red wire (earth)
2 White wire (voltage)
3 Black wire (signal)
4 Green wire (not assigned)
Electrical connections:
Connector (B) between the MFA Device wiring
harness (4) and the PC board (2).
Connector (E) between the MFA Device wiring
harness (4) and the vehicle.
10
EMERGENCY STOP BUTTON WITH PIN ASSIGNMENT

(1) Emergency stop button

1 Switch:
1 White wire (NC)
2 Brown wire (NC)
3 Green wire (NO)
4 Yellow wire (NO)
3
(3) Emergency stop button (4 pins)
2
4
A
5
option)

A
Pin:
E
2 8 Connector NO
9 Connector NO
1
10 Connector NC
11 Connector NC
5
110
Connector (A) between the MFA Device wiring harness (4) and the emergency stop button (1).
Connector (E) between the MFA Device wiring harness (4) and the vehicle.
647364EN
STEERING SWITCH WITH PIN ASSIGNMENT
(1) Steering switch

Connect the switch:
1 1 1 (Signal) Reverse gear
C 2 Voltage
10 3 2 1 9 3 Short-circuit terminal in the plug
C
(2) with pin 5
8 6 5 4 7
4 (Signal) neutral
2
5 Short-circuit terminal in the plug (2) with
3 pin 3
6 (Signal) Forward gear
4
7 - 10 not assigned
1 E
option)

Pin:
1 Voltage
13 (Signal) neutral
14 (Signal) Forward gear
15 (Signal) Reverse gear
4
3337
Connector (C) between the MFA Device wiring harness (3) and the steering switch (1).
110
647364EN
HORN SWITCH WITH PIN ASSIGNMENT
1 2
(1) Horn switch

3 Switch:
D 1 Voltage
2 (Signal) Horn
D
2 (3) Horn switch (2 pins)
4 (4) MFA Device wiring harness (delivery

option)
5
Pin:
1 1 Voltage
E
20 (Signal) Horn
Connector (D) between the MFA Device wiring harness (4) and the horn switch (1).
110
647364EN
MFA DEVICE WIRING HARNESS WITH PIN ASSIGNMENT

C D
v
3
4 (3) MFA Device wiring harness plug (10 pins)
B
5 (4) MFA Device wiring harness plug (2 pins)
2
6
option)
A (6) MFA Device wiring harness plug (37 pins)

1
E Pin:
7 No function
12 Not assigned
16 to 19 no function
21 to 26 no function
27 - 37 not assigned
Connector (A) between the MFA Device wiring harness (5) and the emergency stop button, see page 3.
Connector (B) between the MFA Device wiring harness (5) and the PC board, see page 1.
Connector (C) between the MFA Device wiring harness (5) and the steering switch, see page 4.
Connector (D) between the MFA Device wiring harness (5) and the horn switch, see page 5.
Connector (E) between the MFA Device wiring harness (5) and the vehicle, see pages 1, 3, 4 and 5.
110
647364EN
110.5 CONTROL AND ADJUSTMENTS
110.5.1 REMOVAL AND ASSEMBLY

COMPLETE MFA DEVICE
4
5
1 (!) The MFA console (1) moves up thanks
2
to the pressure of the spring!
3 To facilitate assembly, move the MFA console
(1) to the highest position.
6
2 Disconnect the MFA console's electrical

connector on the vehicle (see the vehicle
manufacturer's instructions).
7
3 Undo the hex screw (2) and remove it with
the washer (3). Installation note: hex screw
6
(2), 25.0 ± 5.0 Nm.
1
4 Undo the flange bolt (2) and remove it with
the washer (5). Installation note: flange bolt
(4), 25.0 ± 5.0 Nm.
5 WARNING Risk of accident! The MFA lift truck

tension spring (7) holds all of the steel parts of
the scissor lift. Gently remove the MFA console
(1) excluding the seat adapter bolts (6).
6 Refit the components by following the removal steps in reverse order.
MFA CONSOLE
3
1 (!) The MFA console (1) moves up thanks to the
pressure of the spring! To facilitate assembly, move
the MFA console (1) to the highest position.
2
2 Disconnect the MFA console's electrical connector

2
on the vehicle (see the vehicle manufacturer's
instructions).
3 Remove the two Bowden traction wires (4) from

the MFA lift truck (see Chapters 3.8 and 3.10).
4 Open the arm support, undo the five hex nuts (3)
4 and remove them with 4 washers (2). Installation
note: hex nuts (3), 7.0 ± 2.0 Nm.
5 Remove the MFA console (1) from the MFA lift

110
1 4
truck (5).
6 Refit the components by following the removal

5 steps in reverse order.
647364EN
MFA LIFT TRUCK

1 (!) The MFA lift truck (1) moves up under the pressure of the spring! To facilitate assembly, move the
MFA truck (1) to the highest position.
2 Remove the MFA console (Chapter 3.2).
4
5
2 3 Remove the two Bowden traction wires

from the MFA lift truck (see Chapters 3.8
3
6
and 3.10).
4 Undo the hex screw (2) and remove it with

the washer (3). Installation note: hex screw
(2), 25.0 ± 5.0 Nm.
1
5 Undo the flange bolt (2) and remove it

with the washer (5). Installation note: flange
6
bolt (4), 25.0 ± 5.0 Nm.
6 WARNING Risk of accident! The MFA lift

truck tension spring (1) holds all of the steel
parts of the scissor lift. Gently remove the
MFA lift truck (1) excluding the seat adapter
bolts (6).
7 Refit the components by following the

removal steps in reverse order.
110
647364EN
FRONT PART OF THE MFA CONSOLE

4 7 8 3
6
C
B
9 D 2
10
5
C D
A
4 B 1 1
11
12
1 (!) The MFA console moves up thanks to the pressure of the spring! To facilitate assembly, move the
MFA console to the highest position.
2 Remove the MFA console (see Chapter 3.2) and place it to one side. Comments and instructions: - Do
not remove the Bowden traction wires on the MFA lift truck. - Do not overstretch the Bowden traction
wires when you place them to one side.
3 Undo the four screws (1) on the bottom cover (2). Installation note: four screws (1), 0.5 Nm.
4 Push the two bolts (4) inwards and remove the front part of the console (6) from the upper console
(3) upwards.
5 Disconnect the connectors between the wiring harness (11) and the front part of the console (6):
- A (KN9) for the emergency stop button (5) - B (KN2) for the PCB (9) - C (KN3) for the steering switch
(7) - D (KN10) for the horn (8)
6 Pull out the three plugs (12) from the blind covers (10).
7 Remove the front part of the console (6) from the upper console (3).

110
647364EN
FORWARD/REVERSE AND HEIGHT ADJUSTMENT HANDLE

1 (!) The MFA console moves up thanks
to the pressure of the spring! To facilitate
4 assembly, move the MFA console to the
highest position.
2 Remove the arm support (see Chapter 3.15).
3 Remove the MFA console (see Chapter

6
3.2) and place it to one side. Comments and
instructions: - Do not remove the Bowden
traction wires on the MFA lift truck. - Do not
overstretch the Bowden traction wires when
you place them to one side.
3 4 Undo the four screws on the front part of

2
3 the MFA console (see Chapter 3.4).
6
3 5 Undo the eight screws (1) and remove the
bottom cover (2). Installation note: eight
screws (1), 0.5 Nm.
5
1 6 Undo the six screws (3) and separate the
stabilisation profile (5) from the top part of
the console (4). Installation note: six screws
1 (3), 0.5
7 Loosen the Bowden traction wires (6) on

1 the wire regulator (see Chapters 3.8 and 3.10).
1
Nm.
110
647364EN
7 8 9
7 12
12 11 10
13
10
8 Unhook the handle cover (13).
9 Take the thread connection (11) off the forward/reverse (10) and height (12) adjustment handle.
10 Push the bolt (9) back and remove the pin (8) in the direction of the arrow.
11 Remove the hinge (7) and the handles (10 and 12).
110
647364EN
FINGERTIP JOYSTICK
2
assembly, move the MFA console to the
highest position.
6
5
4 you place them to one side.
3
3 Remove the front part of the MFA console
(1) (see Chapter 3.4). Comment: do not
1 disconnect connectors A, C and D.
8
7
7 4 Undo the four screws (11) on the PC
9 board (13). Installation note: four screws
(11), 0.5 Nm.
13 5 Remove the PC board (13) from the front

12
10 part of the MFA console (1) and turn it over.
6 Remove the Fingertip joystick plug (6)

from the PC board (13): - Fingertip Joystick
11 11 (2) from FTC4 (10) - Fingertip Joystick (3)
from FTC3 (12) - Fingertip Joystick (4) from
3335
FTC2 (9) - Fingertip Joystick (5) from FTC1 (8)
7 Note down the installation position of the Fingertip joystick.
8 Undo the four screws (7) on the Fingertip joystick (2, 3, 4 or 5). Installation note: four screws (7), 0.5 Nm.
9 Remove the Fingertip joystick through the top of the front part of the MFA console (1). Installation
note: introduce the Fingertip joystick into the front part of the MFA console using the markers and
placing the four wires on the left.

110
647364EN
BLIND COVER

1
3
3
highest position.


2
disconnect connectors A, B, C and D.
4 Push the four side bolts (3) on the blind

1
cover (1) inwards and remove the cover from
the console (2).

3342
110
647364EN
BOWDEN FORWARD/REVERSE ADJUSTMENT TRACTION WIRE
1 (!) The MFA console (1) moves up thanks

5 assembly, move the MFA console (1) to the
highest position.
4
1
3 3 Loosen the Bowden traction wires (8) on
the wire regulator (7) (see Chapter 3.9).
2
4 Unhook the head of the Bowden traction

8 7 6 wire (2) from the support (3).
6
5 Unhook the thread connection (5) from

12 the lever (4).
8
6 Remove the forward/reverse adjustment
8 handle (12) (see Chapter 3.5).
7 Push the head of the Bowden traction wire

(10) out of the support (9).
10
9
8 Note down the location of the Bowden
11 traction wire (8).
9 Open the two corrugated iron pipe supports

(6) and remove the cable binder from the
support (11).
10 Unhook the Bowden traction wire (8) from the MFA Device. Installation instructions:
- Adjust the length of the new Bowden traction wire (8) according to the length of the previous wire.
- Position the Bowden traction wire (8) in the MFA lift truck and in the MFA console using the marks
made previously.
- Check the adjustment of the Bowden traction wire and adjust if necessary (see Chapter 3.9).

110
647364EN
BOWDEN FORWARD/REVERSE ADJUSTMENT TRACTION WIRE:
10
2 9 1
A
8
1
5 4 3
Inspection
1 (!) The MFA console moves up thanks to the pressure of the spring! To facilitate inspection, move the
MFA console to the highest position and move the interface (2) backwards.
2 Stretch/slacken the Bowden forward/reverse adjustment traction wire (6) several times and check
operation thereof: - Check that the Bowden traction wire moves easily (6). - the Bowden traction wire (6)
must pull the locking lever (1) downwards under tension (unlocking) and release the blocking/locking
position of the forward/reverse adjustment. The interface (2) can be moved gently horizontally. - When
the Bowden traction wire is unlocked (locking) (6), the unblocking lever (1) is pushed upwards by the
spring and it blocks the forward/reverse adjustment. It is not possible to move the interface (2) to a
different forward/reverse position.
3 Check (using a sliding calliper) and, if necessary, adjust the measurement between the top of the
thread connection (10) and the top of the support (9) on the head of the Bowden traction wire (7). Test
measurement: A (locked position) = 49.5 ± 1.0 mm Adjustment measurement (guide value): A (locked
position) = 49.5 mm.
Adjustment
1 Loosen the two counternuts (4) on the wire regulator and adjust the metal wire (8) using the setting
screw (3).
• Guide value: adjustment measurement A.
• Move the setting screw (3) away from the adjusting nut (5) to shorten the metal wire (8).
• Move the setting screw (3) closer to the adjusting nut (5) to lengthen the metal wire (8).
Adjusting instruction: once the adjustment is complete, stretch the metal wire (8) gently without using
the unlocking lever (1).
2 Hold the adjusting nut (5) and block adjustment with the two counternuts (4). As you do this, make
sure that the Bowden traction wire (6) does not become twisted.
110
647364EN
BOWDEN HEIGHT ADJUSTMENT TRACTION WIRE

assembly, move the MFA console (1) to the
highest position.
3 4 5
1
2
3 Loosen the Bowden traction wires (4) on

the wire regulator (5) (see Chapter 3.11).
6
8 7 4 Unhook the head of the Bowden traction
wire (3) from the support (7).
12
5 Unhook the thread connection (8) from
4
4 6 Remove the height adjustment handle

(12) (see Chapter 3.5).
7 Push the head of the Bowden traction wire

10
9 (10) out of the support (9).
11
8 Note down the location of the Bowden
traction wire (4).
9 Open the corrugated iron pipe support (6) and remove the cable binder from the support (11).
10 Unhook the Bowden traction wire (4) from the MFA Device. Installation instructions:
- Adjust the length of the new Bowden traction wire (4) according to the length of the previous wire.
- Position the Bowden traction wire (4) in the MFA lift truck and in the MFA console using the marks
made previously.
- Check the adjustment of the Bowden traction wire and adjust if necessary (see Chapter 3.11).

110
647364EN
BOWDEN HEIGHT ADJUSTMENT TRACTION WIRE
1
8 6 5
7
4
3
Inspection
1 (!) The MFA console moves up thanks to the pressure of the spring! To facilitate inspection, move the
MFA console to the highest position and backwards.
2 Stretch the MFA lift truck (1) and stretch/slacken the Bowden height adjustment traction wire (5) several
times and check operation thereof: - Check that the Bowden traction wire moves easily (5). - the Bowden
traction wire (5) must pull the locking lever (9) backwards under tension (unlocking) and release the
blocking/locking position of the height adjustment. The MFA lift truck (1) can be moved up and down. -
When the Bowden traction wire (5) is unlocked (locking), the unblocking lever (9) is pushed forwards by
the spring and it blocks the height. It is not possible to move the MFA lift truck (1) to a different height.
3 Check (using a sliding calliper) and, if necessary, adjust the measurement between the outside of the
thread connection (8) and the outside on the head of the Bowden traction wire (6). Test measurement: A
(locked position) = 61.5 ± 1.0 mm Adjustment measurement (guide value): A (locked position) = 61.5 mm.
Adjustment
1 Loosen the two counternuts (3) and adjust the metal wire (7) using the setting screw (2).
• Guide value: adjustment measurement A.
• Move the setting screw (2) away from the adjusting nut (4) to shorten the metal wire (7).
• Move the setting screw (2) closer to the adjusting nut (4) to lengthen the metal wire (7).
Adjusting instruction: once the adjustment is complete, stretch the metal wire (7) gently without using
2 Hold the adjusting nut (4) and block adjustment with the two counternuts (3). As you do this, make
sure that the Bowden traction wire (5) does not become twisted.
110
647364EN
EMERGENCY STOP BUTTON

6 to the pressure of the spring! To facilitate
5
highest position.
4 2 Remove the MFA console (see Chapter

7 overstretch the Bowden traction wires when
3
2
disconnect connectors B, C and D.
4 Lift up the hood (6) on the head of the

emergency stop button (4) with a small
screwdriver.
1
5 Undo the screw (5) and remove the head

from the emergency stop button (4) outside
the lower part of the button (2). Installation
note: screw (5), 0.3 ± 0.1 Nm.
6 Push the support (7) outside the groove

at the bottom of the switch (2).
7 Undo the blind nut (3).
8 Remove the bottom of the switch (2) on the front part of the console (1) downwards. Installation note:
introduce the bottom of the switch (2) so that the anti-rotation device is in the grooved arrow).

110
647364EN
STEERING SWITCH
2 instructions: - Do not remove the Bowden
3 2

(1) (see Chapter 3.4).
4 Note down the installation position of the

steering switch (3).
1 5 Push the four side bolts (2) on the steering

switch (3) inwards and unhook the steering
switch from the front part of the console
(1). Installation note: introduce the steering
switch (3) in line with the marks with pin
assignments 7, 4, 5, 6 and 8 downwards
into the front part of the MFA console (1).

HORN SWITCH
2 Remove the MFA console (see Chapter 3.2) and place it to
2
one side. Comments and instructions: - Do not remove the
Bowden traction wires on the MFA lift truck. - Do not overstretch
the Bowden traction wires when you place them to one side.
3 Remove the front part of the MFA console (1) (see Chapter
3.4). Comment: do not disconnect connectors A, B, C and D.
4 Note down the installation position of the horn switch (2).
5 Undo the hex nut (4) from the horn switch (3) and remove
the toothed washer (2). Installation note: hex screw (4), 0.5
± 0.1 Nm.
6 Lift up the horn switch (2) from the front part of the console
3
(1). Installation note: install the horn switch wiring harness
4
(2) according to the marking.
110
7 Refit the components by following the removal steps in

reverse order.
647364EN
ARMREST
1 Open the arm support (3), undo the four
flat-head screws (1) on the supports (2).
2
Installation instruction: four flat-head screws
1
(1), 0.5 ± 0.1 Nm.
3
2
2 Remove the arm support (3) from the
4
hinges (4).

4
1
SEAT ADAPTER
3
5
highest position.
2 Remove the MFA Device completely

2 4 (Chapter 2.1).
3 Undo the hex bolt (5) and the assembly

screw (6). Where necessary, remove the
seatbelt attachment (4) from the seat plate
(1). Installation instructions: • Hex screw (5),
5 57.5 ± 7.5 Nm. - assembly screw (6), 25.0 ±
5.0 Nm.
4 Undo the collar screw (3) and remove the

6
seat adapter (2). Installation note: collar
screw (3), 25.0 ± 5.0 Nm.
1 5 Refit the components by following the

110
647364EN
LOWER COVER
1 (!) The MFA console moves up thanks to the

pressure of the spring! To facilitate assembly, move
the MFA console to the highest position.
5
2 Remove the two Bowden traction wires (3) from

the MFA lift truck (see Chapters 3.8 and 3.10).
4
3 Remove the MFA console (5) (see Chapter 3.2).
4 Undo the eight screws (1) and remove the bottom

3
2 cover (2). Installation note: eight screws (1), 0.5 Nm.
5 Unhook the Bowden traction wire (3) and the

MFA Device wire (4).
6 Refit the components by following the removal

steps in reverse order.
1
1 1
1
LOWER PART WITH MFA DEVICE WIRING HARNESS
1 (!) The MFA console moves up thanks to the

1 pressure of the spring! To facilitate assembly, move
the MFA console to the highest position.
3 Remove the MFA console (see Chapter 3.2).
4 Remove the front part of the MFA console (see

Chapter 3.4).
5 Remove the lower cover (see Chapter 3.17).
6 Remove the Bowden forward/reverse adjustment

traction wire (see Chapter 3.8).
110
7 Remove the Bowden height adjustment traction wire (see Chapter 3.10).
8 Refit the internal part with the wire harness (1) of the MFA Device by following the removal steps in
reverse order.
647364EN
110.6 TROUBLESHOOTING
110.6.1 POTENTIAL FAULTS

This chapter describes the MFA Device's possible faults. The information and comments available in
Chapter 2.3 "Repair - Locating the fault" make it easier
to do jobs in the event of a breakdown. The vehicle must be inspected and repaired and faults must be
repaired (see Vehicle Documentation).
Faults resulting from inadequate maintenance or incorrect repairs are not covered here.
Comment: the components mentioned above are illustrated in Chapter 2.1 and the functional components
are illustrated in the repair manual for the upper part of the seat
unless indicated otherwise.
Description of the fault Possible cause Repair

Check attachment control
• Respective Fingertip Joystick defective. (see Chapter 2.3, inspection no. 1.1).
Defective attachment control
• PC board defective. Check attachment control
(see Chapter 2.3, inspection no. 1.1).
The vehicle's functions are not interrupted when Check the emergency stop button
• Faulty emergency stop button.
the emergency stop button is pressed. (see Chapter 2.3, inspection no. 2.1).
The vehicle's functions are not reactivated when Check the emergency stop button
the emergency stop button is released. (see Chapter 2.3, inspection no. 2.1).
Defective steering selection (forward, neutral or Check the emergency stop button
reverse) (see Chapter 2.3, inspection no. 3.1).
Check the horn switch
Defective horn. • Defective horn switch.
(see Chapter 2.3, inspection no. 4.1).
110.6.2 FAULT LOCATION

DIAGNOSIS PRECONDITIONS FOR EACH TEST:
• The individual functions are activated in accordance with the MFA console instructions.
• The vehicle's electrical system has been inspected and it is in order and compliant with the vehicle's
operating instructions.
• The vehicle's attachments controlled by the MFA Device have been inspected and are in order.
• The components have been connected in accordance with the instructions and locked where necessary.
• The MFA Device wiring harness, and in particular the arc forming points and broken conductors
(twisting), has been inspected and is in order.
• The ignition switch is turned off (no voltage that can cause current to pass should be applied to
suspension of the seat).
Comments and instructions:

• The components mentioned above are illustrated in Chapter 2.1, unless indicated otherwise in the text.
• The description of the works completed to establish the diagnosis is available in Chapter 3.
• Check once again that the faulty assemblies have been replaced.
• Assemble the MFA Device once the inspection has been done or before redoing the inspection
(reconnection, for example).
110
647364EN
1 ATTACHMENT CONTROL INSPECTION

Fault diagnosis preconditions:
• See "Fault diagnosis preconditions for each test" at the beginning of the chapter.
Stage Inspection/Use Result/Status specified Repair
• Disconnect connector (E) between the MFA Device

wiring harness (4) and the vehicle (see the vehicle
1.1 manufacturer's instructions).
• Apply a test voltage of 12 V DC to the contacts 1 (+)
and 2 (-) on the MFA Device wiring harness (5).
• Measure the voltage at the contacts 2 (-) = 2.5 V (± 10%)

Go to inspection 1.3.
1.2 and 6 (signal) on the MFA Device wiring harness >> 2.5 V (short-circuit after +)
plug (5): 2 (-) V (CC) 6 (+) or << 2.5 V (break)
• Move the Fingertip joystick (6) forward Comment: the voltage increases constantly
beyond the pressure point and measure the up to the pressure point. Go to inspection 1.4.
1.3
voltage: = 4.5 V (± 10%) >> 4.5 V (short-circuit after Go to inspection 1.6.
2 (-) V (CC) 6 (+) +) or << 4.5 V (break)
• Move the Fingertip joystick (6) backward Comment: the voltage increases constantly
1.4
2 (-) V (CC) 6 (+) +) or << 0.5 V (break)
• Carry out inspections 1.2 to 1.4 for Fingertip
joysticks 7, 8 and 9.
• Measure the voltage at the contacts: = no measurement offset End of inspection.
1.5
2 (-) V (DC) 5 (+ Fingertip Joystick 7) = measurement offset Go to inspection 1.6.
2 (-) V (DC) 4 (+ Fingertip Joystick 8)
• Disconnect connector (B) between the MFA Device
wiring harness (4) and the PC board (2), (see Chapter
1.6 3.4).
• Apply a test voltage of 12 V DC to the contacts 1 (+)
and 14 (-) on the PC board (3).
• Measure the voltage at the contacts 14 (-) and
= 2.5 V (± 10%) >> 2.5 V (short-circuit after Go to inspection 1.8.
1.7 5 (signal) on the PC board (3):
+) or << 2.5 V (break) Go to inspection 1.11.
14 (-) V (CC) 5 (+)
• Move the Fingertip joystick (6) forward Comment: the voltage increases constantly
1.8
14 (-) V (DC) 5 (+) +) or << 4.5 V (break)
• Move the Fingertip joystick (6) backward Comment: the voltage increases constantly
1.9
14 (-) V (CC) 5 (+) +) or << 0.5 V (break)
• Carry out inspections 1.7 to 1.9 for Fingertip
joysticks 7, 8 and 9.
Replace the MFA Device wiring harness (see
• Measure the voltage at the contacts: = no measurement offset
1.10 Chapter 3.18).
14 (-) V (DC) 4 (+ Fingertip Joystick 7) = measurement offset
• Remove the PC board (2) and disconnect the

respective Fingertip joystick connector from the
1.11 PC board (FTC 1, 2, 3 or 4) (see Chapter 3.6).
• Apply a test voltage of 5 V DC to the contacts 1
(+) and 2 (-) on the Fingertip joystick plug (10).
• Measure the voltage at the contacts 1 (-) and 3 Go to inspection 1.13.

= 2.5 V (± 10%) >> 2.5 V (short-circuit after
1.12 (signal) on the Fingertip joystick plug (10): Replace the Fingertip joystick (see Chapter
+) or << 2.5 V (break)
1 (-) V (CC) 3 (+) 3.6).
Comment: the voltage increases constantly
• Move the Fingertip joystick forward beyond Go to inspection 1.14.
up to the pressure point.
1.13 the pressure point and measure the voltage: Replace the Fingertip joystick (see Chapter
= 4.5 V (± 10%) >> 4.5 V (short-circuit after
1 (-) V (CC) 3 (+) 3.6).
+) or << 4.5 V (break)
110
Comment: the voltage increases constantly Replace the front part of the MFA console
• Move the Fingertip joystick backward beyond
up to the pressure point. (see Chapter 3.4).
1.14 the pressure point and measure the voltage:
= 0.5 V (± 10%) >> 0.5 V (short-circuit after Replace the Fingertip joystick (see Chapter
1 (-) V (CC) 3 (+)
+) or << 0.5 V (break) 3.6).
647364EN
2 EMERGENCY STOP BUTTON INSPECTION


• Disconnect connector (E) between the MFA
Device wiring harness (4) and the vehicle (see
the vehicle manufacturer's instructions). Comment: the emergency stop button
• The emergency stop button (1) is not contact is NO (normally open). Go to inspection 2.2.
2.1
activated. = Break MΩ (=> ∞) << MΩ (=> 0) (short- Go to inspection 2.5.
• Measure the resistance on the contacts 8 and circuit)
9 on the MFA Device wiring harness plug (5):
8Ω9
• Activate the emergency stop button (1).
• Measure the resistance on the contacts 8 and 9 on = 0.4 Ω (± 0.2 Ω) Go to inspection 2.3.
2.2
the MFA Device wiring harness plug (5): >> 0.4 Ω (=> ∞) (break) Go to inspection 2.6.
8Ω9
• Unblock the emergency stop button (1). Comment: the emergency stop button
• Measure the resistance on the contacts 10 and contact is NC (normally closed). Go to inspection stage 2.4.
2.3
11 on the MFA Device wiring harness (5): = 0.4 Ω (± 0.2 Ω) Go to inspection stage 2.7.
10 Ω 11 >> 0.4 Ω (=> ∞) (break)
• Activate the emergency stop button (1).
• Measure the resistance on the contacts 10 and = Break MΩ (=> ∞) End of inspection.
2.4
11 on the MFA Device wiring harness (5): << MΩ (=> 0) (short-circuit) Go to inspection stage 2.8.
10 Ω 11
• Disconnect the connector (A) between the MFA
Device wiring harness (4) and the emergency stop Replace the MFA Device wiring harness
button (1), (see Chapter 3.4). = Break MΩ (=> ∞) (see Chapter 3.18).
2.5
• Measure the resistance on the contacts 3 and 4 on << MΩ (=> 0) (short-circuit) Replace the emergency stop button
the emergency stop button plug (3): (see Chapter 3.12).
3Ω4
button (1), (see Chapter 3.4). = 0.4 Ω (± 0.2 Ω) (see Chapter 3.18).
2.6
• Measure the resistance on the contacts 3 and 4 on >> 0.4 Ω (=> ∞) (break) Replace the emergency stop button
3Ω4
button (1), (see Chapter 3.4). = 0.4 Ω (± 0.2 Ω) (see Chapter 3.18).
2.7
• Measure the resistance on the contacts 1 and 2 on >> 0.4 Ω (=> ∞) (break) Replace the emergency stop button
1Ω2
button (1), (see Chapter 3.4). = Break MΩ (=> ∞) (see Chapter 3.18).
2.8
• Measure the resistance on the contacts 1 and 2 on << MΩ (=> 0) (short-circuit) Replace the emergency stop button
1Ω2
110
647364EN
3 STEERING SWITCH INSPECTION


• Disconnect connector (E) between the MFA Device wiring
harness (3) and the vehicle (see the vehicle manufacturer's
instructions).
= 0.4 Ω (± 0.2 Ω) Go to inspection 3.2.
3.1 • Switch the steering switch (1) to position N.
>> 0.4 Ω (=> ∞) (break) Go to inspection 3.4.
• Measure the resistance on the contacts 1 and 13 on the
MFA Device wiring harness plug (4):
1 Ω 13
• Switch the steering switch (1) forward to Forward
position.
= 0.4 Ω (± 0.2 Ω) Go to inspection 3.3.
3.2 • Measure the resistance on the contacts 1 and 14 on
the MFA Device wiring harness plug (4):
1 Ω 14
• Switch the steering switch (1) backward to Reverse
position.
= 0.4 Ω (± 0.2 Ω) End of inspection.
3.3 • Measure the resistance on the contacts 1 and 15 on
1 Ω 15
• Disconnect the connector (C) between the MFA
Device wiring harness (3) and the steering switch
(1), (see Chapter 3.4). Replace the MFA Device wiring harness
• Short-circuit of pins 3 and 5 of the steering = 0.3 Ω (± 0.2 Ω) (see Chapter 3.18).
3.4
switch (1). >> 0.3 Ω (=> ∞) (break) Replace the steering switch
• Measure the resistance on the contacts 2 and 4 (see Chapter 3.13).
on the emergency stop button (1):
2Ω4
3.5
on the steering switch (1):
2Ω6
3.6
on the steering switch (1):
2Ω1
110
647364EN
4 HORN SWITCH INSPECTION


• Disconnect connector (E) between the MFA Device
wiring harness (4) and the vehicle (see the vehicle
Comment: the horn switch is open.
manufacturer's instructions). Go to inspection 4.2.
4.1 = Break MΩ (=> ∞)
• Measure the resistance on the contacts 1 and 20 on Go to inspection 4.3.
<< MΩ (=> 0) (short-circuit)
1 Ω 20
• Press on the horn switch (1).
• Measure the resistance on the contacts 1 and 20 on = 0.4 Ω (± 0.2 Ω) End of inspection.
4.2
the MFA Device wiring harness plug (5): >> 0.4 Ω (=> ∞) (break) Go to inspection 4.4.
1 Ω 20
• Disconnect the connector (D) between the MFA
Replace the MFA Device wiring harness
(1), (see Chapter 3.4). = Break MΩ (=> ∞)
4.3 (see Chapter 3.18).
• Measure the resistance on the contacts 1 and 2 << MΩ (=> 0) (short-circuit)
Replace the horn switch (see Chapter 3.14).
on the horn switch plug (3):
1Ω2
• Disconnect the connector (D) between the MFA
Device wiring harness (4) and the steering switch (1),
(see Chapter 3.4). Replace the MFA Device wiring harness
= 0.4 Ω (± 0.2 Ω)
4.4 • Press on the horn switch (1). (see Chapter 3.18).
>> 0.4 Ω (=> ∞) (break)
• Measure the resistance on the contacts 1 and 2 on Replace the horn switch (see Chapter 3.14).
1Ω2
110

MI25D Exq Elect

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647364EN (07/06/2018)

DATE OF ISSUE OBSERVATION

15 / 11 / 2011 - 1st ISSUE

21 / 03 / 2014 - 2nd ISSUE

03 / 12 / 2014 - 3rd ISSUE

07 / 06 / 2018 - 4th ISSUE : Add MI 20-25-30-35 D Y E3 S3

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

HOW TO USE THIS REPAIR MANUAL ?

3 4 General instructions and safety

RULES FOR MAINTENANCE

GENERAL INSTRUCTIONS AND SAFETY NOTICE

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

Before carrying out any operation on an electrically powered

Before carrying out any welding operations, think about

A machine operating in a contaminated environment should be

547982 : See the repair manual N° 547982.

70 - HYDRAULIC : See the group N° 70 called «Hydraulic».

- GENERAL CHARACTERISTICS AND

- GENERAL COMPONENTS LOCATION

- GENERAL CONTROL AND ADJUSTMENT

In order to reduce accident risks, make sure to:

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

When you see this symbol:

Before any intervention:

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

RULES FOR MAINTENANCE

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

ECU bb  efore carrying out any welding operations, think of

A machine operating in a contaminated environment should be

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

When carrying out maintenance operations near a mobile object,

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

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

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

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

Never control any leaks using a hand.

MAX Never adjust a component to over the maximum capacity indicated

Data from the Operator’s Manuel :

Data from the Operator’s Manuel :

Data from the Operator’s Manuel :

Data from the Operator’s Manuel :

LOCATION OF NAME AND IDENTIFICATION PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

LOCATION OF NAME AND IDENTIFICATION PLATE

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

STANDARD TIGHTENING TORQUES

b Standard tightening torques

For hexagon screws with flanges (NF E 25-030-1) :

- ENGINE COMPONENTS LOCATION

- ENGINE CONTROL AND ADJUSTMENT

- CHARACTERISTICS AND SPECIFICATIONS l 647507EN

- CONTROL AND ADJUSTMENT (4TNV94L

- SPECIFIC TOOLING l 647120EN

(K21 - K25 GAS ENGINE)

(K21 - K25 LPG ENGINE)

MI 15 to 35 G - S1 (UP TO MACHINE N°856887)

Gasoline (K21 - K25 GAS ENGINE)

MI 15 to 35 G - S2 (FROM MACHINE N°856888)

LPG Single fuel (K21 - K25 LPG ENGINE)

MI 15 to 35 D - S1 E3 (UP TO MACHINE N°_____)

Diesel (4TNE92 - 4TNE98 DIESEL ENGINE)

(FROM MACHINE N°____)

K21 - K25 GAS ENGINE - LPG CARBURETION OPERATION

OPERATING A CASOLINE CARBURETION

ECU bb efore carrying out any welding operations, think of

bb If gaseous capture phase

4 - Remove the filter and screen.